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Case 621 Loader History and Transmission Design
The Case 621 wheel loader was introduced in the early 1990s as part of Case Corporation’s push into mid-size, high-performance loaders for construction and municipal use. Powered by a turbocharged diesel engine and equipped with a powershift transmission, the 621 offered four forward and three reverse speeds, with electronic solenoid control and torque converter drive. Case, founded in 1842, had by then become a global leader in construction machinery, and the 621 series became a staple in North American fleets. Later variants like the 621B and 621C introduced refinements in hydraulic flow, cab ergonomics, and transmission logic.
Transmission Symptoms and Gear Loss
A common issue reported with the 621B is the loss of first and second gear in both forward and reverse, while third and fourth gears remain functional. This behavior suggests a failure in the solenoid valve control system, which governs gear selection via electrical signals and hydraulic actuation.
The transmission uses five solenoids mounted on the valve body, each responsible for engaging specific clutch packs. When gears 1 and 2 fail to engage, it typically indicates that solenoids M1 and M3 are not receiving power or are malfunctioning. In forward gear, M3 is critical; in reverse, M1 is essential. If both are inactive, the loader defaults to higher gears, bypassing the failed clutch packs.
Electrical Diagnostics and Lever Assembly Testing
Technicians often begin by checking voltage at the solenoid terminals. If power is absent at M1 and M3 during gear selection, the fault may lie in the forward/reverse lever assembly, wiring harness, or transmission control module. In one case, replacing the lever assembly did not resolve the issue, suggesting that the problem was downstream—either in the wiring or the control logic.
Recommended steps include:
If electrical signals are confirmed but gears still fail to engage, the issue may be hydraulic. The transmission relies on charge pressure to activate clutch packs. A drop in pressure due to a worn pump, clogged filter, or internal leakage can prevent gear engagement.
Charge pressure should be approximately 17.5 bar (250 psi) at operating temperature. If pressure is low, technicians should:
Preventive Maintenance and Operator Tips
To avoid transmission faults and extend service life:
Conclusion
The Case 621 transmission relies on a precise balance of electrical control and hydraulic pressure. Loss of first and second gear often points to solenoid or wiring faults, but hydraulic issues must also be considered. With methodical diagnostics and proper maintenance, the transmission can be restored to full functionality. The 621 remains a durable and capable machine, and understanding its transmission logic is key to keeping it productive.
The Case 621 wheel loader was introduced in the early 1990s as part of Case Corporation’s push into mid-size, high-performance loaders for construction and municipal use. Powered by a turbocharged diesel engine and equipped with a powershift transmission, the 621 offered four forward and three reverse speeds, with electronic solenoid control and torque converter drive. Case, founded in 1842, had by then become a global leader in construction machinery, and the 621 series became a staple in North American fleets. Later variants like the 621B and 621C introduced refinements in hydraulic flow, cab ergonomics, and transmission logic.
Transmission Symptoms and Gear Loss
A common issue reported with the 621B is the loss of first and second gear in both forward and reverse, while third and fourth gears remain functional. This behavior suggests a failure in the solenoid valve control system, which governs gear selection via electrical signals and hydraulic actuation.
The transmission uses five solenoids mounted on the valve body, each responsible for engaging specific clutch packs. When gears 1 and 2 fail to engage, it typically indicates that solenoids M1 and M3 are not receiving power or are malfunctioning. In forward gear, M3 is critical; in reverse, M1 is essential. If both are inactive, the loader defaults to higher gears, bypassing the failed clutch packs.
Electrical Diagnostics and Lever Assembly Testing
Technicians often begin by checking voltage at the solenoid terminals. If power is absent at M1 and M3 during gear selection, the fault may lie in the forward/reverse lever assembly, wiring harness, or transmission control module. In one case, replacing the lever assembly did not resolve the issue, suggesting that the problem was downstream—either in the wiring or the control logic.
Recommended steps include:
- Verifying 12V power supply to the solenoid harness
- Testing continuity from the lever switch to the solenoid terminals
- Inspecting ground connections and fuse integrity
- Using a breakout box or diagnostic tool to simulate gear commands
If electrical signals are confirmed but gears still fail to engage, the issue may be hydraulic. The transmission relies on charge pressure to activate clutch packs. A drop in pressure due to a worn pump, clogged filter, or internal leakage can prevent gear engagement.
Charge pressure should be approximately 17.5 bar (250 psi) at operating temperature. If pressure is low, technicians should:
- Replace the transmission filter and inspect for metal debris
- Check suction lines for air leaks
- Test the pump output and relief valve settings
- Inspect clutch pack seals and piston wear
Preventive Maintenance and Operator Tips
To avoid transmission faults and extend service life:
- Change transmission fluid and filters every 1,000 hours
- Use OEM-grade solenoids and connectors during repairs
- Avoid aggressive gear changes under load
- Monitor gear engagement behavior during cold starts
- Keep diagnostic records for each service interval
Conclusion
The Case 621 transmission relies on a precise balance of electrical control and hydraulic pressure. Loss of first and second gear often points to solenoid or wiring faults, but hydraulic issues must also be considered. With methodical diagnostics and proper maintenance, the transmission can be restored to full functionality. The 621 remains a durable and capable machine, and understanding its transmission logic is key to keeping it productive.
