Group 2 Operational Checks and Troubleshooting

GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING
1. POWER TRAIN OPERATIONAL CHECKS

This procedure is designed so that the mechanic can make a quick check of the system using a
minimum amount of diagnostic equipment. If you need additional information, read Structure and
function, Group 1.
A location will be required which is level and has adequate space to complete the checks.
The engine and all other major components must be at operating temperature for some checks.
Locate system check in the left column and read completely, following the sequence from left to right.
Read each check completely before performing.
At the end of each check, if no problem is found(OK), that check is complete or an additional check is
needed. If problem is indicated(NOT OK), you will be given repair required and group location.
If verification is needed, you will be given next best source of information :
Chapter 2 : Troubleshooting
Group 3 : Tests and adjustments
3-64
Transmission oil must be at operating temperature for these checks.

Item
Description
Transmission oil warmup procedure
Service action
Start engine. Apply service OK

brakes and release parking brake. Check completed.
Select full automatic switch to
manual mode .
Move gear selector lever to 3rd
speed.
Move gear selector lever to
forward "F" position.
1
2
Increase engine speed to high idle

for 30 seconds.

neutral "N" position and run for 15
seconds.
1
2
3
4
Gear selector lever and

neutral lock latch
checks
Engine OFF.
F
N
R
Repeat procedure until

transmission temperature gauge
arrow points to bar above dial.
Move gear selector lever to each OK
position.
Check completed.
1
2
3
4
NOTE : Gear selector lever

NOT OK
position changes slightly as
Repair lock or replace
steering column is tilted.
switch.
FEEL : Lever must move freely
through all positions.
Engage neutral lock.
Apply slight effort to move lever
into forward(F) and reverse(R).
LOOK : Neutral lock must stay
engaged.
Automatic shifting
check
Start engine.
1
2
3
4
F
N
R
Move gear selector lever to 4th

speed.
NOT OK
Go to transmission error
code group at page 3-32~
LOOK : Automatic sign on
3-51.
display.
Repair or replace the
Move gear selector lever to display or harness.
forward or reverse position.
Turn full automatic switch ON.
Automatic sign
OK
Check completed.
Increase engine rpm.

LOOK : Speed on display must
vary with machine speed.
Mode 1 : 1st
4th
Mode 2 : 2nd
4th
3-65
Item
Transmission noise
check
Engine running.
Description
1
2
3
4
Service action
Run engine at approximately OK

1600rpm.
Check completed.
Drive unit with transmission in NOT OK
each forward and reverse speed.
Go to transmission makes
excessive noise, chapter
LISTEN : Transmission must not
2 in this group.
make excessive noise in any
range.
Engine rpm must not "lug down"
as unit is shifted between gears.
Transmission "quick
shift" check
Engine running.
Release parking brake and select

full automatic switch to manual OK
mode .
Check completed.
NOT OK
Check connector at base
Drive machine at approximately
of control valve.
5km/h and press gear selector
lever kick down switch or RCV IF OK
levers switch once.
Go to transmission
controller circuit in group
LOOK/FEEL : Transmission must
1.
shift to and remain in 1st gear.
Shift to 2nd forward.
Press gear selector lever kick

down switch once.
1
2
3
4

shift back to 2nd gear.
Shift to (3rd or 4th) gear and press
gear selector lever kick down
switch once.
not shift down.
Select full automatic switch to
automatic mode .
Drive machine at approximately
90 speed of max speed in each
gear(2nd or 3rd or 4th).
Shift to(2nd or 3rd or 4th) gear in
each forward and reverse speed
and press gear selector kick down
lever switch or RCV lever switch
once.
LOOK/FEEL : It shift down quickly
from current gear to one step lower
speed and recover to original
speed quickly when push the
switch one more time.(Mode 1)
3-66
Item
Description
Service action
LOOK/FEEL : If shifts down from

current gear to one step lower
speed when push the switch
everytine and recover when push
the switch in 1st gear.(Mode 2)
Forward, reverse and
4th speed clutch pack
drag check
Transmission must
be warmed up for
this check.
Engine running.
Park unit on level surface.

1
2
3
4
Apply service brakes.
OK
Check completed.
NOT OK
If unit moves, repair
neutral.
transmission.
Move gear selector lever to 1st.
Release parking brake and
service brakes.
Run engine at low idle.
LOOK : Unit must not move in
either direction.
NOTE : If unit moves forward,
either the forward pack or the 4th
speed pack is dragging.
Transmission shift
modulation check
Engine running.
1
2
3
4
Run engine at approximately OK

1300rpm.
Check completed.
Put transmission in 1st forward, NOT OK
shift several times from forward to Go to unit shifts too fast,
reverse and reverse to forward. chapter 2 in this group.
Repeat check in 2nd gear.
LOOK : Unit must slow down and
change direction smoothly.
Torque converter check

1
2
3
4
Start engine. Apply service OK

brakes and release parking brake. Check completed.
Move gear selector lever to 3rd NOT OK
speed.
If stall rpm are too low or
too high, problem may be
Move gear selector control lever
engine power or torque
to forward "F" position.
converter.
Increase engine speed to high
IF OK
idle.
Replace transmission
LOOK : Torque converter stall torque converter.
rpm must be within the following
range.
Stall rpm : 2050 70rpm
Move gear selector control lever
to neutral "N" position and run for
15 seconds.
3-67
2. TROUBLESHOOTING
1) TRANSMISSION
Diagnose malfunction charts are arranged from most probable and simplest to verify, to least
likely, more difficult to verify. Remember the following steps when troubleshooting a problem :
Step 1. Operational check out procedure(See group 3 in section 1.)
Step 2. Operational checks(In this group.)
Step 3. Troubleshooting
Step 4. Tests and/or adjustments(See group 3.)
Problem
Transmission slippage
Cause
Remedy
Low oil level.
Add oil.
Wrong oil grade.
Change oil.
Restricted transmission pump Remove and clean screen.

suction screen.
Leak in transmission control valve Remove valve and inspect gaskets.
or gasket.
Low transmission pump flow due Do transmission pump flow test.
to worn pump.
Weak or broken pressure regulat- Do transmission system pressure test.
ing valve spring.
Error code on display
Something wrong in transmission. Go to transmission error code group at page

3-32~3-51.
3-68
Problem
Machine will not move
Cause
Remedy
Low oil level.
Add oil.
Applied park brake.
Check parking brake fuse.

Check continuity to parking brake switch.
No power to transmission contro- Check transmission controller fuse.

ller.
Malfunctioning parking brake Remove and inspect parking brake solenoid
solenoid valve.
valve.
Check for power to solenoid valve.
Machine does not

engage in low gear
Restricted orifice of PPC valve.
Remove orifice and check for contamination

and/or plugging.
(Do not remove valve housing for this purpose.)
Excessive leakage in
transmission element.
Do transmission element leakage test using

system pressure.
Worn clutch disks.
Repair transmission.
Low or no transmission
pressure.
See transmission pressure is low in this group.
Service brake will not release.
Do brake pedal operational check.

Do service and park system drag checks.
Failed torque converter.
Do torque converter stall test.

If engine pulldown in normal, torque converter is
good.
Broken shafts or gears.
Drain transmission to determine if large pieces

of metal contamination are present.
Broken drive shafts.
Inspect drive shafts and universal joints for

external damage. Repair.
Broken ring or pinion gear.
If drive shaft rotate with transmission in gear but

machine does not move, a differential failure is
indicated. Repair.
Malfunctioning transmission Check solenoid valve.

control solenoid valve.
Stuck spool in transmission Remove and inspect transmission control valve
control valve.
spools.
Stuck PPC valve.
Remove end cover to inspect PPC valve.

Replace if necessary.
Malfunctioning transmission Check speed sensor.

speed sensor.
3-69
Problem
Cause
Remedy
Transmission pressure is Low oil level.

low(All gears)
Check transmission oil level and refill if

necessary.
Failed transmission pressure Verify transmission system pressure. Do

switch.
transmission system pressure test.
Plugged suction strainer.
Transmission pump may be noisy if transmission

suction screen is clogged. Drain transmission.
Remove and clean suction screen.
Also, check condition of transmission filter.
Stuck transmission pressure Remove transmission pressure regulating valve.

regulating valve or broken spring. Inspect for damage(See transmission control
valve).
Failed control valve gasket.
Inspect transmission control valve for external

leakage. Remove control valve.
Inspect or replace gasket.
Stuck PPC valve.
Remove end cover to inspect modulation spool

and check torque on cap screws retaining
control valve to transmission.
Transmission system Failed transmission pump.

Do pump flow test.
pressure is low (One or
Failed transmission control valve Inspect transmission control valve for external
two gears)
leakage. Remove control valve.
gasket.
Inspect or replace gasket.
Leakage in clutch piston or seal Disassemble and repair.
ring.
Transmission shifts too Low oil level(Aeration of oil).
low
Low transmission pressure.
Add oil.
Do transmission system pressure test.
Restricted transmission pump Remove and clean screen.

suction screen.
Low transmission pump flow.
Do transmission pump flow test.
Excessive transmission
element leakage.
Do transmission element leakage test using

system pressure.
Stuck PPC valve.
Remove end cover to inspect modulation spool.

Restricted PPC valve orifice.
Remove orifice and inspect for contamination

and /or plugging.
Restricted oil passages between Remove control valve and inspect oil passage.
control valve and transmission
elements.
Incorrect transmission oil.
3-70
Change oil(SAE 10W-30/15W-40)
Problem
Cause
Remedy
Transmission shifts too Wrong transmission controller.

fast
Check if transmission controller has been

changed
System pressure too high.
Stuck PPC valve.
Remove and inspect PPC valve.

Replace if necessary. Also remove end cover to
inspect PPC valve and control valve housing.
Stuck or missing check valves.
Inspect transmission control valve.
Missing O-ring from end of Remove orifice and inspect port for O-ring.
modulation orifice.
Machine "creeps"
in neutral
Broken piston return spring.
Disassemble and inspect clutch.
Change oil(SAE 10W-30/15W-40)
Warped disks and plates in Check transmission.

transmission.
Transmission hydraulic High oil level.

system overheats
Transmission overfilled or hydraulic pump seal

leaking.
Low oil level.
Add oil.
Wrong oil grade.
Change oil.
Park brake dragging.
Check for heat in park brake area.
Pinched, restricted or leaking lube Check cooler lines.

lines.
Machine operated in too high gear Operate machine in correct gear range.
range.
Malfunction in temperature gauge Install temperature sensor the verify temperature.
or sensor.
Do tachometer/temperature reader installation
procedure.
Restricted air flow through oil Do radiator air flow test.
cooler or radiator.
Failed oil cooler bypass valve(In Disassemble and inspect.
thermal bypass valve).
Failed thermal bypass valve.
Remove thermal bypass valve and check to see

if machine still overheats. Do transmission oil
cooler thermal bypass valve test.
Internally restricted oil cooler.
Do oil cooler restriction test.
Leakage in transmission hydraulic Do transmission system pressure, element

system.
leakage test.
Malfunction in converter relief Do converter out pressure test.
valve.
Low transmission pump output.
3-71
Problem
Cause
Remedy
Excessive transmission Too low engine low idle.

Check engine low idle speed.
noise(Under load or no
Worn parts or damaged in Remove transmission suction screen.
load)
for metal particles.
transmission.
Repair as necessary.
Inspect
Warped drive line between engine Inspect drive line.

and torque converter.
Foaming oil
Low or no lube.
Do converter-out and lube pressure test.

transmission pump flow test.
Do
Incorrect type of oil.
Change oil.
High oil level.
Transmission overfilled or hydraulic pump seal

leaking.
Low oil level.
Add oil.
Air leak on suction side of pump.
Check oil pickup tube on side of transmission.
Oil ejected from dipstick Plugged breather.
Inspect breather on top of transmission.

Replace.
Machine vibrates
Aerated oil.
Add oil.
Low engine speed.
Check engine speed.
Failed universal joints on Check universal joints.

transmission drive shaft or
differential drive shafts.
Machine lacks power Engine high idle speed set too Check high idle adjustment.
and acceleration
low.
Change oil.
Aerated oil.
Add oil.
Low transmission pressure.
Warped transmission clutch.
Do transmission clutch drag checks.
Torn transmission control valve Inspect gasket.

gasket.
Brake drag.
Do brake drag check.
Failed torque converter.
Do torque converter stall speed test.
Low engine power.
Do engine power test.
Torque converter stall Aerated oil.

RPM too high
Put clear hose on thermal bypass outlet port.

Run machine to check for bubbles in oil.
Stuck open converter relief valve.
Do converter-out pressure test.
Leakage in torque converter seal. Do converter-out pressure test.

Torque converter not
transferring power(Bent fins, Replace torque converter.
broken starter).
3-72
Problem
Cause
Remedy
Torque converter stall Low engine power.

RPM too low
Mechanical malfunction.
Do engine power test.
Transmission pressure Low oil level.

light comes ON when
Cold oil.
shifting from forward to
reverse(All other gears Leak in reverse pack.
OK)
Add oil.
Transmission pressure Cold oil.

light comes ON for each
No time delay in monitor.
shift
Restriction in modulation orifice.
Warm oil to specification.
Remove and inspect torque converter.
Warm oil to specification.

Do transmission pressure, pump flow, and
leakage check.
Stuck PPC valve.
Do monitor check.
Remove orifice and inspect for restriction and/or
plugging.
Remove and inspect.
Low transmission pressure circuit. Do transmission system pressure test.

Leak in transmission pressure Do converter out pressure test.
circuit.
Failed transmission pump.
Clogged filter.
Inspect filter. Replace.
3-73
2) DIFFERENTIAL / AXLE
Problem
Differential low on oil
Cause
Remedy
Inspect axle and differential for leaks.
External leakage.
Excessive differential Low oil level in differential.

and/or axle noise
Check oil. Remove drain plug and inspect for

metal particles in differential case.
Disassemble and determine cause.
Incorrect type of oil.
Change oil
Dragging brakes.
Do brake check.
Failed pinion bearing.
Remove and inspect pinion.

Check to ensure pinion housing was indexed.
Incorrect gear mesh pattern Remove pinion gear housing and inspect ring
between ring and pinion gear.
and pinion gear.
Failed differential pinion gears Remove differential housing drain plug and
inspect for metal particles. Disassemble and
and/or cross shafts.
inspect.
Do axle bearing adjustment check.
Failed axle bearing.
Mechanical failure in axle Remove differential. Inspect, repair.

planetary.
Oil seeping from outer Excessive end play in axle.
axle seal
Worn outer bearing and/or cup.
Axle overheats
Do axle bearing adjustment check.

Disassemble and inspect outer axle bearing,
cup, spacer, and seal. Replace, if necessary.
Overfilled differential.
Check differential oil return system for excessive

internal restriction.
Low differential oil.
Add oil.
Overfilled differential.
See differential overfills with oil in this group.
Brake drag.
See brakes drag in this group.
3) DRIVE LINE
Problem
Cause
Remedy
Excessive drive line Yokes not in line on drive shafts. Inspect. Align drive shaft yokes.
vibration or noise
Worn front drive line support Inspect, repair.
bearing.
Bent drive shaft.
Inspect all drive shafts. Replace.
Loose yoke retaining nuts(Drive Inspect. Replace.

shafts wobble at high speed).
Rear axle oscillating support.
Inspect, repair.
Lack of lubrication.
Lubricate with proper grade of grease.
3-74

Group 2 Operational Checks and Troubleshooting

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GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING

1. POWER TRAIN OPERATIONAL CHECKS

Transmission oil must be at operating temperature for these checks.

Transmission oil warmup procedure

Start engine. Apply service OK

Increase engine speed to high idle

Move gear selector lever to

Gear selector lever and

Repeat procedure until

NOTE : Gear selector lever

Move gear selector lever to 4th

Increase engine rpm.

Run engine at approximately OK

Release parking brake and select

Press gear selector lever kick

LOOK/FEEL : Transmission must

LOOK/FEEL : If shifts down from

Park unit on level surface.

Apply service brakes.

Run engine at approximately OK

Torque converter check

Start engine. Apply service OK

Low oil level.

Wrong oil grade.

Restricted transmission pump Remove and clean screen.

Something wrong in transmission. Go to transmission error code group at page

Low oil level.

Applied park brake.

Check parking brake fuse.

No power to transmission contro- Check transmission controller fuse.

Machine does not

Restricted orifice of PPC valve.

Remove orifice and check for contamination

Do transmission element leakage test using

Worn clutch disks.

See transmission pressure is low in this group.

Service brake will not release.

Do brake pedal operational check.

Failed torque converter.

Do torque converter stall test.

Broken shafts or gears.

Drain transmission to determine if large pieces

Broken drive shafts.

Inspect drive shafts and universal joints for

Broken ring or pinion gear.

If drive shaft rotate with transmission in gear but

Malfunctioning transmission Check solenoid valve.

Remove end cover to inspect PPC valve.

Malfunctioning transmission Check speed sensor.

Transmission pressure is Low oil level.

Check transmission oil level and refill if

Failed transmission pressure Verify transmission system pressure. Do

Transmission pump may be noisy if transmission

Stuck transmission pressure Remove transmission pressure regulating valve.

Inspect transmission control valve for external

Stuck PPC valve.

Remove end cover to inspect modulation spool

Transmission system Failed transmission pump.

Restricted transmission pump Remove and clean screen.