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

Case 521G XR Troubleshooting

The Case 521G XR wheel loader driveline system components: FPT F4H FE413NB 4-cylinder direct injection turbocharged diesel engine with a rated power of 129 hp (96 kW), and 4-speed transmission with a torque converter. The hydraulic system has a pump with a rated capacity of 35.4 gal/min (134 l/min). The system relief pressure is 3625 psi (250 bar). The Case 521G XR is equipped with a power steering system, hydraulic multiple wet disc brakes, and 17.5x25 tires. The wheel loader has a maximum lift height of 156.9" (3985 mm) and bucket breakout force of 21010 lbs (9530 kg). The rated operating capacity is 8690 lbs (3940 kg), and tipping load is 17380 lbs (7880 kg).

Engine Troubleshooting

Engine difficult to start or won't start
Air in the fuel system - Air bleeding.
Dirty fuel filter - Change filter element.
Burnt or defective injection nozzle - Install a new kit of correctly balanced nozzles.
Dirt or water in fuel system - Drain water or flush dirt from the system.
The valve clearance is incorrect - Adjustment procedure required.
Damaged fuel injection pump - Repair or install a new fuel pump.

Engine starts and stalls suddenly
Clogged air filter - Install new air filter element.
Fuel filter plugging - Change or clean the filter element.
Problems with fuel injection pump tightness - Inspect fuel injection pump for leaks.
Dirty or defective injectors - Replace fuel injectors.
Fuel injection pump malfunction - Replace injection pump or repair it.

Engine shuts off suddenly while running
Engine is not preheated - Warm up the engine.
Clogged fuel filter - Clean or change the filter.
Air in fuel tank - Bleed fuel tank.
Clogged injection nozzle - If necessary, replace with a new nozzle.
Improper setting of fuel injection pump timing - Set the fuel pump timing correctly.

Engine stops at idle
Improperly adjusted low idle speed - Adjustment required.
Fuel injection pump is not working correctly - Replace or rebuild injection pump.
Clogged or defective injectors - Replace or clean fuel injectors.
Valve clearance is out of adjustment - Adjust valve clearance according to specifications.

Diesel power loss
Clogged air filter - Clean or change filter.
Clogged or defective injection nozzles - Inspect nozzles and replace if necessary.
Fuel injection pressure is wrong - Check the fuel injection pressure and adjust if necessary.
The valve clearance is incorrect - Need to adjust valve clearance.
Too low idle RPM - Need to adjust idle speed.
Fuel lines or hoses clogging - Fuel lines and hoses need to be cleaned.
Cylinder-head gasket is broken - Install a new gasket.
Worn or broken piston rings - Piston rings need to be replaced.

Engine overheating
Engine has a lack of coolant - Top up coolant fluid and check system for leaks.
Engine oil insufficient - Fill the crankcase with engine oil.
Radiator core is clogged or radiator cap is leaking - Clean radiator or install new cap.
Excessive wear of the fan belt - Replace the fan belt.
Diesel engine is overloaded - Reduce engine load.

Oil pressure too low
Low oil level - Need to add oil.
Oil filter is clogged - Replace or service engine oil filter.
Incorrect engine oil Fill up with the correct oil viscosity.
Excessive oil clearance of crankshaft bearing - Bearings need to be reinstalled.
Defective oil pump - Repair or replace.

Engine knocking or noise
Low engine oil level - Checking oil level and add if necessary.
Engine is not warmed up to required temperature - Warm up the engine.
Improper setting of fuel injection pump timing - Use the correct fuel injection pump timing adjustment.
Low idle speed set incorrectly - Correct low idle settings.
Fuel injectors are faulty or clogged - Replace or clean fuel injectors.
Connecting rod is misaligned or defective - Need to align or replace the connecting rod.
Piston wear or scoring - Pistons need to be replaced.

Transmission Troubleshooting

Transmission fluid pressure is insufficient
Lack of transmission oil supply - Fill the transmission housing with oil.
Dirty transmission fluid filter (if fitted) - Service or replace the transmission fluid filter.
Relief valve failure - Replace relief valve.

Transmission noises
Low oil level - Fill the transmission housing with oil.
Transmission fluid contamination - Transmission fluid change required.
Incorrect backlash or gears are worn - Install new gears and set backlash correctly.
Worn or damaged bearings - Bearings replacement required.
Worn or bent gear shift forks - Shift forks need to be replaced.
Worn or stuck shaft splines - Install a new shaft.

Difficult to shift gears
Stuck or worn gear shift linkage - Lubricate or replace shift linkage.
Shift forks are bent or worn out - Shift forks need to be replaced.
Gearshift mechanism malfunction - Identify and replace failed parts.
Clutch is faulty or misadjusted - Adjust clutch or change if necessary.

Transmission fluid leaks
Transmission oil level is exceeded - Correct the oil volume.
Seals or gaskets are broken - Replace worn seal or gaskets.

Hydraulics Troubleshooting

Hydraulic system has overheating
Incorrect hydraulic pressure setting - Adjust pressure correctly.
Main relief valve malfunction or improper adjustment - Adjust the valve or replace if necessary.
Dirty hydraulic fluid - Hydraulic fluid change required.
Lack of hydraulic fluid - Fill the hydraulic system with oil.
Hydraulic pump is defective - Repair or change pump if required.

Boom can't lift or drop
Lift controls are faulty - Repair or change.
Damaged hydraulic oil pump - Repair or change pump if required.
Faulty hydraulic control valve - Repair or change the valve.
Damaged hydraulic cylinder - Change or repair lift cylinder.
Hydraulic fluid is insufficient - Fill up the hydraulic fluid.

Bucket is not working
Bucket tilt controls are defective - Check and repair as required.
Hydraulic pump not working - Repair or install new hydraulic pump.
Hydraulic control valve malfunction - Install a new valve or repair it.
Bucket cylinder malfunction - Repair or change cylinder.
Hydraulic fluid level low - Checking hydraulic fluid level and add if necessary.

Boom or bucket is working slowly
Defective hydraulic pump - Test pump flow rate and replace pump if required.
Hydraulic cylinder oil leakage - Change cylinder piston seals.
Hydraulic oil level low - Check and refill the hydraulic oil.
Defective or not adjusted hydraulic control valve - Repair or adjust properly.
Hydraulic pressure has dropped - Set pressure correctly.

Jerky operation of the bucket or boom
Air in the hydraulic system - Bleed air from hydraulic system.
Dirty hydraulic oil filter element - Service or replace the hydraulic filter.
Hydraulic fluid is dirty - Hydraulic fluid change required.
Cylinder rod or tube is scuffed - Change damaged component.

Hydraulic pump makes excessive noise
Low oil level or hydraulic leaks - Repair hydraulic leaks or add oil as required.
Clogged hydraulic filter - Replace or clean the filter.
Clogged suction line - Need to clean the suction line.
Pump is sucking air - Bleed air.
Worn pump components - Install new hydraulic pump or rebuild it.

Electrical Troubleshooting

Battery will not charge
Loose or corroded wire connections - Service or tighten cable connections.
Faulty battery terminal clamps - Change terminal clamps.
Worn-out battery - Battery change required.
Damaged or loose belt - Install a new belt or adjust belt tension.

Starter turns slowly
Low battery power - Battery is drained, charge it.
Battery will not hold charge - Service charging system or replace battery.
Battery cables are disconnected or terminals are faulty - Check wiring and clean or replace terminals.

Starter will not crank
Battery is low or faulty - Charge or replace the battery.
Wiring is incorrectly connected or disconnected - Inspect wiring and connect correctly.
Low battery power - Low battery charging, charge as required.
Starter motor is damaged - Repair or replace starter.

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WHEEL LOADERS SPECIFICATIONS

Wheel Loaders, Skid Steers, and Compact Track Loaders