Lull 6K Service Manual - Manual (Page 552)

Transmission
8-4 Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K
Troubleshooting and Test Procedures
Troubleshooting Options
ZF Transmission with DW-2 Shifter
644B-37 (S/N 101–880)
6K-37 (S/N 101–397)
6K-42 (S/N 101–131)
644B-42 (S/N 101–241)
844C-42 (S/N 101–783)
8K-42 (S/N 101–261)
1044C-42 (S/N
101–121)
10K-42 (S/N 101–107)
1044C-54 (S/N 101–25)
10K-54 (S/N 101–107,
109) 1. Check for correct fluid and fluid level. Consult Service/Lubrication
Schedule and see the Transmission Oil Selection Chart located in the
Owner/Operator Manual.
2. Check vehicle electrical supply.
a. See “Testing ZF Transmission Electrical System” on page 8-6.
b. Monitor voltage supply for interruption. Check to make sure there is
an uninterrupted 10.5–16.5 volts.
c. Check 7.5 amp fuse.
d. Check ground connections and plug connectors.
3. Isolate pressure/proximity switches. The park brake pressure switch,
the service brake pressure switch in conjunction with the transmission
declutch switch, and the rear oscillation lock proximity switch in
conjunction with the proximity switch relay (R1 relay) can declutch the
transmission.
a. Unplug the park brake pressure switch.
b. Unplug the service brake pressure switch or position the
transmission declutch switch to the “OFF” setting.
c. Remove the proximity switch relay (R1 relay).
4. Check shifter signals. See “DW-2 Shifter System Tests” on page 8-7.
5. Check computer signals. See “DW-2 Shifter System Tests” on
page 8-7.
6. Check inductive transmitter. See “Inductive Sensor Test” on page 8-9.
The correct readings should be 1.35–1.55 kW. Check for pinched or
severed wires on units employing a computer and utilize the inductive
transmitter.
7. Check transmission valve solenoids (M1, M2, M5, M3, M4; resistance
should be 24–40 W).
8. Check long harness. It adapts the vehicle’s power supply to the ZF
transmission system and completes the electrical connections
between the EST-19 microprocessor, shifter, transmission valve
assembly, and the inductive transmitter.
a. Inspect connections.
b. Inspect harness for damage.
c. Perform continuity tests. See Section 4, “Reference Diagrams” for
system schematics.