Manitowoc 999 Service And Maintenance Manual

Reference Only
Manitowoc Published 05-16-17, Control # 233-03 10-i
10
SECTION 10
TROUBLESHOOTING
TABLE OF CONTENTS
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Safety Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
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 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 Crawler travels at slow speed.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8
Problem 7 Crawlers will not travel in either direction (one or both tracks). . . . . . . . . . . . . . . . . 10-9
Problem 8 No front or rear load drum operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10
Problem 9 Front or rear load drum will not raise load, but will lower load. . . . . . . . . . . . . . . . 10-11
Problem 10 Front or rear load drum will not lower load, but will raise load. . . . . . . . . . . . . . . 10-12
Problem 11 Front or rear load drum will not reach load drum maximum speed. . . . . . . . . . .10-13
Problem 12 No boom hoist operation.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14
Problem 13 Boom hoist will not reach maximum speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-15
Problem 14 Boom will not boom up, but will boom down.. . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16
Problem 15 Boom will not boom down, but will boom up.. . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-17
Problem 16 No swing operation, but engine loads.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-19
Problem 17 No swing operation, engine does not load. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20
Problem 18 Travel system response is sluggish. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-21
Problem 19 Closed-loop hydraulic system response is sluggish. . . . . . . . . . . . . . . . . . . . . . . 10-22
Problem 20 Hydraulic system is operating hot.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-23
Problem 21 Gantry cylinders will not raise or lower. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-24
Problem 22 Mast cylinders will not raise or lower. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-25
Problem 23 Boom hinge pin cylinders will not extend or retract. . . . . . . . . . . . . . . . . . . . . . . 10-26
Problem 24 Jacking cylinder(s) will not extend or retract.. . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-27
Problem 25 Crawler pin cylinder(s) will not extend or retract (left or right set).. . . . . . . . . . . . 10-28
Problem 26 System pump will not return to neutral. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-29
Problem 27 Counterweight pins will not extend or retract. . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30
Problem 28 Pawl on load drum or boom hoist is not operating correctly. . . . . . . . . . . . . . . . . 10-31
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-32
Test 1 – Battery Test (12 and 24 volts DC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-32
Test 2– Checking Resistance at Engine Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . . . 10-33
Test 3 – Checking Resistance at Engine Oil Pressure Sender . . . . . . . . . . . . . . . . . . . . . . . . . 10-34
Test 4 – Cleaning and Adjusting the Engine RPM Transducer . . . . . . . . . . . . . . . . . . . . . . . . . 10-35
Test 5 –Test Adapters for Checking Electrical Inputs/Outputs . . . . . . . . . . . . . . . . . . . . . . . . . 10-36
Test 5 – Continued . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-37
Test 6 – Testing for Voltage at the Fuse Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-38
Test 7 – Checking Voltage at the Control Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-39
Test 8 – Adjusting the Control Handle Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40
Test 9 – Checking Voltage at the Pressure Senders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-41
Test 10 – Checking Voltage at the Speed Encoders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-42
Test 11 – Checking Voltage at the Hydraulic Brake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-43
Test 12 – Checking Voltage at the Hydraulic Valve Assemblies . . . . . . . . . . . . . . . . . . . . . . . . 10-44
Test 13 – Testing the Pump EDC and Motor PCP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-45
Test 14 – Location of Pump Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-46
Test 15 – Location of Motor Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-47
Test 16 – Manually Stroking the Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-48

Manitowoc 999 Specifications

General

Brand	Manitowoc
Model	999
Category	Construction Equipment
Language	English