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

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Transmission oil must be at operating temperature for these checks.

Item Transmission oil warm-up procedure Description Service action

Start engine. Apply service brakes OK and release parking brake. Check completed. Move gear selector lever to 3rd speed. Move gear selector lever to forward "F" position. Increase engine speed to high idle for 30 seconds.
F N R

Move gear selector lever to neutral "N" position and r un for 15 seconds. Repeat procedure until warm-up operation is completed.

Gear selector lever Engine OFF.

F N R

Move gear selector lever to each OK position. Check completed. NOTE : Gear selector lever position NOT OK changes slightly as steer ing Repair lock or replace column is tilted. switch. FEEL : Lever must move freely through all positions. Run engine at approximately 1600 OK rpm. Check completed. Drive unit with transmission in each NOT OK forward and reverse speed. Go to transmission makes excessive noise, chapter 2 LISTEN : Transmission must not in this group. make excessive noise in any range. Engine rpm must not "lug down" as unit is shifted between gears.

Transmission noise check Engine running.

F N R

Forward, reverse and 4th speed clutch pack drag check Transmission must be warmed up for this check. Engine running.

Park machine on level surface.

F N R

Apply service brakes. Move gear selector lever to neutral. Move gear selector lever to 1st. Release parking brake and service brakes. Run engine at low idle. LOOK : Machine must not move in either direction. NOTE : If unit moves forward, either the forward pack or the 4th speed pack is dragging.

OK Check completed. NOT OK I f u n i t m ove s, r e p a i r transmission.

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Item Torque converter check

F N R

Description

Service action

Start engine. Apply service brakes OK and release parking brake. Check completed. Move gear selector lever to 4th NOT OK speed. If stall rpm are too low or too high, problem may be Move gear selector control lever to engine power or torque forward "F" position. converter. Increase engine speed to high idle. IF OK LOOK : Torque converter stall rpm Replace transmission must be within the following range. torque converter. Stall rpm : 2020 70 rpm Move gear selector control lever to neutral "N" position and run for 15 seconds.

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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 Low oil level. Wrong oil grade. Cause Add oil. Change oil. Remedy

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. Machine will not move Low oil level. Applied park brake. Add oil. Check parking brake fuse. Check continuity to parking brake switch.

Malfunctioning parking brake Remove and inspect parking brake solenoid solenoid valve. valve. Check for power to solenoid valve. Excessive leakage in transmission element. Worn clutch disks. Low or no transmission pressure. Service brake will not release. Failed torque converter. Do transmission element leakage test using system pressure. Repair transmission. See transmission pressure is low in this group. Do brake pedal operational check. Do service and park system drag checks. Do torque converter stall test. If engine pull down in normal, torque converter is good. Drain transmission to determine if large pieces of metal contamination are present. Inspect drive shafts and universal joints for external damage. Repair.

Broken shafts or gears. Broken drive shafts. Machine does not engage in low gear

Malfunctioning transmission Check solenoid valve. control solenoid valve. Stuck spool in transmission Remove and inspect transmission control valve control valve. spools.

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Problem Transmission pressure is Low oil level. low (all gears)

Cause

Remedy Check transmission oil level and refill if necessary.

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.

Tr a n s m i s s i o n s y s t e m Failed transmission pump. Do pump flow test. pressure is low (one or Failed transmission control valve Inspect transmission control valve for external two gears) gasket. leakage. Remove control valve. Inspect or replace gasket. Leakage in clutch piston or seal Disassemble and repair. ring. Transmission shifts too Low oil level (aeration of oil). late Low transmission pressure. Add oil. Do transmission system pressure test.

Restricted transmission pump Remove and clean screen. suction screen. Low transmission pump flow. Excessive transmission element leakage. Do transmission pump flow test. Do transmission element leakage test using system pressure.

Restricted oil passages between Remove control valve and inspect oil passage. control valve and transmission elements. Incorrect transmission oil. Transmission shifts too System pressure too high. fast Broken piston return spring. Incorrect transmission oil. Change oil (SAE 10W-30/15W-40) Do transmission system pressure test. Disassemble and inspect clutch. Change oil (SAE 10W-30/15W-40).

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Problem Transmission hydraulic High oil level. system overheats Low oil level.

Cause

Remedy Transmission overfilled or hydraulic pump seal leaking. Add oil. Change oil.

Wrong oil grade.

Pinched, restricted or leaking lube Check cooler lines. lines. Machine operated in too high Operate machine in correct gear range. gear range. Malfunction in temperature gauge I n s t a l l t e m p e ra t u r e s e n s o r t h e ve r i f y temperature. or sensor. Do tachometer/temperature reader installation procedure. Restricted air flow through oil Do oil cooler flow test. cooler. 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. Do transmission pump flow test.

Excessive transmission Too low engine low idle. Check engine low idle speed. noise (Under load or no Wo r n p a r t s o r d a m a g e d i n Drain transmission oil via plug. load) transmission. metal particles. Repair as necessary. Low or no lube. Foaming oil Incorrect type of oil. High oil level. Low oil level. Air leak on suction side of pump. Machine vibrates Aerated oil. Low engine speed.

Inspect for

Do converter-out and lube pressure test. transmission pump flow test. Change oil.

Do

Transmission overfilled or hydraulic pump seal leaking. Add oil. Check oil pickup tube on side of transmission. Add oil. Check engine speed.

Fa i l e d u n i ve r s a l j o i n t s o n Check universal joints. transmission dr ive shaft or differential drive shafts.

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Problem

Cause

Remedy

Machine lacks power and Engine high idle speed set too Check high idle adjustment. acceleration low. Incorrect transmission oil. Aerated oil. Low transmission pressure. Warped transmission clutch. Change oil. Add oil. Do transmission system pressure test. Do transmission clutch drag checks.

Torn transmission control valve Inspect gasket. gasket. Brake drag. Failed torque converter. Low engine power. Torque conver ter stall Aerated oil. RPM too high Stuck open converter relief valve. Do brake drag check. Do torque converter stall speed test. Do engine power test. Run machine to check for bubbles in oil. Do converter-out pressure test.

Leakage in torque converter seal. Do converter-out pressure test. Torque converter not Replace torque converter. transferring power (Bent fins, broken stator). Torque conver ter stall Low engine power. RPM too low Mechanical malfunction. Do engine power test. Remove and inspect torque converter.

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2) DIFFERENTIAL / AXLE
Problem Differential low on oil Cause External leakage. Remedy Inspect axle and differential for leaks. Check oil. Remove drain plug and inspect for metal particles in differential case. Disassemble and determine cause. Change oil Do brake check. Remove and inspect pinion. Check to ensure pinion housing was indexed.

Excessive differential Low oil level in differential. and/or axle noise Incorrect type of oil. Dragging brakes. Failed pinion bearing.

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 and/or cross shafts. inspect for metal particles. Disassemble and inspect. Failed axle bearing. Do axle bearing adjustment check.

M e c h a n i c a l fa i l u r e i n a x l e Remove differential. Inspect, repair. planetary. Oil seeping from outer Excessive end play in axle. axle seal Worn outer bearing and/or cup. Overfilled differential. Axle overheats Low differential oil. Overfilled differential. Brake drag. Do axle bearing adjustment check. Disassemble and inspect outer axle bearing, cup, spacer, and seal. Replace, if necessary. Check differential oil return system for excessive internal restriction. Add oil. See differential overfills with oil in this group. See brakes drag in this group.

3) DRIVE LINE
Problem Cause Remedy

E x c e s s i v e d r i v e l i n e 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). Lack of lubrication. Lubricate with proper grade of grease.

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