TROUBLESHOOTING

Electrical System

Starter System
Weak or dead battery Recharge or replace.
Short or open circuit Repair or replace.
Starter will not crank
engine Poor continuity in starter switch Replace.
Starter or starter relay defective Replace.

Starter switch Forward-reverse lever not in neutral Move lever to neutral

position position.

Turning off starter Open or short circuit Repair or replace.

switch will not stop Engine stop solenoid defective Replace or readjust.
engine
Control timer defective Replace.

Gauges
Open or short circuit Repair or replace.
Will not indicate at
all Gauge internally defective Replace.
Gauge unit defective Replace.
Gauge or gauge unit not of the type Replace.
Temperature Will not indicate called for
gauges accurately
Loose terminal connection Repair.

Will indicate higher Circuit between gauge and gauge unit Repair.
than actual grounded
temperature
Gauge internally defective Replace.

Open or short circuit Repair or replace.

Will not indicate at
all Gauge internally defective Replace.
Gauge unit defective Replace.
Gauge or gauge unit not of the type Replace.
Will not indicate called for
accurately
Loose terminal connection Retighten.
Circuit between gauge and gauge unit Repair.
Fuel gauge Will indicate “full” open or short
regardless of amount
of fuel left in tank Gauge internally defective Replace.
Gauge unit defective Replace.

Will indicate Circuit between gauge and gauge unit Repair.

“empty” regardless grounded
of amount of fuel Gauge unit defective Replace.
left in tank
Gauge internally defective Replace.

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TROUBLESHOOTING

Lighting System
Weak or dead battery Recharge or replace.
Fuses blown out Check and replace.
Will not light Open or short circuit Repair or replace.
Poor grounding Clean ground spot and
re-make connection.
Bulbs burnt out Replace.
Lamps - general
Weak or dead battery Check and recharge.
Burned contact points in switches Repair or replace.
Loose terminals Retighten.
Will light dimly
Dirty lenses Clean.
Waterdrops inside lenses Dry and replace packings.
Bulbs expired in service life Replace.

Lighting switch defective Replace.

Head lamps Will not light
Bulbs burnt out Replace.

Turn signal switch defective Replace.

Will not flicker
Turn signal relay defective Replace.
Turn signal relay defective Replace.
Will not go out
Bulbs burnt out Replace.
Turn signals Wrong wattage of bulbs Replace.
Will flicker too
slow Bulbs burnt out Replace.
Turn signal relay defective Replace.

Will flicker too Wrong wattage of bulbs Replace.

fast Turn signal relay defective Replace.

Backup lamp switch defective Correct if improperly

Backup lamps installed: replace if
will not light internally defective.
Bulbs burnt out Replace.
Other lamps
License number Lighting switch defective Replace.
plate lamp will
not light Bulb burnt out Replace.

Alarm Unit
Fuse blown out Check and replace.
Open or short circuit Repair or replace.
Will not give
blast of sound Horn switch defective Replace.
Horn defective Replace.
Horn Horn button defective Repair or replace.
Will give ugly Horn switch defective Replace.
blast of sound Horn defective Replace.

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 TROUBLESHOOTING

Battery
Drive belt slipping Readjust.

❋ Alternator
Stator coil grounded or open-circuited Repair or replace.
Rotor coil open Replace.
Brushes poorly seating on slip rings Replace brushes if worn.
Clean holder and polish
slip rings.
Diode ruptured Replace.

❋ Regulator
Regulated voltage setting too low Readjust.
Tends to run down
rapidly ❋ Battery
Not enough electrolyte or wrong proportion of acid to Add electrolyte and check
water specific gravity.
Battery cell plates deteriorated (forming, possibly Replace.
internal short-circuit)
Terminal connections loose Clean and retighten.

❋ Wiring
Open or loose connection between starter switch and Repair.
regulator IC terminal
Fuse blown, or loosely set in holder Replace and repair.
Open or loose connection between F terminals of Repair.
regulator and alternator

❋ Wiring
Regulator IC and F terminals shorted or miswired Repair.
Poor grounding of regulator F terminal Repair.
Tends to get
overcharged ❋ Regulator
Pressure coil open-circuited Replace.
Regulated voltage too high Readjust.

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Powershift Transmission

Engine lacks power Tune up engine.

Engine
Poor performance of engine Tune up engine.

Oil level too low Add oil.

Air being sucked in on suction side Replace gasket and
retighten.
Faulty action of spool in main regulator valve Repair or replace.
Weakened spring in main regulator valve Replace.
Torque
converter Worn gears in oil pump, resulting in Overhaul and check or
reduced capacity replace defective parts.
Magnet strainer clogged Replace.
Seal rings or O-rings worn Replace.
Stator freewheel seized Replace stator assembly,
hub, roller.
Blades of running members damaged or Repair or replace.
Not enough rubbing Replace bearing.
output power

Air being sucked in on suction side Retighten or replace.

Outlet pressure too low to suppress internal Readjust.
foaming
Water in oil Change oil.
Oil level too low Add oil.

Transmission Pedal linkage maladjusted (brake shift and Readjust.

forward reverse)
Main pressure too low, resulting in slipping Readjust.
clutches
Seal rings or O-rings worn Replace.
Clutch piston damaged Replace.
Friction plate seized or dragging Replace.

Road wheels High mechanical resistance in road wheels Check and adjust brake
system

Flexible plate broken Replace.

Not enough oil Add oil.
No power Torque
flow converter Oil pump drive defective Replace.
Turbine shaft broken Replace.
Main pressure too low Check pump gears for
wear or replace.

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 TROUBLESHOOTING

Not enough oil Add oil.

Inching pedal link maladjusted Readjust.
Seal ring worn in servo case Replace.
O-rings on input shaft worn Replace.
Plug on input shaft loose or slipped off, Repair.
resulting in oil leaks
No power Clutch seized Replace.
Transmission
flow Shafts broken Replace.
Clutch drum, particularly snap ring groove, Replace.
defective
Snap ring fitted to clutch drum broken Replace.
Oil way for supplying oil pressure to clutch Clean or replace.
piston clogged
Shaft splines worn Replace shafts.
Power train Broken parts in reduction differential or Repair or replace.
front axle

Flexible plate broken Replace.

Bearings damaged Replace.
Torque Rubbing blades of running member Replace.
converter Bolts loose Retighten or replace.
Splines worn Replace.
Oil pump worn Repair or replace.
Clutch seized and dragging Replace clutch plate.
Bearings worn or seized Replace.
Transmission Gears broken Replace.
Bolts loose Retighten or replace.
Splines worn Replace.
Abnormal Oil strainer clogged Clean.
noise Main regulator valve defective Wash or replace.
Restriction in oil pipe Replace.
Loud noise
Oil too viscous in cold weather Change oil.
Instruments out of order Replace.
Wrong kind of oil used Change oil.
Oil strainer clogged Clean or replace.
Oil pump defective Replace.
Excessive oil leaks
• Main regulator valve spring broken or Replace.
Low noise weakened
• Main regulator valve spool defective Repair or replace.
Air being sucked in Retighten or replace
packing.
Oil level too low Add oil.

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TROUBLESHOOTING

Leaking oil seals Check lips and sliding

surfaces for wear.
Replace seals.
Leaking joint of case Retighten or replace
packing.
Leaking pipe connection or joint Repair or replace pipe,
gasket and O-rings.
Leaking drain plug Retighten and replace
Oil leaks gasket.
Cracks or blowholes in case Replace.
Oil blowing out of transmission case
• Water in oil Change oil.
• Air being sucked in suction side Replace packing and
retighten.
• Oil leaks from air breather Repair.
Oil level too high Lower oil level.

Oil level too high or too low Keep correct oil level.
Oil strainer clogged Clean or replace.
Rubbing blades of running members Repair or replace.
Stator freewheel defective Replace stator assembly.
Air being sucked in Retighten or replace
Torque
gasket.
converter
Water in oil Change oil.
Restriction in oil pipe (resulting in Repair or replace.
reduced circulation flow)
Bearings worn or seized Repair or replace.
Oil temperature
Instruments out of order Replace.
is too high
Clutches dragging Replace clutch plate.
Transmission Bearings worn or seized Repair or replace.
Control linkage defective Repair or replace.
Truck not operated properly Urge user to drive truck
Others properly.
Others
• Cooling fan belt damaged Replace.
• Oil cooler clogged Clean or replace.
• Brakes grabbing Check and readjust.

Main regulator valve defective Repair or replace valve

assembly.
Main pressure is too high Oil viscosity too high because of low Change oil.
temperature
Wrong kind of oil used Change oil.

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 TROUBLESHOOTING

Magnet strainer clogged Clean or replace.

Oil pump worn Replace.
Coil spring defective in main regulator valve Replace.
Erratic movement of main regulator valve spool Repair or replace.
Main pressure is too
low Air being sucked in Retighten or replace
packing.
Not enough oil Add oil.
Control linkage defective Repair or replace.
Clutch valve out of order Repair or replace.

Magnet strainer clogged Clean or replace.

Oil pump worn or otherwise defective Replace.
Coil spring defective in main regulator valve Replace.
Erratic movement of main regulator valve spool Repair or replace.
Air being sucked in Retighten or replace
Clutch pressure is too packing.
low
Not enough oil Add oil.
Control linkage out of order Repair or replace.
Inching valve defective Repair or replace.
Seal ring broken in servo case Replace.
Clutch seal rings broken Replace.

Lack of engine power if the speed is slightly low in Tune up engine.

both forward and reverse drive
Stall speed out of
Stator and freewheel damaged if the speed is Replace stator assembly.
specification
excessively low in both forward and reverse drive
Inching pedal linkage defective, or clutch slipping Repair or replace.
if the speed is too high

Travel speed select switch not in “AUTO” position Move switch to “AUTO”
position.
No automatic shifting Solenoid valve defective Replace.
(automatic 2-speed
Solenoid valve inlet orifice clogged Clean or replace.
transmission)
Solenoid valve spool or spring defective Repair or replace.
ECU control box internally defective Check and replace.

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TROUBLESHOOTING

Front Axle and Reduction Differential

Reduction bevel gear teeth badly worn Replace.

Gear noise comes Bearing preloads too much or too little, or bearings Readjust or replace.
out continuously worn excessively
during normal run Hub bearings damaged Replace.
Improper tooth contact between reduction bevel pinion Readjust.
(on output shaft) and reduction gear

Reduction bevel gear bearing or hub bearings broken Replace.

Irregular noise Differential gears having broken teeth, or thrust Replace gears or washers.
comes out during washers worn
normal run Metal piece in axle housing Clean and change oil.
Bolts securing axle shaft or differential carrier loose Retighten.

Fit of differential gears in differential case out of Replace worn parts.

Abnormal noise specification due to wear
comes out when
turning a corner
Teeth broken or differential bevel pinions or side gears, Replace defective parts.
or pinions seized on spiders.

Bearings broken due to too large a preload Replace bearings and

Differential readjust preload.
overheats
Backlash between reduction bevel pinion (on output Readjust tooth contact
shaft) and reduction bevel gear too small and backlash.

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 TROUBLESHOOTING

Rear Axle
(Also refer to the steering system troubleshooting.)
Toe-in not set to the specification Readjust.
Hard steering Lack of lubrication in rear axle or steering linkage Relubricate.
Tire inflation pressure too low Reinflate.

Poor steering
reaction Joints and connections in steering or rear axle linkage Retighten to specified
too tight torque.

Truck pulls to one Tire diameter differs between right and left Replace tire.
side Tires inflated unequally Reinflate tires equally.

Excessive clearance between kingpin and its bearings Repair or replace.

Taper roller bearings badly worn or damaged in hub Replace.

Shimmy

Excessive rattle of ball stud in socket in tie rod Replace.

Steering system defective Check and readjust.

Rear wheel tires Wheel alignment out of adjustment Readjust.

wear rapidly or
unevenly
Tires on one side differ in kind from those on the other, Replace tires and
or tires inflated unequally reinflate.

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TROUBLESHOOTING

Brake System

Oil leaking past primary cup in master Replace piston cup if cylinder
cylinder, or oil leaking past cups in is worn. Replace the cup and
Lack of braking wheel cylinders fluid if the cup is distorted.
force Oil leaking from oil pipe connection Replace pipe and connector
and retighten.
Shoe linings excessively worn Replace.
Linings dirty with oil or grease Clean or replace.
Air trapped in brake oil line Bleed air at brake booster
and wheel cylinder.
Piston cup defective in master Replace.
cylinder
Pedal stroke is Not enough fluid in reservoir Add fluid.
too large Push rod to piston clearance too large Readjust.
in master cylinder
Brake fluid leakage Replace piston cup if cylinder
is worn. Replace the cup and
fluid if the cup is distorted.
Automatic adjuster out of order Check cable guide and adjusting
spring installation. If they
are defective, replace fitting
cable, lever and adjusting
screw.
Uneven braking Lining or drum dirty with oil or Clean or replace.
(wheel brake is grease in less effective brake
more effective on Wobbly or loose-mounted drum in Replace drum. Readjust and
Service one side than on less effective brake retighten.
brakes the other) Wheel tires inflated unequally Reinflate.
Linings glazed Sand.
Linings badly worn Replace shoe and lining
assembly.
Brake squeals Backing plate securing bolts loose Retighten.
Wheel bearings loose Readjust preload and
retighten.
Brake drum dirty Clean.
Anchored ends of shoes rattling on Slight noises are normal.
Brake chatters or anchor Repair or replace if excessive.
clatters Shoe ledges badly worn Replace backing plate.
Piston badly worn in wheel cylinder Replace.
Vacuum hose joint loose Retighten.
Vacuum hose flat or ruptured Replace.
Vacuum pump malfunctioning Repair or replace.
Pedal will give Alternator drive belt loose Readjust.
resistance Vacuum valve or atmospheric pressure Repair or replace.
valve dirty or damaged in brake booster
Brake booster element clogged Clean or replace.
Brake booster diaphragm defective Replace.
Brake cylinder internally dirty Clean and lubricate.
Lack of brake cylinder fluid Add fluid.
Spongy pedal Brake cylinder fluid leaks Repair or replace.
Air in system Bleed.

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 TROUBLESHOOTING

Linings worn to the service limit Replace shoe and lining

assembly.
Weak stopping Shoe-to-drum clearance too large Readjust. Check operation of
force of parking automatic adjusting device.
brake
Lever lacks operating force Adjust by turning lever grip.
Excessive distance between cable lock Adjust by changing positions of
nuts and cable bracket lock nuts.
Parking
brake
Shoe-to-drum clearance too small Inspect mechanisms inside
Parking brake wheel brakes.
lever abnormally Increase clearance by manual
difficult to move adjustment.
or impossible to
move to upright Operating effort of parking brake lever Adjust by turning lever grip.
position. incorrectly adjusted
Insufficient distance between cable Adjust by changing positions of
lock nuts an cable bracket lock nuts.

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TROUBLESHOOTING

Steering System
(Also refer to the rear axle troubleshooting.)
No steering flow, because of:
• Clogged orifice in spool Clean.
• Fatigued spool spring Replace.
If flow priority Relief valve out of order, because of:
valve is out of • Reduced relief pressure Readjust.
order • Damaged valve seat Replace valve assembly.
• Fatigued spring Replace spring and
readjust relief setting.
Oil pressure leaking through relief valve Replace O-ring.
due to broken O-ring on valve body
Bearings defective Replace.
Erratic movement of valve spool Clean or replace
assembly.
Hard If steering gear Spring retainer defective Clean or replace.
steering is defective Ball screw assembly defective Clean or replace
assembly.
Sector shaft adjusting screw too tight Readjust.
Gears meshing improperly Disassemble and
readjust.

If steering linkage Linkage bent Repair or replace.

is abnormal Interference with frame Repair or replace.
Joint too tight Retighten.
Pipe or tube flattened, or restriction in Clean or replace.
oil line
Bearings defective Replace.
Erratic movement of valve spool Clean or replace
If steering gear assembly.
is defective Spring retainer defective Clean or replace.
Ball screw assembly defective Clean or replace
Poor assembly.
steering Gears meshing improperly Disassemble and
reaction readjust.
Pipe or tube flattened, or restriction in Clean or replace.
oil line

If steering gear Steering lock nut loose Retighten.

is defective Spring fatigued Replace.
Truck Improper backlash Readjust.
wanders
Pipe or tube flattened, or restriction in Clean or replace.
oil line
Steering lock nut loose Retighten.
Vibration or noise Air in system Bleed.
Power cylinder or socket end loose in Repair or replace.
installation
Backlash of ball screw with sector shaft Readjust.
out of adjustment
Excessive steering wheel play Sector shaft loose in installation Replace.
Drag link ball stud loose in socket Repair or replace.
Air in system Bleed.

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 TROUBLESHOOTING

Hydraulic System

Not enough oil in hydraulic tank Add oil.

Oil viscosity improper Change oil.
Overload Check working conditions and,
if over-loaded, urge the operator
to stay within the load limit.
Hydraulic tank Local overheating of oil line due Repair or replace.
heats excessively to a large restriction to flow
Relief valve adjustment improper Readjust pressure setting.
Pressure drop due to fatigued or Repair or replace and readjust.
broken springs
Hydraulic pump worn Replace.
Hydraulic
tank Outlet pipe or tube flattened, or Repair or replace.
restriction to flow

Shortage of oil due to a natural Add oil.

loss
Cylinders move
too slow Oil leakage due to damaged oil Repair or replace.
line seals
Oil viscosity too higher Change oil.

Hydraulic pump defective Check pump and piping; repair

or replace.
Oil leakage from oil line Check oil for level and condition;
Cylinders move add or change oil.
too slow
Abnormal oil temperature rise Check control valve spools for
misalignment; repair or replace.
Hydraulic
pump Hydraulic pump internally leaking Replace pump.

Poor pumping Check oil level; add oil if

Noisy necessary.
Cavitation 1) Check suction pipe for any
flat portion or loose connection;
retighten or replace.
2) Check shaft oil seal for
airtightness; replace pump.
3) Check pump body for any
outside interference; repair.

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TROUBLESHOOTING

Pump case, drive Pressure too high Replace pump. (Check to see if
gear or pump port relief valve setting is correct.)
flange damaged Distortion or damage due to Replace pump.
external strain or stress
1) Check to see if return line
is restricted.
2) Check to see if pipe
Hydraulic connection have been
pump externally strained or stressed.

Oil leakage past oil seal Replace seal.

Oil leakage past sliding surfaces Replace whole pump assembly.
Oil leakage from of drive shaft
pump
Pump securing bolts loose Retighten.
Excessive internal leakage Replace O-ring.

Relief valve setting too low Readjust.

Relief valve piston seizure Clean piston and check to see if
Slow or no motion it moves smoothly; or replace
of lift and tilt whole relief valve assembly.
cylinders O-ring on relief valve body Replace O-ring.
damaged
Control lever installed loose, Readjust.
resulting in not enough spool stroke

Control
valve Load drops or
Control valve internally leaking Replace a leaky block
mast tilts forward
assembly.
with control lever
in neutral
Oil leakage from spool ring cap Replace O-ring; check spool
for flaws and if any, repair or
replace a leaky block assembly.
Oil leakage
Loose plugs Retighten.
O-ring damaged Replace.

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 TROUBLESHOOTING

Not enough oil in hydraulic tank Add oil.

Relief valve out of order,
because of:
Will not lift nor
tilt • Seized main valve Replace.
• Broken valve spring Replace.
Hydraulic pump defective Replace.

Relief valve out of order,

because of:
• Too low a relief valve setting Readjust.
• Defective plunger or poppet seat Replace.
Will not lift rated
load • Fatigued spring Replace.
• Damaged O-ring in valve case Replace O-ring.
Hydraulic pump defective Replace.
Piston seals worn or damaged Replace.

Lift and tilt

Engine speed too low Adjust.
cylinders
Control lever installed loose, Repair or replace.
Lifting speed is resulting in not enough spool stroke
too low
Tank strainer clogged Clean or replace.
Pump not delivering enough oil Repair or replace.

Sleeve seized in flow regulator Repair.

valve
Lowering speed is
Dirt in flow regulator valve Clean, repair system and
too low
replace defective hose.
Abnormal resistance to flow due Replace hose.
to flattened hose or local clogging

Piston rod distorted Repair or replace.

Cylinder vibrates Air in oil circuit Bleed air by operating cylinder
when actuated through full stroke.
Not enough oil in hydraulic tank Add oil.

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TROUBLESHOOTING

Control valve spool internally Replace.

leaking
Sliding (inside) surface of cylinder Repair or replace cylinder
tube slightly grooved assembly.
Load will not hold
Sliding (inside) surface of cylinder Replace.
tube badly grooved
Piston seals broken or distorted Replace seal kit.
Oil leakage from piping Repair or replace.

Control valve spool internally Replace.

leaking
Mast tilts forward Foreign particles lodged between Replace packing.
(drift) packing and mating surface

Lift and tilt Piston seals damaged Replace.

cylinders Cylinder distorted Repair or replace.

Lift cylinders drop Sliding surface of cylinder tube Repair or replace.

or tilt cylinders tilt badly grooved or rusted at one
forward (drift) at a point
certain point of
stroke Cylinder tube distorted Replace.

Foreign particles lodged between Replace.

sealing members such as oil seals
and dust seals
Bushing leaks Oil seals and dust seals defective Replace.
O-rings damaged Replace.
Cylinder distorted Repair or replace.

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 TROUBLESHOOTING

Masts and Forks

Clearance of lift rollers and side rollers incorrect Readjust clearance.

Lift bracket and inner Rollers binding on their shafts Relubricate or replace.
mast will not move
smoothly Lift chains erratic in movement Relubricate or replace.
Mast strip clearance incorrect Shim adjust.

Too much clearance on side rollers Readjust with shims.

Lift bracket or inner
mast cocks Lift chains unequally tensioned Readjust.
Shim adjustments unequally made on between left and Readjust.
right lift cylinders (at maximum height)

Mast makes noise Rollers not rotating smoothly on their shafts Relubricate or replace.

Lift cylinder packing damaged Replace.

Load will not hold
Sliding (inside) surface of lift cylinder tube damaged Replace.

Mast shakes entirely Mast-support bushing or metal worn Retighten or replace.

Mast is distorted Off-center loading or overloading Replace mast assembly.

Finger bar bent Repair or replace.

Fork tips differ in
height Forks bent Repair or replace.
Careless stacking Repair or replace.

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