GROUP 2 TROUBLESHOOTING

Trouble symptom Probable cause Remedy

1. Excessive oil
temperature rise ÂImproper oil level. ÂCheck oil level. Add or drain oil as
1) Torque converter necessary.
ÂImpeller interfering with surroundings. ÂAfter draining oil from oil tank and tra-
nsmission, check and replace interfe-
ring parts.
ÂStator and free wheel malfunctioning. ÂCheck engine (stalling) speed.
If necessary, replace.
ÂAir sucked in. ÂCheck the inlet side joint or pipe.
If necessary, retighten joint or repla-
ce gasket.
ÂWater intruding into transmission ÂCheck drained oil.
case. If necessary, change oil.
ÂBearing worn or seizing. ÂDisassemble, inspect, repair or repla-
ce.
ÂGauge malfunctioning. ÂCheck and, if necessary, replace.
2) Transmission ÂClutch dragging. ÂCheck to see whether or not machi-
ne moves even when transmission is
placed in neutral position. If so, repl-
ace clutch plate.
ÂBearing worn or seized. ÂDisassemble, check and replace.
2. Noise operation
1) Torque converter ÂCavitation produced. ÂChange oil, replace parts leaking air.
ÂFlexible plate damaged. ÂListen to rotating sound at lowspeed
operation. If necessary, replace flex-
ible plate.
ÂBearing damaged or worn. ÂDisassemble, check and replace.
ÂGear damaged. ÂDisassemble, check and replace.
ÂImpeller interfering with surroundings. ÂCheck impeller or check drained oil
for mixing of foreign matter.
If necessary, change oil.
ÂBolt loosening. ÂDisassemble and check. If necessa-
ry, retighten or replace.
ÂSpline worn. ÂDisassemble, check and replace.
ÂNoise gear pump operation. ÂDisassemble, check and replace.
2) Transmission ÂDragging caused by seizing clutch. ÂCheck to see whether or not machine
moves even when transmission is in
neutral position. If so, replace clutch
ÂBearing worn or seizing. plate.
ÂGear damaged. ÂDisassemble, check and replace.
ÂBolt loosening. ÂDisassemble, check and replace.
ÂDisassemble, check and retighten or
replace.
ÂSpline worn. ÂDisassemble, check and replace.

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 Trouble symptom Probable cause Remedy
3. Low output power
1) Torque converter ÂInsufficient hydraulic pressure :

Low oil level. 
Check oil level and add oil.
 Air sucked in. 
Check joints and pipes.
If necessary, retighten joint or repla-
ce packing.
 Oil filter clogging. 
Check and replace.
 Oil pump worn. 
Check oil pressure. If necessary rep-
(Low delivery flow) lace pump.

Regulator valve coil spring fatigu- 
Check spring tension. If necessary,
ed. replace.
 Control valve spool malfunctioning. 
Disassemble, check and repair or re-
place.
 Piston or O-ring worn. 
Disassemble, check measure and re-
place.
ÂStator free wheel cam damaged. 
Check stalling speed.
(Increased engine load will cause ex-
cessive drop of stalling speed.)

Check oil temperature rise.
If any, replace free wheel.
2) Transmission ÂFlexile plate deformed ÂReplace flexible plate.
ÂStator free wheel seizing. 
Check temperature plate.
(No-load will cause temperature rise)

Replace free wheel if a drop of start-
ing output is found.
ÂImpeller damaged for interfering with 
Check drained oil for foreign matter.
the surroundings. If any, change oil.
ÂUse of poor quality of oil or arising of 
Check and change oil.
air bubbles.
 Air sucked in from inlet side. 
Check joints and pipes.
If necessary, retighten joint or replace
packing.
 Low torque converter oil pressure 
Check oil pressure.
accelerates generation of air bub-
bles.
 Oil mixing with water. 
Check drained oil and change oil.
 Inching rod out of adjustment. 
Check and adjust.
ÂClutch slipping
 Lowering of weight. 
Check oil pressure.
 Piston ring or O-ring worn. 
Disassemble, check, measure and
replace.
 Clutch piston damaged. 
Disassemble, check and replace.
 Clutch plate seizing or dragging. 
Check to see whether or not machine
moves even when transmission is in
neutral position. If so, replace.

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 Trouble symptom Probable cause
4. Unusual oil pressure
1) Oil pressure is high ÂControl valve malfunctioning.
ÂCold weather. (high oil viscosity)
ÂUse of improper oil.
2) Oil pressure is low ÂGear pump malfunctioning(worn).
ÂOil leaks excessively :
(1)Control valve oil spring defective.
(2)Control valve spool defective.
ÂAir sucked in.
ÂLow oil level.
ÂOil filter clogging.
3) Transmission ÂOil leaks excessively.
5. Power is not transmitted
1) Torque converter ÂClutch plate damaged.
ÂLow oil level.
ÂOil pump driving system faulty.
ÂShaft broken.
ÂLack of oil pressure.
2) Transmission ÂLow oil level.
ÂInching valve and link lever improper- ÂCheck measure and adjust.
ly positioned.
ÂForward/reverse spool and link lever ÂCheck and adjust.
improperly positioned.
ÂClutch fails to disengage :
(1)Clutch case piston ring defective. ÂDisassemble, check and replace.
(2)Main shaft plug slipping out.
ÂClutch seizing.
ÂShaft broken off.
ÂClutch drum damaged (spring groove). ÂDisassemble, check and replace.
ÂClutch snap ring broken.
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Remedy
(1)Check for spool operation.
If necessary, replace valve.
(2)Check for clogging of small hole in
valve body. If necessary, clean or
repair.
ÂWhen atmospheric temp is below fr-
eezing point
(when normal oil pressure is recover-
ed if heated to 60 ~ 80ÁC), change
oil.
ÂCheck and change oil.
ÂDisassemble, check and replace.
ÂCheck spring tension (see spring sp-
ecification).
If necessary replace.
ÂDisassemble, check, and repair or re-
place valve.
ÂCheck joints and pipes. If necessary,
retighten joint or replace packing.
ÂCheck oil level and add oil.
ÂCheck and replace.
ÂDisassemble, check (piston ring and
O-ring for wear and other defects),
and replace.
ÂCheck for damage by listening to ab-
normal sounds at a low converter sp-
eed and replace.
ÂCheck oil level and add oil.
ÂDisassemble and check for wear of
pump gear, shaft and spline.
Replace defective parts.
ÂCheck and replace.
ÂCheck oil pump gear for wear and for
oil suction force.
If necessary, replace pump.
ÂCheck oil level and add oil.
ÂDisassemble, check and repair or re-
place.
ÂCheck to see whether or not machine
moves even then transmission is in
neutral position. If so, replace.
ÂDisassemble, check(main shaft, etc.),
and replace.
ÂDisassemble, check and repair or re-
place.
 Trouble symptom Probable cause
6. Power is not transmitted ÂForeign matter intruding into oil pass- ÂDisassemble, check and repair or
(Continue) age to clutch.
ÂShaft spline worn.
7. Oil leakage ÂOil leaks from oil seal.
(Transmission and torque
converter)
ÂOil leaks from case joining surfaces.
ÂOil leaks from joint or pipe.
ÂOil leaks from drain plug.
ÂOil leaks from a crack.
Remedy
replace.
ÂDisassemble, check and replace.
ÂDisassemble and check for wear of
seal lips and mating sliding surfaces
(pump boss, coupling etc.)
Replace oil seal, pump boss, coupl-
ing, etc.
ÂCheck and retighten or replace pack-
ing.
ÂCheck and repair or replace gasket.
ÂCheck and retighten or gasket.
ÂCheck and replace cracked part.

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