Manitowoc Grove TMS700E13 Service Manual – PDF DOWNLOAD

Manitowoc Grove TMS700E13 Service Manual – PDF DOWNLOAD

FILE DETAILS:

Manitowoc Grove TMS700E13 Service Manual – PDF DOWNLOAD

Language : English
Pages :352
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Manitowoc Grove TMS700E13 Service Manual – PDF DOWNLOAD

SECTION 1 13
Introduction 13
Description 13
List Of Specifications 14
General 14
Dimensions 14
Capacities 14
Transmission 14
Clutch 14
Engine 14
Cummins ISX12-2013 or QSMT3 inline 6 cyl Turbo-Charged 14
Axles 14
Front 14
Rear 14
Brakes 14
Wheel and Tires 14
Swing Gearbox 14
Boom 14
Swivel Assembly 14
Hydraulic Pumps 14
Pump #1 15
Pump #2 15
Pump #3 15
Hoists 15
General Maintenance 20
Cleanliness 20
Removal and Installation 20
Disassembly and Assembly 20
Pressing parts 20
Locks 20
Wires and Cables 21
Shims 21
Bearings 21
Antifriction Bearings 21
Double Row, Tapered Roller 21
Heating Bearings 21
Installation 21
Preload 21
Sleeve Bearings 21
Gaskets 21
Batteries 21
Hydraulic Systems 22
Cleanliness 22
Keep the System Clean 22
Sealing Elements 22
Hydraulic Lines 22
Visual Inspection of Hoses and Fittings 22
Electrical System 23
Connectors, Harnesses, Wires, and Cables 23
Fatigue of Welded Structures 23
Loctite® 23
Application of Medium Strength Loctite 23
Primer Application 24
Adhesive/Sealant Application 24
Fasteners and Torque Values 24
Torque Wrenches 24
Torque Values 25
Weld Studs 27
Wire Rope 28
General 28
Environmental Conditions 28
Dynamic Shock Loads 28
Lubrication 28
Precautions and Recommendations During Inspection or Replacement 28
Wire Rope Inspection (Running Ropes and Pendant Cables) 29
Frequent Inspection 29
Periodic Inspection 29
Wire Rope Inspection (Boom Extension and Retraction Cables) 29
Periodic Inspection 29
Wire Rope Replacement (All Wire Rope) 30
Seizing Wire Rope 30
Method 1 30
Method 2 30
Installing 35×7 Class Wire Rope 31
Procedures for Cutting and Preparing 35×7 Class Wire Rope 31
Synthetic Hoist Rope 32
SECTION 2 33
Hydraulic System 33
Description 34
Maintenance 34
Hydraulic Oil Recommendations 34
Draining and Flushing 34
Removing Air from the Hydraulic System 37
Parts Replacement 38
Directional Control Valves 38
Inspection 38
Valve Leakage 38
Binding Spools 38
Visual Inspection of Hoses and Fittings 38
Supply Pressure And Return Circuit 39
Description 39
Hydraulic Reservoir and Filter 39
Pump Distribution 39
No 1 Pump 39
No 2 Pump 40
No 3 Pump 40
Maintenance 41
Troubleshooting 41
Return Hydraulic Filter Assembly 42
Element Removal 42
Element Installation 42
Reservoir Breather 42
Removal and Replacement 42
Oil Cooler 44
Description 44
Maintenance 44
Removal and Disassembly 44
Assembly and Installation 44
Hydraulic Pumps 46
Description 46
Maintenance 46
No 1 Pump Removal 46
No 1 Pump Inspection and Repair 46
No 1 Pump Installation 46
No 2 Pump Removal 46
No 2 Pump Inspection and Repair 47
No 2 Pump Installation 47
Pump Startup Procedure and Test Procedure After Repair or Replacement 47
Pump Drive 47
Description 47
Maintenance 48
Troubleshooting 48
Removal 48
Installation 48
Valves 51
General 51
Pressure Setting Procedures 54
Description 54
Maintenance 54
General 54
Preparation 54
Procedure for Checking Main Directional Control Valve Reliefs 55
Procedure for Checking Main Directional Control Valve Pilot Supply Pressure 56
Procedure for Checking Swing Brake Pilot Supply Pressure 56
Procedure for Checking Swing Valve Main Relief Pressure 57
Procedure for Checking Relief Setting for Counterweight Supply Control Valve 57
Procedure for Checking Outrigger Selector Valve Relief Pressure 58
Procedure for Checking the Air Conditioning Circuit Relief Valve Pressure 58
Procedure for Checking Center Front Jack Cylinder (Fifth Jack) Relief Valve Pressure 59
Procedure for Checking Pump Mounted Relief Valve Pressure 59
Procedure For Checking Front Steering Relief Valve Pressure 60
Directional Control Valves 60
Description 60
Maintenance 61
Swing Valve Bank Removal 61
Swing Valve Bank Installation 61
Hoist/Lift/Telescope Valve Bank Removal 61
Hoist/Lift/Telescope Valve Bank Installation 61
Counterweight Removal Valve Bank Removal 61
Counterweight Removal Valve Bank Installation 61
Functional Check (All Valve Banks) 61
Functional Check (RCL Lockout Valves) 61
Check Valves 66
Description 66
Maintenance 66
Removal 66
Installation 66
Hydraulic Remote Control Valve 66
Description 66
Maintenance 66
Armrest Control Valve Removal 66
Armrest Control Valve Installation 66
Armrest Control Valve Functional Check 66
Telescope Pedal Control Valve Removal (with Auxiliary Hoist Option) 66
Telescope Pedal Control Valve Installation (with Auxiliary Hoist Option) 66
Telescope Pedal Control Valve Functional Check (with Auxiliary Hoist Option) 67
Outrigger Selector Valve 69
Description 69
Maintenance 69
Removal 69
Installation 69
Functional Check 69
Outrigger Control Manifold 70
Description 70
Maintenance 70
Removal 70
Inspection 70
Installation 70
Functional Check 70
Pilot Operated Check Valve 72
Description 72
Maintenance 72
Removal 72
Installation 72
Holding Valves 73
Description 73
Maintenance 73
Removal 73
Installation 73
Swing Brake and Armrest Lockout Valve Manifold 75
Description 75
Maintenance 75
Removal 75
Installation 75
Functional Check – Swing Brake Release Valve 75
Functional Check – Crane Function Valve 75
Inlet Filter Screen Replacement 75
High Speed Boost Selector Valve 77
Description 77
Maintenance 77
Removal 77
Installation 77
Front Center Jack Relief Valve 78
Description 78
Maintenance 78
Removal 78
Installation 78
Pump Mounted Relief Valve 78
Description 78
Maintenance 78
Removal 78
Installation 78
Needle Valve 79
Description 79
Maintenance 79
Removal 79
Installation 79
Needle Valve With Reverse Free Flow Check 79
Description 79
Maintenance 79
Removal 79
Installation 79
Swing Power Brake Valve 79
Description 79
Maintenance 79
Removal 79
Installation 80
Functional Check 80
Swing Brake Release Valve (Optional) 81
Description 81
Maintenance 81
Removal 81
Installation 81
Priority Flow Divider Valve 82
Description 82
Maintenance 82
Removal 82
Installation 82
Auxiliary Water Jacket Cooler Flow Control Valve 83
Description 83
Maintenance 83
Removal 83
Installation 83
Cylinders 84
General 84
Maintenance 84
General 84
Leakage Check 84
Temperature Effects on Hydraulic Cylinders 84
Lift Cylinder 86
Description 86
Maintenance 86
Disassembly 86
Inspection 86
Assembly 88
Lower Telescope Cylinder 89
Description 89
Maintenance 89
Disassembly 89
Inspection 89
Assembly 89
Upper Telescope Cylinder 92
Description 92
Maintenance 92
Disassembly 92
Inspection 92
Assembly 92
Bleeding Procedure 94
Cylinder on Test Bench 94
Cylinder Installed on Crane 95
Steer Cylinder 95
Description 95
Maintenance 96
Disassembly 96
Inspection 97
Assembly 98
Outrigger Extension Cylinder 99
Description 99
Maintenance 99
Disassembly 99
Inspection100
Assembly102
Outrigger Jack Cylinder102
Description102
Maintenance102
Disassembly102
Inspection103
Assembly105
Test106
Center Front Jack Cylinder106
Description106
Maintenance106
Disassembly106
Inspection107
Assembly109
Test110
Counterweight Removal Cylinder110
Description110
Maintenance110
Disassembly110
Inspection111
Assembly111
SECTION 3115
Electric System115
Description115
General115
Alternator115
Battery115
Carrier Relay and Circuit Breaker Panel115
Fuses115
Relays118
Superstructure Relay Panel and Fuse Panel118
Fuses118
Relays121
Maintenance122
General122
General Troubleshooting122
Troubleshooting Engine Starting Problems122
Troubleshooting Engine Charging Problems123
Troubleshooting Accessories123
Troubleshooting Swivel-Caused Electrical Problems123
Connector Troubleshooting123
Troubleshooting Lights125
Carrier125
Superstructure125
Troubleshooting Gauges and Meters125
Troubleshooting Alarms, Indicators, and Emergency Components126
Troubleshooting Crane Components and Accessories127
Carrier127
Superstructure127
Alternator Replacement128
Removal128
Installation129
Check129
Starter Replacement129
Removal129
Installation129
Check129
Battery Replacement130
Removal130
Installation130
Relay Panel Component Replacement130
Accessory Relay and Flasher Replacement130
Buzzer Replacement130
Plug-in Relays Replacement130
Instrument Replacement131
Removal131
Inspection131
Installation131
Check131
Switch Replacement131
Rocker Switch131
Removal131
Inspection131
Installation131
Check131
All Other Switches132
Removal132
Inspection132
Installation132
Check132
Windshield Wiper Assembly Replacement132
Removal132
Inspection132
Installation133
Check133
Windshield Washer Assembly Replacement133
Removal133
Inspection134
Installation134
Check134
Skylight Wiper Assembly Replacement134
Removal134
Inspection134
Installation134
Check134
SECTION 4135
Boom135
Description135
Theory of Operation135
Boom Extension135
Boom Retraction136
Maintenance136
Removal136
Disassembly138
Boom Nose Sheaves143
Removal143
Installation143
Assembly143
Installation146
Functional Check147
Inspection147
Boom Alignment and Servicing147
Cam Operated Check Valve Adjustment148
Guide Block Adjustment148
Boom Extension and Retraction Cable148
Maintenance148
Inspection148
Adjustment149
Telescope Circuit149
Description149
Theory of Operation150
Maintenance150
Troubleshooting150
Removal and Installation152
Disassembly and Assembly152
Lift Circuit152
Description152
Theory of Operation153
Maintenance154
Troubleshooting154
Removal156
Disassembly and Assembly156
Installation156
Swingaway Boom Extension158
Description158
Maintenance158
Removal158
Installation164
Boom Extension Alignment Device Adjustment165
Swingaway Mounting Adjustment166
Hook Block166
Description166
Maintenance166
Periodic Maintenance166
SECTION 5167
Hoist and Counterweight167
Description167
Theory Of Operation167
Maintenance167
Removal167
Installation168
Functional Check168
Usage and Inspection168
Preventative Maintenance170
Oil Change171
Gear Oil Sampling and Analysis171
General Guidelines for Iron Contaminant Level171
Brake Test Procedure171
Hoist to Boom Alignment172
Preparation172
Tools Required172
Procedure172
Motor And Brake174
Description174
Maintenance174
Removal174
Installation174
Cable Guard Roller And Cable Guide Roller174
Description174
Maintenance174
Removal174
Cleaning and Inspection174
Assembly175
Hoist Drum Indicator System176
Description176
Maintenance176
General176
Rotation Sensor176
Drum Rotation Indicator Control Module (CPU)176
Thumb Thumper Solenoid176
Troubleshooting176
Green LED176
Red LED176
Amber LED178
Hoist Rotation Indicator (HRI) Display System178
Pressure Switches178
HRI Display178
HRI Control Module179
Hoist Control Valves179
Description179
Hydraulic Hoist Motor Control Valve179
Hoist Directional Control Valve179
Counterweight179
Description179
Maintenance180
Cylinders180
Removal180
Installation180
Jack Screws180
SECTION 6183
Swing System183
Description183
Theory Of Operation183
Swing Drive183
Swing Brake184
Maintenance186
Troubleshooting186
Swing Motor189
Description189
Maintenance189
Removal189
Installation189
Test189
Swing Gearbox and Brake189
Description189
Maintenance189
Swing Brake189
Removal189
Installation189
Testing190
Gearbox190
Removal190
Installation190
Servicing190
Testing190
Swing Bearing190
Description190
Maintenance190
General190
Torquing Turntable Bolts191
General191
Torque Values192
Tools Required192
Inner Race Torquing192
Outer Race Torquing192
Removal193
Inspection194
Installation194
Testing195
Swivels195
Description195
Hydraulic Swivel197
Description197
Theory of Operation197
Maintenance197
Removal197
Installation198
Two Port Water Swivel199
Description199
Maintenance199
Removal199
Disassembly199
Cleaning and Inspection199
Assembly199
Installation199
Electrical Swivel200
Description200
Theory of Operation200
Maintenance200
Removal200
Installation200
Preventative Maintenance201
Slew Potentiometer Preliminary Zero Adjustment Procedure201
Slew Potentiometer Adjustment201
Swing Lock Pin202
Description202
Maintenance202
360° Swing Lock Control (Positive Lock Type) (Optional)202
Description202
Maintenance202
SECTION 7205
Power Train205
Description205
Maintenance206
Removal206
Installation208
Engine Drive Belts210
Engine Control System211
Description211
Functional Operation211
Engine Control System Switches and Indicator Lights211
Engine Diagnostics/Idle Switch (+/-)211
Regen Initiate/Inhibit Switch211
Hand Throttle Switch (Engine Increment/ Decrement Switch)211
Engine Stop Light212
Engine Warning Light212
Fault Code Flashing Sequence212
Regen Needed/Inhibit Indicator212
High Exhaust Temp Indicator212
Fuel System213
Description213
Fuel Tank213
Injection Fuel Pump213
Fuel Filter-Water Separator213
Draining213
Filter Replacement213
Maintenance213
Fuel Tank213
Removal213
Installation213
Air Intake System215
Description215
Maintenance215
Troubleshooting215
Check For Filter Restriction215
Filter Element Replacement215
Element Cleaning216
Air Cleaner Body217
Vacuator Valve218
Duct Work218
Exhaust System219
Description219
ISX System Removal219
ISX System Installation219
QSM System Removal219
QSM System Installation219
Slip Joint Exhaust Connectors219
After 1000 Hours, or One Year220
2000 Hours or 2 Years220
4000 Hours or 4 Years220
5000 Hours or 5 Years220
ISX Exhaust System220
QSM Exhaust System221
Aftertreatment Diesel Exhaust Fluid (DEF)222
DEF Tank222
Description222
Removal222
Installation222
DEF Dosing Unit Filter223
Initial Check223
Preparatory Steps223
Removal224
Clean and Inspect for Reuse224
Install224
Finishing Steps224
Water Cooling System225
Description225
Maintenance225
General225
Effects Of Cooling System Neglect225
Overheating225
Overcooling225
Rust Prevention225
Engine Antifreeze/Coolant Fill Procedure (when level is low)225
Engine Antifreeze/Coolant Fill Procedure (after a complete draining of the system)226
Antifreeze/Supplemental Coolant Additives Maintenance Summary226
Cooling System Level Check Interval226
SCA Level Check/Coolant Filter Change Interval226
Cleaning227
Pressure Flushing227
Component Inspection228
Radiator/Recovery Tank228
Engine Water Jacket228
Water Pump228
Fans and Belts228
Thermostat228
Hoses and Clamps228
Test Equipment228
Antifreeze/Coolant229
Coolant Filter229
Radiator Assembly Removal and Installation229
Removal229
Installation232
Drive Train233
Description233
Maintenance233
Transmission233
Drive Shafts233
Removal233
Installation233
Lubrication233
Clutch235
Description235
Maintenance237
Troubleshooting237
Removal239
Inspection239
Installation240
Clutch Adjustment Procedure242
Clutch Adjustment Inspection Procedure243
General Maintenance243
Lubrication243
Gearshift And Transmission Shift Air System244
Description244
Theory of Operation244
Shifting Gears244
Maintenance245
Troubleshooting245
Removal245
Installation245
Lubrication245
Manual Transmission246
Description246
Theory of Operation246
Maintenance246
Troubleshooting246
Diagnostics246
Transmission Removal249
Special Procedure for Changing Transmission Input Shaft249
Disassembly249
Assembly249
Transmission Installation249
Clutch Adjustment Procedure250
Lubrication251
General251
Draining Oil251
Refilling Oil251
Adding Oil251
Operating Temperature251
Proper Lubrication251
Preventive Maintenance251
SECTION 8253
UnderCarriage253
Front Axle And Suspension254
Description254
Front Axle254
Suspension254
Maintenance254
General254
Beam Center Cap Fasteners254
Beam End Connections and Bushings254
Saddle Assembly End Cap Fasteners254
Beam Center Bushings254
Beam Center Cross Tube254
Air Bags256
Height Control Valves256
Shock Absorbers256
Removal256
Disassembly256
Assembly256
Installation257
Axle Alignment Procedure257
Toe-In Adjustment259
Axle Stop Settings259
Drag Link Installation and Axle Synchronization259
Final Adjustments260
Setting Axle Stops and Steering Gear Relief Plungers261
Front Air Ride Adjustment263
Steering System264
Description264
Steering Pump267
Description267
Steering Gearbox267
Description267
Maintenance267
Removal267
Installation267
Steer Cylinder268
Description268
Maintenance268
Removal268
Installation268
Rear Axle And Suspension269
Description269
Rear Axle269
Suspension269
Maintenance269
General269
Beam Center Cap Fasteners269
Beam End Connections and Bushings269
Saddle Assembly End Cap Fasteners269
Beam Center Bushings269
Beam Center Cross Tube269
Air Bags269
Height Control Valves271
Shock Absorbers271
Removal271
Disassembly271
Assembly271
Installation272
Rear Air Ride Adjustment272
Wheels and Tires273
Description273
Maintenance273
Mounting the Wheels on the Front Axle273
Mounting the Wheels on the Rear Axle274
Brakes275
Description275
Maintenance275
Non-Asbestos Warning275
Front Brakes275
Description275
Maintenance276
Troubleshooting276
Brakes276
Disassembly276
Inspection279
Repair/Replacement280
Assembly281
Automatic Slack Adjuster282
Description282
Maintenance282
Alternative 1282
Removal282
Installation282
Adjustment Procedures283
Brake Applied Stroke Measurement283
Brake Free Play Measurement and Adjustment283
Alternative 2286
Installation286
Adjustment Procedures286
Brake Applied Stroke Measurement286
Brake Free Play Measurement and Adjustment287
Rear Brakes289
Description289
Brakes289
Spring Brake Actuator289
Maintenance290
Troubleshooting290
Spring Brake Actuator291
Removal291
Installation292
Disassembly292
Assembly292
Rear Brake Assembly292
Disassemble Brakes292
Brake Shoe Removal293
Clean and Inspect Parts293
Inspect Parts294
Assemble Brakes294
Camshaft Installation294
Brake Shoe Installation295
Automatic Slack Adjuster296
Description296
Maintenance296
Removal296
Installation296
Brake Adjustment298
Air System299
Description299
Theory of Operation299
Braking299
Maintenance299
Leak Detection299
Air System Operational Test302
Air System Components303
Description303
Air Compressor303
Air Governor303
Air Dryer303
Reservoirs304
Low Pressure Indicator Switches304
Stop Light Switch304
Air Pressure Gauge304
Safety Valve304
Automatic Drain Valve304
Pressure Protection Valve305
Double Check Valve305
Relay Valve305
Dual Brake Valve306
Spring Brake Control Valve306
Park Brake Control Valve306
Quick Release Valve306
Maintenance306
Air Compressor306
Removal306
Installation307
Air Governor307
Removal307
Installation307
Operational Test307
Leakage Test307
Preventive Maintenance307
Air Dryer307
Removal307
Installation307
Preventive Maintenance307
Leak Tests308
Reservoirs308
Removal308
Maintenance308
Cleaning308
Installation308
Low Pressure Indicator Switches308
Operating and Leakage Checks309
Removal309
Installation309
Preventive Maintenance309
Stop Light Switch309
Operational Test309
Leakage Test309
Removal309
Installation309
Air Pressure Gauge309
Removal309
Installation309
Functional Check309
Safety Valve309
Removal309
Installation309
Operating and Leakage Checks309
Automatic Drain Valve309
Removal309
Disassembly309
Cleaning310
Assembly310
Installation310
Preventive Maintenance310
Operating Leaks and Checks310
Pressure Protection Valve310
Removal310
Installation310
Operational Check310
Leakage Test310
Preventive Maintenance310
Double Check Valve311
Removal311
Disassembly311
Cleaning311
Assembly311
Installation311
Operating Check311
Leak Test311
Preventive Maintenance311
Relay Valve311
Removal311
Inspection311
Installation311
Operating Test311
Leakage Test311
Preventive Maintenance312
Dual Brake Valve312
Removal312
Installation312
Operating Test312
Leakage Test312
Preventive Maintenance312
Park Brake Control Valve312
Removal312
Installation312
Operating and Leakage Check313
Preventive Maintenance313
Quick Release Valve313
Removal313
Disassembly313
Cleaning and Inspection313
Assembly313
Installation313
Operating and Leakage Tests313
Preventive Maintenance313
Outriggers314
Description314
Theory of Operation314
Maintenance315
Troubleshooting315
Outrigger Beam318
Description318
Theory of Operation318
Maintenance318
Removal318
Inspection318
Installation319
Wear Pad Adjustment321
Outrigger Extension Cylinder321
Description321
Maintenance321
Removal321
Installation321
Functional Check322
Outrigger Monitoring System (Optional—Standard in North America)322
Description322
Removal322
Installation323
Outrigger Jack Cylinder323
Description323
Maintenance323
Removal323
Installation323
Functional Check324
Outrigger Jack Cylinder Internal Leak Test324
Checking Cylinder for Internal Piston Seal Leak324
Testing Pilot Operated Check Valve for Leakage325
Outrigger System Valves325
Description325
Pilot Operated Check Valve325
Integrated Outrigger Valve325
Outrigger Control Manifold325
Center Front Jack Circuit Relief Valve325
Center Front Jack Cylinder325
Description325
Maintenance325
Removal325
Installation327
Functional Check327
SECTION 9329
Lubrication329
General329
Environmental Protection329
Arctic Conditions Below -9°C (15°F)329
All Weather Package & Lubricants329
Standard Lubricants Package330
Lubrication Points331
Carrier Lubrication333
Superstructure Lubrication338
Boom, Boom Extension, and Boom Accessories Lubrication339
Wire Rope Lubrication341
Carwell® Rust Inhibitor343
Protecting Cranes From Rusting343
Cleaning Procedures343
Inspection and Repair344
Application344
Areas of Application345

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