Escolar Documentos
Profissional Documentos
Cultura Documentos
1. Engine
2. Transmission
3. Brake
4. Hydraulic
5. Steering
6. Electrical
7. A/C
1
1. ENGINE
1.1 The Engine Crankshaft Will Not Turn When The Start Switch Is On.
Probable Cause
1. Low Output from The Battery
Check the condition of the battery.
Charge the battery or replace the battery, as required.
2. Defective Wires or Switches
Repair the wires or the switches or replace the wires or the switches, as required.
3. Defective Starting Motor Solenoid
Install a new starting motor solenoid.
4. Defective Starting Motor
Install a new starting motor.
5. An Internal Problem Prevents The Turning Of The Engine Crankshaft.
If the crankshaft cannot be turned after disconnecting the driven equipment, inspect the
cylinders for fluid while the crankshaft is being turned. If fluid in the cylinders is not the
problem, the engine must be disassembled. After disassembling the engine, inspect the
engine for other internal problems. Possible internal problems include the following
conditions:
Bearing seizure
Piston seizure
Valve and piston contact
2
1.3 The Engine Is Misfiring Or The Engine Is Running Rough.
Probable Cause
1. Air In Fuel System
Find the air leak in the fuel system and correct the air leak. If there is air in the fuel
system, the air generally enters the fuel system on the suction side of the fuel transfer
pump. Remove the air from the fuel system. Refer to the Testing and Adjusting, "Fuel
System" topic.
2. Low Fuel Pressure
The fuel pressure at the outlet of the fuel filter housing must be a minimum of 105 kPa
(15 psi) at high idle. If fuel pressure is lower than the above pressure, check the
following items:
Plugged fuel filters
Fuel transfer pump
Ensure that there is fuel in the fuel tank. Look for leaks or bends in the fuel line between
the fuel tank and the fuel transfer pump. Look for air in the fuel system. Also look for a
defective return fuel pressure regulating valve.
3. Leakage Or Breakage In Fuel Line Between Fuel Injection Pump And Fuel Injector
Nozzle
Install a new fuel line.
4. Defect In Fuel Injector Nozzle(s) Or Fuel Injection Pump(s)
Run the engine at an rpm that gives the maximum misfiring or rough running. Then,
loosen a fuel line nut on the fuel injector nozzle for each cylinder one at a time. When a
fuel line nut is loosened, the misfiring or rough running will increase. If the misfiring or
rough running does not increase then test the fuel injection pump. Then check the fuel
injector nozzle for that cylinder. Install new parts, if necessary.
5. Wrong Fuel Injection Timing
Make the adjustment to the timing, if necessary.
6. Wrong Valve Lash
Make adjustment to valve lash. Refer to theTesting And Adjusting, "Air Inlet And
Exhaust System" topic.
7. Bent Pushrod Or Broken Pushrod Make a replacement of pushrod, if necessary.
8. Worn Valve Seat Or Face Of Valve A reconditioning of the cylinder head is necessary.
9. Bent Valve Or Broken Valve Use a new valve, if necessary
3
1.5 There Are Sudden Changes In Engine RPM.
Probable Cause
1. Failure Of Governor Or Fuel Injection Pump Look for the springs, the linkage or other
parts that are damaged or broken. Remove the governor. Check for free travel of the
fuel rack. Ensure that the fuel
injection pumps are installed correctly. Check for the correct governor spring.
Install new parts for those parts that are damaged or defective.
4
1.7 The Engine Has Too Much Vibration.
Probable Cause
1. Loose Vibration Damper Or Loose Pulley
Inspect the vibration damper and the pulley for damage. Tighten the bolts, if necessary.
If the vibration damper or pulley bolt holes have damage or wear, replace the vibration
damper or pulley bolt holes with new parts.
2. Defective Vibration Damper Or Pulley
Inspect the vibration damper and the pulley for leakage. Inspect the vibration damper
and the pulley for a damaged case assembly. Either of the above conditions can cause
the weight to come into contact with the housing. If the weight contacts the housing, the
operation of the vibration damper and the pulley is affected.
3. Driven Equipment Is Not In Alignment Or Driven Equipment Is Not In Balance. Check
alignment and balance. Correct alignment and balance, if necessary.
4. Engine Supports Are Loose or Defective. Tighten all mounting bolts. Install new
components, if necessary.
Valves
Springs
Camshaft
Lifters
Rocker arms
Pushrods
Valve guides
Check for worn parts or damaged parts. Replace worn parts or damaged parts, as
required.
2. Not Enough Lubrication Check the lubrication in the valve compartment. There must
be a small flow of oil through the rocker arm shaft and rocker arms. The oil then flows to
the tops of the pushrods and the tops of the valve stems. Oil passages must be clean.
The oil passages that send the oil through the cylinder head to the rocker arm shaft are
particularly important.
3. Too Much Valve Lash
Make adjustment to valve lash. Refer to Testing And Adjusting, "Air Inlet And Exhaust
System".
5
1.10 Oil Is In The Cooling System.
Probable Cause
1. Defect In Core Of Engine Oil Cooler
Inspect each engine oil cooler. Repair any defective oil cooler or replace any defective
oil cooler, as required.
2. Defect In Head Gasket Install a new head gasket.
1.13 The Engine Has A Loud Noise (Clicking) From The Valves Or From The Valve
Operating Components.
Probable Cause
1. Damage To Valve Spring(s)
Replace the damaged parts.
2. Damage To Camshaft
Replace the damaged parts. Clean the engine thoroughly.
3. Damage To Valve Lifter
Clean the engine thoroughly. Replace the camshaft and the valve lifters. Look for valves
that do not move freely. Adjust the valve lash. Refer to the Testing and Adjusting, "Air
Inlet and Exhaust System" topic for additional information.
4. Damage To Valve(s)
Replace the damaged parts and make an adjustment, if necessary.
6
1.14 Little Movement Of The Rocker Arm And Too Much Valve Lash Is Present.
Probable Cause
1. Too Much Valve Lash
Adjust the valve lash. Refer to the Testing and Adjusting, "Air Inlet and Exhaust System"
topic for additional information.
2. Not Enough Lubrication
Check the lubrication in the valve compartment. There must be a strong flow of oil at
engine high rpm. There must be a small flow of oil at low rpm. Oil passages must be
clean. The oil passages that send the oil to the cylinder head are particularly important.
3. Worn Rocker Arm
If the face of the rocker arm that makes contact with the valve bridge has too much
wear, install new parts or rocker arms. Make adjustment to valve lash. Refer to Testing
And Adjusting, "Air Inlet And Exhaust System".
4. Worn Valve Stem
If the end of the valve stem has too much wear, install new valves. Make adjustment to
valve lash. Refer to Testing And Adjusting, "Air Inlet And Exhaust System".
5. Worn Pushrods
If the pushrods have too much wear, install new pushrods. Make adjustment to valve
lash. Refer to Testing And Adjusting, "Air Inlet And Exhaust System".
6. Broken Valve Lifters Or Worn Valve Lifters
Install new valve lifters. Check the camshaft for wear. Check for free movement of
valves or bent valve stem. Clean the engine thoroughly. Make adjustment to valve lash.
Refer to Testing And Adjusting, "Air Inlet And Exhaust System".
7. Worn Camshaft Check valve lash. Check for wear on camshaft lobes. Check for free
movement of valves or bent valve stems. Install a new camshaft. Install new valve lifters.
Make adjustment to valve lash. Refer to Testing And Adjusting, "Air Inlet And Exhaust
System".
7
1.18 The Engine Has Early Wear.
Probable Cause
1. Dirt In Lubrication Oil
Remove dirty lubrication oil. Install new filter elements. Put clean oil in the engine.
2. Air Inlet Leaks Inspect all gaskets and connections. Make repairs if leaks are found.
3. Fuel Leakage Into Lubrication Oil This will cause high fuel consumption and low
engine oil pressure. This condition may also increase the oil level in the crankcase.
Make repairs if leaks are found. Install new parts-probably Injector and/or Pump, as
required.
1.26 Coolant Leaks Outside The Engine And Coolant Leaks Inside the Engine.
Probable Cause
1. Coolant Leaks In Hoses Or Coolant Leaks In Hose Connections.
Check all hoses and connections for signs of leakage. Repair the damaged parts or
replace the damaged parts.
2. Leaks In The Water Pump.
Check the water pump for leaks before starting the engine. Then start the engine and
look for leaks. Repair the damaged parts or replace the damaged parts.
3. Cylinder Head Gasket Leakage
Look for leaks along the surface of the head gasket. If leaks are present replace the
head gasket.
4. Crack(s) In The Cylinder Head
Cracks in the cylinder head will allow coolant to flow into the crankcase. Repair the
cylinder head or replace the cylinder head.
5. Crack(s) In The Cylinder Block
Cracks in the cylinder block will allow coolant to flow into the crankcase.
Repair the cylinder block or replace the cylinder block.
10
1.27 The Exhaust Temperature Is Too High.
Probable Cause
1. Restriction At The Air Inlet System Or The Exhaust System
Remove the restriction.
2. Wrong Fuel Injection Timing Make adjustment to timing. Refer to Testing And
Adjusting, "Fuel System".
1.30 The Alternator Charge Rate Is Low Or The Alternator Charge Rate Is Not
Regular.
Probable Cause
1. Loose Drive Belt For The Alternator
Adjust the drive belt in order to obtain the correct tension.
2. Defective Charging, Ground Return Circuit Or Battery Connections
Inspect all cables and connections. All connections should be cleaned and tightened.
Replace all defective parts.
3. Defective Alternator Regulator
Install a new alternator regulator.
4. Brushes In The Alternator Are Defective.
Install new brushes.
5. Defective Rectifier Diodes
Replace the defective rectifier diode.
6. Defective Rotor (Field Coil)
11
1.32 The Alternator Has Noise.
Probable Cause
1. Drive Belt For The Alternator That Is Worn Or Defective
Drive Belt For The Alternator That Is Worn Or Defective
2. Loose Alternator Drive Pulley
Check the groove in the pulley for a key that holds the pulley in place. If the groove is
worn, install a new pulley. Refer to the Specifications, "Alternator and Regulator" topic
for the proper torques.
3. Misaligned Drive Belt And Drive Pulley For The Alternator Misaligned Drive Belt And
Drive Pulley For The Alternator
4. Worn Alternator Bearings
Install new bearings in the alternator.
5. Bent Rotor Shaft
Replace the rotor shaft.
6. Shorted Rectifiers In The Alternator Replace the diode assembly.
12
2.Transmission
2.1 Transmission oil pressure is too low in every gear.
Cause Remedy
Transmission oil level is too low
Oil leakage in main pipe lines
1 Fill transmission oil level to the
proper fill marks
Transmission oil pump is damaged
2 Check and repair
3 Repair or replace the pump
2.4 Loader cannot move after the engine has been started
1 Gear shift not selected
1 Shift to desired gear or adjust the
transmission control lever to the
desired position
2 Low transmission oil pressure
2 Refer to 2.1 and 2.2
engaged
5 Check and repair the brake
system, and/or disengage the service
and/or parking brake
13
Trouble-Shooting of Power-shift ZF Transmission
Instructions for functional Measuring and Trouble –Shooting on 4WG200
1, Precondition for a functional measuring is a gearbox temperature of 80-1000C
2, Oil level as well as oil quality must be corresponding to the Lubrication Instructions
3, It is absolutely necessary to pay attention that the prescribed operation instructions
are used.
4, Carry out the functional test of the electric system with the prescribed Tester and
Adapter cable (if have this equipment).
5, NOTE:
In case of mechanical clutch defects is in most cases always that clutch defective in
which the vehicle can be moved.
Check oil level see operation instructions (wrong) control to Max.oil level at engine
idling speed
watch the breather function
Check cooler difference temperature 8-100C. (external contamination) clean
Ok
14
Check converter output pressure (nominal valve 3-6.5bar) too high repair converter
holding valve
Wrong operation---drive vehicle in the correct speed
(Too low): check converter relief valve ok renew converter sealing
(defective) Repair
Check current on the solenoids (use PR test boxes), shift through all gears, don not
actuate pressure cut off-switch.
No coding Check pressure cut off switch with PR test boxes
No reaction Pressure switch on parking or service brake defective
Ok check current input on all solenoids with PR test boxes
Wrong Replace defective solenoids
Ok repair control valve assembly
15
3.Brake system
3.1 Insufficient service brake force
1 Brake system oil leakage
2 Air present in the brake system
1 Replace the sealing parts
2 Bleed the air out of the brake
hydraulic brake lines system hydraulic brake lines
lines
3 Insufficient pressure in the air
3 Check the sealing performance in
the air compressor, storage tank, and
lines
4 Leather cup of booster is worn
5.Oil on friction plates
4 Replace the leather cup
5. Investigate root cause and
determine corrective action
6 High abrasion of the friction disc
6 Replace with a new friction disc
3.3 Rapid air storage tank pressure loss after the machine is parked
1 Brake inlet valve is blocked or
damaged
1 Brake continuously for several
times to remove dirt, or replace with a
new valve
2 Pipe connectors are loose or lines 2 Tighten the connectors or replace
are damaged the lines
3 Relief valve is not sealed
3 Investigate and replace the valve
if necessary
16
4. Hydraulic system
4.1 Lift arm raise and bucket tilt functions are slow or dysfunctional
1 Damaged cylinder oil seals
2 Oil leakage in hydraulic lines
1 Replace with new seals
3 Severe inner leakage of the pump 2 Check and repair
4 Improper adjustment of the safety
valve, resulting in low system
3 Repair or replace the pump
4 Adjust the system pressure to the
pressure required specification
5 Air enters into the oil suction lines
of the hydraulic pump, or the oil filter
5 Clean the filter and/or replace the
oil suction pipe
is blocked
6 Repair or replace the valve
6 Excessive hydraulic valve fitting
clearance
1 Hydraulic oil level is too low
2 Filter is blocked
1 Fill oil to the required level
2 Clean the filter
3 Damaged oil pump
4 Air leakage in oil suction linesor
3 Repair or replace the pump
4 Repair or replace the damaged
parts
damaged pump seals
5 Contaminated and/or deteriorated
hydraulic oil
5 Replace with recommended new
hydraulic oil
1 Excessive time running the
machine at high loads
1 Stop the machine to cool it down
2 Adjust to the required pressure
2 Hydraulic system pressure is too
low
3 Fill oil to the required level
4 Repair or replace the pump
3 Hydraulic oil level is too low
4 Damaged oil pumps
5 Repair, clean, or replace the
hydraulic lines and/or filter screen
5 Blocked hydraulic lines and/or filter
screen
6 Adjust the engine fan belt to meet
the engineering requirement
6 Insufficient engine fan cooling
1 Deformation of the reset spring in
PPC valve
1 Replace
2 Dirt between the PPC valve clamp
rod and the fitting hole
2 Clean the parts
3 Deformation of the multi-way valve
reset spring
3 Replace
4 Oily dirt between multi-way valve
spools
4 Clean the parts
17
4.5 Unreliable positioning of the PPC valve
Cause Remedy
1 Insufficient power of the solenoid 1. Replace
2 Dirty contacting surface between
the solenoid and spring seat
3. Gap between the sway and the
2
Clean the parts
press bar is not adjusted per the 3 Adjust according to the engineering
engineering requirement requirement
5.STEERING SYSTEM
5.1 Heavy Steering
5.1 -1
fast
Normal steering when the steering is slow, heavy steering when the steering is
5.1 –2 Foam in the oil, abnormal sound coming from the oil, the cylinders sometimes
move and stop while the steering wheel is being turned
5.1 - 3 Easy steering without load, heavy steering with load
Set the steering safety valve pressure Readjust the steering safety valve
lower than the operation pressure pressure setting
Steering safety valve is blocked Clear the dirt off
Viscosity Replace with the recommended oil
5.1 - 4 Heavy steering when the throttle is low
Normal steering when the throttle is high
18
5.2 No tactile operator feedback that the tires are at its maximum steering limit
Operation of the steering wheel is still light when the tires are at their maximum
limited steering position
5.3 –1 Steering wheel cannot return to the neutral position, and the pressure drop
increases in the neutral position
5.3 – 2 Steering wheel freely moves in the vertical direction, and cannot even rotate
6.Electric system
6.1 Generator does not generate electricity, or the voltage is low
Cause Remedy
1 Belt is slipping
2 Commutator contains oily dirt
1 Adjust the belt
2 Clean the oily dirt off using a clean cloth
or is worn moistened with gasoline or grind it using fine
3 Loose contact between electric abrasive paper
brush and commutator
4 Excitation coil is broken
3 Check and repair
4 Inspect the outer magnetic field and check
5 Residual magnetism the excitation loop with a light bulb
disappears
generator
5 Magnetically charge or replace with a new
Cause Remedy
1 Damaged voltage regulator
2 Loose wire contacts or a broken
1 Repair or replace the regulator
2 Check connecting wires between
circuit the generator and battery
6.3 Large spark between the generator brush and commutator
Cause Remedy
Severe commutator wear Clean commutator, clear the dirt out
from the filters
19
7. Air conditioning system
7.1 Cool air not emitted from the air conditioning vents
Drive belt is too loose or is broken Tighten belt or replace with a new
Fuse is blown, wire is disconnected, belt
cooling air switch is damaged, or Replace with new fuse, repair wire,
blower motor stops working switch, and/or blower motor.
Compressor does not rotate; belt is
slipping on the pulley. Disassemble the compressor, repair
Compressor does not work. When or replace it.
the engine speed varies, only slight Repair or replace with a valve plate.
changes are observed between low
and high-pressure readings.
Cooling system lines are broken, or Repair cooling system lines, inspect
refrigerant is leaking. , Low and high system for leakage, evacuate lines,
pressure readings are zero and fill with Freon.
Dryer of the receiver or expansion
valve is blocked. Disassemble, repair or replace
Insufficient volume of air in the vent Clean or replace the air filter screen,
duct, air leakage in the vent duct clear off obstructions in the vent
Blower motor does not function duct, reconnect the vent duct.
properly Repair or replace the blower motor.
Compressor electromagnetic clutch Repair or replace the
slips electromagnetic clutch.
Compressor efficiency decreases Repair or replace the compressor.
Air exists in the cooling system, Exhaust air, evacuate the lines, and
excessively high pressure shown in fill with Freon.
the high pressure gauge, misty /
murky substances seen in the sight
glass.
Insufficient refrigerant, bubbles can Add refrigerant until the bubbles
be seen in the sight glass, disappear.
excessively high pressure shown in
the high pressure gauge
Insufficient air circulation around the Clean the radiator and engine water
radiator, excessively high pressure tank, or add a condensation fan.
shown in the high pressure gauge
21
Note:
22