Manitowoc Published 10-01-2012, Control # 045-08 10-i
10
SECTION 10
TROUBLESHOOTING
TABLE OF CONTENTS
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Safety Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
General Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
Troubleshooting Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
Problem 1 Engine will not turn over to start.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
Problem 2 Engine turns over, 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 Engine fault alerts enable during engine operation. . . . . . . . . . . . . . . 10-7
Problem 6 Engine will not go to high idle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 load drum maximum speed. 10-14
Problem 13 No boom cylinder operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-15
Problem 14 Boom will not reach maximum speed. . . . . . . . . . . . . . . . . . . . . . . 10-16
Problem 15 Boom will not boom up or boom down.. . . . . . . . . . . . . . . . . . . . . . 10-17
Problem 16 No swing operation, but engine loads. . . . . . . . . . . . . . . . . . . . . . . 10-18
Problem 17 No swing operation, engine does not load.. . . . . . . . . . . . . . . . . . . 10-19
Problem 18 Travel system response is sluggish. . . . . . . . . . . . . . . . . . . . . . . . . 10-20
Problem 19 Closed-loop hydraulic system response is sluggish. . . . . . . . . . . . 10-21
Problem 20 Hydraulic system is operating hot. . . . . . . . . . . . . . . . . . . . . . . . . . 10-22
Problem 21 Jacking cylinder(s) will not extend or retract. . . . . . . . . . . . . . . . . . 10-23
Problem 22 Crawler pin cylinder(s) will not extend or retract (left or right set). . 10-24
Problem 23 System pump will not return to neutral.. . . . . . . . . . . . . . . . . . . . . . 10-25
Problem 24 A load drum pawl is not operating correctly. . . . . . . . . . . . . . . . . . . 10-26
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-28
Test 1 – Battery Test (12 and 24 VDC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-28
Test 2 – Electric Fuel Control (EFC) Box Test Points. . . . . . . . . . . . . . . . . . . . . . 10-29
Test 3 – Checking Resistance at Engine Temperature Switch. . . . . . . . . . . . . . . 10-31
Test 4 – Checking Resistance at Engine Oil Pressure Sender. . . . . . . . . . . . . . . 10-32
Test 5 – Cleaning and Adjusting the Engine RPM Transducer (Past Production) 10-33
Test 6 – Testing for Voltage at the Fuse Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-34
Test 7 – Checking Voltage at the Control Handle. . . . . . . . . . . . . . . . . . . . . . . . . 10-35
Test 8 – Adjusting the Control Handle Potentiometer. . . . . . . . . . . . . . . . . . . . . . 10-36
Test 9 – Location of Pump Test Ports. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-37
Test 10 – Location of Motor Test Ports. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-39
Test 11 – Manually Stroking the Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-41
Test 12 – Setting the Pump Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-42
Test 13 – Setting Pump Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-43
Test 14 – Adjusting Pump Charge Pressure Relief . . . . . . . . . . . . . . . . . . . . . . . 10-44
Test 15 – Checking Pump Charge Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-45
Test 16 – Checking Charge Pressure at Motor Port X1 . . . . . . . . . . . . . . . . . . . . 10-46
Test 17 – Testing the Motor PCP and Pump EDC . . . . . . . . . . . . . . . . . . . . . . . . 10-47
Test 18 – Testing for Pump and Motor Leakage. . . . . . . . . . . . . . . . . . . . . . . . . . 10-48
Test 19 – Testing Hydraulic Solenoid Brake Valves. . . . . . . . . . . . . . . . . . . . . . . 10-49
Test 20 – Checking Hydraulic Brake Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50
Test 21 – Adjusting the Lower Accessory Relief Valve. . . . . . . . . . . . . . . . . . . . . 10-51
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