ELECTRIC SYSTEM TMS700E SERVICE MANUAL
3-8 Published 01-29-2015, Control # 512-01
MAINTENANCE
General
Electrical system maintenance includes troubleshooting and
replacement of damaged components. Observe standard
wiring practices when replacing components.
General Troubleshooting
NOTE: Make voltage checks at terminations when
components are installed and operating. Make
continuity checks when components are isolated or
removed. Troubleshoot per the following
guidelines:
1. First, use reported symptoms to identify a problem or a
suspect component.
2. Test the suspect component per instructions in this
section. The instructions identify the circuit breakers and
components and guide you from the easiest and most
likely problems to the hardest and least likely problems.
3. Using a multimeter, test the circuit for continuity if you
suspect a broken circuit or for voltage if you suspect a
power problem. Check the electrical schematic and
wiring diagram for most accurate wiring information.
4. If the component proves faulty, replace it with a known
working component. If wiring proves faulty, replace it
with wiring of equal diameter.
5. After troubleshooting, test and repair the repaired circuit.
Verify the circuit works properly.
Troubleshooting Engine Starting Problems
1. Verify the battery terminals are connected and clean, the
transmission is in neutral, and the machine is fueled.
2. Try to turn on the head lights, tail lights, marker lights,
dome light, work light, or gauge lights and panel lights to
verify the battery has at least some charge. If none of
these lights comes on, suspect the battery. Charge
battery as needed, or replace the battery if you can
jump-start the crane from another crane.
3. If you hear the starter relay clicking repeatedly, power is
reaching the starter, but not enough. Suspect the
battery. Charge battery as needed, or replace the
battery if you can jump-start the crane from another
crane.
4. Verify the anti-restart relay, K120, is working properly.
5. If the problem remains, suspect Fuse 53. Replace Fuse
53 and make repairs to the circuit.
6. Turn the ignition switch(es) to RUN (1). Check the
voltmeter. If it doesn’t move (but the head lights, tail
lights, marker lights, dome light, work light, or gauge
lights and panel lights will come on), suspect the ignition
switch(es) and the power circuit to it starting at the
ignition switch(es) circuit breaker (CB 2). Repair or
replace circuit, switch, or fuse as needed.
7. If the battery, fuses, ignition switches, and power circuit
to the ignition switch check out, do one of the following:
a. If you hear no noise when you try to engage the
starter, troubleshoot the start circuit (ignition switch,
electric shifter, neutral start relay K110, the anti-
restart relay K120 and wiring from ignition switch to
starter relay). Make repairs as needed.
b. If the engine still won’t start, and you hear no noise
or just a single click, suspect the starter.
Troubleshoot the start circuit from the starter relay
through the starter solenoid to the starter motor and
ground. Make repairs as needed. If the starter
solenoid or the starter motor is faulty, replace the
starter.
c. If the starter engages but can’t turn the engine (and
the lights dim, signaling power drain during start
attempt), check the starter’s feed circuit from the
batteries for resistance. If the resistance is high,
make repairs. If the circuit checks out, replace the
starter. If the engine still won’t start, suspect a
seized engine.
d. If the starter turns the engine, but it still won’t start,
suspect a faulty engine control system. Refer to the
engine manual for further instructions.
CAUTION
If it is necessary to perform electrical maintenance on live
or hot circuits, remove all rings, watches, and other
jewelry before performing maintenance as serious burns
result from accidental grounding or shorting circuits.
Ensure the battery is disconnected before performing any
maintenance on an electrical circuit which is not fused.
CAUTION
Never replace original wiring with wiring of a smaller size
(gauge).
CAUTION
Many steps in the troubleshooting procedures require live
(energized) components. Perform these steps observing
good safety practices to avoid electrical shock injury.
Reference Only
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