Manitowoc 2250 Service Maintenance Manual

Reference Only
Manitowoc Published 07-19-16, Control # 249-01 10-i
10
SECTION 10
TROUBLESHOOTING
TABLE OF CONTENTS
Basic Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Safety Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
General Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
Troubleshooting Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
PROBLEM 1 Engine will not turn over to start. . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
PROBLEM 2 Engine rotates, but will not start.. . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
PROBLEM 3 Engine runs, but no hydraulic operation. . . . . . . . . . . . . . . . . . . . . 10-5
PROBLEM 4 Engine runs, but battery is not charging. . . . . . . . . . . . . . . . . . . . . 10-6
PROBLEM 5 Unable to build more than 6 bar (90 psi) air pressure. . . . . . . . . . . 10-7
PROBLEM 6 Engine fault alerts enable during engine operation. . . . . . . . . . . . . 10-8
PROBLEM 7 Crawler travels at slow speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9
PROBLEM 8 Crawlers will not travel in either direction (one or both tracks). . . 10-10
PROBLEM 9 No front or rear load drum operation. . . . . . . . . . . . . . . . . . . . . . . 10-11
PROBLEM 10 Front or rear load drum will not raise load, but will lower load.. . 10-12
PROBLEM 11 Front or rear load drum will not lower load, but will raise load.. . 10-13
PROBLEM 12 Front or rear load drum will not reach maximum speed. . . . . . . 10-14
PROBLEM 13 No boom hoist operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-15
PROBLEM 14 Boom hoist will not reach maximum speed. . . . . . . . . . . . . . . . . 10-16
PROBLEM 15 Boom will not boom up, but will boom down. . . . . . . . . . . . . . . . 10-17
PROBLEM 16 Boom will not boom down, but will boom up. . . . . . . . . . . . . . . . 10-18
PROBLEM 17 No swing operation, but engine loads. . . . . . . . . . . . . . . . . . . . . 10-19
PROBLEM 18 No swing operation, engine does not load.. . . . . . . . . . . . . . . . . 10-20
PROBLEM 19 Travel system response is sluggish.. . . . . . . . . . . . . . . . . . . . . . 10-21
PROBLEM 20 Closed-loop hydraulic system response is sluggish. . . . . . . . . . 10-22
PROBLEM 21 Hydraulic system is operating hot. . . . . . . . . . . . . . . . . . . . . . . . 10-23
PROBLEM 22 Gantry cylinders will not raise or lower. . . . . . . . . . . . . . . . . . . . 10-24
PROBLEM 23 Frame connecting pin cylinders will not extend or retract. . . . . . 10-25
PROBLEM 24 Jacking cylinder(s) will not extend or retract. . . . . . . . . . . . . . . . 10-26
PROBLEM 25 Boom hinge pin or crawler pin cylinders will not operate.. . . . . . 10-27
PROBLEM 26 Boom handling cylinders will not extend or retract. . . . . . . . . . . 10-28
PROBLEM 27 System pump will not return to neutral. . . . . . . . . . . . . . . . . . . . 10-29
PROBLEM 28 Counterweight pins will not extend (engage).. . . . . . . . . . . . . . . 10-30
PROBLEM 29 Counterweight pins will not retract (disengage).. . . . . . . . . . . . . 10-31
PROBLEM 30 A load drum pawl is not operating correctly.. . . . . . . . . . . . . . . . 10-32
PROBLEM 31 Upper and lower valve cylinders are not operating. . . . . . . . . . . 10-33
Testing Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-34
Test 1—Testing the Battery (12 and 24 volts DC) . . . . . . . . . . . . . . . . . . . . . . . . 10-34
Test 2—Checking Resistance at the Engine Temperature Switch . . . . . . . . . . . . 10-35
Test 3—Checking Resistance at the Engine Oil Pressure Switch . . . . . . . . . . . . 10-36
Test 4—Testing the Pump EDC and Motor PCP . . . . . . . . . . . . . . . . . . . . . . . . . 10-37
Test 5—Cleaning and Adjusting the Engine RPM Transducer . . . . . . . . . . . . . . . 10-38
Test 6—Location of Motor Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-39
Test 7—Testing for Pump and Motor Leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40
Motor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40
Pump Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40
Test 8—Location of Pump Ports. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-41
Test 9—Checking Voltage at the Hydraulic Brake Valve . . . . . . . . . . . . . . . . . . . 10-42
Test 10—Manually Stroking the Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-43
Test 11—Testing for Voltage at the Fuse Box . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-44
Test 12—Checking Voltage at the Control Handle . . . . . . . . . . . . . . . . . . . . . . . . 10-45

Manitowoc 2250 Specifications

General

Brand	Manitowoc
Model	2250
Category	Construction Equipment
Language	English