Lull 6K Service Manual - Manual (Page 558)

Transmission
8-10 Service Manual — Models 644B, 6K, 844C, 8K, 1044C, 10K
Inductive sensor failure can be eliminated as soon as the sensor signal is
sensed by the microprocessor. Inductive sensor failure can be corrected
with the following steps:
1. Check for pinched or severed wire(s) between the EST-19 and the ZF
transmission system harness. Repair or replace, if necessary.
2. Check for a loose or separated plug connection at the transmitter on
the transmission.
3. Check for a failed inductive transmitter by checking resistance. The
correct resistance should be 1.35–1.55 W.
4. Check required clearance between contact face of inductive
transmitter and the spur gear. Clearances should be 0.6–0.8mm
(.024–.031”).
DW-3 Shifter System Tests
6K-37 (S/N 398–)
6K-42 (S/N 132–)
644B-37 (S/N 881–)
644B-42 (S/N 242–)
8K-42 (S/N 262–)
844C-42 (S/N 784–)
10K-42 (S/N 108–)
10K-54 (S/N 108, 110–)
1044C-42 (S/N 122–)
1044C-54 (S/N 216–)
DW-3 Speed Range/Direction Signal Test for a 3WG-100 Transmission
1. Park the machine on level ground, lower the boom, and block the
wheels.
2. Make sure the parking brake is disengaged and the service brake is
not applied.
3. Transmission declutch switch must be in “OFF” position.
4. With the engine off, turn ignition switch to the “ON” position. Do not
start the engine.
5. Probe colored wires from shifter at the front of the sealed connectors.
Test all direction and speed range signal combinations shown in
Fig. 8-4. If no power is present at Red or Violet wires, proceed to
Step 7. If other discrepancies are found, contact the JLG Service
Department
Note:Use a 12V test light or a multimeter.
6. If no discrepancies are found, shifter integrity is OK. See “DW-3
Signals at Transmission Test” on page 8-14 for further test procedures.