TROUBLESHOOTING GUIDE

SERVICE TRAINING

Manitowoc Engineering Co.

07-19-96

P.O. Box 70, Manitowoc, WI 54221-0070

ST132

Phone: 414-684-6621 • Fax: 414-683-6277

2501031
 NOTICE

Because of a program of continuing improvements, Manitowoc Engineering Co.

reserves the right to change this publication at any time, without notice, to reflect those
improvements. This publication describes optional systems which may or may not be a
part of your crane.

ST132-2
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 CONTENTS
ABOUT THIS MANUAL
Introduction ................................................. ST132-iii
Safety Summary ............................................. ST132-iii
General Guidelines ST132-iii
Test Equipment ............................................... ST132-iv
SECTION 1 - TROUBLESHOOTING CHARTS
Problem 1 Engine will not crank or
cranks slowly ............................ ST132-1
Problem 2A Engine model NT 855 with Step Timing
Control system (past production) cranks
but will not start. No smoke from
exhaust..................................... ST132-2
Problem 2B Engine model NT 855 with Step Timing
Control system (past production) starts
hard or will not start. Exhaust smoke
present ..................................... ST132-3
Problem 2C Engine model N14 with electronic
system (current production) starts hard
or will not start. No smoke from
exhaust..................................... ST132-4
Problem 2D Engine model N14 with electronic
system (current production) starts hard
or will not start. Exhaust smoke
present ..................................... ST132-5
Problem 3 Engine runs but no hydraulic
operation .................................. ST132-6
Problem 4 Engine runs but no battery
charging ................................... ST132-7
Problem 5 Unable to build more than 90 psi
air pressure .............................. ST132-8
Problem 6 Engine fault alerts activate during
proper engine operation ........... ST132-9
Problem 7 Frame connecting pin
cylinder(s) will not extend
or retract................................. ST132-10
Problem 8 Crawler travels at slow speed. ST132-11
Problem 9 Crawlers will not travel in either
direction (one or both tracks).. ST132-12
Problem 10 No load hoist operation
(front or rear drums) ............... ST132-13
Problem 11 Will not raise load, but will lower
load (front or rear drums) ....... ST132-14
Problem 12 Will not lower load, but will raise
load (front or rear drums) ....... ST132-15
Problem 13 Will not reach load drum maximum
speed (front or rear drums) .... ST132-16
Problem 14 No boom hoist operation ........ ST132-17
Problem 15 Boom hoist drum will not
reach maximum speed........... ST132-18
Problem 16 Boom will not boom up, but
will boom down....................... ST132-19
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Problem 17 Boom will not boom down,
but will boom up ......................ST132-20
Problem 18A No swing operation.
Engine loads; Swing not
operational .............................. ST132-21
Problem 18B No swing operation.
Engine does not load;
Swing not operational ............. ST132-22
Problem 19 Crawler system response
is sluggish ............................... ST132-23
Problem 20 System (closed-loop)
response is sluggish ...............ST132-24
Problem 21 System is operating hot .......... ST132-25
Problem 22 Gantry cylinder(s) will not
raise or lower .......................... ST132-26
Problem 23 Jacking cylinder(s) will not
extend or retract..................... ST132-27
Problem 24 Boom hinge pin cylinder(s)
or crawler pin cylinder(s)
will not extend or retract
(right or left set)...................... ST132-28
Problem 25 Boom butt cylinder will not
extend or retract..................... ST132-29
Problem 26 Function pump will not return
to neutral ................................ ST132-30
Problem 27 Counterweight pin(s) will not
extend (engage)..................... ST132-31
Problem 28 Counterweight pin(s) will not
retract (disengage)................. ST132-32
Problem 29 Pawl not operating (boom hoist,
load drums, or luffing jib hoist
if equipped) ............................ ST132-33
Problem 30 All cylinders functioning off
the upperworks and adapter
frame valve assemblies are
not operating.......................... ST132-34
SECTION 2 - TESTING
Test 1 Battery Test (12 and 24 Volts DC) .... ST132-35
Test 2 Checking Resistance at Engine
Temperature Switch.......................... ST132-36
Test 3 Checking Resistance at Engine Oil
Pressure Sender .............................. ST132-37
Test 4 Servicing the Motor Purge Valve
Assembly .......................................... ST132-38
Test 5 Testing the Pump EDC and
Motor PCP ....................................... ST132-39
Test 6 Cleaning and Adjusting the Engine
RPM Transducer............................... ST132-40
Test 7 Location of Motor Ports .................... ST132-41
Test 8 Testing for Pump and Motor
Leakage............................................ ST132-43
Test 9 Location of Pump Ports .................... ST132-45
ST132-i
 Test 10 Checking Voltage at the Hydraulic
Brake Valve.......................................ST132-46
Test 11 Manually Stroking the Pump.............ST132-47
Test 12 Testing for Voltage at the Fuse
Panel ................................................ST132-48
Test 13 Checking Voltage at the Control
Handle ..............................................ST132-49
Test 14 Adjusting the Control Handle
Potentiometer ...................................ST132-50
Test 15 Checking System Voltage at the Air
Solenoid Panels................................ST132-51
Test 16 Checking System Voltage at the
Upperworks Valve Assembly ............ST132-52
Test 17 Checking Pump Charge
Pressure ...........................................ST132-53
Test 18 Setting the Pump Pressure...............ST132-54
APPENDIX
Test 19 Adjusting Pump Charge
Pressure Relief .................................ST132-55
Test 20 Setting Pump Neutral .......................ST132-56
ST132-ii
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Test 21 Checking Voltage at the Speed
Senders............................................ ST132-57
Test 22 Adjusting the Counterbalance
Valves............................................... ST132-58
Test 23 Bleeding a Hydraulic Brake
Circuit ............................................... ST132-59
Test 24 Checking Hydraulic Brake
Pressure........................................... ST132-60
Test 25 Checking and Adjusting Auxiliary
System Working Pressure................ ST132-61
Test 26 Checking Pin Cylinder Seals ............ ST132-63
Test 27 Checking Solenoid Magnetism......... ST132-64
Test 28 Pressure Sender Electrical Test ....... ST132-65
Test 29 Actuating the Solenoid Valve
Manual Overrides ............................. ST132-66
Abbreviations ................................................ ST132-67
Symbols ........................................................ ST132-67
 ABOUT THIS MANUAL
INTRODUCTION
This two part manual is designed as a troubleshooting
resource for qualified service technicians familiar with the
operation and repair of electrical, hydraulic, and pneu-
matic equipment. It is not possible to predict all problems
which might occur or the proper procedure for trouble-
shooting each situation. If you encounter a problem not
covered in this manual, first consult your dealer. The
factory Service Department can provide further
assistance if necessary.
Section 1 provides a series of flow charts that identify
problems which could be encountered during normal
operation of the Manitowoc M250. These charts contain
step by step instructions to assist you in identifying and
correcting such problems efficiently and effectively. Fol-
low the procedural steps in the order indicated. Some
steps will direct you to other charts in this manual or ref-
erence specific tests which must be performed in order
for you to successfully move through and complete the
prescribed troubleshooting procedure. These tests are
described in Section 2. If directed to do so, consult the
factory Service Department before proceeding.
Section 2 contains specific instructions for testing and
servicing the various systems and components described
in the troubleshooting charts. Use this section to perform
the tests correctly in accordance with the factory recom-
mendations.
SAFETY SUMMARY
Hazards are always encountered when performing trou-
bleshooting operations on heavy equipment. To minimize
the risk of potential hazards and prevent serious injury or
death, you must comply with the following:
• Carefully read the Manitowoc M250 Troubleshooting
Guide and Description of Operation. Make sure you
understand all instructions and warnings contained in
these manuals before beginning troubleshooting oper-
ations.
• You must be a qualified service technician competent
in the repair and testing of electrical, hydraulic, and
pneumatic equipment. Manitowoc Engineering Com-
pany shall not be responsible for the training of person-
nel who might use this manual to perform the
operations herein.
• Whenever possible, turn off the engine for your protec-
tion and keep unauthorized personnel away from the
crane while troubleshooting.
• Never troubleshoot alone. Always perform trouble-
shooting procedures with a qualified operator stationed
in the crane cab. Maintain constant communication
with this operator when performing operations that
require the crane to be running.
• Do not return crane to service after completion of
maintenance or repair procedures until all guards and
covers have been reinstalled, trapped air has been
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bled from hydraulic systems, safety devices have been
reactivated, and maintenance equipment has been
removed.
• Perform a function check to ensure proper operation at
completion of maintenance or repair operations.
The following warnings apply to all troubleshooting oper-
ations, but are not all inclusive. Manitowoc Engineering
Company cannot foresee all hazards which might be
encountered.
You must be familiar with the equipment, trained in test-
ing methods, and use common sense while troubleshoot-
ing to avoid other hazards.
EYE, SKIN, AND RESPIRATORY
! WARNING HAZARDS!
Wear proper eye and skin protection and avoid direct
contact with battery acid, exhausting air, oil, or ether
spray when searching for leaks, opening connec-
tions, or installing pressure gauges.
Pressurized air and hydraulic oil can cause serious
injury. Turn OFF engine, render starting means inop-
erative, and relieve pressure on system before dis-
connecting, adjusting, or repairing any component.
Ensure that reconnections are properly made, O-
rings or gaskets are in place, and connectors are
tight before pressurizing system.
Use necessary precautions against electrical burns
when checking battery charging and starter circuits.
Death or serious injury can occur if these warnings
are ignored.
! WARNING UNEXPECTED MOVING
PART HAZARD!
Keep personnel away from crane while manually
actuating a valve or pump to avoid unexpected
equipment movement which can result in death or
serious injury.
GENERAL GUIDELINES
The following guidelines apply to all troubleshooting oper-
ations:
• Terms RIGHT, LEFT, FRONT, and REAR used in this
manual to describe specific crane component locations
correspond to the operator’s right, left, front, and rear
sides when seated in the operator’s cab looking for-
ward.
• Do not remove cylinders or remove counterbalance
valve(s) from a cylinder until its working unit has been
securely restrained against movement.
• Do not use your hands to check for air and hydraulic oil
leaks.
ST132-iii
 NOTE Use soap and water solution to check for air
leaks (apply to fittings and lines and watch for bub-
bles). Use a piece of cardboard to check for hydraulic
oil leaks.
• Use gauges of the appropriate pressure range when
checking air and hydraulic circuits.
• When applicable, use the standard test plug adapter
(available from Manitowoc Engineering Company) for
electrical testing.
• Check ground potentials when testing electric circuits
for continuity, voltage, or resistance (ohms).
NOTE When checking voltages, use ground point for
circuit being checked. If voltage does not register on
multimeter, use a known ground; if reading is then
obtained, the ground of the circuit in question is proba-
bly faulty.
• Check all terminal points for cleanliness and tight con-
nection.
• Check pressures at the specified air and hydraulic
component ports.
• Check the motor pressure control pilots at the PCP
valve assembly located on the motor under test. Like-
wise, test the pump electric displacement controls at
the EDC assembly located on the pump under test.
• Check the individual pressure sender electric supplies
at the transducer manifold assembly located next to the
pump control junction box behind the left side rotating
frame.
• Check the individual air solenoid electric supplies at
the air solenoid valve manifold located in the air valve
junction box on the left side of the crane.
ST132-iv
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• Check control handle electrical input and output volt-
ages at the individual control handle under test.
• Check programmable controller (PC) input and output
cables at the connector pins.
• Check electrical supply, switch outputs, and diodes for
the crane set-up remote controller at the air valve junc-
tion box mounted on the left side rotating frame. Check
these items for the jacking remote controller at the aux-
iliary valve junction box mounted on the right side rotat-
ing frame.
• Check the speed sender (encoder) electric supplies at
the hydraulic control junction box mounted on the
inside of the right side rotating frame, or at the individ-
ual encoder under test if using a test plug adapter.
• Check the crane operating limit electric supplies at the
adapter frame junction box forward of the swivel, or by
viewing the diagnostic operator display in the cab.
• Check the cab power relay MS2 supply at the MS2
relay component mounted inside the cab power switch
section of the right control console.
• Check all other basic system electric supplies at the
fuse panel mounted inside the upper switch panel sec-
tion of the right control console.
TEST EQUIPMENT
The test equipment shown or described herein, is avail-
able for testing the M250 hydraulic, electric, and air sys-
tems. This equipment can be purchased in kit form (with
or without equipment carrying case) or separately, as
needed, by contacting the factory Parts Department.
 SECTION 1 - TROUBLESHOOTING CHARTS

PROBLEM 1
Engine will not crank or cranks slowly.

POSSIBLE CAUSES
Dead battery; Loose connection on battery terminal; Bad starter;
Bad MS1 solenoid; Bad starter solenoid.

CHECKS
Check for voltage at battery terminals while attempting to turn over engine.
> 10 VDC See test 1. < 10 VDC

Check 120 A breaker. Check battery static volts. See test 1.

If good If bad > 12 VDC < 12 VDC

Replace. Charge or replace battery.

Check MS1 solenoid. Check electrical connections in the starter

circuit from battery to starter.
If good If bad
Connections good Connections bad

Replace.
Check cab start Clean or replace.
switches and starter
Check starter solenoid and motor. circuit connections.
If good If bad

Repair or replace.

Check engine for mechanical binding in the pump drive train.

Try to turn the engine at pulley end with wrench while holding
fuel shut-off in the off position.
Engine does not turn

Disengage clutch and attempt to turn engine.

Engine turns Engine does not turn

Possible pump or drive damage. Engine or flywheel has suffered damage.

Disassemble and investigate. Disassemble and investigate.
BB-193

ST132-1

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 PROBLEM 2A
Engine model NT 855 with Step Timing Control system (past production)
cranks but will not start. No smoke from exhaust.

POSSIBLE CAUSES
Fuel tank empty; Fuel shut-off closed; No fuel to injectors; Loose fuel connection; Fuel flow circuit plugged
or restricted; No fuel in pump; Intake or exhaust system restricted; Defective fuel pump; Damaged gear
pump shaft; AFC “No-Air” screw out of adjustment; Gear pump check valve stuck; Damaged camshaft.

CHECKS
Check fuel tank level and fill if necessary. Attempt re-start.
No start

Shut-off valve may be closed. Using valve manual override, attempt re-start.
Engine starts No start

Electrical fuel shut-off valve not responding. No fuel to injectors. Loosen fuel rail line between
Check for loose wires and verify starter fuel pump and cylinder head while cranking engine
solenoid is functioning. to remove possible air in fuel line. Attempt to re-start.
No start

Loosen connections on suction side of fuel pump.

Tighten all fuel filter fittings and connections from
fuel tank to fuel pump and attempt re-start.
No start

Replace fuel filter and check suction

hose for obstruction.
No obstruction Obstruction

No fuel in pump. Prime fuel pump Clear obstruction.

and attempt re-start.
No start

Possible intake or exhaust system restriction.

Isolate and clear restriction and attempt re-start.
No start

Check for pump tachometer shaft rotation while cranking engine.

Shaft rotates Shaft does not rotate

Check for rotation and suction of gear pump while cranking engine. Repair or replace
Fully functional Not functional fuel pump.

AFC “No-Air” screw out of adjustment. Replace damaged

See engine manual and attempt re-start. gear pump shaft.
No start

Gear pump check valve is stuck open or gear pump

is worn. Replace check valve or pump if necessary.
No start

Check for irregular rocker lever movement while rotating engine.

Smooth operation Irregular operation

Consult engine manual Replace camshaft.

and/or factory. BB-164A

ST132-2

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 PROBLEM 2B
Engine model NT 855 with Step Timing Control system (past production)
starts hard or will not start. Exhaust smoke present.

POSSIBLE CAUSES
Inadequate battery amperage to gain starting RPM; Excessive load on engine; Cold start aid not
functioning; Air in fuel sysyem; Plugged fuel filter; Fuel suction line restricted; Intake air system restricted;
Fuel contaminated; AFC “No-Air” screw out of adjustment; STC oil control system problem; Defective injectors.

CHECKS
Check engine for adequate cranking RPM.
Low (150 RPM or Less)

Check batteries individually. See test 1. Does voltage drop exceed 6 volts while cranking engine?
Yes No

Replace battery. Disengage drive clutch to reduce load at start-up.

No start

Verify cold start aid is functioning properly if applicable. Note: A fuel additive is recommended in cold weather.
Functional Not functional

Replace fuel filter and verify fuel suction lines are not obstructed. Repair or replace start aid.
Attempt re-start.
No start

Possible air in fuel system. Tighten fuel connections and filter,

and check tank stand pipe and road speed governor. See
engine manual. Purge air from system and attempt re-start.
No start

Check fuel lines on suction side of fuel pump for obstruction.

No obstruction Obstruction

Check intake air system for obstruction. Clear obstruction.

No obstruction Obstruction

Clear obstruction.

Possible fuel contamination. Attempt engine operation from a temporary supply tank.
Engine starts No start

Drain tank and replace Check and adjust AFC “No-Air” screw. See engine manual.
with fresh fuel. No start

STC oil control valve may not be advancing engine timing.

Check STC valve calibration. See engine manual.
No start

Oil from STC valve may not be reaching injectors. Check

oil lines, check valve, and STC oil manifolds for leakage,
blockage, or improper installation. Isolate and correct problem.
No start

STC injectors may not be advancing engine timing. Remove

injectors and repair or replace tappets. See engine manual.
BB-164B

ST132-3

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 PROBLEM 2C
Engine model N14 with electronic system (current production)
starts hard or will not start. No smoke from exhaust.

POSSIBLE CAUSES
Electronic fault code problem; Low fuel; Bad starter; Fuel shut-off valves closed; Bad auxiliary shutdown valve;
Voltage supply lost to electronic control module; Fuel filter or suction line restricted; Loose fuel fittings; Fuel
drain line restricted; Bad fuel tank component; Bad fuse; Piston o-ring seal leakage; Bad injector.

CHECKS
Are electronic fault codes active or are there high counts of inactive fault codes?
Yes No

See engine manual for trouble- Check fuel tank level and fill if necessary. Attempt to re-start.
shooting the electronic system. No start

Check direction of crankshaft rotation.

Correct Not correct

See engine manual. Check electronic Repair or replace starter

and mechanical fuel shut-off valves motor if necessary.
and circuits. Correct problem.
No start

Isolate and repair problem with auxiliary device (Skinner valve)

or external governor.
No start

Check for loose battery connections, bad fuses and for problems with
the unswitched battery supply circuit. See engine manual.
No start

Replace fuel filter and check for fuel suction line restriction.
No restriction Restriction

Replace fuel line.

Tighten all fuel fittings and connections between fuel

tank and fuel pump. Attempt re-start.
No start

Check fuel drain line for restriction. Clear or replace

lines, check valves, or tank vents.
No start

Check and repair fuel suction stand pipe in fuel tank.

See engine manual.
No start

Isolate and replace bad fuses in OEM interface harness.

See engine manual.
No start

See engine manual. Check the air-actuated RSG piston o-ring seal
in fuel pump for leakage. Repair fuel pump if necessary.
No start

Consult engine manufacturer. BB-164C

ST132-4

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 PROBLEM 2D
Engine model N14 with electronic system (current production)
starts hard or will not start. Exhaust smoke present.

POSSIBLE CAUSES
Electronic fault code problem; Inadequate battery amperage to gain starting RPM; Cranking fuel pressure
wrong; fuel contaminated; Fuel line obstruction; Air in fuel system; Intake air system restricted; Plugged
cylinder head fuel drillings; Start aid not functioning; Fuel pump problem; Overhead settings wrong;
Damaged injector o-rings; Malfunctioning injector; Valve protrusion wrong.

CHECKS
Are electronic fault codes active or are there high counts of inactive fault codes?
Yes No

See engine manual for trouble- Check engine for adequate cranking speed using
shooting the electronic system. handheld tachometer or electronic service tool.
> 150 RPM < 150 RPM

See engine manual. Verify cranking fuel pressure at fuel pump is 25 psi. See PROBLEM 1
> 25 psi < 25 psi

Fuel may be contaminated. Attempt engine See engine manual.

operation from a temporary supply tank.
Engine starts No start

Drain tank and replace Check the fuel line between fuel pump and cylinder head for sharp bends.
with fresh fuel. No restriction Restriction

Check for air in the fuel system. See engine manual. Replace fuel line.
Correct problem and attempt re-start.
No start

Check the air intake system for restriction. Clean or replace air
filter and inlet piping as necessary. Attempt re-start.
No start

Fuel drillings in cylinder head may be plugged.

Check for plastic fuel passage plug obstructing fuel to the injectors.
No obstruction Obstruction

Clear obstruction.

Verify cold start aid is functioning properly if applicable. Note: A fuel additive is recommended in cold weather.
Functional Not functional

Fuel pump AFC operation may be malfunctioning or pump is not calibrated. Repair or replace start aid.
Isolate and correct problem. See engine manual. Attempt re-start.
No start

See engine manual. Adjust the overhead settings.

No start

See engine manual for specific injector system. Remove and inspect the
injectors and injector o-rings. Repair or replace injectors as necessary.
No start

Check valve protrusion and replace valve seat inserts or cylinder head.
No start

Consult engine manufacturer.

BB-164D

ST132-5

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 PROBLEM 3
Engine runs but no hydraulic operation.

POSSIBLE CAUSES
Clutch not engaged; No hydraulic fluid in tank; Blocked charge inlet to pumps;
Clogged tank vent; Drive train damaged from flywheel to pump mount.

CHECKS
Check hydraulic filter service shut-off valve.
OK Not OK

Open filter service

Check clutch engagement. shut-off valve or replace
filters if necessary.
Clutch engaged Clutch not engaged

Engage clutch.

Remove tank cap and check vent, fluid level, and viscosity.
Note: In extreme cold conditions, oil may not flow freely to
pump inlets causing cavitation to occur.

Tank vent, oil level, viscosity OK Not OK

Service hydraulic
system.

Check manual overrides on two or more pumps. Does the

engine load when manual override is applied? See test 11.
Note: Be sure all brakes are applied and swing lock is in
place before this test.
Pump loads Pump does not load

Check electrical input from Consult factory.

controller to pump. See test 5.

BB-165

ST132-6

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 PROBLEM 4
Engine runs but no battery charging.

POSSIBLE CAUSES
Belt loose or broken; No input to alternator terminals; Corroded or
loose battery connection; Damaged alternator; Bad battery.

CHECKS
Check drive belt for proper tightness
(no more than 1/2" deflection of drive belt).
OK Not OK

Connect voltmeter between alternator 12 V terminal and GND terminal. Replace or tighten.
Take reading with cab power on and engine running.
Zero (0) VDC Less than 13.6 VDC More than 13.6 VDC

Repair wiring Replace alternator. Test batteries for

or weak cells.
connections.
BB-194

ST132-7

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 PROBLEM 5
Unable to build more than 90 psi air pressure.

POSSIBLE CAUSES
Malfunctioning safety valve, unloader valve, compressor,
shut-off valve, or bleed valves.

CHECKS
Is gauge pressure > 90 psi?
Yes No

Replace pressure sensor.

Verify bleed valves are closed, shut-off

valve is open, and safety valves are
operating properly.

Proper unloader valve

operation.
Yes No

Check compressor Adjust or replace

output. unloader valve.

BB-166

ST132-8

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 PROBLEM 6
Engine fault alerts activate during proper engine operation.

POSSIBLE CAUSES

High engine temperature Low oil pressure

Check coolant
level and quality. Check oil level.
OK Not OK
OK Not OK

Check fan belt. Add or replace

coolant. Check pressure Add oil.
OK Not OK sender.
See test 3.
Not OK
Check temperature Adjust or replace
switch. See test 2. fan belt.
Not OK
See engine
manual.

See
engine manual.
BB-167

ST132-9

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 PROBLEM 7
Frame connecting pin cylinder(s)
will not extend or retract.

POSSIBLE CAUSES
Faulty relief valve; Faulty auxiliary system disable valve;
Faulty proportional flow control valve; Cylinder failure;
Faulty control valve section; Defective pump;
Mechanical malfunction.

CHECKS
Check for 3500 psi pressure at upperworks valve assembly while
activating any upperworks valve assembly function. See test 16.
> 3500 psi < 3500 psi

Activate problem frame connecting pin cylinder Adjust auxiliary

up and down solenoids and verify solenoid system disable valve
LEDs are lit, indicating voltage is present. and re-check pressure.
Voltage No voltage See test 25.

Check for mechanical problem Check for 12 volts at respective

at frame connecting pin cylinder. connecting pins switch wire #53.
No problem Problem Voltage No voltage

Repair Replace Replace

as needed. appropriate diode function switch.
to wire #89D1.

Disconnect and plug hoses to

problem cylinder. Actuate valve function.
> 3100 psi < 3100 psi

Test cylinder
for seal leakage. Replace control
See test 26. valve section.
No leakage Leakage

Replace Replace
cylinder. cylinder
seal.
BB-168

ST132-10

2501031
 PROBLEM 8
Crawler travels at slow speed.

POSSIBLE CAUSES
Partial control voltage from handle to PC; Partial control voltage from PC to pump EDC; Defective pump or motor.

CHECKS
Is engine RPM >1600?
Yes No

Check speed transducer Increase engine

for proper setting and speed.
operation. See test 6.
Has speed problem
been corrected?
No

When moving the applicable travel control handle fully in both directions, the TRACK
diagnostic screen (banks 1 or 2) obtains 100% handle control in each direction.

Yes No

When moving the travel handle fully in both directions, the TRACK Repair or replace
diagnostic screen (banks 3 or 4) obtains control handle.
100% pump control in each direction.
Yes No

Check for proper control voltage (2.3 V or above) and coil resistance Consult factory.
(24-26Ω) at pump EDC. See test 5.
Voltage and coil OK Voltage and/or coil not OK

Purge valve assembly of Repair or replace coil or wiring.

affected motor is defective,
blocked or out of adjustment.
Adjust, repair or replace
purge valve assembly.
See test 4.
Has speed problem
been corrected?
No

Does crane drum

attempt to rotate when
traveling?
Yes No

Possible diverter See test 7. Is system

valve problem. pressure above 3900 psi at
Consult factory. motor system pressure port?
Yes No

Crane is in low speed. Crane is in high speed.

Consult factory. Check for pump and motor
leakage. See test 8.
BB-169

ST132-11

2501031
 PROBLEM 9
Crawlers will not travel in either direction (one or both tracks).

POSSIBLE CAUSES
Defective brake valve; Defective control handle; Defective EDC; No voltage through control handle to controller;
No voltage out of controller to EDC on pump; Low brake pressure; Wiring defect.

CHECKS
Diagnostic display TRACK screen (bank 7) displays 1 when affected handle(s) are moved
in direction of no movement.
Yes No

Engine loads when moving handle(s) in either direction. Consult

Yes No factory.

12 volts at right console terminal 82E.

Yes See test 12. No

Consult factory.
When moving the applicable travel control handle fully
Use test plug adapter. See test 10. in both directions, the TRACK diagnostic screen (banks 1 or 2)
Is voltage present at hydraulic brake obtains 100% handle control in each direction.
solenoid 82E when handle is moved? Yes No
Yes No

When moving the applicable travel

Does track turn while moving control handle fully in both directions, the
handle and actuating manual TRACK diagnostic, screen (banks 3 or 4)
override on brake valve? See obtains 100% pump control in each
test 29. direction.
Yes No Yes No

Replace See test 24.

solenoid. Is pressure at Manually stroke pump. Voltage at handle (83P or 84P) is greater
brake >300 psi? See test 11. Does pump than 0 with handle moved. See test 13.
Yes No pressurize? Yes No
Yes No
Repair brake
or gearbox. 10 volts at handle
Use test plug Isolate pump. Consult (87FA). See test 13.
See test 17. Is system adapter. See test 11. factory. Yes No
charge pressure >300 psi? See test 5. Does manually
Yes No Is voltage stroked pump
present at pump? pressurize? Repair or
Re-adjust charge replace
Replace Yes No Yes No
pressure relief handle.
brake
valve. or replace pump.
Repair or
See test 19. Repair or replace
replace
motor. fuse 87F and/or
Repair or replace wiring or Replace EDC. wiring. See test 12.
consult factory.
Repair or
Repair or replace wiring replace
or consult factory. pump.
BB-170

ST132-12

2501031
 PROBLEM 10
No load hoist operation (front or rear drums).

POSSIBLE CAUSES
Load hoist brake not releasing; Load hoist pawl not released or hung up; No voltage through control
handle to controller; No voltage out of controller to EDC on pump; Wiring or switch defect.

CHECKS
Diagnostic display DRUM 1, 2, or 3 screen displays 1 (for bank 5) and
0 (for bank 6) when affected handle(s) are moved in direction of no movement.
Yes No

Engine loads when moving handle(s) in either direction. Drum full power/free fall switch
Yes No is in an operative position.
Yes No

Consult Place switch

Use test plug adapter. factory. in operative
See test 10. Is voltage position.
present at air brake
solenoid 81E, 81EL,
or 80E when handle When moving the applicable drum control handle fully in both
is moved? directions, the DRUM 1, 2, or 3 diagnostic screen (bank 1)
obtains 100% handle control in each direction.
Yes No
Yes No

Does drum turn

without engine When moving the applicable drum control Voltage at handle
load while moving handle fully in both directions, the DRUM 1, (80P or 81P) is greater
handle and 2, or 3 diagnostic screen (bank 2) obtains than 0 with handle moved.
actuating 100% pump control in each direction. See test 13.
manual override
Yes No Yes No
on brake valve?
See test 29.
Yes No
Consult factory. 10 volts at
handle (87FA)?
Repair or See test 13.
Replace replace wiring Yes No
brake or consult
valve. Manually stroke pump.
factory. See test 11. Does pump Repair Replace fuse
pressurize? or replace 87F and/or
Is pressure at Yes No handle. wiring.
brake >90 psi? See test 12.
Yes No
Use test plug See test 11. Isolate pump. Does
adapter. See test 5. manually stroked pump pressurize?
Is voltage present? Yes No
Repair Is system charge
brake or pressure >90 psi? Yes No
gearbox. Yes No Repair or Repair or
Replace EDC. replace replace
motor. pump.
Re-adjust charge
Replace pressure relief or
brake replace pump. Repair or replace wiring or
valve. See test 19. consult factory.
BB-171

ST132-13

2501031
 PROBLEM 11
Will not raise load, but will lower load (front or rear drums).

POSSIBLE CAUSES
Block up limit opened; Pump is defective;
LMI circuit opened; Control handle is defective;
Maximum bail limit opened; Speed sender is defective.

CHECKS
Check Diagnostic Screen D2
(Use table 3 of Diagnostic Display Reading ST-130)
When applicable switch was activated...
Bank 1 changed by 16 (left rear), 2 (front), 64 (right rear)...........Max bail limit
Bank 1 changed by 32..............................................................Block up limit
Bank 6 changed by 16.............................................................................LM I
All bank numbers Any bank number
increased by not increased
number shown. by number shown.

Diagnostic DRUM 1, 2, or 3 screen Check for problem and repair

(bank 1) approaches 100% handle limit switch function, wiring,
control with handle pulled backward. or fuse.
Yes No

Diagnostic DRUM Repair or

1, 2, or 3 screen (bank 2) replace
approaches 100% pump handle.
control with
handle pulled backward.
Yes No

See test 5. Consult

Do –2.3 to –2.8 factory.
volts exist at pump
EDC with handle
pulled backward?
Yes No

Replace Repair or replace wiring

EDC. or consult factory.
BB-172

ST132-14

2501031
 PROBLEM 12
Will not lower load, but will raise load (front or rear drums).

POSSIBLE CAUSES
Pawl in; Control handle is defective;
Minimum bail limit opened;
Pump is defective; Speed sender is defective.

CHECKS
Check Diagnostic Screen D2.
(Use table 3 of Diagnostic Display Reading ST-130)
When applicable switch was activated...
Bank 1 changed by 8 (left rear), 4 (front), 128 (right rear)....Min bail limit
Bank number Bank number
increased not increased
by number shown. by number shown.

Diagnostic DRUM 1, 2, or 3 Check for problem

screen (bank 1) approaches and repair limit switch,
100% handle control wiring, or fuse.
with handle pushed forward.
Yes No

Repair or
replace
handle.

Diagnostic DRUM 1, 2, or 3
screen (bank 2) approaches
100% pump control
with handle pushed forward.
Yes No

Consult factory.

Use test plug adapter. See test 15. Are 12 volts

present at brake solenoid when handle is moved?
Yes No

See test 5. Repair or replace wiring or consult factory.

BB-173

ST132-15

2501031
 PROBLEM 13
Will not reach load drum maximum speed
(front or rear drums).

POSSIBLE CAUSES
Partial control voltage from handle to PC; Partial control
voltage from PC to pump EDC; Defective pump or motor;
Defective divert switch or diverter valve.

CHECKS
When moving the load drum hoist control handle fully in both directions, diagnostic
display DRUM 1, 2, or 3 screen (bank 1) obtains 100% handle control in each direction.
Yes No

When moving left or right divert switch, Diagnostic Screen D2 Repair or replace
(bank 3) changes by 8 for left track or 16 for right track divert. control handle.
Yes No

Repair switch
or wiring.

When moving left or right divert switch, Diagnostic Screen D1

(bank 3) changes by 8 for left track or 16 for right track divert.
Yes No

Consult factory.
When moving the load drum hoist control
handle fully in both directions,
diagnostic DRUM 1, 2, or 3 screen (bank 2)
and diagnostic display TRACK screen
(bank 3 or 4 if divert is activated)
obtain 100% pump control in
each direction.
Yes No

Consult factory.

Check for proper control voltage and

coil resistance at hoist pump or selected
divert pump EDC. See test 5.

Voltage Voltage
and and/or
coil OK. coil not OK.

Check for pump and Repair or

motor leakage. replace coil
See test 8. or wiring.
High
Normal leakage

Repair or Repair or
replace replace
diverter pump or
valve. motor.
BB-174

ST132-16

2501031
 PROBLEM 14
No boom hoist operation.

POSSIBLE CAUSES
Boom hoist brake not releasing; Boom hoist pawl not released or hung up; No voltage through control handle to controller;
No voltage out of controller to pump EDC; Wiring or switch defect.

CHECKS
Diagnostic display DRUM 4 screen (bank 4) displays 1 when boom hoist control handle is moved
in direction of no movement.
Yes No

Engine loads when moving handle in either direction.

Yes No

Use test plug

adapter. See test 10.
Is 12 volts present at hydraulic When moving the boom hoist control handle fully in both directions,
brake solenoid 82E when the DRUM 4 diagnostic screen (bank 1) obtains 100% handle control
handle is moved? in each direction.
Yes No
Yes No

Repair or replace wiring

or consult factory.
Does drum turn
while moving handle
and actuating When moving the boom hoist control handle fully in both Voltage
manual override directrions, the DRUM 4 diagnostic screen (bank 2) at handle (82P) is
on brake valve? obtains 100% pump control in each direction. greater than 0.
Yes No Yes No Yes No

Replace
Manually stroke pump. See test 11. Consult 10 volts at
solenoid.
Does pump pressurize? factory. handle (87FA)?
Is pressure at Yes No See test 13.
brake >300 psi? Yes No
Yes No
Use test plug adapter. See test 11.
See test 5. Isolate pump. Does manually Repair or Replace
Repair brake Is voltage present? stroked pump pressurize?. replace fuse 87FA
or gearbox. Yes No Yes No handle. and/or
replace
Is system charge
Replace EDC. wiring.
pressure >300 psi?
Check for pump See test 12.
Yes No
and motor leakage.
Repair or replace wiring or See test 8.
Replace brake Consult
consult factory.
valve. factory
if problem
Repair or Repair or
is not
Re-adjust charge pressure replace pump replace
corrected.
relief or replace pump. and/or motor. pump.
BB-175

ST132-17

2501031
 PROBLEM 15
Boom hoist drum will not reach maximum speed.

POSSIBLE CAUSES
Partial control voltage from handle to PC; Partial control voltage from PC to pump EDC;
Pump or motor defective; Malfunctional max displacement solenoid valve.

CHECKS
Is operating system pressure > 3500 psi?
Yes No

Motor is in max displacement

mode; speed is reduced.

When moving the boom hoist control handle fully in both directions, the diagnostic
DRUM 4 screen (bank 1) obtains 100% handle control in each direction.
Yes No

When moving the boom hoist control handle fully in both Repair or replace
directions, the diagnostic DRUM 4 screen control handle.
(bank 2) obtains 100% pump control in each direction.
Yes No

When raising or lowering the boom, with Consult

full handle actuation, the Diagnostic Screen D1 factory.
(bank 3) changes by 32.
Yes No

Manually actuate boom hoist

max displacement solenoid valve. Consult
See test 29. factory.
Max speed No max speed

Repair or replace
displacement valve
or wiring.

Check for proper control voltage

and coil resistance at pump EDC.
See test 5.
Voltage and Voltage and/or
coil OK coil not OK

Check for pump Repair or replace

and motor leakage. coil or wiring.
See test 8.

Repair or replace
pump or motor.
BB-176

ST132-18

2501031
 PROBLEM 16
Boom will not boom up, but will boom down.

POSSIBLE CAUSES
Maximum bail limit opened; Pump is defective; Boom max up limit opened;
Equalizer/boom stop limit opened; Control handle is defective.

CHECKS
Check Diagnostic Screen D2.
(Use table 3 of Diagnostic Display Reading ST-130)
When applicable switch was activated...
Bank 1 changed by 16 (left rear), 2 (front), 64 (right rear) ...................Max bail limit
Bank 2 changed by 32 ...........................................................................Max up limit
Bank 6 changed by 4.........................................................Equalizer/boom stop limit
All bank numbers Any bank number
increased by not increased by
number shown number shown

Diagnostic DRUM 4 Check for problem and repair

screen (bank 1) approaches mechanical function, limit switch
100% handle control function, wiring, or fuse function.
with handle pulled backward.
Yes No

Repair or replace
handle or wiring.

Diagnostic display DRUM 4 screen

(bank 2) approaches 100% pump
control with handle pulled backward.
Yes No

See test 5. Do –2.3 to –2.8 Consult

volts exist at pump EDC factory.
with handle pulled backward?
Yes No

See test 11. Repair or replace wiring

Can pump or consult factory.
be manually
stroked down?
Yes No

Replace Repair or
EDC. replace pump. BB-177

ST132-19

2501031
 PROBLEM 17
Boom will not boom down, but will boom up.

POSSIBLE CAUSES
Boom maximum down limit opened; Pawl in; Pump is defective;
Block up limit opened; Control handle is defective;
LMI circuit opened; Speed sender is defective; Minimum bail limit opened.

CHECKS
Check Diagnostic Screen D2.
(Use table 3 of Diagnostic Display Reading ST-130)
When applicable switch was activated...
Bank 1 changed by 8 (left rear), 4 (front), 128 (right rear)..........Min bail limit
Bank 1 changed by 32..............................................................Block up limit
Bank 3 changed by 16............................................................Max down limit
Bank 6 changed by 16..............................................................................LMI
All bank numbers increased Any bank number not
by number shown increased by number shown

Does Diagnostic Screen D2 Check for problem and repair

(bank 2, boom pawl command) change mechanical function, limit
by 16 when moving pawl switch? switch, wiring, or fuse.
Yes No

Visually check pawl. Repair or replace switch

Out In or wiring to PC.

See PROBLEM 29.

Does diagnostic display DRUM 4 screen (bank 1) approach

100% handle control with handle pushed forward?
Yes No

Repair or replace handle or wiring.

Does diagnostic display DRUM 4 screen (bank 2) approach

100% pump control with handle pushed forward?
Yes No

See test 5. Do +2.3 to +2.6 volts Consult factory.

exist at pump EDC with
handle pushed forward?
Yes No

See test 11. Can pump

be manually stroked down? Repair or replace wiring
or consult factory.
Yes No

Replace
Repair or
EDC.
replace pump.
BB-178

ST132-20

2501031
 PROBLEM 18A
No swing operation.
Engine loads; Swing not operational.

POSSIBLE CAUSES
Mechanical hang-up; Solenoid failure; Wiring fault.

CHECKS
Check swing operation in both directions.
Slight swing movement No swing movement

Inspect swing lock for damage. Check for voltage to brake solenoid with
swing park brake switch in off position.
No damage Damage Voltage No voltage

Check for voltage to Repair or replace Repair or replace wiring.

swing lock solenoid. damaged parts
Voltage No voltage as needed. Check solenoid coils for magnetism
with screwdriver. See test 27.
Magnetic Not magnetic
Repair or replace switch, fuse, or wiring.

Replace valve.
Check solenoid coils for magnetism with screwdriver.
See test 27. Actuate manual override on brake valve.
Magnetic Not magnetic See test 29. Does swing brake release?
Yes No

Replace valve.
Replace valve.

Disconnect air lines and check

Check pressure at brake valve or brake
air output.
assembly with a 0-500 psi gauge. See test 24.
Air at line A Air at line B
300 psi 300 psi

Replace cylinder. Replace valve. Repair or See test 17. Is swing brake release
replace brake. pressure 300 psi or greater?
Yes No

Repair or Set relief pressure

replace brake to 300 psi. See test 19.
valve. Is 300 psi pressure
obtained?
No

Replace relief valve or pump.

BB-179

ST132-21

2501031
 PROBLEM 18B
No swing operation.
Engine does not load; Swing not operational.

POSSIBLE CAUSES
No voltage through control handle to controller; No voltage out of controller to pump EDC;
Defective wiring or switch; Damaged pump or motor; Swing holding brake switch actuated.

CHECKS
Diagnostic Screen D2 (bank 6) changes by 2 when
actuating swing holding brake switch on control handle.
Yes No

Diagnostic display SWING screen (bank 1) Check Swing holding brake

approaches 100% handle control when handle is switch and wiring to PC.
extended in either non-swinging direction. See test 13.
Yes No

Repair or replace Swing

Diagnostic display SWING screen Repair or holding brake switch
(bank 2) approaches 100% pump replace and/or wiring to PC.
control when handle is extended handle
in either non-swinging direction. or wiring.
Yes No

Manually stroke swing Consult

pump. See test 11. factory.
Does engine load?
Yes No

Use test plug adapter. See test 11.

See test 5. Is voltage present Isolate pump. Does manually
at pump EDC? stroked pump pressurize?
Yes No Yes No

Replace Repair or replace Repair or Repair or

EDC. wiring to PC or replace replace
consult factory. motor. pump.
BB-180

ST132-22

2501031
 PROBLEM 19
Crawler system response is sluggish.

POSSIBLE CAUSES
Defective pump diverter valve; Defective pump or motor;
Crawler speed out of adjustment.

CHECKS
Use gauge to check charge pressure at diagnostic station.
See test 17.
! 300 psi 300 psi

Manually stroke pump with brakes applied. Adjust charge pressure relief for 350 psi.
See test 11. Is system pressure See test 19. Is 350 psi obtained?
greater than 6000 psi? No
Yes No

Adjust multifunction
valve for 6000 psi system pressure. See test 18.
Retest with brakes applied. Is pressure OK?
Yes No

Adjust crawler speed per shop procedure #SP3. Is correct speed obtained?
Yes No

Crawler system Check for leakage at motors. See test 8.

response should Normal High leakage
be correct.

Check for leakage at pump. Repair or replace

See test 8. affected motor.
Normal High leakage

Repair or Repair or
replace diverter replace pump.
valve.
BB-181

ST132-23

2501031
 PROBLEM 20
System (closed-loop) response is sluggish.

POSSIBLE CAUSES
Low hydraulic oil level in reservoir; Reservoir shut-off valve is closed;
Dirty filter; System multifunction valves set improperly;
Pump or motor problem.

CHECKS
Hydraulic oil level in reservoir is OK and
reservoir shut-off valve is fully open.
Yes No

With pump in neutral, system charge pressure

is > 350 psi at diagnostic manifold
and/or diagnostic display screen.
Yes
Fill tank to proper level and/or
open shut-off valve.
No

Does tank filter read

< 7 psia on diagnostic
display screen?
Yes No

Adjust charge pressure relief valve

Replace suction filters.
for 350 psi. See test 19.
350 psi obtained 350 psi not obtained
System multifunction valves
operating at recommended
Yes system pressures. No

Adjust or replace faulty valve.

Check for internal leakage at pump and motor. See test 8.

Normal High leakage

Check control pressure at pump Repair or replace pump

servo pressure ports. See test 9. or motor as required.
Pressure OK Pressure not OK

Consult Repair or replace

factory. pump EDC.
BB-182

ST132-24

2501031
 PROBLEM 21
System is operating hot.

POSSIBLE CAUSES
Low hydraulic oil level in reservoir; Heat exchanger problem; Dirty filter;
System multifunction valves set improperly; Pump or motor problem.

CHECKS
Hydraulic oil level in reservoir is OK.
Yes No

Is heat exchanger radiator clean? Fill tank to proper level or open

Yes No shut-off valve.

Clean, repair or replace

Are fans turning?
Yes No heat exchanger radiator.

Adjust, repair, or replace fan motor,

fan relief valve, or pump.

System charge pressure of 350 psi

at pressure sensor station.
Yes No

Are suction filters clean?

Yes No

Replace filters.

Adjust charge pressure relief valve

for 350 psi. See test 19.
350 psi obtained 350 psi not obtained

System should be
operating at proper
temperature.

System multifunction valves

operating at recommended system
pressures.
Yes No

Adjust or replace faulty valve. See test 18.

Check for internal leakage at pump and motor. See test 8.

Normal High leakage

Is system operating pressure excessive? Repair or replace pump

Yes No or motor as required.

Locate and reduce load on Repair or replace pump

motor transmission assembly. or motor as required.
BB-183

ST132-25

2501031
 PROBLEM 22
Gantry cylinder(s) will not raise or lower.

POSSIBLE CAUSES
Switch failure; Solenoid failure; Mechanical malfunction;
Wiring problem; Cylinder failure.

CHECKS
Does the system pressurize to 3500 psi when moving the gantry switch
from neutral to the lower position at the remote controller?
Yes No

Are mechanical problems present at Activate gantry extend and retract solenoids
the gantry cylinder assembly? and verify solenoid plug LEDs are lit,
Yes No indicating voltage is present.
Voltage No voltage

Repair problem. Adjust cylinder

counterbalance Check appropriate diode
valve. See test 22. to wire #89D1.
Does cylinder
Diode good Diode bad
function?
No
Replace solenoid Replace diode.
Replace cylinder or valve section.
consult factory.
Check for 12 volts at switch wire #43
for raise or #44 for lower.
Voltage No voltage

Check wiring to Replace

solenoid and replace function switch.
if necessary.
BB-184

ST132-26

2501031
 PROBLEM 23
Jacking cylinder(s) will not extend or retract.

POSSIBLE CAUSES
Faulty relief valve; Faulty control valve section;
Faulty auxiliary disable valve; Bad pump; Faulty cylinder.

CHECKS
Check for 3500 psi pressure at auxiliary system disable valve while
retracting any jacking cylinder valve assembly other than the problem cylinder.
3500 psi See test 25. < 3500 psi

Check for 2250 psi pressure at auxiliary system disable Adjust upperworks relief valve for
valve while extending the malfunctioning cylinder using 3500 psi and re-check pressure. See test 25.
the control handle. See test 25. < 3500 psi
2250 psi < 2250 psi

Repair or replace
Exchange both counterbalance upperworks relief valve.
valve cartridges on the
malfunctioning jacking cylinder.
Does cylinder function with handle
movement?
Yes No

Replace Repair or replace

counterbalance valve. cylinder.

Activate jacking extend and retract solenoids and

verify solenoid plug LEDs are lit, indicating
voltage is present.
Voltage No voltage

Adjust upperworks relief valve for 3500 psi Check for 12 volts at the respective jacking
and re-check pressure. See test 25. cylinder switch #54.
< 3500 psi Voltage No voltage

Repair or replace upperworks Replace appropriate Replace function

relief valve or valve section. diode to wire #89D1. switch.
BB-185

ST132-27

2501031
 PROBLEM 24
Boom hinge pin cylinder(s) or crawler pin cylinder(s) will not extend or retract (right or left set).

POSSIBLE CAUSES
Faulty relief valve; Faulty auxiliary disable valve; Faulty proportional flow control valve:
Cylinder failure; Faulty control valve section; Bad pump; Mechanical malfunction.

CHECKS
Check for 3500 psi pressure at the upperworks valve assembly while
activating any upperworks valve assembly function in the retract direction.
See test 25.
3500 psi < 3500 psi

Adjust auxiliary system disable valve and re-check pressure.

See test 25.
Check for mechanical problem < 3500 psi
at pin cylinder assembly.
Problem No Problem
Replace auxiliary
system disable valve.

Repair as Check for 3500 psi pressure at auxiliary system

needed. disable valve while activating any adapter frame
valve section other than the problem section
in the retract direction. See test 25.
3500 psi < 3500 psi

Disconnect and plug hoses to Activate cylinder extend and retract

problem cylinder. Re-check solenoids at adapter frame valve
pressure. assembly and verify solenoid plug
3500 psi < 3500 psi LEDs are lit, indicating voltage is
present.
Voltage No voltage
Test cylinder Replace
for leakage. valve
See test 26. section. Check for 12 volts at respective
cylinder switch wire #51 or #52.
Voltage No voltage
Disconnect adapter frame valve assembly from
proportional flow control valve and plug valves.
Check pressure at auxiliary system disable Replace Replace
valve while actuating any adapter frame valve appropriate function
assembly function. diode to switch.
3500 psi < 3500 psi
wire #89D1.

Repair or replace Repair or replace

proportional flow adpater frame
control valve. valve assembly.
BB-186

ST132-28

2501031
 PROBLEM 25
Boom butt cylinder will not extend or retract.

POSSIBLE CAUSES
Faulty relief valve; Faulty auxiliary disable valve; Faulty proportional flow control valve;
Cylinder failure; Faulty control valve section; Defective pump.

CHECKS
Check for 3500 psi pressure at auxiliary system disable valve while activating
any upperworks valve assembly function in the retract direction.
See test 25.
≥ 3500 psi < 3500 psi

Check for 3500 psi pressure at auxiliary Adjust auxiliary system disable valve
system disable valve while activating adapter and re-check pressure. See test 25.
frame valve section other than problem
section in the retract direction.
Replace auxiliary system
> 3500 psi < 3500 psi disable valve.

Check for 3500 psi at Activate boom butt cylinder up and down solenoids and
auxiliary system disable verify solenoid plug LEDs are lit, indicating voltage
valve while activating the is present.
boom butt cylinder control Voltage No voltage
in the retract direction.
See test 25.
Disconnect adapter frame Check for 12 volts at boom butt
> 3500 psi < 3500 psi
valve assembly from proportional cylinder switch wire #55.
flow control valve. Plug valves. Voltage No voltage
Repair or replace Check pressure at auxiliary system
valve section. disable valve. See test 25.
Replace Replace
> 3500 psi < 3500 psi
appropriate function
Exchange boom butt diode to switch.
counterbalance valve wire #89D1.
cartridges. Does problem Repair or Repair or
cylinder function when replace proportional replace adapter
actuated? flow control frame valve
Yes No valve. assembly.

Replace Repair or
counterbalance replace
valve. cylinder.
BB-187

ST132-29

2501031
 PROBLEM 26
Function pump will not return to neutral.

POSSIBLE CAUSES
Defective function pump control handle; Function pump EDC
defective or out of adjustment; Defective function pump.

CHECKS
Does diagnostic display screen FUNCTION show
function activity at function control handle?

Yes No

Repair or Does diagnostic display screen

replace applicable FUNCTION show function command
control handle activity at pump?
or wiring.
Yes No

Consult See test 11.

factory. Does function pump EDC
manually return to neutral?
Yes No

Adjust pump neutral. Repair or replace

See test 20. function pump.

See test 11. Does function pump

EDC manually return to neutral?
No

Replace function
pump EDC.
BB-188

ST132-30

2501031
 PROBLEM 27
Counterweight pin(s) will not extend (engage).

POSSIBLE CAUSES
Set-up controller switch or wiring failure; Solenoid valve failure;
Cylinder failure; Mechanical malfunction.

CHECKS
Check for voltage at controller switch (wire #56B for
upper counterweight and #56C for lower counterweight) while
on/off and function switch are in OFF position.
Voltage No voltage

Replace faulty switches or Air at extend cylinder valve port when

repair shorted wiring. engagement is selected.
Yes No

Check counterweight pin(s) for Replace

binding or seizure. malfunctioning
Yes No counterweight
valve.

Repair as needed. Repair or

replace affected
cylinder.
BB-189

ST132-31

2501031
 PROBLEM 28
Counterweight pin(s) will not retract (disengage).

POSSIBLE CAUSES
Set-up mode is not selected and confirmed;
Set-up switch or wiring failure; Solenoid valve failure;
Cylinder failure; Faulty fuse.

CHECKS
Reselect and confirm set-up mode.

Counterweight pins still malfunctional

Check for 12 volts at remote controller switch (wire #56B for

upper counterweight or wire #56C for lower counterweight)
while toggling the applicable switches to the ON position.
Voltage No voltage

Is solenoid valve plug LED lit, Check for 12 volts at wire #8SR
indicating voltage is present? in applicable remote controller.
Yes No Voltage No voltage

Air pressure at retract Repair or replace Test for voltage at Check for 12
valve cylinder port when wiring or switches in remote volts at fuse
disengagement is selected. consult factory. controller and change 8SR.
Yes No applicable switch. Yes No

Is system air Repair or replace wiring from PC

pressure <120 psi? to applicable remote controller.
Repair or replace
Yes No malfunctioning air control valve.
Replace fuse 8SR.
BB-190
Adjust or
replace Check counterweight pin
pressure for binding or seizure.
regulator.
Yes No

Repair as needed. Replace affected

cylinder.

ST132-32

2501031
 PROBLEM 29
Pawl not operating (boom hoist, load drums,
or luffing jib hoist if equipped).

POSSIBLE CAUSES
Mechanical malfunction; Air pressure problem;
Solenoid valve failure; Cylinder failure; Electrical problem.

CHECKS
Check for damage to pawl or pawl linkage. Check
for pawl or pawl cylinder freedom of movement.
No damage Damage

Move pawl selector switch and verify pawl Repair damage.

solenoid is energized. See test 27. Adjust and test.
Note: one valve will always be energized.
Voltage No voltage

Check and replace defective

8S fuse, pawl selector switch
or wiring.

While activating the applicable pawl switch, check pawl

cylinder for system air pressure at desired valve cylinder ports.
Air pressure Low or no air pressure

Repair air system.

Air pressure is present at both valve cylinder

ports or at other cylinder port than desired.
Yes No

Replace defective air control valve. Repair or replace cylinder. BB-191

ST132-33

2501031
 PROBLEM 30
All cylinders functioning off the upperworks and adapter frame
valve assemblies are not operating.

POSSIBLE CAUSES
Faulty relief valve; Faulty auxiliary system disable valve;
Faulty switch or wiring; Fan circuit component failure;
Faulty pump; Wiring fault.

CHECKS
Check for 3500 psi pressure at auxiliary system disable valve
while activating any of the upperworks valve assembly functions.
See test 25.
> 3500 psi < 3500 psi

Check pressure at pilot/brake Activate any upperworks valve assembly

pressure relief valve. function in both directions and verify
See test 24. the auxiliary system disable valve solenoid
< 300 psi plug LED is lit, indicating voltage is present.
Voltage No voltage

Are fan impellers

turning? Adjust auxiliary Does diagnostic display screen D1
Yes No system working (bank 3) change by 4 when activating
pressure. See any auxiliary system valve function?
test 25. Are No
Yes
Adjust or Check fan cylinders
replace circuit for functioning
pilot/brake component properly?
Repair or Is crane set-up mode
pressure failure. No replace selected and confirmed
relief valve. wiring. at operator display?
See test 24.
Yes No
Repair or
replace
auxiliary Select and
Replace fuse
system confirm
8SR or
disable set-up
repair or
valve. mode.
replace power
switch or
wiring. BB-192

ST132-34

2501031
 SECTION 2 - TESTING
TEST 1 Battery Test (12 and 24 Volts DC)

12 VDC

BB-248

(1) Positive probe (2) Negative probe

To test the 12 VDC accessory system voltage using a cranking may indicate a charging system fault. A drop of
digital multimeter, record the voltage before and during 4 volts or more indicates the battery is failing.
cranking. A voltage reading of 12 volts or less before

24 VDC

BB-249

(3) Positive probe (4) Negative probe

To test the 12 VDC starting batteries connected in series or less before cranking may indicate a charging system
for 24 volts using a digital multimeter, record the voltage fault. A drop of 8 volts or more during cranking indicates a
before and during cranking. A voltage reading of 24 volts failing battery.

ST132-35

2501031
 TEST 2 Checking Resistance at Engine Temperature Switch

BB-195

(1) Temperature switch

(2) Positive probe

Set the digital multimeter to test resistance and make the

appropriate test lead adapter connections at the meter.
Connect the negative probe to a grounded component on
the machine and the positive probe to the engine temper-
ature switch wire terminal. With the engine cold, verify
the resistance is approximately 0.67 ohms.

ST132-36

2501031
TEST 3 Checking Resistance at Engine Oil Pressure Sender

BB-196

(1) Oil pressure sender

(2) Positive probe
(3) Negative probe

Set the digital multimeter to test resistance and make the

appropriate test lead adapter connections at the meter.
Connect the negative probe to a grounded component on
the machine and the positive probe to the engine oil pres-
sure switch wire terminal. The correct approximate resis-
tance is 240 ohms.

ST132-37

2501031
 TEST 4 Servicing the Motor Purge Valve Assembly

2
4

BB-197

(1) Motor (3) Mounting bolt

(2) Purge valve assembly (4) Shuttle valve hex nut

Problems associated with a defective purge valve are

best corrected by replacing the complete purge valve
assembly. With engine off, fully drain motor hydraulic fluid
by removing an accessible case drain port plug or
attached hydraulic line. Refer to TEST 7 for location of
motor ports. After drainage, replace drain plug or hose.

Remove the four 8 mm hex head mounting bolts from the

purge valve unit and mount the functional valve assembly
in its place. Secure the four hex head mounting bolts to
47 ft. lbs. (64 Nm), and fill the hydraulic fluid reservoir as
needed.

The shuttle valve located inside the purge valve assem-

bly can be checked by removing the 36 mm hex nut at the
bottom of the unit. Secure the hex nut to 107 ft. lbs. (145
Nm).

ST132-38

2501031
 TEST 5 Testing the Pump EDC and Motor PCP
3
1
2
BB-198
(1) PC input cable
(2) Adapter cable connections
(3) Pump EDC
Testing a pump EDC or motor PCP requires the use of a
standard test plug adapter (which can be ordered from
Manitowoc Engineering Company) and a digital multime-
ter.
To test pump functionality, first disconnect the PC input
cable from the pump EDC to be tested. In place of the PC
cable, connect the double-ended test plug adapter to the
EDC, leaving the PC end of the test plug disconnected.
Set the digital multimeter for testing resistance and make
the appropriate connections (white and black) from the
adapter cable to the digital multimeter jacks. Verify the
EDC coil resistance is between 23 and 26 ohms.
Leave the test plug adapter installed at the pump EDC.
Set the digital multimeter for testing volts DC and recon-
nect the PC input cable to the PC end of the test plug
2501031
5
BB-199
(4) Test plug adapter
(5) Motor PCP
adapter. With engine running, slowly actuate the control
handle in the operator’s cab that activates the function of
the pump under test. Verify the range of voltage change
is between 0 and ±2.45 volts DC. The load current (or
amperage draw) at any given point in the high speed to
low speed range and vice versa is equivalent to the volt-
age at the given point in the speed range. Load current
can be measured directly by making the appropriate
adapter cable connections (red and white) to the digital
multimeter jacks.
To test motor functionality, remove the PC input line from
the motor PCP, and connect the test plug adapter in its
place. Perform the resistance and voltage tests in the
same manner as described for the pump EDC. Motor
PCP coil resistance should be 23 to 26 ohms, and the
voltage should be between 0 and 1.96 volts DC.
ST132-39
 TEST 6 Cleaning and Adjusting the Engine RPM Transducer

3
2

BB-200

(1) Flywheel housing (2) RPM transducer (3) Lock nut

Loosen the lock nut and remove the threaded transducer

from the flywheel housing. Clean any metallic debris from
the magnetic pickup on the transducer with a cleaning
solvent. Re-install the transducer so the magnetic pickup
makes contact with the flywheel. Loosen transducer 1/4-
turn and secure the lock nut.

ST132-40

2501031
 TEST 7 Location of Motor Ports

M8
PORT L2
M3(Y2) M6

M1 M2
PORT “A” PORT “B”
M9
M5 M4(Y1)
M4
M9

M7 M2
PORT “B”
X1 PORT L1
M8 BB-201 M6
BB-202

LUFFING JIB HOIST

PORT “B” CASE DRAIN

PORT “A”

CASE DRAIN
BB-204
PORT “A” BB-203 CASE DRAIN
BOOM HOIST

CASE DRAIN

PORT PORT
“B” “A”
BB-205
CASE
%% DRAIN
SWING

ST132-41

2501031
 CASE DRAIN

PORT “A”

PORT “B”

BB-207

BB-208
CASE DRAIN
TRAVEL

RHL

PORT “A”
A
A

CASE DRAINS
B
B

PORT “B”
BB-209

BB-210

MAIN HOIST

Boom
Port Description Luffing Jib Hoist Travel Swing Main Hoist
Hoist
*Case drain Case pressure 600 psi minimum gauge requirement SAE 10
(L1 and L2) SAE 12 O-ring fitting SAE 10 O-ring fitting O-ring boss port
“A” and “B” Main system pressure 1" code 62 port flange 1-1/4" port flange 2" code 62 port
flange
M1 Gauge port for Port “A”
M2 Gauge port for Port “B”
M3 (Y3) Servo pressure gauge port M3 or
servo pressure supply Y2 (mini- 10,000 psi minimum
mum displacement) gauge requirement;
M4 (Y1) Servo pressure gauge port M4 or SAE 6 O-ring fitting
servo pressure supply Y1 (maxi-
mum displacement)
M5 and M9 Servo pressure supply
M6 Charge pressure 600 psi minimum
M7 and M8 Control pressure gauge requirement;
SAE 6 O-ring fitting
X1 External PCP supply pressure 1,000 psi minimum
gauge requirement;
SAE 6 O-ring fitting

* Use highest port as outlet.

ST132-42

2501031
 TEST 8 Testing for Pump and Motor Leakage

PUMPS

2
3

BB-211
MOTORS

1
1

3
3

BB-212 BB-213

(1) Case drain hose (2) Inline flow meter (3) Hose to highest case drain port

Testing for pump and motor leakage requires a 0-3,000
psi inline flow meter with a minimum flow rate capacity of
30 gpm. Suitable flow meters can be ordered from Mani-
towoc Engineering Company.
Since the amount of flow from the individual pump and
motor drains is dependent on several operational factors
and settings, it is difficult to define leakage rates in exact
numbers. Therefore, acceptable leakage is generally
based on the combined case flow of the pump and motor.
The combined case flow out of the main hoist pump and
motor should be approximately equal to a charge pump
flow of 8.9 gpm per 1,000 rpm of the engine. The com-
bined case flow out of the boom hoist, swing, travel, or
luffing jib hoist pump and motor should be approximately
equal to a charge pump flow of 4.8 gpm per 1,000 rpm of
the engine.
To test a motor, begin by connecting the flow meter
between the motor case drain hose and the highest

ST132-43

2501031
motor case drain port (designated L1 or L2 on the swing
motor). Refer to TEST 7 for location of motor ports. With
the engine running at 1,000 rpm, measure the flow rate of
the motor. Due to the continuous loop flushing modifica-
tion of the main hoist motor, case flow at neutral or very
light loads should be approximately 5 gpm. At heavier
loads, normal case flow for the main hoist motor may go
up to approximately 7 gpm. Since the boom hoist, swing,
travel, and luffing jib hoist motors are not modified for
continuous loop flushing, case flow at neutral should not
exceed approximately 1.5 gpm. At heavier loads and
higher rpm, case flow for these systems may increase to
4.5 or 5.5 gpm. Record the measurement at neutral and
reconnect the motor case drain hose to its motor port.
ST132-44
2501031
The difference between the circuit’s charge pump flow
and motor case flow at neutral is the acceptable pump
case flow at neutral for the circuit under test.
Next, connect the flow meter between the pump case
drain hose and pump port L1 or L2 (use the highest port
for testing). Refer to TEST 9 for location of pump test
ports. With the engine running at 1,000 rpm, measure the
flow rate of the pump at neutral and compare to the cal-
culated acceptable pump case flow.
Major deviations from the normal or major changes
with increasing system pressure more than ±1 gpm
are indicators of pump or motor problems.
 TEST 9 Location of Pump Ports

M2
PORT “B”
SIDE

PORT S

BB-214

PORT “A”
M1 PORT L2

Note: M3 is located between

the multifunction valves
TOP
M4

PORT L1

BB-215

CHARGE PRESSURE
RELIEF VALVE M5
PORT S

Port Port Gauge

Designation Description (psi) O-Ring Fitting

“A” and “B” Main system pressure 6,000 1" code 62 port flange

*L1 and L2 Case pressure 600 SAE 12

M1 Gauge port for Port “A” 10,000 SAE 6

M2 Gauge port for Port “B” 10,000 SAE 6

M3 Charge pressure gauge port 600 SAE 6

M4 and M5 Servo pressure gauge port 600 SAE 6

S Charge pump inlet 600 SAE 12

*Use highest port as outlet.

ST132-45

2501031
 TEST 10 Checking Voltage at the Hydraulic Brake Valve

BB-216

(1) Hydraulic brake valve

(2) Test plug adapter
(3) DIN plug
(4) Test plug adapter cable

Testing for voltage at any hydraulic brake valve requires

the use of a standard test plug adapter (which can be
ordered from Manitowoc Engineering Company) and a
digital multimeter.

Connect the test plug adapter between the brake valve

and the DIN plug. Make the appropriate connections
(white and black) from the adapter cable to the digital
multimeter and verify 12 volts DC while actuating the
appropriate system function that releases the brake
under test. Load current (amps) can be measured
directly by making the appropriate adapter connections
(red and white) to the digital multimeter.

ST132-46

2501031
 TEST 11 Manually Stroking the Pump

AA 316

(1) Manual stroke override

(2) Pump EDC

With the engine running and all brakes and locks

engaged, rotation of the manual override in the clockwise
direction will cause engine load down and pressure rise
in port “A” of the pump under test. Counterclockwise rota-
tion of the manual override will cause engine load down
and pressure rise in port “B” of the pump under test.
Refer to TEST 9 for location of pump ports “A” and “B”.

ST132-47

2501031
 TEST 12 Testing for Voltage at the Fuse Panel

2
BB-217

4
4

MS2

8P1
8
TO TERMINAL
5D 8H 8SR 20 STRIP 3
0 0

5H 8M 8T 10 8

3
NO

COIL
COIL
NC
8D 8Q 8W 10
C
5 5
8 8
5 5 8
0
8F 8S 87FA 5
BB-218 BB-219

Fuse Identification (1) Fuse panel (3) Metal fuse contacts

Fuse/ (2) Right console chassis (4) MS2 cab power relay
Wire No. Function Amps
5D Engine Start 15
5H Horn 20
Use a digital multimeter for testing voltage at the fuse
8D Digital Inputs, X-Spander 10 panel located in the right console in the operator’s cab.
8F Defogger Fan 15
8H Cab Heater 10 To test for volts DC at any given fuse socket, place the
8M Moisture Ejector, Equalizer/Boom 10 positive probe on either of the metal fuse contacts and
Stop Limit Switch the negative probe on the grounded console chassis.
8Q Throttle Relays 15 Repeat this procedure using the other fuse contact as a
test point. Note all fuse sockets excluding F12 (3A, 10V)
8S Swing Lock/Brake, Boom/Luffing 15
should yield 12 volts DC.
Pawls
8SR Jacking/Set-up Remote 15
To determine if relay MS2 is fully functional, ground off
8T Pressure/Speed Senders, Load 5
Sensor the console chassis and verify 12 volts DC exist at relay
wire 8 when the relay is energized. Also verify 12 volts
8W Wipers/Washer 20
constant at relay wire 5.
87FA 10VDC Reg. Supply 3
Spare --------------- 20
Spare --------------- 10
Spare --------------- 10
Spare --------------- 5

ST132-48

2501031
 TEST 13 Checking Voltage at the Control Handle

AA318

(1) Load drum handle (3) Crawler handle (5) Ground terminal “R”
(2) Boom/swing handle (4) Test terminals

Use the following test points to determine the correct volt-
ages are present at the desired control handle. With
engine off/power on, and all brakes and locks engaged,
actuate the desired control handle and measure the volt-
age with a digital multimeter. The positive probe must be
placed on the test terminal and the negative probe on a
grounded component of the machine or terminal “R” on
the control handle. Voltages outside the normal range
may indicate a problem with the control handle, its cir-
cuits, or inline components such as relays and fuses.

Hand *Test Acceptable Hand *Test Acceptable

Wire No. Wire No.
Controller Terminal Voltage (VDC) Controller Terminal Voltage (VDC)
L 87FA 10 L 87FA 10
R 0 Ground Left Travel R 0 Ground
Swing C 85P 1.4 to 8.6 C 84P 1.4 to 8.6
3 85EB (Brake) 12 L 87FA 10
4 85EC (Brake) 12 R 0 Ground
L 87FA 10 C 80P 1.4 to 8.6
R 0 Ground Front or 8A (Drum
C 82P 1.4 to 8.6 Right Rear 1 Rotation 12
Load Drum Indicator)
8A (Drum
Boom Hoist 1 Rotation Ground 81N (Drum
Indicator) 2 Rotation 12
82N (Drum Indicator)
2 Rotation 12 L 87FA 10
Indicator) R 0 Ground
L 87FA 10 Rear or C 81P 1.4 to 8.6
R 0 Ground Left Rear 8A (Drum
Right Travel C 83P 1.4 to 8.6 Load Drum 1 Rotation 12
3 8D 12 Indicator)
4 89X 12 81N (Drum
2 Rotation 12
* L = Left, R = Right, C = Center position. Indicator)

ST132-49

2501031
 TEST 14 Adjusting the Control Handle Potentiometer
2 1
3 4 5 6
7 Double Axis
(1) Neutral (snap) switch
(2) Jumper connection (N/O)
(3) Groung terminal “R”
(4) Slotted set screw
An abnormal reaction of a crane system function in rela-
tion to the degree of hand control movement may indicate
a misalignment of the handle potentiometer. Adjusting a
single axis controller (crawler and load drum handles) or
double axis joystick (boom/swing handle) requires align-
ing the hand lever assembly and the potentiometer in the
correct neutral position. Neutral is the position at which 5
volts DC is present from the potentiometer.
With engine off, begin by connecting a jumper wire
between the normally open (N/O) terminal on the neutral
switch and terminal “C” on the handle terminal block.
Connect the positive lead of a digital multimeter to termi-
nal “C” and the negative lead to a grounded contact on
the machine or control handle.
ST132-50
2501031
Single Axis
Controller
AA319
Controller
AA320
(5) Terminal “C” (center)
(6) Potentiometer
(7) Socket set screw (1 of 2)
For single axis controller adjustment, fully loosen the slot-
ted set screw with a screwdriver and allow the hand lever
to return to its inactivated position. Retighten the set
screw and move the hand lever until a reading of 5 volts
DC is obtained on the digital multimeter. Keeping the
hand lever in the 5 volt DC position, fully loosen the set
screw, allow the hand lever to return to its inactivated
position, and retighten the set screw.
The double axis joystick is adjusted in the same manner
but involves loosening and tightening two socket set
screws on the gear collar instead of the slotted set screw
on the single axis controller.
 TEST 15 Checking System Voltage at the Air Solenoid Panels

Main System
(front to back) Solenoid Enclosure
Front drum (top to bottom)
brake
Left rear drum Ringer aux. drum pawl
brake OUT if equipped
Right rear drum (not shown)
brake Luffing pawl OUT
Boom pawl OUT
Swing lock OUT
(top to bottom) Backhitch pins OUT
Ringer aux. Upper counterweight
drum pawl IN pins OUT
if equipped Lower counterweight
(not shown) pins OUT
Luffing pawl IN Rear or right rear
Boom pawl IN drum clutch
Swing lock IN Left rear drum clutch
Front drum clutch if
equipped (not
shown)

BB-223

Optional Drum Pawl

Solenoid Enclosure
(left to right)
Front hoist drum pawl
Rear hoist drum pawl
Front ringer hoist drum pawl
Rear ringer hoist drum pawl

BB-224

To verify system voltage is present at the air solenoid
panels, energize the valve under test by actuating the
appropriate valve control function. If the air valve DIN
plug LEDs illuminate, system voltage is present.
Measuring precise system voltage at a particular air sole-
noid valve should be completed with a digital multimeter.
Set the meter for DC volts and make the appropriate con-
nections from the test probe leads to the meter jacks.
Slightly loosen the DIN plug and insert the positive probe
between the valve electrical socket and the DIN plug. Use
the solenoid panel enclosure as GND. Energize the valve
control function and verify 12 volts DC is present.
Remove the probes and re-tighten the DIN plug.

ST132-51

2501031
 TEST 16 Checking System Voltage at the Upperworks Valve Assembly

Proportional Flow
Control Valve

BB-220

Upperworks
Valve Assembly
(top to bottom)

1 Spare
Spare
Right front jack
Right rear jack
2
Left rear jack
Left front jack
Front frame connect pins
Rear frame connect pins
Gantry cylinders
BB-221

Auxiliary System
Disable Valve

BB-222

(1) DIN plug (2) Test plug adapter

Measuring system voltage at various locations on the
upperworks valve assembly requires the use of a stan-
dard test plug adapter (which can be ordered from Mani-
towoc Engineering Company) and a digital multimeter.
Set the meter for volts DC and make the appropriate con-
nections (white + and black -) from the test plug adapter
cable to the meter jacks. Install the test plug between the
valve electrical socket and the DIN plug. Energize the
valve under test by actuating the appropriate system
function and verify approximately 12 volts DC for the
upperworks valve assembly and auxiliary system disable
valve. Voltage at the proportional flow control valve
should be between 3.25 and 7.22 volts DC.

ST132-52

2501031
TEST 17 Checking Pump Charge Pressure

9
3

BB-225

(1) Right travel (6) Right swing

(2) Left travel (7) Left swing
(3) Hoist charge (8) Diagnostic gauge couplers
(4) Hoist system (9) 0-600 psi gauge
(5) Boom hoist

The most convenient method of measuring the pump

charge pressure is to install a 0-600 psi gauge at the
desired system diagnostic gauge coupler at the pressure
sender manifold. Start the system and record the charge
pressure at engine idle speed. No hydraulic systems
should be energized. A measurement of 350 psi is nor-
mal charge pressure. A measurement under 350 psi indi-
cates a charge pressure relief adjustment is necessary.
Refer to TEST 19.

ST132-53

2501031
 TEST 18 Setting the Pump Pressure

4 3

BB-247 BB-226

(1) Multifunction valve adjusting screw for port “A”

(2) Multifunction valve adjusting screw for port “B”
(3) Lock nut
(4) Bypass hex

Remove the protective cap from the multifunction valve

and loosen the lock nut with a wrench. Insert a hex
wrench into the multifunction valve adjusting screw. Turn-
ing the adjusting screw clockwise will increase relief pres-
sure. Turning the adjusting screw counterclockwise will
decrease the valve pressure.

NOTE The bypass hex is intended for special bypass

function applications only and must not be
rotated during setting of the pump pressure or
without first consulting the pump manufacturer lit-
erature.

PLASTIC
ADJUSTING CAP Pump Port Control Function
SCREW
(INSIDE) Pump Port A Port B
LOCK NUT
BYPASS Travel Reverse Forward
HEX
Main Hoist Lower Hoist

Boom Hoist Lower Hoist

MULTI-FUNCTION VALVE Swing Left Right

BB-229

ST132-54

2501031
 TEST 19 Adjusting Pump Charge Pressure Relief

3
BB-228

(1) Adjusting screw

(2) Adjusting lock nut
(3) Port M3
(4) Port M1
(5) Port M2

The pump charge pressure must be measured in order to
accurately adjust the charge pressure relief. For conve-
nience of adjustment, charge pressure should be mea-
sured using a 0-600 psi gauge installed at system
pressure gauge ports M1 or M2, or at charge pressure
gauge port M3 if it unused in the hydraulic circuit applica-
tion. Charge pressure can also be measured at the pres-
sure sender (transducer) manifold as indicated in TEST
17. Refer to TEST 9 for location of pump test ports M1,
M2, and M3.
Install the gauge at the selected test port. Start the
machine and make sure all brakes are in the lock posi-
tion, and all hydraulic systems remain off. A measure-
ment of approximately 350 psi indicates correct charge
pressure relief.
To adjust charge pressure relief, loosen the adjusting lock
nut and turn the adjusting screw with a screwdriver until
350 psi is obtained. Torque the lock nut to 34-41 ft. lbs.
(46-56 Nm). Remove the gauge and replace the port
plug.

ST132-55

2501031
 TEST 20 Setting Pump Neutral

BB-229 BB-230

(1) Neutral adjusting screw and lock nut

(2) Servo gauge ports

To set pump neutral, set the pawls and brakes, and dis-
able the pump from the PC by disconnecting the PC
cable at the EDC. Install a 0-600 psi gauge in each of the
servo gauge ports. Start and operate the engine at nor-
mal speed. Loosen the lock nut and rotate the neutral
adjusting screw with a hex wrench until pressure
increases in one of the gauges. Note the handle position
of the hex wrench at this time, and without removing the
wrench, rotate the neutral adjusting screw counterclock-
wise until pressure increases in the other gauge. Note
the position of the hex wrench now, and rotate the neutral
adjusting screw clockwise halfway between the wrench
positions. The control should now be in neutral with both
gauges reading the same case pressure. While holding
the neutral adjusting screw with the hex wrench, tighten
the lock nut. Remove the gauges and reinstall the servo
gauge port plugs.

ST132-56

2501031
 TEST 21 Checking Voltage at the Speed Senders

Load Drum Main Hoist Motor

2
1 1

2 3

AA331 AA332

(1) Encoder
(2) Test plug adapter
(3) Adapter cable connections

Testing the main hoist motor speed sender or a load
drum speed sender for correct voltages requires the use
of a standard test plug adapter (which can be ordered
from Manitowoc Engineering Company) and a digital
multimeter. Disconnect the output cable from the speed
sender electrical connector and install the test plug
adapter in its place. Set the digital multimeter for measur-
ing volts DC.
Make the appropriate connections from the adapter cable
(red + and black -) to the meter jacks for testing incoming
system power. Start the machine; the motor or drum
should remain at rest. Verify approximately 12 volts DC. If
12 volts DC is not present, check fuse 8T (5 amps) at the
fuse panel located in the operator’s cab (refer to TEST
12).
To verify the correct output voltage from the encoder to
the PC, make the appropriate connections at the meter
jacks (white + and black -, channel 1) or (green + and
black -, channel 2). With the motor or load drum at rest,
verify 0.00 or approximately 7.40 volts DC exists. With
the motor or load drum actuated, verify 3.5 to 3.9 volts
DC. If these readings are not obtained, check the
encoder drive assembly and wiring.

ST132-57

2501031
 TEST 22 Adjusting the Counterbalance Valves

1 2
6

3 4

BB-233 BB-234

2 8
2

7
5
BB-116 BB-235 BB-112

(1) Gantry cylinder (4) Jacking cylinder (7) Rod end adjusting screw
(2) Counterbalance valve (5) Retract adjusting screw (8) Piston end adjusting screw
(3) Extend adjusting screw (6) Boom butt cylinder

NOTE Special instructions and warnings apply when
adjusting the gantry cylinders and boom butt cyl-
inder counterbalance valves as specified in Shop
Procedure No. 3 (publication SP3). This proce-
dure MUST be followed carefully to ensure cylin-
der adjustments are perfor med safely and
correctly, using the appropriate side (rod or pis-
ton end) adjusting screw. The gantry cylinders
will not actuate evenly without adequate counter-
weights attached to the crane. All gantry cylinder
adjustments must be performed with counter-
weights installed.
position) and allows the cylinders to be adjusted
for uniform operation on level terrain.
NOTE Counterbalance valves are pre-adjusted at the
factory and are not calibrated. To avoid over-
adjusting the cylinders, use the hex wrench as a
guide and never turn a counterbalance valve
more than 1/2-turn in either direction.
All counterbalance valves are mechanically adjusted in
the same manner using a close-ended wrench and hex
wrench.

To adjust a counterbalance valve, loosen the adjusting

NOTE Each jacking cylinder is equipped with a single
counterbalance valve located at the piston end of
the cylinder. The retract adjusting screw is found
at the valve assembly and provides adjustment
for individual jacking cylinder load support. The
extend adjusting screw on each cylinder is
located on top of the cylinder (when in stowed
lock nut and rotate the counterbalance adjusting screw
1/2-turn clockwise (IN) to lower the holding pressure or
1/2-turn counterclockwise (OUT) to increase the pres-
sure setting. While holding the counterbalance adjusting
screw with the hex wrench, tighten the lock nut. Recheck
the cylinder or cylinder set for proper load support and
uniform operation if applicable.

ST132-58

2501031
 TEST 23 Bleeding a Hydraulic Brake Circuit

2 3

BB-236

(1) Swing motor

(2) Swing brake
(3) Bleed valve

Air in the hydraulic brake circuit can be removed by

bleeding the brake assembly. Using a wrench, loosen the
bleed valve on the brake housing and allow the hydraulic
fluid to drain.

ST132-59

2501031
 TEST 24 Checking Hydraulic Brake Pressure

Swing and Travel Systems Boom/Luffing Jib System

4
1
2
3

BB-237 BB-238

(1) Pilot/brake pressure relief valve

(2) Test port (adjusting screw on opposite side)
(3) Boom hoist brake control valve
(4) 90° elbow
(5) Flexible hose

The hydraulic brakes for the swing and travel systems
function off the exhaust pressure generated from the fan
motor circuit; boom/luffing jib hoist brakes are released off
the low pressure side of the boom hoist closed-loop cir-
cuit.
Measuring the hydraulic brake pressure of the swing and
travel systems is performed by connecting a 0-1,000 psi
gauge at the diagnostic quick-disconnect fitting on the
pilot/brake pressure relief valve located between the top
of the diesel engine and the radiator and oil cooler fans.
Start engine and set at high idle (2,000 RPM). Activate
the desired system brake and verify brake pressure is 325
to 375 psi. If pressure is not within range, adjust the pilot/
brake pressure relief valve by loosening the adjusting lock
nut and turning the adjusting screw IN to INCREASE
pressure or OUT to DECREASE pressure until correct
pressure is obtained. Secure the locknut, remove the
pressure gauge and replace the fitting cap. If adequate
pressure cannot be obtained, replace and re-adjust the
valve assembly.
Check the hydraulic brake pressure of the boom hoist cir-
cuit at the boom hoist brake control valve located below
the boom hoist drive assembly on the left side of the
machine. Install a 0-1,000 psi gauge between the 90°
elbow on the control valve and the flexible hose. With
engine at high idle (2,000 RPM), activate the boom hoist
brake and verify the gauge indicates 325 to 375 psi (or
500 to 550 psi if the boom hoist is equipped with luffing
jib). If adequate brake pressure is not available, check the
boom/luffing jib hoist charge pressure in accordance with
TEST 17.

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 TEST 25 Checking and Adjusting Auxiliary System Working Pressure
1
2 6
3 4
BB-239
(1) Proportional flow control valve
(2) Upperworks valve assembly
(3) Auxiliary system disable valve
(4) Disable valve adjusting screw
To determine if piston actuation problems are attributed
to low auxiliary system pressure, the pressure may be
checked at the auxiliary system disable valve located at
the upperworks valve assembly.
With engine off, remove the cap from the 1/8 inch diag-
nostic gauge coupler on the auxiliary system disable
valve and install a 0-6,000 psi gauge. Start engine and
retract any functional hydraulic cylinder directly driven off
the upperworks valve assembly. Continue to stroke the
valve section after the cylinders are fully retracted during
the entire test procedure.
Verify the pressure is 3,325 to 3,500 psi. If pressure is not
within range, loosen the adjusting screw lock nut on the
bottom of the auxiliary system disable valve and turn the
screw IN to increase pressure or OUT to decrease pres-
sure until correct pressure is obtained.
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7
BB-121
BB-240
(5) Disable valve gauge port
(6) Upperworks relief valve
(7) Relief valve adjusting screw
! CAUTION POSSIBLE COMPONENT
DAMAGE!
Do not over-tighten the auxiliary system disable valve
adjusting screw in the IN position; doing so may
result in damage to the valve seat.
NOTE If at this time, gauge pressure does not change or
fluctuates erratically with movement of the adjust-
ing screw, the auxiliary system disable valve is
suspect. Repair or replace the auxiliary system
disable valve and re-check for even pressure fluc-
tuation.
If gauge pressure fluctuation corresponds with movement
of the adjusting screw, but hydraulic pressure remains
below 3,325 psi, turn the auxiliary system disable valve
adjusting screw all the way IN. At the upperworks valve
assembly relief valve, loosen the lock nut and turn the
flathead adjusting screw IN until gauge indicates 3,500
psi. Secure the lock nut.
ST132-61
NOTE If at this time, 3,500 psi cannot be obtained, the
upperworks relief valve is suspect. Repair or
replace the relief valve and attempt to re-adjust
pressure.
Returning to the auxiliary system disable valve, turn the
adjusting screw OUT until pressure begins to drop; then
turn screw IN until gauge indicates 3,500 psi. Secure the
lock nut.
NOTE If at this time 3,500 psi cannot be obtained, the
auxiliary system disable valve is suspect. Repair
or replace the auxiliary system disable valve and
re-check pressure.
If pressure is adequate but cylinder still malfunctions,
resume pressure testing at the auxiliary system disable
valve to determine if the valve assembly or proportional
flow control valve is defective.
ST132-62
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If problem cylinder is directly driven off a valve section of
the upperworks, disconnect the cylinder from the upper-
works valve assembly and plug the lines. Actuate the
problem cylinder valve in the retract direction and check
pressure. If pressure is 3,325 to 3,500 psi, repair or
replace the cylinder. If pressure is less than 3,325 psi,
repair or replace the valve assembly.
If problem cylinder is directly driven off a valve section of
the adapter frame valve assembly, disconnect the flow
control valve to the adapter frame valve assembly and
plug the line. Actuate the problem cylinder in either direc-
tion and check pressure. If pressure is less than 3,325
psi, repair or replace the proportional flow control valve.
 TEST 26 Checking Pin Cylinder Seals
1
(1) Hydraulic hose (extend)
(2) Hydraulic hard line fittings
Problems associated with hydraulic cylinder piston move-
ment can be caused by defective cylinder seals. Since
the frame connecting pin, crawler pin, and boom hinge
pin cylinders are not equipped with load-holding valves,
the piston seals and rod end wiper seal can be checked
for leakage.
If the problem cylinder is in the extend position, discon-
nect the cylinder retract hydraulic hose from the hydraulic
hard line fitting. If in the extend position, disconnect the
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2
BB-241
(3) Hydraulic hose (retract)
(4) Pin cylinder
retract hydraulic hose. Immediately plug the hard line fit-
ting and place the flexible hose from the cylinder into a
holding tank or bucket. Start the machine and pressurize
the cylinder. Leakage from the disconnected hose indi-
cates a defective piston seal.
The wiper seal, located at the rod end of the cylinder,
should also be inspected for leakage while actuating the
cylinder in the extend direction.
ST132-63
 TEST 27 Checking Solenoid Magnetism

1
2

BB-242

(1) Solenoid coil

(2) Screwdriver

To determine if an air or hydraulic solenoid is energized,

simply place any metallic tool, such a screwdriver, on the
solenoid coil. The solenoid is energized if the tool is mag-
netically pulled toward the valve.

ST132-64

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 TEST 28 Pressure Sender Electrical Test

BB-243

(1) DIN plug

(2) Test plug adapter
(3) DIN plug connection point
(4) Pressure sender
(5) Adapter cable

Testing the voltage and resistance at a pressure sender
requires the use of a standard test plug adapter (which
can be ordered from Manitowoc Engineering Company)
and a digital multimeter. Connect the test plug adapter
between the desired pressure sender and its DIN plug.
Turn the cab power switch on with engine off.
To test incoming power, make the appropriate connec-
tions from the adapter cable to the digital multimeter for
testing incoming power (white + and black -) and verify
approximately 12 volts DC. If this reading is not obtained,
check the 8T (5 amp) fuse at the fuse panel (refer to
TEST 12).
When checking for the correct voltage output from the
pressure sender to the programmable controller, test with
engine off/power on. Make the appropriate connections
at the digital multimeter (green + and black -) and verify
1.00 to 1.04 volts DC. Note: the PC nulling routine per-
mits the equipment to operate outside of the 1.00 to 1.04
voltage range. However, if readings less than or equal to
0.50 volts, or greater than or equal to 2.0 volts are
obtained, the pressure sender must be replaced.

ST132-65

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 TEST 29 Actuating the Solenoid Valve Manual Overrides

1 Brake
Valve

BB-244

Air
3 Valve

BB-245

Maximum Displacement
Valve

4 2

BB-246

(1) Hydraulic brake valve (3) Air control valve

(2) Manual override (4) Boom hoist max. displacement valve

To verify a solenoid valve is functioning properly or to
manually activate a valve function such as brake release
for testing purposes, start engine and actuate the manual
override on the valve assembly. Hydraulic brake valves
are equipped with an override push-button, air valves with
a slotted override switch, and the boom hoist maximum
displacement valve with an inset push-button at the elec-
trical plug connector end of the valve. If operating prop-
erly, the valve will shift and perform its control function.

ST132-66

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 APPENDIX — ABBREVIATIONS AND SYMBOLS USED IN THIS MANUAL

Abbreviations Symbols
A (amp) Ampere + Positive or negative numerical value
AC Alternating Current + Positive voltage
AFC Air Fuel Control - Negative voltage
aux. Auxiliary > Greater than
DC Direct Current > Greater than or equal to
EDC Electric Displacement Control (Pump) < Less than
EFC Electric Fuel Control % Percent
ft. lbs. Foot Pounds ¾ Ohms
GND Ground ° Angular degrees
gpm Gallons Per Minute °F Degrees Fahrenheit
LCD Liquid Crystal Display " Inches
LED Light Emitting Diode
LMI Load Moment Indicator
max Maximum
min Minimum
mm Millimeter
Nm Newton Meters
N/O Normally Open (Switch)
No. Number
OEM Original Equipment Manufacturer
PC Programmable Controller
PCP Pressure Control Pilot (Motor)
pot Potentiometer
psi Pounds Per Square Inch
psia Pounds Per Square Inch Absolute
Reg. Regulated
RPM (rpm) Revolutions Per Minute
RSG Road Speed Governor
SAE Society of Automotive Engineers
STC Step Timing Control
TB Terminal Block
V Volts
VAC Volts Alternating Current
VDC Volts Direct Current

ST132-67

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 NOTES

ST132-68

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