Troubleshooting

Clutch

 

S No PROBLEM PROBABLE CAUSES REMEDIES
1 Noise while pressingthe clutch pedal Lack of lubrication in Clutch Release Bearing Lubricate
Clutch Release Bearing damage Replace
2 Noise while releasingclutch pedal Lack of lubrication in Pilot Bearing Lubricate
Pilot Bearing damage Replace
Clutch disk hub loose on Input shaft Replace the worn out parts
3 Clutch slippage Clutch Pedal free play Adjust & correct (25 to 35 mm)
Broken or Weak pressure spring Replace springs
Release lever height incorrect AdjUSt & COrreCt (SC.40to44mm)(DC28to36mm)
Grease or oil on facings Replace the facing, check source of
Glazed clutch facing Replace facing
Glazed flywheel or Pressure plate face Correct by machining or replace
Wraped Clutch facing Replace the clutch facing
Wraped Flywheel or Pressure plate face Correct by machining or replace
4 Clutch not disengagewhile pressing clutch Clutch Pedal free play more Adjust & correct
Release lever height setting improper Adjust & correct
5 Wear of clutch facing Driver Clutch pedal riding Keep foot off clutch pedal
Excessive and incorrect use of clutch Reduce use
Cracks in flywheel or pressure plate face Correct by machining or replace
Weak or broken pressure spring Replace spring
Clutch pedal free play less Adjust & correct
6 Clutch pedal hard Lack of lubrication in pedal linkage Lubricate
Clutch pedal jam on clutch shaft Grease the shaft
Release lever height setting improper Adjust & correct
7 Clutch Pedal Pulsation Engine and Transmission not improper Realign
Flywheel face run out more Correct run out or replace
Release lever not evenly adjusted Adjust & correct
Pressure plate assembly misaligned Realign
Warped pressure plate or clutch facing Replace
Clutch plate nut free on De and check clean
Workest clutch facing

 

Brakes

 

S.No. PROBLEM PROBABLE CAUSES REMEDIES
1. NO BRAKING ACTION Pedal linkage broken or disconnected Replace or Repair
2. POOR BRAKING ACTION Brake setting improper Adjust & correct
Glazed brake liners Replace
Glazed brake disc Correct by machining or replace
3. BRAKE STUCKING Linkage retracting spring loose Replace springs
Brake disc plate spring tension less Replace springs
Binding in linkage Lubricate & free
4. NOISE WHILE BRAKING Loose rivets of brake lining Correct or replace
Worn out brake lining Replace
Rough or worn out brake disc plate Correct by machining or replace
Foreign matter imbedded in lining Clean the liners
Loose part in the system. Tighten the loose

 

Brake & Clutch Pedal

 

S. No. PROBLEM PROBABLE CAUSES REMEDIES
1 Noise while pressing the clutch pedal Lack of lubrication in Clutch Release Bearing Lubricate
Clutch Release Bearing damage Replace
2 Noise while releasing clutch pedal Lack of Lubrication in Pilot Bearing Lubricate
Pilot Bearing damage Replace
Clutch disc hub loose on input shaft

 

Replace the worn out parts
3Clutch pedal hardLack of lubrication in pedal linkageLubricate Clutch pedal jam on clutch shaft Grease the shaft Release Lever height setting improper Adjust & correct4Clutch pedal pulsationEngine and Transmission not alignedRealign Flywheel face run out more Correct run out or replace Release lever not evenly adjusted.Adjust & correct Pressure plate assembly misalignedRealign Warped pressure plate or clutch facingReplace

 

GEARBOX

 

S.No. PROBLEM PROBABLE CAUSES REMEDIES
1 NOISE
Humming Wear on gear teeth flank Replace the gear.
(a pecutior noise) Damage on gear teeth flank Replace the gear.
Metallic grinding Oil lever low. Top up oil lever.
Whine (Bullet passing sound) Backlash less Correct the back lash either by replacing gears on housing.
Gear machining improper Replace the gear.
Hissing Worn out bearing Replace the gearing.
(Leaking noise tent-tire to air lack) Bearing ball/race pitted Replace the gearing.
Ratting (Ruppict series of short loud noise) Backlash more Correct the back lash either by
replacing gears or housing.
Bearing seat loosen Replace the gearing or replace the housing.
Bearing play more Replace the gearing.
Excessive end play Correct the end play by tightening the Hex retaining nut or replacing spacers/gears.
Knocking (Noise of sharp blue) Dent on the Gear Tooth Remove the dent by polishing.
Gear tooth damage Replace the gear.
Foreign matters present Clean the Gear train and strain the Oil.
Insufficient oil. Top up the oil.
Detent Lock assy. Tight Replace detent-retaining spring.
Bent in Shifter rod Replace the shifter rod.
Gear tooth battered Replace the gear.
2 HARD SHIFTING Sliding Gears tight on shaft Free the Gears shaft by polishing or by replacing gear/shaft.
Pilot Bearing Jam Replace the gearing
Excessive Clutch Free Paly Adjust & correct Free Play.
Inter-lock pin tight Loosen the pin by polishing.
Clutch is not disengaging. Adjust & Correct
Incomplete Gear Engaging Engage Gear fully.
Weak Detent Retaining spring Replace the spring.
3 GEAR SLIPPING OUT Shifter rod retaining groove worn out Replace shifter rod.
Gear teeth rounded off Replace the gear.
Worn out / Bent Shifter Fork Replace the Shifter Fork.
Detent balls/ spring stuck Free & Lubricate.
4 GEAR STICKING Scoring on Fork. Replace fork
Clutch not disengaging. Adjust & correct.

 

DIFFERENTIAL

 

S.NO. TROUBLE PROBABLE CAUSE REMEDIES
1 HUMMING 1 .Incorrect adjustment of Crown Wheel & 1 .Re-adjust as per the procedure.
Tail Pinion. 2.Tooth contact pattern not correct. 2.Correct the tooth contact pattern by doing the adjustment as per the procedure.
2 NOISE WHILE ACCELERATING Tooth contact shifted towards thick end. Adjust Tooth Contact pattern as per the procedure.
3 NOISE WHILE DE-ACCELERATING Tooth contact shifted towards thin end. Adjust Tooth Contact pattern as per the procedure
1 .Bevel Pinion tight on Bevel Gear. 1 .Correct the gap.
NOISE WHILE 2.Damaged teeth of Bevel 2.Replace the damaged gear.
4 TURNING 3. Excessive backlash between Bevel Pinion 3.Correct the backlash.
and Bevel Gear 4.Replace the bearing.
4.Defective axle bearing