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Home / Wheel Loaders / Case Wheel Loaders / Case 521G

Case 521G Troubleshooting

The Case 521G wheel loader is powered by 274 cu.in (4.5L) FPT F4H FE413NB 4-cylinder turbocharged aftercooled diesel engine with a rated power of 129 hp (96 kW) at 2000 rpm. The Case 521G is equipped with a 4x3 autoshift transmission, power steering system, hydraulic multiple wet disc brakes, and 17.5x25 standard tires. The hydraulic system has a piston pump with fluid flow rate of 35.4 gpm (134 lpm). The hydraulic pressure is 3625 psi (250 bar). The wheel loader has a rated operating capacity of 10180 lbs (4620 kg) and tipping load of 20360 lbs (9240 kg). The maximum lift height is 142" (3605 mm) to hinge pin, and breakout force is 20935 lbs (9495 kg).

Engine Troubleshooting

Engine difficult to start or doesn't start
Air in fuel system - Bleed fuel system.
Fuel filter element clogging - Clean the filter or install new filter element.
Fuel injection nozzles are clogged or faulty - Install a new kit of correctly balanced nozzles.
Water in the fuel system - Change fuel and repair fuel system.
Valve clearance is wrong - Check and adjust.
Fuel injection pump is damaged - Replace injection pump or repair it.

Engine starts and stalls suddenly
Plugged air filter - Replace or clean air filter element.
Fuel filter element is clogged - Change filter element.
Fuel injection pump leakage - Check the fuel injection pump for leaks and fix it.
Damaged or clogged injectors - Clean or replace fuel injectors.
Fuel injection pump is not operating properly - Rebuild or replace pump.

Engine shuts off suddenly while running
Coolant temperature is low - Warm up engine as required.
Clogged fuel filter - Replace the filter element.
Air in the fuel lines - Bleed the fuel lines.
Fuel injection nozzles fault - Check injection nozzles and replace if required.
Fuel injection pump timing is not adjusted - Adjust the pump as required.

Engine stops when idle
Incorrect low idle speed adjustment - Adjust as required.
Fuel injection pump is faulty - Repair or replace injection pump.
Dirty or defective injectors - Clean or replace fuel injectors.
The valve clearance is not adjusted - Have it adjusted.

Diesel engine loses power
Dirty air cleaner - Clean or change.
Fuel injection nozzles are clogged or faulty - Replace injection nozzles.
Fuel injection pressure is wrong - Adjust to proper pressure.
Excessive valve clearance - Check and adjust as required.
Low idle speed setting is not correct - Adjust low idle speed.
Fuel hoses or lines are dirty - Fuel lines and hoses need to be cleaned.
Leaking cylinder head gasket - Cylinder-head gasket replacement required.
Damaged or leaking piston rings - Replace piston rings.

Engine overheats
Low engine coolant - Add coolant fluid and inspect the cooling system for leaks.
Lack of engine oil - Fill the crankcase with engine oil.
Damaged radiator cap or dirty radiator core - Install new cap or clean radiator.
Loose or damaged fan belt - Fan belt must be replaced.
Diesel engine overloaded - Load reducing is recommended.

Oil pressure is insufficient
Engine oil insufficient - Add oil as required.
Engine oil filter is plugged - Change or clean engine oil filter element.
Oil grade or viscosity is incorrect - Drain and refill with oil of correct grade and viscosity.
Incorrect oil clearance in crankshaft bearing - Bearing replacement required.
Defective oil pump - Inspect and change as required.

Engine knocking or noise
Engine oil level is low - Add oil to the engine crankcase.
Low coolant temperature - Warm up the engine.
Improper setting of fuel injection pump timing - Adjust the pump as required.
Low idle speed setting is not correct - Adjustment required.
Fuel injector fault - Clean fuel injectors or change it.
Connecting rod is defective or not aligned - Need to align or replace the connecting rod.
Worn or broken pistons - Replace the pistons as required.

Transmission Troubleshooting

Low transmission pressure
Lack of transmission oil supply - Fill up the transmission oil.
Clogged transmission oil filter element (if fitted) - Clean or replace the transmission filter.
Stuck relief valve - Replace the valve.

Transmission is excessively noisy
Transmission oil level is low - Check and refill the transmission oil.
Transmission fluid is contaminated - Fill up with fresh transmission fluid.
Defective gears or improper backlash - Adjust backlash properly or replace the gears.
Worn or damaged bearings - Bearings need to be replaced.
Worn or bent gear shift forks - Shift forks need to be changed.
Shaft splines are damaged or worn - Change defective shaft.

Difficult to shift gears
Worn or rusty gear shift linkage - Shift linkage need to be replaced.
Shift forks are worn or bent - Change defective shift forks.
Worn gear shifting mechanism - Repair or change worn components if necessary.
Clutch is out of adjustment or defective - Change or adjust clutch.

Transmission fluid leaking
High transmission oil level - Correct the oil level.
Damaged seals or gaskets - Install new components.

Hydraulics Troubleshooting

Hydraulic system overheating
Hydraulic pressure is not adjusted correctly - Hydraulic pressure must be set correctly.
Main relief valve is defective or unadjusted - Replace or set up the relief valve.
Dirty hydraulic fluid - Hydraulic fluid change required.
Hydraulic fluid level is insufficient - Check and refill the hydraulic fluid.
Defective hydraulic pump - Repair or change pump if required.

Boom cannot be lowered or raised
Lift controls are defective - Repair or replace.
Hydraulic pump is broken - Install new pump or repair it.
Damaged hydraulic control valve - Replace or repair the valve.
Hydraulic cylinder not working - Repair or replace hydraulic cylinder.
Hydraulic oil is insufficient - Check and refill the hydraulic oil.

Bucket can't tilt
Faulty bucket tilt controls - Check and repair as required.
Hydraulic pump is broken - Change or repair hydraulic pump if required.
Hydraulic control valve failure - Repair or change hydraulic valve.
Bucket cylinder failure - Change or repair cylinder.
Hydraulic oil is insufficient - Check and refill the hydraulic oil.

Boom or bucket runs slowly
Worn hydraulic oil pump - Test the pump performance and change pump if required.
Hydraulic cylinder leaking - Repair leak by replacing the seals.
Insufficient hydraulic oil - Check and refill the hydraulic oil.
Damaged or incorrect adjusted hydraulic control valve - Repair or set properly.
Hydraulic pressure has dropped - Set pressure correctly.

Lift arm or bucket is moving jerkily
Air leaks in hydraulic system - Need to bleed air.
Dirty hydraulic oil filter - Clean or change the filter.
Hydraulic oil is dirty - Hydraulic oil change required.
Cylinder tube or rod is scored - Change damaged component.

Hydraulic pump is excessively noisy
Hydraulic leaks or lack of oil - Refill hydraulic oil or repair leaks in system.
Hydraulic filter is clogged - Replace or clean the filter.
Clogged suction line - Clean suction line as required.
Air in hydraulic pump - Bleed air from hydraulics.
Damaged pump parts - Rebuild or install new pump.

Electrical Troubleshooting

Battery is not charging
Wiring connections are corroded or loose - Clean or tighten wiring connections.
Battery terminal clamps are defective - Terminal clamps need to be replaced.
Dead cell in battery - Use a new battery.
Belt is damaged or loose - Adjust belt tension or replace belt.

Starter motor cranks slow
Battery capacity is low - Recharge the battery.
Battery is draining quickly - Service charging system or replace battery.
Disconnected wires or corroded battery terminals - Connect wiring correctly or install new terminals.

Starter is not working
Battery is discharged or defective - Charge or replace the battery.
Battery cables are disconnected or incorrectly connected - Check cables and connect as needed.
Low battery output voltage - Recharge the battery.
Faulty starter motor - Replace or repair starter.

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WHEEL LOADERS SPECIFICATIONS

Wheel Loaders, Skid Steers, and Compact Track Loaders