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Home / Wheel Loaders / Case Wheel Loaders / Case 921G

Case 921G Troubleshooting

The Case 921G wheel loader is powered by 410 cu.in (6.7L) FPT F4H FE613R 6-cylinder turbocharged diesel engine with a rated power of 224 hp (167 kW) at 2000 rpm. The Case 921G is equipped with a 4x3 autoshift transmission, power steering system, hydraulic wet disc brakes, and 23.5R25 standard tires. The hydraulic system has pumps with fluid flow rate of 42.6 gpm (162 lpm) and 31.6 gpm (120 lpm). The hydraulic pressure is 3625 psi (250 bar). The wheel loader has a rated operating capacity of 18960 lbs (8600 kg) and tipping load of 37920 lbs (17200 kg). The max lift height is 162.4" (4125 mm) to hinge pin, and breakout force is 37688 lbs (17095 kg).

Engine Troubleshooting

Engine hard to start or will not start
Air in the fuel pipes - Bleed the fuel pipes.
Dirty fuel filter - Service the filter.
Burnt or defective injection nozzle - Clean or replace injection nozzles.
Dirt or water in fuel system - Drain water or flush dirt from the system.
Valve clearance is out of adjustment - Adjust valve clearance.
Fuel injection pump is not operating properly - Replacement or repair required.

Diesel starts and stalls immediately
Air filter is clogged - Service or replace the air filter.
Fuel filter plugged - Change the filter element.
Fuel injection pump has loose connections - Tighten the connections.
Damaged or clogged injectors - Clean fuel injectors or change it.
Fuel injection pump failure - Repair or change injection pump.

Engine shuts off while running
Engine is not fully warmed up - Warm up the engine.
Fuel filter plugging - Replace filter element.
Air trapped in fuel system - Bleed air.
Dirty or faulty injection nozzles - Check injection nozzles and replace if required.
Timing of fuel injection pump is incorrect - Adjust as recommended.

Engine stalls at low idle speed
Low idle speed adjustment is incorrect - Correct low idle adjustment.
Defective fuel injection pump - Repair or install new pump.
Fuel injectors are dirty or defective - Replace fuel injectors.
Valve out of adjustment - Adjust valve clearance.

Engine power is too low
Plugged air filter - Clean or replace element.
Defective or clogged injection nozzle - Clean or replace injection nozzles.
Fuel injection pressure is wrong - Adjust to correct pressure.
The valve clearance is incorrect - Adjust valve clearance.
Wrong adjustment of low idle speed - Correct the settings.
Dirt in the fuel lines or hoses - Clean fuel system lines and hoses.
Cylinder head gasket defective - Replace cylinder head gasket.
Defective or worn piston rings - Piston rings replacement required.

Engine overheating
Low coolant level - Add coolant fluid and inspect the cooling system for leaks.
Not enough engine oil - Fill the crankcase with engine oil.
Radiator core is dirty or radiator cap is damaged - Clean radiator or install new cap.
Excessive wear of the fan belt - Fan belt must be replaced.
Diesel engine is overloaded - Reduce engine load.

Oil pressure is insufficient
Low crankcase oil level - Check oil level and add oil as required.
Clogged oil filter element - Clean or change engine oil filter.
Improper type of engine oil - Drain crankcase and refill with correct oil.
Incorrect oil clearance in main bearing - Change bearings.
Oil pump failure - Repair or replace.

Engine noises or knocks
Lack of engine oil - Checking oil level and add if necessary.
Engine is not preheated - Warm up to required temperature.
Timing of fuel injection pump is incorrect - Check the fuel injection pump timing adjustment.
Low idle speed setting is not correct - Correct low idle adjustment.
Fuel injector fault - Clean fuel injectors or change it.
Connecting rod failure or misalignment - Replace or align connecting rod.
Worn or broken pistons - Install new pistons.

Transmission Troubleshooting

Insufficient transmission fluid pressure
Lack of transmission fluid - Add fluid to the transmission housing.
Plugged transmission oil filter (if equipped) - Service or change transmission oil filter.
Relief valve is stuck - Replace the valve.

Transmission makes noise
Low fluid level - Check and refill the transmission fluid.
Transmission oil is contaminated - Fill up with fresh transmission oil.
Worn gears or incorrect backlash - Adjust backlash correctly or replace the gears.
Worn or damaged bearings - Faulty bearings should be replaced.
Shift forks are bent or worn out - Shift forks need to be replaced.
Worn or stuck shaft splines - Replace defective shaft.

Difficulty shifting gears
Worn or rusty gear shift linkage - Lubricate or replace the shift linkage.
Damaged or worn gear shift forks - Change defective shift forks.
Worn parts of the gear shifting mechanism - Change worn parts.
Malfunction or incorrect clutch adjustment - Clutch needs to be adjusted or changed.

Transmission fluid leaking
Too much oil in transmission - Drain the excess oil.
Worn seals or gaskets - Install new components.

Hydraulics Troubleshooting

Hydraulic system has overheating
Hydraulic pressure incorrectly adjusted - Set pressure correctly.
Faulty or improperly adjusted main relief valve - Adjust or replace the relief valve.
Hydraulic oil is dirty - Change hydraulic oil.
Not enough hydraulic fluid in the system - Fill the hydraulic system with oil.
Worn hydraulic oil pump - Repair or replace pump if necessary.

Lift arm cannot be raised or lowered
Lift controls are defective - Repair or replace.
Damaged hydraulic oil pump - Repair or change pump if required.
Faulty hydraulic control valve - Repair or replace hydraulic valve.
Hydraulic cylinder is broken - Repair or change hydraulic cylinder.
Hydraulic fluid level low - Add fluid as required.

Bucket tilt does not work
Faulty bucket tilt controls - Repair or change.
Damaged hydraulic oil pump - Change or repair hydraulic pump if required.
Hydraulic control valve failure - Repair or change hydraulic valve.
Bucket cylinder malfunction - Replace or repair cylinder.
Low hydraulic oil level - Fill the system to proper hydraulic oil level.

Bucket or lift arm is moving slowly
Hydraulic pump is worn - Check the pump capacity and replace pump if required.
Hydraulic cylinder oil leakage - Replace cylinder piston seals.
Insufficient hydraulic oil - Checking hydraulic oil level and add if necessary.
Hydraulic control valve is unadjusted or worn - Repair or set properly.
Hydraulic pressure has dropped - Adjust pressure as required.

Jerky operation of the bucket or boom
Air trapped in hydraulic system - Bleed air from hydraulic system.
Clogged hydraulic oil filter element - Clean or install new filter.
Hydraulic oil is dirty - Change hydraulic oil.
Scratched cylinder rod or tube - Change failed component.

Hydraulic pump is excessively noisy
Hydraulic leaks or low oil level - Add hydraulic oil or correct system leaks.
Hydraulic filter is clogged - Replace or clean the filter.
Suction line is clogged - Suction line needs to be cleaned.
Air enters the pump - Air bleeding is required.
Damaged pump components - Change or rebuild pump.

Electrical Troubleshooting

Battery will not charge
Corroded or loose electrical wire connections - Service or tighten cable connections.
Battery terminal connectors are faulty - Terminal connectors should be replaced.
Battery is defective - Use a new battery.
Belt is damaged or loose - Adjust belt tension or change the belt.

Starter cranks slowly
Battery voltage is low - Charge the battery.
Battery will not hold charge - Service charging system or install new battery.
Battery cables are disconnected or terminals are faulty - Check cable connections and replace or service terminals.

Starter does not work
Battery is drained or defective - Recharge or replace battery.
Disconnected or incorrectly connected wires - Inspect battery wires and connect correctly.
Low battery voltage - Battery needs to be recharged.
Faulty starter motor - Starter should be replaced.

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