Service & Parts

Agriculture Equipment

Service & Parts | Maintenance |

1

The engine doesn't start up or has start-up difficulty.

Phenomenon of Manifestation

When starting up with the starting switch, the starter has no response or only sounds the actuation, and the engine does not work.
Diagnosis

1、The safety starting switch is damaged or unconnected;;
2、the starting switch and the starting relay are damaged;
3、the fuse is broken after burning;
4、the circuit connection is not well;
5、the storage battery has no electricity;
6、the starter is damaged.
Troubleshooting
1、Use the screw driver to short circuit the linking pillar of the storage batter and the linking pillar of the electromagnetic switch. If the starter works well, it means the starter and its power part are normal. The Malfunctionals are always caused by starting switch, the safe starting switch, the starting relay, burnout of fuse or bad connection of the circuit;
2、If the starter does not rotate after short circuit, open the head lamp to see the lightness of the light. If the lightness is high, it means the started is damaged; if the lightness is low, check whether the connection between the storage battery and the starter is well and whether the storage battery has any electricity.

Phenomenon of Manifestation

When starting up, the starter is running and weak , with low rotation speed or just runs half a circle.
Diagnosis

1、he storage battery has insufficient electricity or the connection of the power circuit is not well;
2、The coil inside the starter shorts out or the connections of the carbon brush are not well;
3、the load is not immediately unloaded when starting up, namely the power output device and the handle of the transmission are not at the neutral position.
Troubleshooting
1、Turn on the head lamp to observe the lightness. If the lightness is high, it means the starter is damaged; if the lightness is low, check whether the connection between the storage battery and the starter is well and whether the storage battery has any electricity;
2、Before starting up, check whether the gearshift of the gearbox and power output device is at neutral position.

Phenomenon of Manifestation

starter can drive the diesel engine, but the diesel engine has no sign to run.
Diagnosis

Loosen the deflated plug of the oil injection pump and press the manual pump of the oil transfer pump. If there is no fuel flowing out from the deflated plug, it means there is no fuel entering the oil injection pump. If there is some foam diesel flowing out from the deflated plug, it means the fuel enters the oil injection pump with air and the air cannot be exhausted resulted from pressing the manual oil pump for a longtime:
1、there is no oil or insufficient oil inside the tank;
2、the tank switch is not turned on or the air hole on the tank cap is jammed;
3、the upper oil pipe inside the tank is jammed or broken from the upper side (with upper oil-taking tank );
4、the oil pipe between the tank and the oil transfer pump is jammed;
5、the element of the diesel filter is jammed;
6、the filtering net of the oil transfer pump is jammed;
7、he oil valve of the oil transfer pump is viscous , the piston is damaged or the rubber ring is ineffective;
8、the oil pipe between the oil tank and the oil transfer pump has cracks or the joint is loosened.
Troubleshooting
1、the tank is enough or not. Check whether the tank switch is opened and whether the vent valve of the fuel tank cap is smooth or not;
2、Check whether the oil pipe between the tank and the oil transfer pump has any crack or leakage;
3、Manual pump oil: ·If there is no oil pressure or suction during the oil pumping, the fault is from the damage of the manual pump oil device and it shall be replaced. ·If there is obvious oil pressure but with no oil overflow during the oil pumping, the fault is from the serious jamming between the inlet joint of oil transfer pump and the tank. · If there is obvious oil pressure but with air overflow or with some oil foam during the oil pumping, the fault is from the insufficient oil storage cups inside the tank or the serious leakage of the oil pipe.
4、Remove the inlet joint of the oil transfer pump, turn off the tank switch and blow into the tank. Put soup-suds on each oil pipe jiont. If there is bubble, it means the oil pipe joint leaks;
5、Check the oil suction capacity and oil supply pressure, oil supply capacity and sealing of the oil transfer pump. Replace the oil transfer pump if its performance is not good;
6、As for the type with the electric oil transfer pump, check the oil pumping capacity of the oil transfer pump. Remove the inlet joint of the fuel filter and connect to the fuel pressure gauge. Get connected to the starting switch to make the oil transfer pump work. Check the outlet oil pressure (more than 21kPa) and the confining pressure (40~50kPa) of the oil pump. If the pressure is too low or there is no pressure, the oil transfer pump shall be replaced.

Phenomenon of Malfunction
When starting up, the starter can drive the engine to run normally, but not to fire. There is white smoke from the exhaust pipe.
Judgment of Malfunction
1、The pressure of the cylinder compression is too low;
2、the cold start device does not work or the starting temperature of the engine is too low;
3、the fuel has too much moisture or the cooling liquid enters the cylinder;or
4、the oil injection time is too late.
Troubleshooting
1、Open the cover of the radiator, start up the engine and observe whether a lot of bubbles coming from the upper side of the radiator. If yes, it means the gasket of the cylinder is damaged or the cylinder body or cover has cracks. The high-pressure air comes into the cooling liquid when compressing or running and the bubbles come out. Meanwhile the cooling liquid enters the cylinder to form the white smoke;
2、If there is no bubble coming out, loosen the joint of the low-pressure oil pipe and use little tray to collect the oil. Make the oil pumping by hand. Check whether the released fuel has any water. If there is droplet, it means there is water inside the fuel tank. Emit the water and impurities inside the tank from the releasing plug at the bottom of the fuel tank and replace the element of the diesel filter;
3、Check the running of the low-temperature start-up preheating device. If it does not work, overhaul or replace with new ones;
4、Stamp on the accelerator pedal when starting the engine, the engine can successfully starts up. The fault is caused by the insufficient starting oil or too low idling adjustment. Make adjustment on the oil injection pump;
5、Bring forward the oil injection time and then start up the engine. If it is started up and the exhausting smoke has normal color, it means the oil injection time is too late and it should be adjusted. If there is still a lot of white smoke after starting up and more white smoke when accelerating, check whether the outlet pressure of the oil injection pump is too low, the atomization of the oil injection is not good or the pressure of the cylinder is too low;
6、If the pressure of the cylinder pressure is not enough, check whether the supercharger is working normally, the supercharger shaft is stagnated, the air valve clearance is too small or big, etc. Make adjustment or overhaul if necessary.

2

The idling speed of the engine is unstable.

Phenomenon of Malfunction
Whether in the cold or heat conditions, the idling speed of the diesel engine is not stable. The body shakes seriously with the speed sometimes high and sometimes low, and even cannot maintain the normal operation and turn off.
Judgment of Malfunction
1、The idling speed is too low;
2、There is air in the fuel system;
3、The oil injection pump is not working properly;
4、The oil injection is not at the right time;
5、The oil injector is clogged or not working properly;
6、The engine support pads loose or broken.
Troubleshooting
1、Start the engine and observe the tachometer. If the speed value indicated is low and accompanied by the shake of the body, check whether the idle speed limit screw is loose and disordered. If not, add a litter fuel to raise the speed of the engine to the specified idle speed. If the engine can operate stably and evenly without any shake, it indicates that the failure is the improper adjustment of the idle speed.
2、When the engine is idling, observe whether the high-pressure pipe connection has leakage. If it leaks, the cylinder is of poor operation, which causes the unstable idle speed. Then the high-pressure pipe shall be repaired or replaced.
3、When the engine is idling, loosen the air release screw to observe the oil outlet situation. If there are a lot of bubbles emitting from the air release screw hole, it indicates that there is air in the fuel. Check whether there is leakage at all the connections between the fuel pump and the fuel tank and exclude it if it leaks.
4、If the idle speed is still unstable, respectively touch the high-pressure pipe of each cylinder when it idles by hand and feel the strength of the oil injection pulse of each cylinder. If certain cylinder fuel injection pulse is weak, further cut off the fuel artificially for the cylinder. If the speed of the engine does not have much change when it is cut off, it indicates that the cylinder is of poor operation and the injector of the cylinder shall be removed for examination.
5、When it is in urgent acceleration, if the engine has an obvious metal percussion, it indicates that the injection may be too early. If the engine speed increases slowly after retardation, it indicates that the injection is too late. If the injection is not in the right time, it shall be re-adjusted.
6、If the above tests are normal, detect the cylinder pressure of the engine. The cylinder pressure difference shall not be exceed the specified value.
3

The oil pressure of the engine is too low.

Phenomenon of Malfunction
1、When the clutch petal is loosened at starting, tractor cannot be started or difficult to start;
2、When tractor is accelerated during moving, engine speeds up but the tractor does not speed up simultaneously and cannot move quickly;
3、Clutch slips obviously when tractor works under heavy load, one can smell the burning of clutch friction disc in severe case;
4、Clutch is overheating and its color is changed;
5、Fuel consumption of engine is increased.
Judgment of Malfunction
1、The type of oil is used improperly; the oil viscosity is too low; the oil is not changed according to the seasonal provisions. The oil is too dilute or the oil-replacement period is too long.
2、The oil goes bad and is deterirated (mixed with water or fuel).
3、The oil temperature is too high.
4、The amount of oil does not reach the specified capacity. The oil viscosity is small. The gasoline or cooling water enters the oil sump.
5、The oil set filter and the oil filter are clogged.The pressure limiting valve adjusting spring tension is too low or the spring is borken; the bypass valve is not sealed, or its spring is broken or the stretch adjustment is too small.
6、The oil pump does a bad job with serious wear, resulting in the deterioration of the oil injection performance of the oil pump.
7、The oil pump pressure limiting valve is not firmly closed or the pressure limiting valve spring is damaged.
8、The clearance of the engine crankshaft bearings and the connecting rod bearing is too big or the camshaft bearing clearance is too large. The oil line and pipe have serious leaks.
9、The oil pressure gauge is wrong. Such as the oil pressure gauge, sensor, oil pressure switch, oil pressure warning light and oil pressure alarm fail, etc.
Troubleshooting
1、With the dipstick, check whether the oil surface height is appropriate. Park the vehicles on the level ground, pull out the dipstick, check the lube oil level. If the oil level is low, add enough lubricant.
2、Observe the color of the lubricant on the dipstick. If it turns white, it indicates that the lubricant is penetrated with water and goes bad. The decrease of the viscosity causes that the oil pressure is too low and it shall be replaced.
3、Remove the oil pressure sensor and install the oil pressure test gauge. If the oil pressure reaches the specified value but the oil pressure indicated in the oil pressure gauge is too low (or the oil warning light cannot be turned off), it indicates that the oil pressure sensor or the oil pressure gauge fails. Replace a new oil pressure sensor, start the engine for idling. If the oil pressure gauge is normal (or the oil warning light is off), the oil pressure sensor fails. If the failure phenomenon remains the same, it indicates that the oil pressure gauge fails.
4、If the oil pressure indicated in the oil pressure gauge are lower than the specified values when at idle and 2000r/min, install the test gauge on the oil pressure sensor of the main oil passage of the cylinder. Start the engine, test the oil pressure. If the pressure is still lower than the specified value, it indicates that there is the blockage between the filter and the main oil passage or the pressure limiting valve fails. If the pressure does not have much change and is lower, remove the pressure limiting valve for cleaning. Install a gasket at the end of the spring and re-test the pressure. If the oil pressure is significantly increased, it indicates that the pressure limiting valve fails.
5、If it is still low after adding the gasket, remove the oil sump and check whether the set filter is blocked, whether the clearance between the crankshaft bearing and the connecting rod bearing is too large. If yes, restore it.
6、If the above examinations are normal, it indicates that the failure are due to the over wear of the oil pump.
4

Slipping of Clutch

Phenomenon of Malfunction
1、When the clutch petal is loosened at starting, tractor cannot be started or difficult to start;
2、When tractor is accelerated during moving, engine speeds up but the tractor does not speed up simultaneously and cannot move quickly;
3、Clutch slips obviously when tractor works under heavy load, one can smell the burning of clutch friction disc in severe case;
4、Clutch is overheating and its color is changed;
5、Fuel consumption of engine is increased.
Judgment of Malfunction
1、Clutch pedal has no free travel or too little free travel and release lever is adjusted inappropriately, which makes pressure plate in a semi-detached state;
2、Pressure spring or disc spring is too soft or broken;
3、Friction disc is worn too thin with hardening surface and exposed rivet or is stained with greasy dirt;
4、Flywheel or pressure plate is warped and deformed, and screws that connect clutch cover and flywheel are loose;
5、The pressure plate of clutch is worn too thin or deformed;
6、Operation or usage is improper. Overload operation of tractor makes clutch slipped or over-burning; clutch is used in a semi-detached state frequently for a long time, such as when doing front loading operation, speed is slowed by stepping on the clutch to make it slip during operation.
Troubleshooting
1、When starting engine, tightening parking brake, using low gear, loosening clutch pedal slowly and stepping down accelerator pedal, if tractor does not move and engine dose not die, that is clutch slipping;
2、When running tractor is accelerated, the engine speed increases but the tractor does not move faster, that is clutch slipping;
3、The free travel of clutch pedal should be checked. It should be adjusted if it does not meet the requirements. Otherwise, the bottom cover of clutch housing should be removed, and the screws that connect clutch cover and flywheel should be checked. They should be tightened if loose. If they are not loose, the pressure plate and cover of clutch should be checked to find out if their color is changed due to high temperature. The clutch is slipped and burned if the color is changed, and should be removed and repaired. If there is grease dirt on the clutch, the clutch should be removed. And the polluted parts should be cleaned with gasoline and dried. The oil source shall be found out and removed at the same time.
4、If the slipping still occurs after the above-mentioned examinations, the clutch assembly shall be removed and the clutch friction plate be inspected. The friction plate that becomes thinned or with an exposed rivet head shall be replaced.
5、If the friction plate works well, the clutch should be disassembled and the hold-down spring (butterfly-type spring) should be inspected. If it is deformed or with poor elasticity, it should be replaced.
6、The deformation and abrasion of clutch pressure plate or engine fly wheel should be inspected. In case of a serious deformation, they shall be repaired or replaced.
5

Incompletely Separated Clutch

Phenomenon of Malfunction
1、When clutch pedal is pressed to the end, it is difficult to put into gear or cannot put into gear for gear-box and at the same time there is impact sound of gears in it.
2、When tractor is started with synchronizer and clutch pedal is pressed to the end, it is still difficult to put into gear. Although it is put into gear barely, the tractor moves forward or its engine stalls when the pedal is not loosened;
3、When the assistant clutch of dual clutch is separated, power take-off shaft still drives machine running.
Judgment of Malfunction
1、The free travel of clutch pedal is too large;
2、The inner ends of release lever are not on the same plane;
3、The limit screws of the clutch pedal travel are not adjusted properly;
4、Driven disc is warped and deformed, rivets are loose or newly replaced friction disc is too thick;
5、Driven disc is fixed reversely;
6、Flywheel or the end surface of pressure plate is bending and deformed;
7、The spline hole of driven disc or the spline tooth of gear-box’s input shaft is rusting or tightened to make driven disc move difficult;
8、The clearance between main and assistant release levers of TE, TB and TA dual clutch is too large.
Troubleshooting
1、The free travel of clutch pedal should be checked. It should be adjusted if too large;
2、If free travel meets the needs, the side cover of clutch housing should be removed and the inner ends of release lever should be checked to find out if they are on the same level. And they should be adjusted if not.
3、The clearance between limit screws of pedal travel should be checked. And it should be adjusted if it does not meet the needs;
4、The height and flexibility of disc spring should be checked and replaced if not high enough or too soft;
5、If newly replaced friction disc is too thick, it should be adjusted by adding a shim with proper thickness between clutch cover and flywheel, but various shims should have the same thickness and the inner and external diameters;
6、If it is invalid after the above mentioned checking and adjustment, clutch should be removed and driven disc should be checked to find out if it is fixed reversely, and should be reassembled if reversed;
7、Driven disc should be checked to confirm whether it moves flexibly in the input shaft spline teeth of gear box. If not, the rusting shall be removed and the spline teeth be polished. Driven disc shall be checked to confirm whether the rivet thereof is loose, bend or deformed. In case of any nonconformity with the requirements, it should be replaced;
8、If the adjustment still fails after the above-mentioned examinations, the clutch assembly should be disassembled and the hold-down spring (or butterfly-type spring), clutch pressure plate or engine fly wheel and other related parts should be inspected as well as repaired and replaced if necessary.
9、As for the dual clutch for combined operation, if only the power take-off is not properly detach, the total travel of clutch, as well as the clearance between the main and auxiliary release levers should be firstly checked. And as for the dual clutch for single operation, the free travel of control handle should be firstly checked.
6

Abnormal Sound of Gear-box

Phenomenon of Malfunction
The abnormal noise of gear-box means that there is abnormal noise in gear-box which is mainly caused by the looseness of worn bearings and unusual engaged gears. The abnormal noise roughly takes place when tractor is in neutral or put into a certain gear. If there is always abnormal noise in different gears, the bearings are usually damaged; if there is continuous and high-pitched noise in a certain gear, it is caused by the gears; if tractor is put in a certain gear and there is continuous and depressing impact noise, it is caused by broken tooth; if there is no noise when pressing clutch pedal or have noise when loosing clutch pedal during parking, it is caused by normally engaged gears. Relevant parts should be focused on and repaired according to noise characteristics.
Judgment of Malfunction
1、There is less fuel in gear-box, fuel quality is bad, the specifications of gear oil do not meet the requirements or there are impurities in it;
2、Bearings are worn to loose or damaged;
3、There is gear eccentric wear or deformation of tooth caused by the inaccuracy of gear or improper process of heat treatment, the meshing clearance of gears is too small, gears are over-worn or the meshing clearance is too large;
4、The metal on the tooth surface of gear peels, the tooth of gear is broken or gear is assembled wrongly;
5、Spline hole and spline groove are worn severely and their match is loose;
6、Input shaft or output shaft is distorted;
7、The locking block of synchronizer falls off or synchronizer hub is worn and out of round;
8、The lower end surface of gear shift lever and the groove of fork guide block are worn and cause looseness. The groove of self-locking device or steel ball is worn excessively, or self-locking spring is fatigue and broken;
9、The first or second shaft of gear-box or shifting fork is bended. The shifting fork is deformed or its fixing pin is loose.
10、The gear box is not properly installed and positioned, and its fitting or connecting part of the operating mechanism is loose.
Troubleshooting
1、If tractor drives at any speed in any gear, there is always the sound of metallic material’s dry friction in gear-box and a hot feeling is felt on the gear-box case, the oil level height of gear oil and its color should be checked. If oil level is too low or its quality is deteriorating, it should be refilled or replaced according to the requirements.
2、When engine runs on idle, if there is noise when gear-box is in neutral but the noise disappears after pressing clutch pedal, the gear box should be removed, and the rear bearing of the first shaft and normally engaged gears should be checked. Over-worn or damaged components should be repaired or replaced;
3、On the moment of pressing clutch pedal during starting or changing gear, there is strong sound of metallic material’s friction but the sound disappears when the clutch completely joints, the front bearing of gear-box’s first shaft should be checked to find out if it is worn loosely or damaged. If so, it shall be replaced immediately;
4、If there is no abnormal noise during the travel in neutral gear but the noise occurs during the start-up in any gear or during the shifting or travelling in any gear, the engagement of wheel gear or spline should be checked to confirm whether there is any abrasion, loose or damage, and whether there is any too small gap of engagement. The repair or replacement should be conducted if necessary;
5、If the gear box has any abnormal noise during its travel in neutral gear, but the noise weakens or disappears during its travel in high-speed gear, and the abnormal noise of “swoosh” occurs during the sliding in neutral gear, the loose degree of the second axle bearing of the gear box shall be checked. In case of any too serious loose or damage, it should be replaced;
6、If there is no abnormal noise during the travel in direct gear and the noise occurs in any other gears, the front and rear axle bearings on the direct gear thereof should be checked. In case of any abrasion, loose or damage, the replacement should be conducted;
7、Whether the gear box has noise during its travel in any gears, and the noise sounds louder during the speeding up, the gear box shall be disassembled. The housing, axle, wheel gear, spline and bearing thereof should be checked to see whether there is any serious abrasion or deformation. The repair or replacement should be conducted if necessary.

7

Abnormal noise of Rear Drive Axle

Phenomenon of Malfunction
1、When tractor starts, makes a turn or changes speed suddenly, there is noise in drive axle;
2、There is noise in rear drive axle when driving, but the noise becomes weak or disappears when tractor slides in neutral gear;
3、There is always noise in rear drive axle when tractor drives in a certain gear or slides in neutral gear;
4、There is always noise in rear drive axle when tractor moves during uphill or downhill traveling;
5、There is noise or heavy abnormal sound when rear wheels run.
Judgment of Malfunction
1、The bevel gear and cylindrical gear of final drive in rear drive axle, differential planetary gear and axle shaft gear etc. are worn severely, tooth surface is damaged or gear tooth is broken;
2、The bearing of final drive in rear drive axle or differential bearing is worn loosely;
3、The mesh of driving and driven bevel gear of final drive is adjusted improperly, tooth surface is worn severely, gear tooth is broken or deformed, or meshing mark does not meet the requirements;
4、The spline groove of axle shaft gear in rear drive axle and the spline on axle shaft gear are worn loosely;
5、Differential planetary gear and axle shaft gear do not match or mesh well;
6、The journal of differential planetary gear is worn excessively, the supporting shim of planetary gear is worn too thin, or planetary gear and the shaft of differential planetary gear take place clamping stagnation or are assembled improperly;
7、Driven bevel gear of final drive and fastening bolts of differential case are loose, and fastening screw of differential case bearing cap is loose.
8、Rear wheel bearing is damaged and outer bearing ring is loose.
9、Wheel rim is damaged and bolt hole thereof is greatly damaged, thus resulting in poor fixation of the rim.
10、Rear axle housing is not properly lubricated.
Troubleshooting
1、If there is no noise when tractor drives along a straight line but there is noise in rear drive axle when it makes a turn, the malfunction may come from the part of differential. The bearings on the end of differential should be checked to find out whether they are loose and adjusted if necessary. If not loose, the differential should be removed and disassembled to check whether planetary gear, axle shaft gear and planetary gear shaft are worn loosely and planetary gears do not mesh well. If they do not meet the requirements, repairing or replacing should be done;
2、If there is noise in rear drive axle when tractor drives in a certain gear, but the noise becomes weak or disappears when it slides in neutral gear, the malfunction may come from the part of central transmission gears. The final drive should be removed and disassembled to check whether the tooth of driving and driven bevel gear in rear drive axle is damaged or broken, mashing clearance is too large, and meshing mark meet the requirements. If they are damaged or fail to meet the requirements, replacing or adjustment should be done;
3、If the rear drive axle has any abnormal noise when tractor drives in a certain gear, the lubricating oil should be checked to see whether it is sufficient and refilled if not. If there is sufficient oil, the final drive and differential should be removed and the mashing clearance of driving and driven bevel gear and differential bearing should be checked. In case of any nonconformity with the requirements, the mashing clearance and bearing tension shall be adjusted. The bearing should be replaced if necessary.
4、If the rear drive axle has any abnormal noise when the loaded tractor slopes up or down, the mashing clearance and mark of driving and driven bevel gear should be checked to confirm with requirements. If not, the adjustment should be made accordingly. Note: If there is any abnormal noise happening to the rear wheel of tractor, the hub bearing should be checked to confirm whether it is loose and the rim is deformed. The bolt hole of tyre rim should also be checked whether there is any serious abrasion. In case of any damage, the repair or replacement should be conducted accordingly.
8

Overheating of Rear Drive Axle

Phenomenon of Malfunction
Overheating of rear drive axle means you cannot bear the hot feeling on the case of reducer after tractor drives for a distance.
Judgment of Malfunction
1、The mesh clearance between the driving and driven bevel gears of final drive is adjusted too small;
2、The preload differential bearing of rear drive axle or the bearing of driving bevel gear is adjusted excessively to make bearing assembly too tight;
3、There is not sufficient oil in rear drive axle, its quality is deteriorate or its specifications do not meet the requirements.
Troubleshooting
1、After tractor drives for a distance, you should touch the case of rear drive axle. If it is all overheating, the quantity of lubricating oil in the axle case should be checked to find out whether it meets the needs. It should be added if not sufficient;
2、If the oil is enough, the quality of lubricating oil should be observed. If its color is changed or the oil becomes thin, a new kind of oil with proper specifications should be filled;
3、If the oil quality is good enough, lifter should be removed and the mesh clearance between driving and driven bevel gears should be checked to find out whether it is normal. The mesh clearance should be adjusted if too small;
4、When you touch different bearing parts of rear drive axle and feel hot feeling, it means the bearings are assembled too tight and should be readjusted.
9

Failure of Generator

Phenomenon of Malfunction
1、Ammeter indication is -3~-5A when engine runs at a medium speed;
2、The warning light of charging is always on;
3、Storage battery runs down after using for a period of time.
Judgment of Malfunction
1、There is break in the connecting wire or the V-belt of fan slips;
2、Ammeter is damaged or connected reversely;
3、The reasons for the failure of generator may be that the inner diode is damaged, the electric brush is clamped and cannot touch with slip ring, the internal winding breaks or is short-circuit, magnetic field circuit, battery post and ground connection and the capacitor for preventing interference is short-circuit;
4、Regulator has fault.
Troubleshooting
1、Ammeter or charging indicator should be observed to find out whether they indicate discharging or on when turning on key switch. If there is not indicating signal, circuit, ammeter or indicator should be checked to solve problems;
2、If indicators work well, wires on the posts (“+” and “F” ) of regulator should be removed and connected when engine is stopped. When starting the engine and keeping it at the idle speed (below medium speed), if charging indicator is off, the failure part is regulator that should be replaced;
3、If battery does not charge and engine stops, the wire on the post (“+”) of engine should be removed with a small bulb of the tractor used as a test lamp, one end of the wire should be connected with the post (“+”) of generator and the other should be connected with case (the wire on the post (“F”) of generator should be connected with the post (“F”) of regulator). Then the engine should be started again and kept at the idle speed, if the test lamp is on, the generator is good, charging circuit is broken, and failure part should be found out.
10

The Lifter of TB Series Tractor That Can Take Up Light Load Instead of Heavy One

Phenomenon of Malfunction
1、Lifter works with light load or without load, but its speed is slow;
2、Lifter works slowly or does not work under heavy load;
3、Farm implements can be lifted when tractor is cold while can not be lifted or lifted slowly when tractor is hot.
Judgment of Malfunction
1、The oil level height in lifter shell is too low;
2、The strainer of oil filter is blocked severely;
3、Inlet line absorbs air;
4、Gear oil pump fails, which causes low pressure of oil supply;
5、High temperature of oil results in large amount of leakage or high viscosity of oil results in low liquidity, which causes the shortage of oil supply;
6、There is leakage at cylinder, distributor, oil pipe and joints, which causes low pressure of oil.
Troubleshooting
1、The oil in lifter shell should be checked to ensure whether it is insufficient or its quality does not meet the requirements, and should be refilled or replaced if necessary; the oil should be checked to find out whether there are lots of bubbles, if so, oil filter or inlet line may be blocked, or inlet line may absorb air. Maintenance and checking should be done according to requirements.
2、Block valve is fully closed firstly, when engine runs at the idle speed and lifting handle is raised, the engine load should be observed to make sure whether it changes. If so, the oil cylinder leaks severely. If not, the reasons for it may be invalid oil pump, low pressure of safety valve and large amount of leakage in distributor etc. Damaged parts should be replaced if necessary.
11

How to check and adjust the engine valve clearance

It is required to check and adjust the valve clearance when overhauling or servicing the diesel engine. The valve clearance is adjusted in the following way:
1)  Remove the cylinder head, and check and fasten the bolts and nuts of the valve rocker arm shaft support.
2)  Rotate the crankshaft till the “O” mark on the crankshaft pulley is aligned with the pointer on the timing gear house cover or the mark at the sight glass on the flywheel housing is aligned with the “O” mark on the flywheel. At this moment, the intake valve of the fourth cylinder is to be opened or the first cylinder is to inject fuel. This position is the compression upper dead center of the first cylinder piston.
3)  The working sequence of the four-cylinder engine is 1-3-4-2. The intake valves shall be checked and adjusted in the following sequence: adjust both intake and exhaust valves of the first cylinder, adjust the exhaust valve of the third cylinder, do not adjust valves of the fourth cylinder and adjust the intake valve of the second cylinder. After the adjustment, rotate the crankshaft by 360 degree, and regulate the remaining valves as required.
The working sequence of the six-cylinder engine is 1-5-3-6-2-4. The intake valves shall be checked and adjusted in the following sequence: adjust both intake and exhaust valves of the first cylinder, adjust the exhaust valves of the fifth and third cylinders, do not adjust the valves of the sixth cylinder, and adjust the intake valves of the second and fourth cylinders. After the adjustment, rotate the crankshaft by 360 degree, and regulate the remaining valves as required.
The working sequence of the three-cylinder engine is 1-3-2. The intake valves shall be checked and adjusted in the following sequence: adjust both intake and exhaust valves of the first cylinder, adjust the exhaust valves of the third cylinders, and adjust the intake valve of the second cylinder. After the adjustment, rotate the crankshaft by 360 degree, and regulate the remaining valves as required.
4)  The valve clearance is generally regulated when the valve is cold. To adjust the clearance, undo the adjustment lock nut, and rotate the adjusting screw to regulate the clearance between the rocker arm head and valve stem to meet relevant requirements (as for the specific valve clearance, refer to the engine instruction).
5)  After the adjustment, rotate the crankshaft by two turns, and check whether clearances of various valves meet relevant requirements. After the adjustment, refit the valve cover.
12

How to properly use and maintain tyres

Tyres are the main wearing parts of the tractor, so attention must be paid to their use and maintenance, so as to maximize their service life; therefore, you should note the following:
1.  Improper driving may cause early wear or damage to the tyre. High-speed driving over obstacles, emergency braking or sharp turning should be avoided during driving. When driving on a gravel road, wheel slip should be avoided as much as possible.
2.  In case of serious slip of the driving wheel, the tractor is not allowed to continue working.
3.  Do not drive at high speed on a bumpy road or over the gravel, tile block or cinder, and avoid emergency braking as far as possible.
4.  Check the tyre pressure regularly to limit it within the specified range, and the left tyre pressure should be the same as the right tyre pressure. High or low pressure will cause early tyre wear.
5.  Do not make the tyre stained with oil, acid or alkali and other chemical corrosives and try to avoid exposure to direct sunshine, so as to prevent aging and deterioration of the rubber. Front wheel alignment and toe-in should also be checked and corrected regularly to avoid eccentric tyre wear.
6.  When the tyre tread wears unevenly, exchange the positions of left and right tyres.
7.  Do not make the tyre stained with fuel, lubricating oil or other contaminants; if it is the case, clean it up.
8.  When to be out of service for a prolonged period, the tractor must be lifted, so that the tyre will not be under pressure.
13

The Engine Maintenance of Lovol Tractor

The service life of the engine for Foton Lovol tractor depends primarily on its timely and normative maintenance.
Proper run-in period and normative maintenance can ensure the engine to operate in a high-performance condition.
Regular and routine maintenance of engine: Perform maintenance on the engine regularly in accordance with the maintenance terms in the Engine Warranty Card.
Maintenance of Air Cleaner: Maintain the air-cleaner system of the engine timely based on the operating conditions. Poor maintenance of the air-cleaner system will cause abnormal wear to the cylinder liners, pistons, piston rings and piston pins of the engine, resulting in reduced engine power.
1. Maintenance of Oil Filter of Air Cleaner: Before operation, check whether the filter housing and each connection are in good conditions. Check the oil pan for oil level and the filter element for cleanliness. If the oil level is below the marked line, be sure to add oil timely until it starts to reach the marked line. If the cleanliness is poor, clean the oil pan and the filter element in time.
2. Maintenance of Paper Filter of Air Cleaner: Before operation, check whether the filter housing and each connection are in good conditions. Make sure the air-cleaner system is functioning properly. Check the filter for its internal cleanliness and do well in its maintenance in a timely manner.
14

Fault Analysis for White Smoke in the Exhaust Pipe When the Engine Starting

1. Symptom
When starting, the starter can drive the engine to operate normally. However, the engine cannot be ignited, and you can see white smoke in the exhaust pipe.
2. Potential Causes:
(1) Low compression pressure in the cylinder(s).
(2) The cold-starting device fails or the engine starting temperature is too low.
(3) There is excessive moisture in the fuel or there is coolant in the cylinder(s).
(4) Retarded injection timing.
3.Troubleshooting
(1) Unscrew and remove the radiator cap, and then start the engine and observe whether a lot of bubbles emerge from the upper of the radiator. If any, this indicates that the cylinder head gasket is damaged or the cylinder block and/or cylinder head have cracks, resulting in coolant being drawn in the cylinders during air intake.
(2) If no bubble emerges, unscrew the low-pressure pipe joint and put a small tray under it. Pump the fuel manually, and check whether there is water in the fuel. If there is drop of water in the fuel, this indicates that there is water in the fuel tank. Be sure to drain the water and debris through the drain plug at the bottom of the fuel tank or the sediment cup, while replacing the diesel oil filter element.
(3) Check whether the cold-start preheating unit is functioning properly. If the preheating unit fails, be sure to repair it or replace it with a new one.
(4) When starting the engine, if you press the accelerator pedal a little hard again, the engine can be started successfully, this indicates it is short of oil for starting or the idle speed is adjusted to be too low. Be sure to re-adjust the injection pump.
(5) Advance the injection timing slightly, and then start the engine. If the engine can be started and the exhaust smoke color gets better to some extent, this indicates the injection timing is retarded. Be sure to adjust the injection timing. If white smoke is still visible after the engine starting and becomes richer during acceleration, be sure to check whether the outlet pressure of the injection pump is low, whether the fuel injection atomization is poor or whether the cylinder pressure is low.
(6) If the cylinder pressure is insufficient, check whether the turbocharger is working properly, whether the turbocharger shaft gets seized, or whether the valve clearance is undersized or oversized. If necessary, adjust or repair them.
15

Newsletter of Service for Big Tractor Customers in Inner Mongolia

In May, 2014, Foton Lovol service trainees Pang Baoxue and Na Lasu attended follow-up service for the project of big customer in Inner Mongolia and mainly got engaged in inventory vehicle state maintenance, returned vehicle maintenance and spare sales.
Since persons responsible for the Mongolia project lacked professional knowledge on product repair and maintenance, a good many inventory vehicle had such problems of product aging and vehicle cold rupture due to inappropriate maintenance and issues arising out of improper usage to bring very big inconvenience to maintenance. Our service staff overcame varied difficulties to provide considerate service for the Mongolia government and end users and spend spare time in explaining common sense of product maintenance and storage to the relevant responsible personnel. Thus, they are unanimously recognized by locals in Inner Mongolia.    
By the end of July, our service staff has altogether finished technology state maintenance on more than 500 inventory vehicles and repair on faulty vehicles more than 20 times. Thus, the service staffs are highly praised by Mongolia users.
16

Exhaust pipe emits black smoke in engine startup

1. Fault phenomenon
In startup, the starter can drive the engine to run normally, but the ignition is failed and the exhaust pipe emits black smoke.
2. Fault causes:
1)The fuel is poor in quality or contaminated.
2) The intake air is blocked.
3) The fuel supply advance angle is inappropriate.
4) The valve clearance is too small.
5) The adjusted injection pressure of injector is too low.
6) The injector needle valve is seized or worn badly.
7) The plunger, tappet and cam of injection pump are over worn.
8) The governor is adjusted improperly.
9) Certain cylinder stops working or works poorly.
10) The compression ratio decreases possibly due to serious wear of cylinder tube and piston.
3. Troubleshooting
1)Check whether the fuel is contaminated or poor in quality.
2)Check whether the air filter and the air intake pipe are blocked, and repair or replace as appropriate.
3)If the diesel engine produces knocking noises and meanwhile emits black smoke, it indicates that the fuel is injected too early. In this case, check whether the injection pump coupling bolt gets loosened, whether the key is disengaged from the keyway, and whether the connecting driven disc is dislocated, and then adjust the fuel supply advance angle.
4)Check whether the engine valve clearance is within the specified range.
5)Remove the injector, and check on the calibration stand whether its injection pressure, spray cone angle, injection range and so forth are satisfactory.
6)Remove the injection pump, check its injection pressure on the fuel pump test bench, and repair or replace as necessary.
7)If no abnormalities are found after the above inspections, check the cylinder pressure, and if it is too low, inspect the engine and do repair when necessary.

17

Maintenance of maintenance-free storage battery

1.Status checking of storage battery: A transparent sight hole is on the storage battery and colors will be displayed in the sight hole. Green indicates electricity in the storage battery is sufficient. Black indicates electricity in the storage battery is insufficient, external charging is required. Grey white indicates electricity in the storage battery is used up and the storage battery shall be replaced.

2.Maintenance of storage battery:The storage battery shall be stored at the clean, dry and ventilated warehouse with the temperate being (0-40)℃. Put down gently and avoid inversion during handling and securely fasten the storage battery terminal and power connection, in order to avoid melting and corrosion during starting. Apply Vaseline on the wiring terminal.

Attentions: If the storage battery is stored with liquids, one-time supplementary charge is a must for each month and conduct regular checking conformity of voltage of voltage regulator. Voltage of the regulator is 14.2 ± 0.2 V. Warning: electrolyte in the storage battery is corrosive and is forbidden to be exposed to eyes, skins and clothes, otherwise, immediately use clean water to clean the acid liquor.

18

Maintenance of oil-bath air filter

1. Open agraffe below the filter.

2.Then remover oil basin at the bottom and drain dirty oil, clean with kerosene or diesel and clean the filter cartridge at the same time.

3.Replace with new oil to height of oil level. Then reassemble it.

19

Inspection and maintenance of hydraulic steering tank

1. The hydraulic steering tank is arranged at the right side in the generator cover.

2. Open the oil tank cover (with dipstick) and observe whether the dipstick is subject to oil trace which indicates that the hydraulic steering tank has low oil level. Please check and identify oil leakage causes.

3. Then Add additional oil up to the intermediate marking of the dipstick, and then place it at the original place.

4. Systematically check whether the hydraulic steering cylinder, oil pipe and connection are free of oil leakage, otherwise will cause inflexible steering.

5. Clean or replace the filter screen in the oil tank.

6. When checking the oil level, check whether lifting of the vent valve in the center of the oil tank cover (rivet shaped) is flexible.

7. Clean if oil dirt causes impacts on lifting.

20

Checking oil mass of the engine oil pan and oil replacements

1. Pull out oil dipstick at right front of the oil pan.

2. Check whether oil level falls between upper and lower marking.

3. If oil level is below the lower marking, add oil to the specific oil level.

4. Preheat the engine before maintenance and oil replacement, when oil temperature reaches 50 °C--60°C, screw out the drain plug below the oil pan, empty dirty oil and clean the oil pan. Then fill oil.

 Attentions: it is forbidden to mix new and used oil or oil of different types. Replace oil in strict accordance with regulations in the Operation Instructions of Diesel Engine.

 

21

Phenomenon of Manifestation:Unusual noise is from main clutch of TB series tractor

Detection position:

1. Clutch pedal

2. Guide bearing of flywheel

3. Disengaging bearing housing

4. Disengaging bearing housing

5. Disengaging bearing

6. Clutch

7. Disengaging lever

Causes of failures:

1. The pedal return spring is broken or lost.

2. The guide bearing of flywheel is damaged.

3. The return spring of clutch release bearing falls off or is broken or too soft.

4. The release bearing is lack of grease.

5. The release bearing is damaged.

6. The matching between clutch pressure plate and clutch cover is loose.

7. The clutch release lever or support pin hole is worn.

Troubleshooting measures:

1. Replace return spring.

2. Replace it.

3. Replace return spring of release bearing.

4. Fill grease.

5. Replace damaged release bearing.

6. Tighten fastening bolt of clutch.

7. Replace clutch cover and clutch release lever.

22

Phenomenon of Manifestation:Main clutch of TB series tractor not disengaging

Detection position:

1. Clutch pedal

2. Clutch disengaging lever

3. Flywheel

4. Clutch friction disc

5. Clutch driven plate

Causes of failures:

1. The free stroke of clutch is too large.

2. The inside ends of 3 release levers are not in the same plane or the release spring is broken.

3. It destroys concentricity of crankshaft and clutch shaft and causes deflection of driven plate due to heavy wear of locating bearing of clutch input shaft.

4. The reduction of effective operating stroke and resultant incomplete disengaging of clutch is caused by over thick friction disc or improper mounting.

5. The steel sheet of driven plate warps and deforms, and the friction disc is broken.

Troubleshooting measures:

1. Adjust the free stroke of pedal to be within 15 ~25 mm.

2. Adjust the planeness of clutch disengaging lever to be within 0.2 mm. Replace spring.

3. Replace locating bearing of clutch input shaft.

4. Replace over thick friction disc or add a gasket between clutch cover and flywheel (the thickness of gasket shall not exceed 0.5mm).

5. Replace driven plate or friction disc.

23

Frequent vibration of main clutch

Detection position

1. Clutch disengaging lever

2. Clutch driven plate

3. Clutch pressure plate

4. Clutch

5. Friction disc of clutch

6. Clutch driven plate

Causes of failures:

1. The disengaging levers are not in the same plane.

2. The driven plate has damage or deformation while moving.

3. The pressure plate is deflected while moving, the rivet of driven plate protrudes.

4. There is oil contamination on main friction disc and driven plate.

5. The friction disc is broken.

6. The driven plate warps.

Troubleshooting measures:

1. Adjust the planeness of clutch disengaging lever to be within 0.2mm or replace release spring.

2. Replace the clutch assembly.

3. Replace the clutch assembly.

4. Clean friction disc and driven plate.

5. Replace friction disc.

6. Replace driven plate.

24

Clutch pedal won’t return

Detection position

1. Clutch pedal shaft

2. Clutch pedal shaft

3. Clutch pedal

4. Transmission

5. Clutch

Causes of failures:

1. The clutch pedal shaft gets rusty or is seized.

2. The clutch pedal shaft liner has burrs.

3. The return spring of clutch pedal has failure.

4. The clutch rocker arm combined part gets rusty or is seized.

5. The return spring of release bearing housing falls off or has failure.

Troubleshooting measures:

1. Fill grease for clutch pedal shaft.

2. Replace clutch pedal shaft liner.

3. Replace return spring of clutch pedal.

4. Fill grease for clutch rocker arm combined part.

5. Reinstall or replace return spring of release bearing housing.

25

Clutch pedal turns loose

Detection position

1. Disengaging bearing housing

2. Clutch pressure claw

3. Disc spring

Causes of failures:

1. The return spring of release bearing falls off or is broken.

2. The spring of clutch pressure claw has failure.

3. The butterfly spring of clutch has failure.

Troubleshooting measures:

1. Replace return spring of release bearing housing.

2. Replace the spring of clutch pressure claw.

3. Replace butterfly spring of clutch.

26

Engine fails to start

Detection position:

1. Generator

2. Starting motor

3. Fuel filter

4. Delivery pump

5. Injector

6. Valve clearance

7. Cylinder head gasket

8. Piston ring

9. Injection timing

Causes of failures:

1. Fault in charging generator.

2. Fault in starting motor

3. Air trapped in fuel system

4. Fuel filter blocked

5. Fault in delivery pump

6. Fault in injector

7. Valve clearance is too small

8. Gas leak through cylinder head gasket

9. Fault in piston ring

10. Low temperature and too high oil viscosity

11. Faults in injection timing

Troubleshooting measures:

1. Charge or replace the generator.

2. Check and fasten connections.

3. Check fuel piping and release trapped air with hand delivery pump.

4. Clean or replace fuel filter.

5. Check fuel supply pipe and repair delivery pump.

6. Dismantle the injector and adjust it on test stand.

7. Adjust and lap the valve.

8. Replace the gasket and fasten bolts.

9. Renew, clean and adjust.

10. Pre-warm the engine and use specified oil.

11. Check and adjust injection timing.
27

Engine fails to start

Detection position:

1. Generator

2. Starting motor

3. Fuel filter

4. Delivery pump

5. Injector

6. Valve clearance

7. Cylinder head gasket

8. Piston ring

9. Injection timing

Causes of failures:

1. Fault in charging generator.

2. Fault in starting motor

3. Air trapped in fuel system

4. Fuel filter blocked

5. Fault in delivery pump

6. Fault in injector

7. Valve clearance is too small

8. Gas leak through cylinder head gasket

9. Fault in piston ring

10. Low temperature and too high oil viscosity

11. Faults in injection timing

Troubleshooting measures:

1. Charge or replace the generator.

2. Check and fasten connections.

3. Check fuel piping and release trapped air with hand delivery pump.

4. Clean or replace fuel filter.

5. Check fuel supply pipe and repair delivery pump.

6. Dismantle the injector and adjust it on test stand.

7. Adjust and lap the valve.

8. Replace the gasket and fasten bolts.

9. Renew, clean and adjust.

10. Pre-warm the engine and use specified oil.

11. Check and adjust injection timing.
28

Oil pressure is abnormal

Detection position

1. Oil and oil sump.

2. Leakage at pipe connection and pressure gauge.

3. Bearing of engine.

4. Screw plug.

5. Pressure regulating valve.

Causes of failures:

1. Low oil level and oil viscosity.

2. Broken oil pipe line, leakage at pipe connection, damaged oil pressure gauge.

3. Broken pressure regulating spring.

4. Too big bearing clearance.

5. Loose screw plug.

6. Fault in pressure regulating valve.  Oil return passage blocked.

7. Too low ambient temperature or too high oil viscosity.

8. No oil reaches rocker arm, oil passage blocked in cylinder head or in rocker arm bracket.

Troubleshooting measures:

1. Fill or replace the oil.

2. Weld or replace pipe line.

3. Replace regulating spring.

3. Check and repair the bearing.

4. Check and repair screw plug.

4. Check and adjust pressure regulating valve.

5. Pre-warm the engine and use specified oil.

6. Clean and make the oil passage through.

29

High exhaust smoke

Detection position

1. Nozzle and needle valve.

2. Injection timing.

3. Valve clearance.

4. Injector.

5. Intake pipe and air filter.

Causes of failures:

1. Nozzle chocked by carbon deposit or seized needle valve.

2. Too heavy load.

3. Too late injection timing.

4. Incorrect valve clearance or valve leak

5. Uneven injection.

6. Intake pipe and air filter are blocked

Troubleshooting measures:

1. Check, repair, or replace faulty parts.

2. Adjust the load within specified range.

3. Adjust the injection timing.

4. Check valve clearance, valve sealing band and valve spring force and eliminate all troubles.

5. Adjust injection quantity of every cylinder.

6. Clean or change air filter.
30

The clutch slips

Phenomenon of ManifestationThe clutch slips.

Detection position

1. Clutch housing

2. Clutch clearance

3. Pressure plates

4. Friction piece

5. Three separate rods

Causes of failures:

1. Friction piece and pressure plate have oil spots.

2. Friction piece has been worn differently, or heavily, rivet appears

3. Dish shaped spring pressure becomes weak.

4. Free distance is short, and touch with separate bearing, the robs aren’t in one plane.

5. Driven plate is seriously deformed.

Troubleshooting measures:

1. Disconnect engine and clutch house, check whether gearbox leaks oil or engine leaks oil, and then replace oil seals. Take apart and clean the friction piece, dry and install.

2. Change the friction disc.

3. Change the spring.

4. Adjust according to the regulations.

5. Change the driven plate.
31

Front wheel has worn heavily

Phenomenon of ManifestationFront wheel has worn heavily.

Detection position

1. Front wheel rim.

2. Front wheel web.

3. Front toe-in.

4. Steering connecting pin.

Causes of failures:

1. Front wheel rim or web is worn heavily.

2. Adjust front toe-in in a wrong way.

3. Steering connecting pin is worn heavily.

4. Improperly operation.

Troubleshooting measures:

1. Revise or replace wheel rim or web.

2. Adjust front wheel, then measure and adjust front toe-in.

3. Replace connecting pin.

4. According to requirement, charge and separate front drive.
32

Front wheel has worn heavily

Phenomenon of ManifestationFront wheel has worn heavily.

Detection position

1. Front wheel rim.

2. Front wheel web.

3. Front toe-in.

4. Steering connecting pin.

Causes of failures:

1. Front wheel rim or web is worn heavily.

2. Adjust front toe-in in a wrong way.

3. Steering connecting pin is worn heavily.

4. Improperly operation.

Troubleshooting measures:

1. Revise or replace wheel rim or web.

2. Adjust front wheel, then measure and adjust front toe-in.

3. Replace connecting pin.

4. According to requirement, charge and separate front drive.
33

Big noise in front driving axle

Phenomenon of ManifestationBig noise in front driving axle.

Detection position

1. Transmission gear.

2. The clearance of middle transmission.

3. Differential.

4. Planetary gear or gasket.

5. Finally transmission gear.

6. Finally transmission bearing.

Causes of failures:

1. Front center transmission gear mesh tooth is not good.

2The clearance of middle transmission is too big or broken.

3Differential shaft was worn out or blocked.

4Planetary gear or gasket were broken.

5Finally transmission gear auxiliary did not engage well.

6Finally transmission gear auxiliary bearing is broken.

Troubleshooting measures:

1. Please look at the method to adjust the middle transmission of rear axle.

2. Adjust the clearance of bearings or replace it.

3. Replace the differential shaft.

4. Replace planetary gear or gasket.

5. Replace finally transmission gear auxiliary.

6. Replace finally transmission gear auxiliary bearing.
34

Frequent vibration of main clutch.

Detection position:
1. Clutch disengaging lever
2. Clutch driven plate
3. Clutch pressure plate
4. Clutch
5. Friction disc of clutch
6. Clutch driven plate
Causes of failures:
1. The disengaging levers are not in the same plane.
2. The driven plate has damage or deformation while moving.
3. The pressure plate is deflected while moving, the rivet of driven plate protrudes.
4. There is oil contamination on main friction disc and driven plate.
5. The friction disc is broken.
6. The driven plate warps.
Troubleshooting measures:
1. Adjust the planeness of clutch disengaging lever to be within 0.2 mm or replace release spring.
2. Replace the clutch assembly.
3. Replace the clutch assembly.
4. Clean friction disc and driven plate.
5. Replace friction disc.
6. Replace driven plate.
35

Clutch pedal won’t return.

Detection position:
1. Clutch pedal shaft.
2. Clutch pedal shaft.
3. Clutch pedal.
4. Transmission.
5. Clutch.
Causes of failures:
1. The clutch pedal shaft gets rusty or is seized.
2. The clutch pedal shaft liner has burrs.
3. The return spring of clutch pedal has failure.
4. The clutch rocker arm combined part gets rusty or is seized.
5. The return spring of release bearing housing falls off or has failure.
Troubleshooting measures:
1. Fill grease for clutch pedal shaft.
2. Replace clutch pedal shaft liner.
3. Replace return spring of clutch pedal.
4. Fill grease for clutch rocker arm combined part.
5. Reinstall or replace return spring of release bearing housing.
36

Vibration of clutch pedal.

Detection position:
1. Disengaging bearing.
2. Disengaging lever.
3. Flywheel.
Causes of failures:
1. The clearance between clutch bearing and three pressure claws is too small.
2、Three pressure claws are uneven in height and not in the same plane.
3、The flywheel and pressure plate have not been installed in place and slips at the pressure plate.
Troubleshooting measures:
1. Adjust the clearance between the working face of clutch disengaging lever and the end face of release bearing to be within (2~2.5) mm.
2. Adjust the height difference of ends of three disengaging levers to be within 0.2 mm.
3. Loosen fastening bolt of clutch and reinstall it.
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