TROUBLESHOOTING 999 SERVICE/MAINTENANCE MANUAL Test 14 - Location of Pump Ports Pump Identification Pump rene dentiication zl 0 | Frontoad Dram supercharge | | tp 1 | RearLoad Drum or Pump y Laing Hoist Wiis 2 | Boom Hoist 4 5 y 3 | Swing —L i 4 | Ratt Graver i ~o 5 | Let Grawier Ns; 10 | Aviary Lood Bram we 1 Pump Components 5 Pump Components = Descript E {| EOC (Electonie Dsplacement sae Contre) 1 | 2 | Manual Ovenise Contl sta 3 Caso Drain Port Note 1) x Po) H 4 | Charge Pressure Reet Valve Ne " ‘Charge Pressure Rel Vah oe. a 5 | Fiter Adapter (Note 2) ™~ Sy 6 | MutiFunetion Va (Net 3) 7 aa “3 7 | Charge Pressure Gauge Por 8 | Chae Pu rt Por =;\ & 5 © | Pump Por 8 F $ oN 10 | Pump Pon 8 Gauge Por oa ‘a 1 | Pump Por a 12 | Pump Port Gauge Port oe ) 13 | Neutral Adjusting Srew a : 1 ue Ty 14 | Serve Pressure Gauge Por - 4 From Fite 7 NOTE: Both Sides ot Pure. NOTE 2: AunliryOrum Pump Only ToFiter NOTES: Vato fs Dreety Opposite Port it Protect 10.46 Published 05-1617, ont # 041-14 Q@anirowoc999 SERVICE/MAINTENANCE MANUAL ‘TROUBLESHOOTING Test 15 - Location of Motor Ports K VA 3 00m Hist, Load Orums, nd Travel Motor item | Port | Desiption tem | Port | Description 4 | A Main System Pressure tt | M7 | Conitol Pressure 2 |B Main System Pressure 12 | MB Control Pressure 3 | Ht | CasePressure 13 | M8) Ser Pressure Supply 42 | Gace Pressure 14 X1_ Extemal PCP Supply Pressure 5 MT Gauge Por A 5 Minimum Displacement Limiter 8 | Wa Gauge Pon 6 Charge Pressure Reef valve 7 |B Sere Posi Gauge PoerSano Pres Spry || 17 Pressure Compensator Adjuster @ | MA Servo Pressure Gauge Porto Servo Pressure Supply || 18 Manval Override @ | MS Serv Pressure Supply 79 Conor Start Seng 10 | M6 Charge Pressure Gauge Por 20 Loop Flushing Shut Valve Manitowoc Publishes 0-16-17, Cont 081-18 10.47TROUBLESHOOTING 999 SERVICE/MAINTENANCE MANUAL Test 16 - Manually Stroking the Pump Manual Stroke Override 2 |Pump EDC ‘See Test 13 for location of pump ports. To stroke the pump: + Start with engine running and all brakes and locks engaged. + Rotate the pump manual override in the clockwise direction to load down and raise pressure in port “A ‘+ Rotate the pump manual override in the counter- clockwise direction to load down and raise pressure in port “B 10-48 Published 05-16-17, Control # 041-14 G@anitowoc999 SERVICE/MAINTENANCE MANUAL Test 17 - Checking Pump Charge Pressure ‘TROUBLESHOOTING co ES "Pressure Sender 2 Charge Pressure Test Port 3 Text Gauge Component charge systems can be checked at the desired system diagnostic gauge coupler at pressure sender. To check pump charge pressure: + Install a 0 ~ 600 psi (0 ~ 42 bar) gauge at the desired system diagnostic gauge coupler at pressure sender. + Start system and record charge pressure at engine idle speed + No hydraulic systems should be enabled. + A reading of 350 psi (24 bar) is system charge pressure. + A reading of less than 350 psi (24 bar) indioates a charge pressure relief adjustment is necessary, See Test 18, Manitowoc Published 05-1647, Control # 041-14 10-49TROUBLESHOOTING 999 SERVICE/MAINTENANCE MANUAL Test 18 - Adjusting Pump Charge Pressure Relief Item Eo 1 | Adjusting Screw 2. | Adjusting Lock Nut ‘The pump charge pressure must be measured to accurately adjust the charge pressure relief valve, To adjust pump charge pressure: + Install a 0 - 600 psi (0 - 42 bar) gauge at system diagnostic gauge coupler (see Test 17), + Start engine with all brakes and locks engaged + Cheok gauge for approximately 350 psi (24 bar), + To adjust, loosen and hold 1-1/16 inch adjusting lock nut for series 045 ~ 100 units or 1-5/8 inch adjusting lock nut for series 130 units + Tum adjusting screw until 350 psi (24 bar) is obtained + Torque adjusting lock nut to 34 to 41 febs (46 to 56 Nm) + Remove gauge and replace port plug 10-50 Published 05-16-17, Control # 041-14 Canitowoc999 SERVICE/MAINTENANCE MANUAL ‘TROUBLESHOOTING Test 19 - Setting the Pump Pressure ‘Multifunction Valve Adjusting Screw for Port"A" 2. | Multrunction Valve Adjusting Screw for Port "3" To adjust multifunction valve: + Remove the protective cap from the multifunction valve ‘and loosen the lock nut, + Insert a hex wrench into multifunction valve adjusting + Turning adjusting screw clockwise will increase relief 3 | Lock Nut 4 Bypass Hex Nut + Turning adjusting screw counter-clockwise will decrease relief pressure, NOTE: The bypass hex nut is for special applications only and must not be rotated during setting of pump pressure without first consulting the pump ‘manufacturer Iterature, pressure a en era Hoe J ae Pump Port Control Function Wrench Size Table Pump SL) eT aT Travel Forward | Reverse Eatly Series 042 ~ 100 Unis ‘omm nm Load Drum Hoist | Lower ‘Current Series 042-100 Units | 16mm “mm BoomHoist | Raise | Lower Series 190 Units ‘mm mm Swing Right | Let Manitowoc Published 05-1647, Control # 041-14 10-51‘TROUBLESHOOTING 999 SERVICE/MAINTENANCE MANUAL Test 20 - Setting Pump Neutral co Description 1. Neutral Adjusting Screw and Lock Nut 2 Serve Gauge Ports ‘To set pump neutral 10-52 Engine must be off and power on, with all brakes and locks engaged. Disconnect the PC from the pump EDC by removing the cable at the EDC. Install a 0 ~ 600 psi (0 ~ 42 bar) gauge at each servo ‘gauge port. Start engine with all brakes and locks engages. Loosen the hex lock nut and rotate the neutral adjusting serew with hex wrench unti pressure increases in one of the gauges. Note the handle position of the hex wrench and without moving wrench, rotate the neutral adjusting screw counter-clockwise until pressure increases in the other ‘gauge. Note the handle position of the hex wrench again and without moving wrench, rotate the neutral adjusting screw clockwise halfway between the last position The control should now be in neutral with both gauges reading the same case pressure. Hold the neutral adjusting screw with the hex wrench and tighten the lock nut, Remove the gauges and install the servo gauge port plugs. Wrench Size Table Early Series Units Current Series Units Published 05-16-17, Control # 041-14 G@anitowoc