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Home / Wheel Loaders / Case Wheel Loaders / Case 821G

Case 821G Troubleshooting

The Case 821G wheel loader is powered by 411 cu.in (6.7L) FPT F4H FE613S six-cylinder turbocharged liquid-cooled diesel engine with a rated power of 178 hp (133 kW) at 2000 rpm. The Case 821G is equipped with a 4-speed autoshift transmission, power steering system, hydraulic wet disc brakes, and 23.5R25 standard tires. The closed center hydraulic system has two piston pumps with fluid flow rate of 31.6 gpm (120 lpm) and 31.6 gpm (120 lpm). The wheel loader has a rated operating capacity of 16790 lbs (7615 kg) and tipping load of 33580 lbs (15230 kg). The max lift height is 162.2 inches (4120 mm) to hinge pin, and breakout force is 40610 lbs (18420 kg).

Engine Troubleshooting

Engine starts hard or won't start
Air in the fuel system - Air bleeding.
Clogged fuel filter - Service or replace the filter.
Fuel injection nozzles are faulty or clogged - If necessary, replace with a new nozzle.
Dirt or water in fuel system - Drain water or flush dirt from the system.
Incorrect valve clearance - Adjust valve clearance.
Fuel injection pump damage - Repair or replace injection pump.

Engine starts but then stalls
Dirty air cleaner - Clean or change cleaner.
Clogged fuel filter - Install new filter element.
Poor fuel injection pump tightness - Look for any leaks of fuel pump, tighten it fast.
Damaged or clogged injectors - Change or clean fuel injectors.
Faulty fuel injection pump - Change or repair the pump.

Engine shuts off suddenly during operation
Low coolant temperature - Warm up to required temperature.
Fuel filter plugging - Replace filter element.
Air in fuel system - Bleed fuel system.
Fuel injection nozzles are clogged or faulty - Check injection nozzles and replace if required.
Fuel injection pump timing is not adjusted - Adjust the pump as required.

Engine stops while idling
Incorrectly adjusted low idle speed - Adjust low idle speed.
Fuel injection pump is faulty - Rebuild or install a new injection pump.
Defective fuel injectors - Replace or clean fuel injectors.
The valve clearance is incorrect - Adjust to proper valve clearance.

Engine power is too low
Dirty air filter - Change or service air filter element.
Dirty or damaged injection nozzles - Install a new kit of correctly balanced nozzles.
Improper fuel injection pressure - Check the fuel injection pressure and adjust if necessary.
Valve clearance is not correct - Adjust valve clearance according to specifications.
Incorrectly adjusted low idle speed - Adjust the low idle speed.
Dirty fuel lines or hoses - Clean fuel lines and hoses.
Blown cylinder head gasket - Install a new gasket.
Piston rings are leaking or defective - Change piston rings.

Engine overheated
Lack of coolant in cooling system - The cooling system needs to be refilled and checked for faults.
Not enough engine oil - Fill the crankcase with engine oil.
Defective radiator cap or clogged radiator core - Install new cap or clean radiator.
Broken or loose fan belt - Replace the fan belt.
Engine overloaded - Reduce load on the engine.

Insufficient oil pressure
Low crankcase oil level - Fill up the engine oil.
Clogged oil filter element - Replace or service engine oil filter.
Improper type of engine oil - Drain and refill with oil of correct grade and viscosity.
Crankshaft bearing oil clearance is excessive - Install new bearings.
Oil pump is worn or damaged - Repair or change.

Abnormal engine noise or knocking
Engine oil level is insufficient - Fill the crankcase with engine oil.
Engine is not warmed up to required temperature - Warm up the engine.
Fuel injection pump timing is not adjusted - Set up as recommended.
Wrong adjustment of low idle speed - Adjustment required.
Fuel injector fault - Inspect fuel injectors and change as required.
Connecting rod is defective or not aligned - Align or replace connecting rod.
Piston wear or scoring - Install new pistons.

Transmission Troubleshooting

Low transmission oil pressure
Insufficient transmission fluid - Need to add transmission fluid.
Transmission fluid filter is clogged (if fitted) - Service or change transmission fluid filter.
Stuck relief valve - Replace relief valve.

Transmission noise
Transmission oil insufficient - Fill the transmission housing with oil.
Transmission fluid is contaminated - Fill up with fresh transmission fluid.
Backlash is incorrect or gears are damaged - Replace defective gears or set backlash properly.
Worn or cracked bearings - Bearings replacement required.
Shift forks are bent or worn out - Replace the shift forks.
Damaged or worn shaft splines - Replace the shaft.

Hard shifts
Gear shift linkage is worn or rusty - Lubricate or replace the shift linkage.
Worn or bent shift forks - Change the shift forks.
Worn out parts of the gearshift mechanism - Replace worn parts.
Worn or improperly adjusted clutch - Adjust or install new clutch.

Transmission fluid leakage
Transmission oil level is exceeded - Correct the oil volume.
Damaged gaskets or seals - Gaskets or seal replacement required.

Hydraulics Troubleshooting

Hydraulic system overheated
Hydraulic pressure is not adjusted correctly - Adjust pressure correctly.
Defective or misadjusted main relief valve - Adjust relief valve or change if required.
Hydraulic fluid is dirty - Change hydraulic fluid.
Hydraulic fluid level is insufficient - Need to add fluid.
Hydraulic pump is defective - Change or repair hydraulic pump if required.

Lift arm cannot be raised or lowered
Lift controls are damaged - Change or repair.
Hydraulic pump failure - Replace or repair pump if necessary.
Hydraulic control valve is faulty - Replace or repair the valve.
Hydraulic cylinder not working - Replace or repair boom cylinder.
Hydraulic fluid level low - Add fluid as required.

Bucket can't tilt
Defective bucket controls - Inspect and repair if necessary.
Defective hydraulic pump - Replace or repair pump if necessary.
Hydraulic control valve is defective - Repair or change hydraulic valve.
Bucket cylinder malfunction - Repair or install a new cylinder.
Low hydraulic fluid level - Checking hydraulic fluid level and add if necessary.

Boom or bucket runs slowly
Faulty hydraulic oil pump - Check pump flow and install new pump if necessary.
Hydraulic cylinder oil leakage - Repair leak by replacing the seals.
Hydraulic oil is insufficient - Need to add oil.
Hydraulic control valve is faulty or out of adjustment - Adjust properly or repair.
Low hydraulic pressure - Set pressure correctly.

Bucket or boom is moving jerkily
Hydraulic system is leaking air - Bleed hydraulic system.
Hydraulic oil filter element clogging - Clean or install new filter.
Dirty hydraulic oil - Change hydraulic oil.
Scratched cylinder rod or tube - Change defective component.

Hydraulic pump is excessively noisy
Hydraulic leaks or low oil level - Remedy hydraulic leakage or refill oil as necessary.
Dirty hydraulic filter - Clean or install new filter.
Plugged suction line - Clean suction line as required.
Air trapped in hydraulic pump - Bleed air from hydraulics.
Faulty pump parts - Rebuild or install new pump.

Electrical Troubleshooting

Battery cannot be charged
Electrical cable connections are loose or corroded - Tighten or clean electrical wiring connections.
Faulty electrical terminal connectors - Terminal connectors should be replaced.
Defective battery - Use a new battery.
Belt is loose or defective - Change belt or adjust belt tension.

Starter cranks slow
Low battery output - Charge the battery.
Battery discharges quickly - Service or replace the battery.
Terminals are faulty or battery cables are disconnected - Check wiring connections and replace or clean terminals.

Starter doesn't crank
Battery is discharged or defective - Battery needs to be recharged or replaced.
Disconnected or incorrectly connected wires - Inspect battery wires and connect correctly.
Low battery output voltage - Battery is drained, charge it.
Defective starter motor - Starter needs to be changed.

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WHEEL LOADERS SPECIFICATIONS

Wheel Loaders, Skid Steers, and Compact Track Loaders