Engine part
1. The starting function can drive the engine to run, but there is no sign of starting.
The phenomenon that causes the engine to produce this phenomenon is generally caused by poor fuel system. It is divided into low-pressure oil circuit and high-pressure oil circuit. When checking, first determine which part of the fault is caused. First, deflate the fuel injection pump, loosen the bolt and turn the hand pump to see the oil In case, if there is no oil or foamy diesel is flowing out, it means the low pressure oil circuit, otherwise it is the high pressure oil circuit failure.
(1) Low pressure oil circuit failure
1. No oil in the fuel tank: refueling
2. The oil pipe is blocked, the treatment method: clean and dredge
3. The filter screen of the oil pump is blocked, and the treatment method: clean
4. Oil pipe is aging and leaking, replace
5. The diesel filter is too dirty, replace it
6. The piston of the oil transfer pump is damaged, replace it
(2) High pressure oil circuit failure: 1. Fuel injection pump does not work, correct it 2. Injector does not work correct or replace
(2) The injection time is too early
phenomenon
1. There is a rhythmic and crisp "quack" metal percussion in the cylinder
2. The engine is overheated, weak, and emits black smoke
3. Poor idle speed
4. Not easy to start
Approach
Loosen the fixing screw of the fixed plate and slowly delay the injection time until the injection situation improves. You can also remove the first cylinder high pressure pipe and turn the crankshaft. Pay attention to the oil level in the oil outlet valve compression seat of the injection pump. At the moment when the oil level fluctuates slightly, check whether the fuel injection timing scale line on the flywheel coincides with the mark on the flywheel housing to see if the advance angle meets the regulations. If it does not meet the regulations, make adjustments.
(2) The injection time is too late
phenomenon
1.The cylinder has a low and unclear knocking sound.
2. The engine speed cannot be increased with increasing throttle
3. Engine overheating: weakness and white smoke
Check whether the fixing screw of the connecting plate is loose and shifted. Loosen the fixing screw of the fixing plate and slowly advance the injection time until the injection situation improves. If the adjustment is invalid, check the timing adjustment on the plunger of the injection pump. Whether the screw is out of adjustment, readjust if it is out of adjustment.
(3) Engine weakness
cause of issue
1. Insufficient oil supply in the low-pressure oil circuit, blockage of the fuel tank vent, blockage of the oil pipe, loose joints and loose gasket seals. Treatment method: find out the fault to clear the oil circuit and replace
2. The air filter is clogged and the air intake is not smooth, how to deal with it, please replace or clean the filter
3. Clogged diesel filter, treatment method: replace
4. Insufficient oil supply of the oil pump, treatment method: repair or replace
5. There is air or moisture in the fuel system, treatment method: remove air or moisture
6. If the injection time is too early or too late, the treatment method: adjust
7. The exhaust pipe or muffler is blocked and the exhaust is not smooth. Treatment method: clean
8. Insufficient fuel injection of the fuel injection pump, treatment method: check the fuel pump
9. Poor atomization of individual injectors, treatment method: find out where the cylinder is faulty, replace or repair the injector
10. The engine temperature is too high, check the cooling system to find out the fault and eliminate it
11. Improper adjustment of throttle cable, adjustment
12. Mechanical factors cause the cylinder pressure to be too low. The mechanical factors are: the valve of the valve mechanism is not closed tightly and the piston, piston ring, cylinder liner is seriously worn, etc., adjust the valve clearance, re-grind the valve or replace the piston, piston ring and lining, grinding cylinder liner, etc.
(4) Sudden flameout during operation
phenomenon
1. Sudden flameout during engine operation
2. No abnormal symptoms before flameout
The cause of the failure and the treatment method:
1. No oil in the fuel tank: Treatment method: refuel
2. Diesel oil is mixed with water or air, treatment method: remove water or air
3. The oil pipe is blocked or broken, the treatment method: dredge or replace the oil pipe
4. The fuel filter is clogged, treatment method: replace
5. The oil pipe joint is loose and air intake, the treatment method: squeeze the joint to drain the air in the oil path
6. The oil transfer pump does not supply oil, the treatment method: repair or replace the oil transfer pump
Transmission system part
(1) Technical parameters of hydraulic transmission
1. Transmission power 40KW
2. Input speed 1800-2400N/min
3. Turning (viewed from the input end) clockwise
4. Clutch piston stroke, 1.2-1.7MM
5. Working oil, 20# steam turbine oil (or 6# or 8# hydraulic transmission oil)
6. Working oil temperature 70-95 degrees Celsius
7. The highest oil temperature does not exceed 110 degrees Celsius
(2) Decline in efficiency
(1) Torque converter part
1. The engine speed drops, the treatment method: increase the engine speed
2. There are bubbles in the oil, check the tightness of the pipeline and whether the hydraulic oil has deteriorated
3. The oil temperature rise is too high or too low
(2) Transmission part
1. The grinding disc is stuck or worn, check whether the grinding disc has glue, uneven contact, and warpage
2. The seal ring or O-ring is worn out, check whether the seal ring and groove width are worn out or damaged
(3) The oil temperature is too high
(1) Torque converter part
1. The torque converter works in the low speed ratio area for a long time, the efficiency of the torque converter is very low, or the time in the stall state is too long, this working condition should be changed and attention should be paid to avoid the above working conditions.
2. At a high speed ratio, the one-way clutch is stuck and loses control. It should be checked and ruled out.
3. Too little fuel, or air bubbles are generated in the system, increase the fuel to adjust the discharge valve pressure.
4 If the quality of the oil is unqualified, new oil should be replaced.
(2) Transmission part.
1. Clutch obstacle, check whether the friction plate is slipping.
2 The bearing is damaged, check whether the mating surface is damaged.
(4) The gearbox does not work
1. Check whether the control valve is stuck or broken by the spring.
2.Check whether the main oil pressure is normal. If it is abnormal, check whether the triple pump is excessively worn or damaged.
3. If the main oil pressure is normal, check the clutch oil pressure. If it is abnormal, check whether the seal ring or O-ring is worn or damaged. Check whether the clutch and clutch piston ring are damaged.
4. Check whether the oil pressure of the torque converter is normal, if not, check the torque converter.
2. Mechanical gearbox part
(1) Clutch system failure
The main manifestation of poor clutch technology is the specific performance of clutch slip
1. The vehicle speed should not increase as the engine speed increases.
2. Difficulty starting and unable to exercise.
3. As the temperature of friction parts increases, the friction coefficient decreases.
4. The high temperature caused by long-term slippage can burn the pressure plate and scorch the clutch plate. Adjust the pedal free stroke and the height of the separation lever during maintenance. If it cannot be released, it depends on whether the clutch trembles when the clutch is combined, the separation is not complete, and the combination and separation Or make noise during operation, etc. When these phenomena are found, you should further check and adjust or repair and replace related accessories.
(2) Difficulties in gear shifting
1. Incomplete clutch separation
2. Check the joint end surface of the joint sleeve and the joint gear ring for damage and deformation of the tooth gallery.
3. Whether the friction surface of the synchronous gear ring and the bevel disk (gear) is worn.
4. The spring force of the positioning spring is weakened and the combined sleeve cannot drive the positioning pin (speed control key) to make the synchronous gear ring. Close contact with the stack (gear) to produce synchronization.
5. The shift fork is bent or twisted so that the axis of the coupling sleeve (clutch gear sleeve) and the coupling tooth are not concentric.
6. The fork shaft is bent or corroded.
The above conditions will cause difficulty in gear shifting or even failure to shift gears. Carefully check the fault location to repair or replace related accessories.
(3) Transmission skipping
Gear skipping is the main reason for this situation when the load increases or the vehicle vibrates severely, the gear lever automatically jumps back to the neutral position from the gear position.
1. The gears and engaging teeth are too worn, replace the gears and engaging teeth.
2.The spring of the self-locking device is too soft or broken, replace the spring.
3. There is too much wear between the synchronization adapter sleeve, the synchronization gear ring and the gear, replace the related accessories.
4. The shift fork is bent or worn, replace or correct the shift fork.
5. The steel ring of the self-locking device cannot be completely stuck in the groove of the shift fork shaft. Check whether the connecting pin and pin hole are loose and whether the joystick, shift fork ball head and ball socket are loose. Or repair.
Brake system.
How to adjust the brakes correctly.
Step 1: Completely loosen the hand brake handle and the brake adjustment screw loosen.
Step 2: When the top rod of the brake master cylinder is completely released, the two sides of the stop must be adjusted evenly.
Finally: adjust the hand brake and the master cylinder jack, the free stroke of the brake pedal must be kept between 10-15MM.
How to judge and eliminate brake unilateral failure
1. The barriers between the left and right wheel brake pads and the brake drum are inconsistent.
2. The brake pads of individual wheels are oily or worn too much or the materials of the brake pads of two wheels are different, repair or replace the brake pads.
3. The brake pad of one wheel is in poor contact with the brake drum or the elastic force of the return spring is too different from that of the other side. Repair or replace related accessories.
4. The air pressure on both sides of the wheel or the tightness of the wheel hub bearing are inconsistent, adjust.
Drive axle
How to judge the sound of drive axle?
1. If the drive axle emits messy and continuous noise and the noise increases with the increase in speed, it decreases or disappears when sliding. It is generally the sound produced after the bearing is worn. It should be repaired or replaced and re-adjusted.
2. If the drive plate makes a rhythmic metal crash during driving, especially when the vehicle speed changes sharply or the noise is very obvious when starting, it is mostly caused by the too large gap between the pot gears, and the gap should be adjusted.
3. A continuous "buzzing" sound and heating of the drive axle are found during exercise, which may be caused by the bearing is too tight or the tooth gap is too small, or it may be poor lubrication. The above phenomenon should be stopped and checked and lubricated. Should check and adjust the bearing tightness or gear clearance.
4. If the vehicle suddenly makes a "gnaw" or "quack" during operation, it is usually because the basin gear set is broken or the bearing falls apart. It should be repaired immediately.
Hydraulic system
1. No lift
1. Check whether the hydraulic pump has enough oil. If the oil pressure output is not checked, whether the hydraulic oil in the tank is enough, the treatment method: add hydraulic oil, check the hydraulic pump and the oil inlet pipeline.
2. Check whether the exhaust valve has serious internal leakage and replace it
3. Check whether the oil cylinder is damaged due to internal leakage, and replace the oil seal or cylinder.
2. The cylinder cannot be lifted when it is half lifted.
This phenomenon occurs in the following situations:
1. There are air bubbles in the hydraulic oil in the oil tank, the hydraulic oil filter element should be checked and replaced.
2. There is no air bubbles in the hydraulic oil in the oil tank. Check and replace the oil pipe from the oil tank to the hydraulic pump.
3. Leak in the cylinder, replace the oil seal.
Third, the direction is heavy
1. The oil pressure is too small, adjust the hydraulic oil flow to increase the pressure.
2. Leak in the steering cylinder, replace the oil seal.
3. Severe abrasion or damage in the steering gear. Replace the steering gear.
4. The bearing in the steering wheel system is damaged, replace the bearing.
Internal combustion engine electrical system
First, the characteristics of the forklift circuit
1. Low voltage 2. Direct current 3. Single wire system 4. Negative grounding 5. Parallel connection
2. Simple maintenance method for the generator without generating electricity:
1. Check whether the fuse is damaged and replace it
2. Check whether the electronic regulator has normal voltage input and output (490B), if there is no input voltage, check the circuit from the ignition switch to the electronic regulator, if there is no output, replace the electronic regulator.
3. Check whether the generator carbon brush and diode are damaged, replace
Three, the horn does not sound
1. Check the power to the horn switch to the horn power cord for disconnection. Repair
2. Check whether the horn switch is burned out or have poor contact, and repair it
3. Directly test whether the speaker is damaged on the power supply and replace it
Four, can not warm up
1. Check whether the preheating relay and timer are damaged, replace
2. Check whether the glow plug is burned out and replace it
3. Check whether the preheating circuit is open or short-circuited, and repair it
5. Inspection methods for lighting system failures:
1. Check if the bulb is damaged and replace it
2. Check whether the switch is burned out, replace or repair
3. Check whether the fuse and circuit are short-circuited, replace or repair.
