Recommended maintenance schedule for DI, RX and WT – Models

INTERVALO de EVERY
50 250 500 750 1000 1250
MANUTENÇAO (HRS) 10

ITEM DE SERVIÇO
GERAL
LAVAGEM COMPLETA – W W W W w W

LUBRIFICAÇAO DOS
– G G G G G G
NIPLOS
NIVEL DO
C C C C C C C
REFRIGERADOR
PURIFICADOR DE AR
OLEO DE LIMPEZA DE
C R R R R R R
AR
ELEMENTO DE
LIMPEZA DE AR – K K K K K K
MOLHADO

ELEMENTO DE
– K K R K R K
LIMPEZA DE AR SECO

BRAÇADEIRAS DA
MANGUEIRA DE T T T T T T T
ADMISSAO DE AR
MOTOR
ENGINE VALVE
– A A A A A A
CLEARANCE
ENGINE OIL – R R R R R R
ENGINE OIL FILTER – R R R R R R
ENGINE IDLE SPEED – C C C C C C

FUEL INJECTION
– C C C C C C
TIMING
TURBO CHARGER
INTAKE HOSE – T T T T T T
CLAMPS
BELL HOUSING NUT &
– T T T T T T
BOLTS
COOLING SYSTEM

FAN BELT TENSION C C&A C&A C&A C&A C&A C&A

COOLANT SYSTEM
– – – – R – –
FLUSHING
 CLUTCH

CLUTCH OPERATION
C C&A C&A C&A C&A C&A C&A
& PEDAL FREE PLAY

TRANSMISSION/HYDRAULIC
OPERATION OF
– C C C C C C
GEARS
TRANSMISSION /
– C C C C R C
HYDRAULIC OIL
TRANSMISSION /
HYDRAULIC – R R R R R R
OILFILTER
HYDRAULIC OIL
– K K R K K R
STRAINER

TRANSMISSION
K K K K K K K
BREATHER

OPERATION OF LIFT – C C C C C C
FUEL SYSTEM
PRIMARY FUEL
– – R – R – R
FILTER
SECONDARY FUEL
– – – R – R –
FILTER

FIP FEED PUMP BOWL K K K K K K K

FUEL SEDIMANTOR D D D D D D D

INJECTOR PRESSURE
– – – – C – –
& SPRAY

BRAKES

BRAKE OPERATION &

PEDAL

FREE PLAY C C C C C C C
 BRAKE
– K K K K K K
HOUSING/LINING
STEERING
STEERING
– C C C C C C
OPERATION
STEERING GEAR OIL
– C C C C C C
LEVEL

STEERING OIL FILTER – – – – R – –

LINKAGES FOR PLAY – c c c C c c

KING PIN – c c c C c c
TOE IN – C&A C&A C&A C&A C&A C&A
WHEELS & TYRES
WHEELS NUTS
– T T T T T T
&BOLTS
TYRES INFLATION – C C C C C C
FRONT & REAR AXLE
STUB AXLE GREASE – G G G G G G
WHEEL BEARING
– G G G G G G
GREASE
BATTERY

BATTERY
C C C C C C C
ELECTROLYTE LEVEL

BATTERY TERMINAL
– G G G G G G
GREASE
ELECTRICALS
FUNCTIONING OF OIL
C C C C C C C
GAUGE
FUNTIONING OF
TEMPERATURE C C C C C C C
GAUGE
LEGANDS
A : ADJUST
C : CHECK
K :CLEAN
R : REPLACE
D : DRAIN
G : GREASE
T : TIGHTEN
W: WASHING
1500

A
R
R
C

C&A

R
C&A

C
 K

C
C
C&A

T
C

G
G

C
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Recommended Grade Of Lubricants & Greases Di
TRACTO
DI-745III
RMODE DI-730II DI-730III DI-35II DI-35 DI-35 DI-750III DI-55
(S3)
L
Paddy (S3MEC
(S1A) (S1) (S1A) (S1A) (S3) (S3PS)
Spl H)

DRIVE 2WD 2WD 2WD 2WD 2WD 2WD 2WD 2WD

ENGINE OIL
QUANTI
TY(In 6 8.2 6 8.2 8.2 8.2 11.25 11.25
Litres)
GRADE SAE20W40
VENDO
TIDEWATEROIL& HP
R
AIR CLEANER OIL
QUANTI
TY(In 0.5 0.9-1.0
Litres)
GRADE SAE 20 W 40
VENDO
TIDEWATEROIL& HP
R
BRAKES
MAINBR
I DRY DISC BRAKE OIB
AKE
HYDRAULIC SYSTEM & TRANSMISSION OIL
QUANTI
TY(In 60.5 61 60.5 60.5 50 50 57 63
Litres)
GRADE E P.80.GL-4 ELF-2412
VENDO
HP ELF
R
GREASE
QUANTI
TY(In 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75
Kg)
Recommended Grade Of Lubricants & Greases RX
TRACTO
DI – DI – 42
R DI-40RX TURBO DI-47RX DI-52RX
39RX RX
MODEL
DRIVE 2WD 2WD 2WD 2WD 2WD
ENGINE OIL
QUANTI
TY (In 8.2 8.2 8.2 8.2 8.2
Litres)
GRADE SAE 20W
VENDO
TIDE WATER OIL &
R
AIR
CLEANE DRY AIR CLEANER WITH
R OIL
BRAKES
MAIN
Dry disc/OIB OIB Dry disc/OIB Dry disc/OIB
BRAKE
HYDRAULIC SYSTEM & TRA
QUANTI
TY (In 60.5 60.5 60.5 61 61
Litres)
GRADE E P.80.GL-4 (DRY BRAKES)
VENDO
HP
R
GREASE
QUANTI
TY (In 0.75 0.75 0.75 0.75 0.75
Kg)
Recommended Grade Of Lubricants & Greases – Gardentra
SONALI
KA
TRACTO NTERNA
R TIONAL
MODEL DI-20
GARDE
NTRAC
ENGINE
MVL3E
MODEL
ENGINE OIL
QUANTI
3.6 Liters
TY
15W 40
GRADE
CH/C 14
AIR CLEANER
OIL
QUANTI
0.2 Liters
TY
SAE 20
GRADE
W 40
TRANSMISSION
OIL
QUANTI
17 Liters
TY
GRADE EP 80
In
common
HYDRA
with
ULIC OIL
Transmis
sion oil
Multipurp
GREASE ose
grease
Recommended Grade Of Lubricants & Greases Worldtrac
SPECIFI RECOM
CATION MENDE
S D
ENGINE
SAE
TYPE :
20W-40

14.0 to
VISCOSI
16.0 cST
TY :
at 100T

CLASSIF
ICATION API CD
:
TRANSMISSION,
HYDRAULIC
FLUID, REAR
AXLE AND
FRONT AXLE OIL
ELF –
TYPE :
2412
CLASSIF
API GL4
ICATION
– GL5
:
STEERING OIL
DEXTRO
TYPE :
N II D
FRONT AXLE
TYPE : API GL- 4
Sonalika Branded Engine Oil
 DI75 DI90

2WD/4W 2WD/4W
DOPTIO DOPTIO
N N

11.25 12

DRY AIR
CLEANER

OIB

61 62

ELF-2412
ELF

0.75 0.75

DI-60 MM SUPER
DI-52RX DI-55RX DI-55RX TURBO DI-60RX TURBO DI-60RX
RX

2WD 2WD 2WD 2WD 2WD 2WD

ENGINE OIL
 8.2 8.2 8.2 8.2 8.2 11.25

SAE 20W40
TIDE WATER OIL & HP

DRY AIR CLEANER WITH CLOGGING SENSOR

BRAKES
OIB Dry disc/OIB OIB Dry disc/OIB OIB
DRAULIC SYSTEM & TRANSMISSION OIL

61 61 61 61 61 61

DRY BRAKES) ELF-2412 (OIB)

ELF
GREASE

0.75 0.75 0.75 0.75 0.75 0.75

DI-60RX

2WD
11.25

OIB

61

0.75
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Do & Donts
Engine
DO’S
General
Do release the starter key once the engine has started.
Do check the proper functioning of oil pressure gauge and battery charging indicator once the engine has started
Do get the tightness of cylinder head and manifold nuts checked regularly

Air Inlet System

Do inspect the air element clean if necessary.

Do check are the inlet Hose and clamps regularly.

Fuel System

Do drain sediments from the fuel tank periodically

Do clean fuel tank throughly once in every 500 hrs.
Do drain water and sediments from the water separator & feed pumpstrain bowl.
Do change filter regularly as recommended as per recommended service schedule.
Do fill in diesel in the tank at the end of the day\’s work so as to avoid condensation.
Do ensure that pull to stop cable / knowb is not in pulled condition.

Water cooling System

Do ensure that radiator is always filled with clean (soft)water & radiator cap in tight.
Do clean the radiator front grill to ensure free flow of air when the engine is operating.
Do ensure proper tension of fan belt. Deflection should not be more than (10 mm) when pressure is applied betw
pulley and the crankshaft pulley.
Lubrication System
Do replace engine oil after first 50hrs of operation. Thereafter, should be refilled every 250 engine oil working hrs
Do replace lubricant oil filter element every 20 working hrs. After Ist replacement at 50 hrs.
Do remove fly wheel housing bottom plug and check for oil traces.
DON’T’S
General
Do not keep on continuously cranking the engine with starter key. It will shorten the life of battery & starter.
Do not race the engine in neutral or at the time of cranking.
Air Inlet System
Do not run the tractor if the air cleaner assembly is defective as this will lead to impure air being taken in and con
excessive wear of liners and piston rings.
Fuel System
Do not keep the fuel tank without a proper sealing cap.
Do not use contaminated fuel as if may effect the operation of fuel injection pump and the injections.
Do not use bad quality spurious filters as replacement.
Do not allow leakage through fuel pipe joints.Do not replace both fuel filters at a time.
Water Cooling System
Do not run the tractor with the radiator cap removed/non- acting radiator cap.
Do not run the tractor when the radiator hoses are leaking as it will lead to or heating of the engine.
Do not remove thermostat as it will effect engine performance.
Do not run the belt tight as it will lead to premature failure of water pump and alternator bearing.
Do not run the belt loose as it will lead to inefficient cooling and improper charging of the battery.
Lubrication System
Do not use wrong grade of lubrication oil.
Do not mix different brands of engine oil.
Exhaust System
Do ensure that the exhaust passage is not blocked
Clutch
DO’S
Do ensure that clutch free pedal play is between 15 to 25 mm.
Do ensure that the clutch pedal is released slowly while moving the tractor.
DONT’S
Do not rest the foot on the clutch pedal.
Do not work the tractor by slipping and re-engaging the clutch.
Do not coast down steep slopes with tractor in neutral/with clutch pedal depressed.
Transmission
DO’S
Do change the transmission oil after 400 & subsequently hrs. of operation.
Do check the condition of rubber protection bellows on the gear levers periodically as they prevent infiltration of w
into gear box

DONT’S

Do not use top gears with low engine rpm.

Hydraulic System & Linkage
DO’S
Do ensure that both hydraulic control levers are in down position while draining the transmission oil.
Do ensure that the hydraulic strainer is cleaned at every schedule.
Do adjust the top link for proper length.
Do ensure that the lift cover bolts are always tight.
Do keep the lower links in lifted position when the tractor is moving without an implement mounted on it.
Do keep the ball joints on top and lower links clean and dry. Do not lubricate them.
Do ensure that implements are raised and lower using the position control lever only and not the draft control leve
DONT’S
Do not move the operational control range to fast response, while the tractor is on a hard surface like concrete, a
Do not attempt to pull or tow anything from the top link connection. It is dangerous
Do not use bolts place of linch pins.
Do not reverse the tractor with PTO driven implement attached and PTO lever in ground PTO position implement
Braking System
DO’S
 Do keep the brake pedals locked with interlocking latch when the tractor is not being used in field.
Do use parking brakes when the vehicle is stationary
Do check loose connections in linkage mechanism.
Do grease brake pedal bush, brake bracket connections.
DONT’S
Do not attempt to turn sharply using independent brakes when traveling at high speed. This may cause the tracto
Do not rest foot on the brake pedal.
Front Axle & Steering Mechanism
DO’S
Do lubricate the Bushes and steering drag links periodically.
Do get the toe-in adjusted by an authorised service centre periodically. It should be maintained between (3-6 mm
Do check the tightness of front and rear wheels recommended torque (Front wheel is 160 mm, Rear wheel 200 m
Do flush oil once a year or 1000 hrs which ever is earlier. If tractor is not in operation
DONT’S
Do not use wrong grade of oil for lubrication of steering gear box.
Tyres
DO’S
Do operate the tractor with correct tyre pressure. This will lead to better traction, longer tyre life and better fuel co
DONT’S
Do not allow oil, grease and some crop spray containing considerable amounts of acid and alkalies to contaminat
Do not operate the tractor with excessive tyre pressure
Electricals
DO’S
Do ensure that the battery terminals are kept clean.
Do ensure terminal base is Lubricated with petroleum jelly.
Do earth the tractor by wrapping a chain around the front axle, dropping one end of the chain on the ground.
DONT’S
Do not change leads of the battery terminals as this will lead to failure of electrical components.
Do not leave the battery leads in the connected position if the tractor is not going to be used for a long period of ti
Do not overfill the battery with distilled water. The level should be just enough to submerge the battery plates.
Do not do any welding in the tractor without disconnecting Battery terminals
Save Diesel
Let’s Join hands
Do switch off the engine when tractor is not in operation. Avoid unnecessary idling.
Do operate at Optimum speed and correct gear.
Do maintain the recommended tyre pressure for fuel efficient operation and long life of tyres. Check daily.
Do use matching trailer for transportation. Ensure proper hitching. Never overload the trailer.
Do maintain your tractor in good working condition.
Do replace genuine parts from SONALIKA Authorised Dealers.
EVERY DROP COUNTS
To save oil
Do not allow fuel or oil to leak. Ensure that the joints are adequately tight.
Do not spill fuel or oil while filling or topping up. Use funnel.
Do not overfill engine oil as this can cause excessive oil consumption and oil leaks.
 Do not ride the clutch or brake pedal.
Do not allow the rear wheel to slip. Use ballast, if necessary.
Do not use worn-out tyres.
Do not use inferior quality lubricants, use only recommended grade
For Better performance
Ensure that safety shields are in place and in good condition.
Read all operating instructions before commencing to operate Tractor.
Keep the air cleaner clean.
Fit new sealing rings when the filter elements are changed.
Watch the oil pressure gauge or warning light and investigate any abnormality immediately.
Ensure that the transmission is in neutral before starting the engine.
Keep all fuel in cleans storage and uses a filter when filling the tank.
Attend to minor adjustments and repairs as soon as the necessity is apparent.
Allow the engine to cool before removing the radiator filler cap and adding water, remove the radiator cap slowly.
Shift into low gear when driving down steeps hills.
Latch the brake pedals together when driving on a highway.
Keep draft control lever fully down when not in use.
For safe operation
Do not Run the engine with the air cleaner disconnected.
Do not Start the tractor in an enclosed building unless the doors and windows are open for proper ventilation.
Do not Operate the tractor or engine while lubricating or cleaning.
Do not Temper with the fuel injection pump, (if the seal is broken) the warranty becomes void.
Do not Allow the engine to idle for a long period.
Do not Use the independent brakes for making turns on the highway or at high speeds.
Do not Refuel the tractor with the engine running.
Do not Use the draft control lever for lifting of implements.
Do not Start the engine with the PTO engaged
mplement will crash down and get damaged

et damaged in reverse
yre. These can cause considerable damage to the tyre if they penetrate into plies through small holes or splits.
es or splits.
Solução de problemas
Embraiagem

S No PROBLEMA PROVAVEL CAUSA

Freios

S.No. PROBLEMA CAUSAS PROVÁVEIS

Nenhuma acção de Articulação do pedal quebrada ou
1.
travagem desconectada
Ajuste de freio impróprio
POBRE ACÇÃO DE
2. Revestimentos de freio de vidro
TRAVAGEM
Disco de freio envidraçado
Mola retrátil de ligação solta
Tensão da mola da placa do disco de
3. Travagem de freio
freio
Ligação na ligação
SubstituirRebites soltos de forro de
freio
Forro de freio desgastado
RUÍDO ENQUANTO Placa de disco de freio áspera ou
4.
TRAVAR desgastada

Matérias estranhas embebidas em forro

Parte solta no sistema.

Pedal de freio e embreagem

S. No. PROBLEMA CAUSAS PROVÁVEIS

RUIDO AO Falta de lubrificação no rolamento

1 PRESSIONAR O PEDAL de liberação da embreagem
DE EMBRAIAGEM
Dano do rolamento da liberação da
embreagem
Falta de lubrificação no rolamento
piloto
Ruído ao libertar o Dano do rolamento piloto
2
pedal da embreagem Cubo do disco da embreagem solto
no eixo de entrada

Substitua as peças gastas

3Balanço do pedal da embreagemLubrificação na articulação do pedalLubrificar Atolamento do pedal da embreage
Engraxar o eixo Alinhamento e transmissão não alinhadosRealign Face do volante acabar mais Corrija o trecho o
liberação não ajustada de forma uniforme.Ajustar e corrigir Montagem da placa de pressão desalinhadaRealign Pl
ou face da embreagem Substituir

S No PROBLEMA PROVAVEL CAUSA

BARULHO
Desgaste no flanco dos dentes da
Cantarolando
engrenagem
Danos no flanco dos dentes da
(um ruído pecutior)
engrenagem
Moagem metálica Nível de óleo baixo.

Retrocesso menos
Lamento (som de
passagem de bala)
Maquinação de engrenagens
impróprias
(um ruído pecutior) Rolamento desgastado
(Vazamento de ruído
de tenda de pneu a Bola de rolamento / corrida sem cor
falta de ar)
1 Backlash mais

Ratting (série Ruppict

de curto ruído alto) Assento do rolamento afrouxar
Rolamento jogar mais
Jogo final excessivo
Dent no dente da engrenagem
Dano do dente da engrenagem
Matérias estrangeiras presentes
Batendo (ruído de azul
agudo) Óleo insuficiente.
Conjunto de bloqueio de detenção
Dobrado na vareta do Shifter
Dente de engrenagem golpeado

Engrenagens deslizantes apertadas no

eixo

Atolamento do Rolamento Piloto

A embreagem não está desengatando.

DESLOCAMENTO A embreagem não está desengatando.

2
DURO
 DESLOCAMENTO
2
DURO

Ranhura de retenção da barra de

mudança desgastada…
Ranhura de retenção da barra de
mudança desgastada
Ranhura de retenção da barra de
mudança desgastada
Ranhura de retenção da barra de
mudança desgastada
DESLOCAMENTO Dentes de engrenagem arredondados
3
DURO
Bolas de retenção / mola presa
Bolas de retenção / mola presa
Pontuação no garfo.
4 ENGRENAGEM
Embreagem não desengatada.

DIFFERENCIAL

S No PROBLEMA PROVAVEL CAUSA

1 .Ajuste incorreto da coroa e pinhao da
cauda
1 HUMMING
2.O padrão de contato do dente não
está correto.

Contato dentado deslocado para a

2 RUÍDO AO ACELERAR
extremidade grossa

Contato dentado deslocado para a

RUÍDO ENQUANTO extremidade fina.
DES ACELERAR
3 1 .Pinhão de chanfro apertado na
engrenagem cônica.

RUÍDO ENQUANTO 2.Damaged teeth of Bevel

3. Folga excessiva entre o pinhão

chanfrado
4 GIRANDO
e engrenagem cónica
4.Rolamento do eixo com defeito
 Ruído ao liberar o pedal da embreagem

REMEDIO

RECURSOS

Substituir ou reparar

Ajustar e corrigir
Substituir
Corrigir usinando ou substituindo
Substituir as molas
Substituir as molas
Lubrifique e livre
Corrigir ou substituir
Substituir
Corrigir usando uma maquima ou
substituindo

Limpe os forros
Aperte o que esta solto

em

RECURSOS

Lubrificar

substituir

Lubrificar
substituir

Substitua as peças gastas

ento do pedal da embreagem no eixo da embreagem
bar mais Corrija o trecho ou substitua Alavanca de
são desalinhadaRealign Placa de pressão emendada

REMEDIO

Substitua a engrenagem.

Substitua a engrenagem.
Encha a alavanca do óleo.

Corrija o chicote traseiro, substituindo

as engrenagens no alojamento.

Substitua a engrenagem.
Substitua a engrenagem.

Substitua a engrenagem.

Corrija o chicote para trás

substituindo engrenagens ou
habitação.
Substitua a engrenagem ou substitua
a caixa.
Substitua a engrenagem.
corrija a folga final apertandoa porca
Remova o dente polindo
Substitua a engrenagem.
Limpe o trem de engrenagens e coe o
óleo.
Encha o óleo.
Substitua a mola de retenção.
Substitua a haste do câmbio.
Substitua a engrenagem.
Libere o eixo das engrenagens
polindo ou substituindo a engrenagem
/ eixo.
Substitua a engrenagem
Ajuste e corrija o jogo livre.

Solte o pino polindo.

 Ajustar e Corrigir

Ajustar e Corrigir

Substitua a mola.

Substitua a vareta do manípulo.

Substitua a engrenagem.
Substitua o garfo do deslocador.
Livre e lubrifique.
Substituir o garfo
Ajuste e corrija.

REMEDIO
1 .Reajuste de acordo com o
procedimento.
2.Corrija o padrão de contato do
dente fazendo o ajuste conforme o
procedimento.

Ajuste o padrão de contato do dente

de acordo com o procedimento

Ajustar o padrão de contato do dente

de acordo com o procedimento

1 .Corrija a lacuna.

2.Substitua a engrenagem danificada.

3.Corrija a folga.
4.Substitua o mancal.
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Troubleshooting
Clutch

S No PROBLEM PROBABLE CAUSES

Lack of lubrication in Clutch Release

Noise while pressingthe Bearing
1
clutch pedal
Clutch Release Bearing damage
Lack of lubrication in Pilot Bearing
Noise while
2 Pilot Bearing damage
releasingclutch pedal
Clutch disk hub loose on Input shaft
Clutch Pedal free play
Broken or Weak pressure spring

Release lever height incorrect

Grease or oil on facings

Glazed clutch facing
3 Clutch slippage
Glazed flywheel or Pressure plate face

Wraped Clutch facing

Wraped Flywheel or Pressure plate
face

Clutch not Clutch Pedal free play more

4 disengagewhile pressing
clutch Release lever height setting improper

Driver Clutch pedal riding

Excessive and incorrect use of clutch

5 Wear of clutch facing Cracks in flywheel or pressure plate

face
Weak or broken pressure spring
Clutch pedal free play less
Lack of lubrication in pedal linkage
Clutch pedal jam on clutch shaft
6 Clutch pedal hard
Release lever height setting improper
 Engine and Transmission not improper

Flywheel face run out more

Release lever not evenly adjusted

Pressure plate assembly misaligned

7 Clutch Pedal Pulsation
Warped pressure plate or clutch facing

Clutch plate nut free on

Workest clutch facing

Brakes

S.No. PROBLEM PROBABLE CAUSES

1. NO BRAKING ACTION Pedal linkage broken or disconnected

Brake setting improper

POOR BRAKING
2. Glazed brake liners
ACTION
Glazed brake disc
Linkage retracting spring loose
3. BRAKE STUCKING Brake disc plate spring tension less
Binding in linkage
Loose rivets of brake lining
Worn out brake lining
NOISE WHILE
4. Rough or worn out brake disc plate
BRAKING
Foreign matter imbedded in lining
Loose part in the system.

Brake & Clutch Pedal

S. No. PROBLEM PROBABLE CAUSES

Lack of lubrication in Clutch Release

Noise while pressing the Bearing
1
clutch pedal
 Noise while pressing the
1
clutch pedal
Clutch Release Bearing damage
Lack of Lubrication in Pilot Bearing
Noise while releasing Pilot Bearing damage
2
clutch pedal
Clutch disc hub loose on input shaft

Replace
the worn
out parts
clutch
shaft
Grease
the shaft
Release
Lever
height
setting
improper
Adjust &
correct4
Clutch
pedal
pulsation
Engine
and
Transmis
sion not
alignedR
ealign
Flywheel
face run
out more
Correct
run out
or
replace
Release
lever not
evenly
adjusted.
Adjust &
correct
Pressure

GEARBOX

S.No. PROBLEM PROBABLE CAUSES

NOISE
Humming Wear on gear teeth flank
(a pecutior noise) Damage on gear teeth flank
Metallic grinding Oil lever low.
 Whine (Bullet passing Backlash less
sound)
Gear machining improper
Hissing Worn out bearing
(Leaking noise tent-tire
Bearing ball/race pitted
to air lack)
Backlash more

1
Ratting (Ruppict series of Bearing seat loosen
short loud noise)
Bearing play more

Excessive end play

Dent on the Gear Tooth

Gear tooth damage
Foreign matters present
Knocking (Noise of sharp
Insufficient oil.
blue)
Detent Lock assy. Tight
Bent in Shifter rod
Gear tooth battered

Sliding Gears tight on shaft

Pilot Bearing Jam

Excessive Clutch Free Paly
2 HARD SHIFTING
Inter-lock pin tight
Clutch is not disengaging.
Incomplete Gear Engaging
Weak Detent Retaining spring

Shifter rod retaining groove worn out

3 GEAR SLIPPING OUT Gear teeth rounded off

Worn out / Bent Shifter Fork
Detent balls/ spring stuck
Scoring on Fork.
4 GEAR STICKING
Clutch not disengaging.

DIFFERENTIAL

S.NO. TROUBLE PROBABLE CAUSE

1 .Incorrect adjustment of Crown
Wheel &
1 HUMMING
Tail Pinion. 2.Tooth contact pattern not
correct.
 NOISE WHILE Tooth contact shifted towards thick
2
ACCELERATING end.

NOISE WHILE DE- Tooth contact shifted towards thin end.

3 ACCELERATING
1 .Bevel Pinion tight on Bevel Gear.
NOISE WHILE 2.Damaged teeth of Bevel
3. Excessive backlash between Bevel
Pinion
4 TURNING
and Bevel Gear
4.Defective axle bearing
1; }</style>

REMEDIES

Lubricate

Replace
Lubricate
Replace
Replace the worn out parts
Adjust & correct (25 to 35 mm)
Replace springs
AdjUSt & COrreCt (SC.40to44mm)
(DC28to36mm)
Replace the facing, check source of
Replace facing

Correct by machining or replace

Replace the clutch facing

Correct by machining or replace

Adjust & correct

Adjust & correct

Keep foot off clutch pedal

Reduce use

Correct by machining or replace

Replace spring
Adjust & correct
Lubricate
Grease the shaft

Adjust & correct

 Realign

Correct run out or replace

Adjust & correct

Realign

Replace

De and check clean

REMEDIES

Replace or Repair

Adjust & correct

Replace
Correct by machining or replace
Replace springs
Replace springs
Lubricate & free
Correct or replace
Replace
Correct by machining or replace
Clean the liners
Tighten the loose

REMEDIES

Lubricate
 Replace
Lubricate
Replace

REMEDIES

Replace the gear.

Replace the gear.
Top up oil lever.
 Correct the back lash either by replacing
gears on housing.
Replace the gear.
Replace the gearing.

Replace the gearing.

Correct the back lash either by

replacing gears or housing.

Replace the gearing or replace the housing.

Replace the gearing.

Correct the end play by tightening the Hex
retaining nut or replacing spacers/gears.
Remove the dent by polishing.
Replace the gear.
Clean the Gear train and strain the Oil.
Top up the oil.
Replace detent-retaining spring.
Replace the shifter rod.
Replace the gear.
Free the Gears shaft by polishing or by
replacing gear/shaft.
Replace the gearing
Adjust & correct Free Play.
Loosen the pin by polishing.
Adjust & Correct
Engage Gear fully.
Replace the spring.

Replace shifter rod.

Replace the gear.

Replace the Shifter Fork.
Free & Lubricate.
Replace fork
Adjust & correct.

REMEDIES

1 .Re-adjust as per the procedure.

2.Correct the tooth contact pattern by doing

the adjustment as per the procedure.
Adjust Tooth Contact pattern as per the
procedure.
Adjust Tooth Contact pattern as per the
procedure
1 .Correct the gap.
2.Replace the damaged gear.

3.Correct the backlash.

4.Replace the bearing.