ELECTRIC SYSTEM TMS800E SERVICE MANUAL
3-10
Published 01-29-2014, Control # 496-00
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 fuses 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 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 verify the repaired circuit
works properly.
Troubleshooting Swivel-Caused Electrical
Problems
Many crane component electrical troubles can be traced to
the electrical swivel. Troubles common to the swivel are
improper mounting, foreign material between the brushes
and slip rings, incorrect wiring from the swivel to the
components, incorrect wire size, worn brushes, improper
spring tension on the brush assembly, and loose setscrews
on the slip ring assembly. Refer to the electrical schematic
for slip ring connections and amperages.
Connector Troubleshooting
The cause of an electrical problem may be a loose or
corroded connection in the pin or socket connectors. Check
the connectors to ensure that the pins and sockets are
properly seated and engaged. If the pins and sockets show
any signs of corrosion, use a good quality electrical contact
cleaner or fine sandpaper to clean them. When the pins or
sockets show signs of arcing or burning, it will probably be
necessary to replace them.
Refer to (Tables 3-4 through 3-7) for listing of tools
necessary for connector maintenance.
Because the pins and sockets are crimped to the wires, it is
not possible to remove them. Using the proper extraction
tool, remove the pin(s) or socket(s) from the plug or
receptacle. Cut the wire as close to the pin or socket as
possible. After cutting the pin or socket off, the wire will most
likely be too short. Using a wire that is too short will allow
pressure to be applied to the pin or socket and wire where
they are crimped when the pin or socket is inserted in the
plug or receptacle. Add a short length of the same size wire
to the short wire by crimp splice or solder. Use heat
shrinkable tubing or other suitable material to insulate the
splice.
Table 3-4
Amp Extraction Tool Table
CAUTION
When possible ensure the batteries are disconnected
before performing any maintenance on an electrical
circuit.
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.
Description Deutsch Part Number Grove Part Number
14 gauge wire (connectors) 305183 9-999-100176
12 to 8 gauge wire (connectors) 91019-3 9-999-100175
4 to 9 circuit (in-line connectors) 453300-1 N/A
15 circuit (in-line connectors) 458944-1 N/A
Reference Only
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