If a problem exists, always start with the basics and work towards the more complicated.
First ensure that the crane is receiving full voltage and the pump is generating full flow and pressure. Typical requirements are 12VDC, 6GPM, and 2750PSI. Refer to the crane specification sheet for specifics
Next determine if the problem is electrical or hydraulic. In general, if the crane can be operated manually, then the problem is electrical. If manual operation does not work then the problem is hydraulic.
If no function is working the problem may be loss of electrical or hydraulic power. Make sure that the crane is getting power. Also make sure that the system is getting power.
If functions do not work under load or if hoist down, boom down, and extend in do not work the problem is likely lack of pressure. This may be caused by inadequate supply pressure or malfunction or contamination in the DPS or system relief valve.
If hoist up, boom down, or extend out do not work, the problem may be in the safety system. If all three of these functions do not work and other functions do the problem mustbe in the safety system. The status indicators on the crane control module circuit board should confirm any errors.
If the crane has proportional control and either no functions work or all functions are slow, refer to the proportional troubleshooting section.
To check functions controlled by the safety system check the status indicators. If only one of the safety functions is not working, activate that function and check for error codes and/or its output status indicator.
For non-FM systems, if the status indicator lights then the problem is in the wiring or in the solenoid coil. If the light does not illuminate, check the control pendant. If the control pendant is good then the crane control module needs to be replaced.
For FM systems, check for error codes. If none are present, see the FM Troubleshooting section.
If all three safety functions are not working confirm that the control board has power. Confirm that the board is receiving a signal from the ATB and load sensor. If the board is not receiving both signals Error Code 4 (Error Code 4 or 5 for the FM) should be active.
If the error code is active, ensure that the crane is not overloaded and that the ATB lever is holding the switch closed. Check for voltage at the ATB and Load Sensor inputs.
Check Load Sensor Switch
If the load sensor input is not receiving voltage, locate the load sensor connector inside the crane housing. The plug side will have a red wire and a gray wire, the receptacle side will have a red and a white wire.
Disconnect and check for continuity between the two pins on the receptacle (switch side). If there is no continuity then the load sensor is bad and needs to be replaced.
Check ATB Switch
If the ATB input is not receiving voltage remove the ATB housing cover and disconnect the connector. Check for continuity on the switch side. Lifting the weight should break the continuity. If either of these conditions is incorrect the switch is bad and needs to be replaced.
Check cord reel
Check the ATB switch if not done so already. Locate the ATB connector inside the crane housing. The plug side will have a red wire and a black wire. The receptacle side will have a white wire and a black wire.
Disconnect the plug going to the switch. Check for continuity between the two pins on the receptacle. Have someone lift the weight on the ATB and continuity should be broken. If either of these conditions are incorrect then the cord reel is bad and needs to be replaced.
Check power to safety switches
If the safety switch is good, check for voltage at pin 1 (the red wire) on the plug. If there is no voltage, follow the wire back to the 6-pin power distribution plug, checking for breaks or shorts.
Remove the power distribution receptacle (cap).
Removing the cap will disconnect power to all electrical components. Be sure to replace the cap before continuing.
Check the cap for bent pins. Check that all wires are fully seated in the plug. If they are not, then remove the green locking wedge and push the wires forward until seated. Reinstall the wedge ensuring that no wires are pushed back.
Check the input voltage to the plug (the pin the fuse holder is connected to). If there is no voltage there, then no component will get power. Check the fuse in the crane and any other fuse or circuit breaker that may be installed. Start at the battery and trace the wiring back to the crane checking for power at each component until the problem is found.