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

Case 821G XR Troubleshooting

The Case 821G XR wheel loader driveline system components: FPT F4H FE613S six-cylinder turbocharged diesel engine with a rated power of 178 hp (133 kW), and 4-speed transmission with a torque converter. The hydraulic system has 2 pumps with a rated capacity of 31.6 gal/min (120 l/min) each. The system relief pressure is 3450 psi (238 bar). The Case 821G XR is equipped with a power steering system, hydraulic wet disc brakes, and 23.5R25 tires. The wheel loader has a max lift height to hinge pin of 179.6" (4560 mm) and breakout force of 41300 lbs (18735 kg). The rated operating capacity is 13415 lbs (6085 kg), and tipping load is 26830 lbs (12170 kg).

Engine Troubleshooting

Engine starts up hard or will not start
Air trapped in fuel system - Bleed air.
Fuel filter plugged - Filter maintenance required.
Burnt or clogged injection nozzle - Install a new kit of correctly balanced nozzles.
Water in the fuel system - Change fuel and repair fuel system.
Valve clearance is out of adjustment - Correct valve clearance.
Fuel injection pump is not operating properly - Rebuild or install a new injection pump.

Diesel starts but then stops
Air filter is plugged - Service or replace the air filter.
Fuel filter plugged - Clean or replace the filter.
Fuel injection pump has loose connections - Tighten the connections.
Dirty or defective injectors - Replace or clean fuel injectors.
Fuel injection pump is damaged - Replace or rebuild injection pump.

Engine stalls during operation
Engine not warmed up - Normalize the temperature by warming up the engine.
Fuel filter element clogging - Change the filter element.
There is air in the fuel system - Bleed the system.
Dirty or faulty injection nozzles - Test injection nozzles and change if necessary.
Improper setting of fuel injection pump timing - Check the fuel injection pump timing adjustment.

Engine stops at low idle speed
Low idle speed adjustment is incorrect - Adjustment required.
Fuel injection pump is faulty - Replace or repair injection pump.
Defective fuel injectors - Change or clean fuel injectors.
Excessive valve clearance - Correct valve clearance needs to be set.

Loss of engine power
Air filter is clogged - Service or replace the air filter.
Faulty fuel injection nozzles - Service or change injection nozzles.
Insufficient fuel injection pressure - Correct the pressure settings.
Excessive valve clearance - Need to adjust valve clearance.
Too low idle RPM - Correct low idle settings.
Restricted fuel lines or hoses - Service fuel lines and hoses.
Cylinder-head gasket is leaking - Replace the gasket as required.
Piston rings are worn or damaged - Replace the piston rings as required.

Engine overheated
Coolant level is low - Top up coolant fluid and check system for leaks.
Engine oil insufficient - Fill up the engine oil.
Dirty radiator fins or defective radiator cap - Replace cap or clean radiator.
Excessive wear of the fan belt - Change the fan belt.
Engine overload - Load reducing required.

Oil pressure is low
Engine oil level low - Fill the crankcase with oil.
Oil filter element clogging - Clean or replace engine oil filter element.
Oil grade or viscosity is incorrect - Use correct viscosity oil.
Crankshaft bearing oil clearance is incorrect - Change bearings.
Oil pump is damaged - Inspect and change as required.

Abnormal engine noise or knocking
Engine oil level low - Fill up the oil to required level.
Engine is not warmed up to required temperature - Warm up the engine.
Timing of fuel injection pump is incorrect - Adjust as recommended.
Low idle speed setting is incorrect - Correct low idle adjustment.
Dirty or defective injectors - Replace or clean fuel injectors.
Connecting rod is misaligned or defective - Align or replace connecting rod.
Worn or scored pistons - Pistons replacement required.

Transmission Troubleshooting

Low transmission fluid pressure
Insufficient transmission oil - Need to add transmission oil.
Clogged transmission oil filter element (if fitted) - Clean or replace the transmission filter.
Relief valve is damaged - Install a new relief valve.

Transmission is excessively noisy
Transmission fluid level is low - Fill the transmission housing to proper fluid level.
Transmission fluid is dirty - Transmission fluid change required.
Incorrect backlash or gears are worn - Change the gears or set backlash properly.
Worn or cracked bearings - Bearings replacement required.
Shift forks are worn or bent - Change the shift forks.
Worn or stuck shaft splines - Shaft need to be replaced.

Hard shifting
Worn or rusty gear shift linkage - Change or lubricate shift linkage.
Shift forks are bent or worn out - Replace defective shift forks.
Worn out parts of the gearshift mechanism - Replace worn parts.
Clutch is faulty or misadjusted - Replace or adjust clutch.

Transmission fluid leaks
Transmission fluid level is exceeded - Excess fluid must be drained.
Seals or gaskets are worn - Replace worn seal or gaskets.

Hydraulics Troubleshooting

Hydraulic system is overheated
Hydraulic pressure incorrectly adjusted - Adjust it correctly.
Unadjusted or defective main relief valve - Set up or change the relief valve.
Dirty hydraulic fluid - Hydraulic fluid change required.
Lack of hydraulic oil - Check oil level and add hydraulic oil as required.
Worn hydraulic oil pump - Repair or replace pump if necessary.

Boom can't lift or drop
Defective lift controls - Repair or replace.
Hydraulic pump not working - Repair or replace pump if necessary.
Damaged hydraulic control valve - Install a new hydraulic valve or repair it.
Hydraulic cylinder is faulty - Replace or repair boom cylinder.
Low hydraulic fluid level - Fill up the hydraulic fluid.

Bucket won't move
Bucket controls are faulty - Inspect and repair if necessary.
Hydraulic pump failure - Repair or change pump if required.
Faulty hydraulic control valve - Replace or repair the valve.
Bucket cylinder malfunction - Replace or repair cylinder.
Hydraulic oil level low - Check and refill the hydraulic oil.

Bucket or lift arm functions slowly
Worn hydraulic oil pump - Test the pump performance and change pump if required.
Leaking hydraulic cylinder - Correct leakage by changing the seals.
Insufficient hydraulic fluid - Fill the system to proper hydraulic fluid level.
Hydraulic control valve is not set properly or defective - Set correctly or repair.
Low hydraulic pressure - Adjust pressure as required.

Bucket or boom jerks when working
Air trapped in hydraulic system - Need to bleed air.
Hydraulic oil filter element is clogged - Replace or clean the filter.
Hydraulic oil is dirty - Hydraulic oil change required.
Cylinder rod or tube is scuffed - Replace defective component.

Hydraulic pump is excessively noisy
Hydraulic system leaking or not enough oil - Remedy hydraulic leakage or refill oil as necessary.
Hydraulic filter is dirty - Clean or replace the filter.
Dirty suction line - Need to clean the suction line.
Pump is sucking air - Remove air from hydraulics.
Faulty pump components - Rebuild or replace hydraulic pump.

Electrical Troubleshooting

Battery won’t charge
Wiring connections are loose or corroded - Tighten or service connections.
Faulty battery terminal clamps - Change terminal clamps.
Faulty cell in battery - Battery replacement required.
Loose or defective belt - Need to adjust belt tension or replace belt.

Starter motor turns slow
Low battery power - Battery needs to be recharged.
Battery is draining quickly - Service battery or change it.
Disconnected wiring or bad battery terminals - Check wiring and clean or replace terminals.

Starter motor won't turn
Battery is low or faulty - Recharge or change battery.
Wiring is incorrectly connected or disconnected - Inspect wiring and connect correctly.
Battery capacity is low - Recharge the battery.
Starter motor is damaged - Starter needs to be changed.

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WHEEL LOADERS SPECIFICATIONS

Wheel Loaders, Skid Steers, and Compact Track Loaders