Manitowoc Grove TMS800E Service Manual – PDF DOWNLOAD

Manitowoc Grove TMS800E Service Manual – PDF DOWNLOAD

FILE DETAILS:

Manitowoc Grove TMS800E Service Manual – PDF DOWNLOAD

Language : English
Pages :382
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Manitowoc Grove TMS800E Service Manual – PDF DOWNLOAD

Introduction 15
Description 15
List Of Specifications 16
General 16
Dimensions 16
Capacities 16
Transmission 16
Clutch 16
Engine 16
Cummins ISX12-2013 Tier 4 16
Cummins QSM11 Tier 3 16
Axles 16
Front 16
Rear 17
Brakes 17
Wheel And Tires 17
Swing Gearbox 17
Boom 17
Swivel Assembly 17
Hydraulic Pumps 17
Pump #1 (QSM Engine) 17
Pump #2 (QSM Engine) 17
Pump #3 (QSM Engine) 17
Pump #1 (ISX Engine) 17
Pump #2 (ISX Engine) 17
Pump #3 (ISX Engine) 17
Hoists 17
General Maintenance 24
Cleanliness 24
Removal and Installation 24
Disassembly and Assembly 24
Pressing Parts 24
Locks 24
Wires and Cables 25
Shims 25
Bearings 25
Antifriction Bearings 25
Double Row, Tapered Roller 25
Heating Bearings 25
Installation 25
Preload 25
Sleeve Bearings 25
Gaskets 25
Batteries 25
Hydraulic Systems 26
Cleanliness 26
Keep the System Clean 26
Sealing Elements 26
Hydraulic Lines 26
Fatigue of Welded Structures 26
Loctite® 26
Application of Medium Strength Loctite® 26
Primer Application 27
Adhesive/Sealant Application 27
Fasteners and Torque Values 27
Torque Wrenches 27
Torque Values 28
Weld Studs 30
Wire Rope 31
General 31
Environmental Conditions 31
Dynamic Shock Loads 31
Lubrication 31
Precautions and Recommendations During Inspection or Replacement 31
Wire Rope Inspection (Running Ropes and Pendant Cables) 32
Frequent Inspection 32
Periodic Inspection 32
Wire Rope Inspection (Jib Extension and Retraction Cables) 32
Periodic Inspection 32
Wire Rope Replacement (All Wire Rope) 33
Seizing Wire Rope 33
Method 1 33
Method 2 33
Installing 35×7 Wire Rope 34
Procedures for Cutting and Preparing 35×7 34
Hydraulic System 37
Description 38
Maintenance 38
Hydraulic Oil Recommendations 38
Draining and Flushing 38
Removing Air From the Hydraulic System 42
Parts Replacement 42
Directional Control Valves 42
Inspection 42
Valve Leakage 42
Binding Spools 43
Visual Inspection of Hoses and Fittings 43
Supply Pressure and Return Circuit 43
Description 43
Hydraulic Reservoir and Filter 44
Pump Distribution 44
No 1 Pump 44
No 2 Pump 44
Maintenance 46
Troubleshooting 46
Return Filter Assembly 47
Element Removal 47
Element Installation 47
Reservoir Breather 47
Removal and Replacement 47
Oil Cooler 49
Description 49
Maintenance 49
Removal 49
Installation 49
Hydraulic Pumps 51
Description QSM Cranes 51
Description ISX Cranes 51
Maintenance QSM Cranes 51
No 1 Pump Removal 51
No 1 Pump Inspection and Repair 51
No 1 Pump Installation 51
No 1 Pump Piston Pump Section Startup Procedure 51
No 1 Pump Gear Pump Section Startup Procedure 52
No 2 Pump Removal 52
No 2 Pump Inspection and Repair 53
No 2 Pump Installation 54
No 2 Pump Startup Procedure 54
Maintenance ISX Cranes 55
Pump/PTO Clutch Replacement 55
Removal 55
Disassembly 56
Assembly 56
Installation 56
Pump/PTO Clutch Assembly 57
PTO Clutch Lubrication 57
Valves 58
General 58
Pressure Setting Procedures 60
Procedure A – For Checking/Setting the Main Directional Control Valve for Hoist(s) and Boom Lift 61
Procedure B – For Checking/Setting the Outrigger/Swing Pressures 62
Procedure C – For Checking/Setting Air Conditioner Relief Valve Pressure 62
Procedure D – For Checking/Setting the Front Steer Pressure 62
Procedure E – For Checking/Setting Swing Brake Release Pressure 62
Procedure F – For Checking/Setting the Pilot Supply Pressure 62
Procedure G – For Checking/Setting the Piston Pump (ISX Engine) 63
Procedure H – For Checking the Center Front Stabilizer Pressure 63
Procedure I – Procedures for Checking/ Setting the Piston Pumps (GSM Engine) 63
Procedure J- For Setting Threshold on Electronic Controllers 64
K Procedure for Setting Threshold and Max on Swing Brake Pedal 64
Directional Control Valves 70
Description 70
Maintenance 70
Hoist/Lift/Telescope Valve Bank Removal 70
Hoist/Lift/Telescope Valve Bank Installation 70
Counterweight Removal/Cab Tilt Valve Bank Removal 70
Counterweight Removal/Cab Tilt Valve Bank Installation 70
Functional Check (All Valve Banks) 70
Functional Check (RCL Lockout Valves) 70
Check Valves 74
Description 74
Maintenance 74
Removal 74
Installation 74
Outrigger Selector Valve 75
Description 75
Maintenance 75
Removal 75
Installation 75
Functional Check 75
Outrigger Control Manifold 77
Description 77
Maintenance 77
Removal 77
Inspection 77
Installation 77
Functional Check 77
Pilot Operated Check Valve 79
Description 79
Maintenance 79
Removal 79
Installation 79
Cab Tilt Double Pilot Operated Check Valve 80
Description 80
Maintenance 80
Removal 80
Installation 80
Holding Valves 81
Description 81
Maintenance 81
Lower Lift Cylinder Holding Valve 81
Removal 81
Installation 81
Cartridge Style Holding Valve 82
Removal 82
Installation 82
Manifold Style Holding Valve 82
Removal 82
Installation 82
Accessory Manifold with Swing Directional Control Valve 83
Description 83
Maintenance 83
Removal 83
Installation 83
Functional Check – Swing Brake Release Valve 83
Functional Check – Crane Function Control 83
Inlet Filter Screen Replacement 83
Motor Control Manifold 86
Description 86
Maintenance 86
Removal 86
Installation 86
Swing Power Brake Valve 87
Description 87
Maintenance 87
Removal 87
Installation 87
Functional Check 87
Swing Brake Release Valve (Optional) 88
Description 88
Maintenance 88
Removal 88
Installation 88
Needle Valve (Optional) 89
Description 89
Maintenance 89
Removal 89
Installation 89
Needle Valve With Reverse Free Flow Check (Optional) 89
Description 89
Maintenance 89
Removal 89
Installation 89
Cylinders 90
General 90
Maintenance 90
General 90
Cylinder Rod-Surface Protection 90
Leakage Check 90
Temperature Effects on Hydraulic Cylinders 91
Lift Cylinder 93
Description 93
Maintenance 93
Disassembly 93
Inspection 93
Assembly 95
Lower Telescope Cylinder 96
Description 96
Maintenance 96
Disassembly 96
Inspection 96
Assembly 96
Upper Telescope Cylinder100
Description100
Maintenance100
Disassembly100
Inspection100
Assembly100
Steer Cylinder103
Description103
Maintenance103
Disassembly103
Inspection104
Assembly105
Outrigger Extension Cylinder106
Description106
Maintenance106
Disassembly106
Upper Barrel106
Lower Barrel106
Inspection106
Assembly108
Lower Barrel108
Upper Barrel108
Outrigger Stabilizer Cylinder110
Description110
Maintenance110
Disassembly110
Inspection110
Assembly112
Center Front Stabilizer Cylinder114
Description114
Maintenance114
Disassembly114
Inspection114
Assembly116
Counterweight Removal Cylinder118
Description118
Maintenance118
Disassembly118
Inspection118
Assembly118
Cab Tilt Cylinder121
Description121
Maintenance121
Disassembly121
Inspection123
Assembly123
Electric System125
Description125
General125
Alternator125
Batteries125
Carrier Cab Power Panel126
Fuses126
Relays126
Relays132
Carrier Fuse and Relays132
Fuses132
Superstructure Fuse and Relay Panel133
Fuses133
Relays133
Maintenance133
General133
General Troubleshooting134
Troubleshooting Swivel-Caused Electrical Problems134
Connector Troubleshooting134
Diagnostic Lights136
Alternator Replacement136
Removal137
Installation137
Check137
Starter Replacement137
Removal137
Installation137
Check137
Battery Replacement138
Removal138
Installation138
Relay Panel Component Replacement138
Accessory Relay Replacement138
Buzzer Replacement138
Plug-in Relays Replacement138
Instrument Replacement139
Inspection139
Installation139
Check139
Switch Replacement139
Rocker Switch139
Removal139
Inspection139
Installation139
Check139
Windshield Wiper Assembly Replacement139
Removal139
Inspection140
Installation140
Check141
Windshield Washer Assembly Replacement141
Removal141
Inspection142
Installation142
Check142
Skylight Wiper Assembly Replacement142
Removal142
Inspection142
Installation142
Check142
Troubleshooting142
Boom143
Description144
Lattice Extension144
Optional Lattice Extension144
Theory of Operation144
Extension144
Boom Retraction144
Maintenance144
Removal144
Boom Disassembly145
Boom Nose Sheaves152
Removal152
Installation152
Assembly153
Installation156
Functional Check156
Inspection156
Boom Alignment and Servicing156
Cam Operated Check Valve Adjustment157
Stop Block Adjustment157
Front Upper Pad Adjustment157
Rear Side Wear Pad Adjustment157
Jib and Retraction Cable157
Maintenance157
Inspection157
Adjustment158
Telescope Circuit159
Description159
Theory of Operation159
Maintenance159
Troubleshooting159
Removal and Installation161
Disassembly and Assembly161
Lift Circuit162
Description162
Theory of Operation162
Maintenance162
Troubleshooting162
Lift Cylinder Removal164
Lift Cylinder Disassembly and Assembly164
Lift Cylinder Installation164
Auxiliary Boom Nose166
Description166
Installing the Bi-Fold Manual Jib167
Checking the Transport Condition167
Transport condition with lattice extension folded at the side167
If 7 m (23 ft) section and 10 m (33 ft) section are folded at the side167
If the 7 m (23 ft) section only is folded at the side167
Jib Erecting and Stowing Procedure169
General Warnings169
Preparing the Crane for Jib Erection Procedure169
Requirements for Jib Erection169
Requirements for Stowing the Jib169
Securing Lattice Extension with Tag Line (Rope)169
Erecting Procedure169
33 ft (10 m) Jib169
Relieving the Load on Bearing Points172
56 ft (17 m) Jib174
Stowing Procedure174
56 ft (17 m) Jib174
33 ft (10 m) Jib175
Raising and Lowering the Hydraulic Jib178
When Erecting178
During Operation178
Transportation on a Separate Vehicle178
Lifting Limit Switch on the Lattice Extension179
Overriding Connection on Main Boom179
On 10 m (33 ft) swingaway lattice extension179
On the 17 m (56 ft) Two-Stage Swingaway Lattice Extension179
Folding Out/In the Deflection Sheaves on the 10 m (33 ft) Section179
Folding Rear Deflection Sheave180
Folding Out Deflection Sheave180
Folding In Deflection Sheave180
Positioning/Remove the Hoist Cable180
Removing Hoist Cable180
Setting the Folding Swingaway Extension Offset180
Removing the Bi-Fold Manual Jib182
Installing/Removing 5 m (16 ft) Sections182
Installing the 5 m (16 ft) Sections182
Removing the 5 m (16 ft) Sections183
Jib (Additional Equipment)183
Identification and Slinging Points183
Identification183
Serial numbers on the 5m (16ft) sections183
Slinging Points183
Assembly Of Jibs183
Electrical Connection at the Jib184
Transport Condition of the Connection184
At the 22 m (72 ft) Jib185
At the 27 m (89 ft) Jib185
Unfolding/Folding the Deflection Sheave on the 5 m (16 ft) Section185
Folding Out Deflection Sheave185
Folding In Deflection Sheave186
Positioning/Removing the Hoist Cable186
Positioning Hoist Cable186
Removing Hoist Cable186
Traveling with Manually Offsettable Jib and/ or Inserts Erected187
10 m (33 ft)/17 m (56 ft) Extension Plus 5 m (16 ft) or 10 m (32 ft) Inserts187
Auxiliary Single-Sheave Boom Nose (Additional Equipment)187
Identification187
Installing/Removing Auxiliary Single-Sheave Boom Nose187
Installing Auxiliary Single-Sheave Boom Nose187
Removing the Auxiliary Single-Sheave Boom Nose188
Rigging The Auxiliary Single-Sheave Boom Nose188
Rigging in Transport Position188
Rigging in Working Position189
Attaching and Removing Hoist Cable190
Possible Reeving Methods on the Auxiliary Single-Sheave Boom Nose190
Lifting Limit Switch190
In Operation190
During Transport191
Raising And Setting Down The Main Boom With Rigged Lattice Extension191
Telescoping With Rigged Lattice Extension191
Operating With The Lattice Extension191
Procedure if the Permissible Wind Speed is Exceeded191
Monthly Maintenance Work192
Pins192
Hookblock193
Description193
Maintenance193
Periodic Maintenance193
Hoist and Counterweight195
Description195
Theory of Operation195
Maintenance195
Warm-up Procedure195
Removal196
Installation196
Functional Check197
Servicing197
Hoist to Boom Alignment198
Preparation198
Tools Required198
Procedure198
Piston Motor And Control Valve200
Description200
Maintenance200
Removal200
Installation200
Idler Drum and Cable Follower201
Description201
Maintenance201
Idler Drum201
Removal and Disassembly201
Cleaning and Inspection201
Assembly and Installation201
Cable Follower201
Removal and Disassembly201
Cleaning and Inspection201
Assembly and Installation201
Complete Assembly203
Removal203
Installation203
Hoist Drum Indicator System204
Description204
Maintenance204
General204
Rotation Sensor204
Thumb Thumper Solenoid204
Troubleshooting204
Hoist Control Valves205
Description205
Hoist Motor Control Valve205
Hoist Directional Control Valve205
Counterweight205
Description205
Maintenance205
Cylinders205
Removal205
Installation205
Jackscrews205
Mounting the Counterweight205
Stowing the Counterweight206
Swing System209
Description209
Theory of Operation209
Swing Drive209
Swing Brake210
Maintenance212
Troubleshooting212
Swing Motor216
Description216
Maintenance216
Removal216
Installation216
Test216
Swing Gearbox and Brake217
Description217
Maintenance217
Swing Brake217
Removal217
Installation217
Testing217
Gearbox217
Removal217
Installation218
Servicing218
Checking the Oil Level218
Testing218
Swing Bearing219
Description219
Maintenance219
General219
Tightening Turntable Bolts219
General219
Torque Values220
Tools Required220
Inner Race Torquing220
Outer Race Torquing220
Removal221
Inspection222
Installation222
Testing223
Swivels224
Description224
Hydraulic Swivel226
Description226
Theory of Operation226
Maintenance226
Removal226
Installation227
Integral W/Hydraulic Water Swivel227
Description227
Maintenance227
Removal227
Disassembly228
Cleaning and Inspection228
Assembly228
Installation228
Electrical Swivel228
Description228
Theory of Operation228
Maintenance229
Removal229
Installation229
Preventative Maintenance230
Slew Angle Zero Adjustment Procedure230
Slew Angle Verification230
Swing Lock Pin230
Description230
Maintenance230
360° Swing Lock Control (Positive Lock Type) (Optional)230
Description230
Maintenance230
Power Train233
Description233
Maintenance234
Removal234
Installation239
Engine Drive Belts240
Engine Control System241
Description241
Functional Operation241
Engine Control System Switches and Indicator Lights241
Engine Idle/Increment-Decrement Switch241
Increment/Decrement Switch (Superstructure Cab)241
Engine Regeneration Start Switch241
Engine Stop Light242
Engine Warning Light242
Engine Regeneration Inhibit Switch242
Fuel System242
Description242
Fuel Tank242
Injection Fuel Pump242
Fuel Filter-Water Separator242
Maintenance242
Fuel Tank242
Removal242
Installation242
Fuel Filter-Water Separator243
Draining243
Filter Change Procedure243
Air Intake System245
Description245
Maintenance245
Troubleshooting245
Check For Filter Restriction245
Filter Element Replacement245
Cleaning with Compressed Air246
Air Cleaner Body248
Vacuator Valve248
Duct Work248
QSM Engine Muffler250
Removal250
Installation251
ISX Engine Diesel Particulate Filter/ Selective Catalyst Reduction Assembly251
Removal251
Installation253
Diesel Exhaust Fluid (DEF) Tank254
Description254
Removal254
Installation254
Water Cooling System255
Description255
Maintenance255
General255
Effects Of Cooling System Neglect255
Overheating255
Overcooling255
Antifreeze/Coolant255
Rust Prevention256
Engine Antifreeze/Coolant Fill Procedure256
Cooling/SCA Maintenance Summary256
Supplemental Coolant Additives (SCA)256
DCA4256
Coolant Filter256
DCA4 Filter Change Interval256
6 months or 500 hours256
1 year or 1000 hours256
Cleaning256
Pressure Flushing257
Component Inspection257
Radiator/Recovery Tank257
Engine Water Jacket258
Water Pump258
Fans and Belts258
Thermostat258
Hoses and Clamps258
Test Equipment258
Radiator Assembly Removal and Installation258
Removal258
Installation258
Winter Front Grill Cover259
Pump/PTO Clutch Assembly (ISX engine)262
PTO Clutch Lubrication262
Pump/PTO Clutch Replacement262
Removal262
Disassembly263
Assembly263
Installation263
Air Valve Replacement264
Removal264
Installation264
Drive Train265
Description265
Maintenance265
Drive Lines265
Removal265
Installation265
Lubrication265
Clutch267
Description267
Theory Of Operation267
Maintenance269
Troubleshooting269
Removal272
Inspection272
Installation273
Clutch Adjustment Procedure275
Clutch Adjustment Inspection Procedure276
General Maintenance276
Gearshift276
Description276
Maintenance276
Troubleshooting276
Removal277
Installation277
Manual Transmission277
Description277
Theory of Operation277
Maintenance277
Troubleshooting277
Removal of the Transmission280
Special Procedure for Changing Clutch (Input) Shaft280
General280
Disassembly280
Assembly280
Installation of the Transmission281
Lubrication281
General281
Draining Oil281
Refilling Oil281
Adding Oil281
Operating Temperature281
Proper Lubrication281
Preventive Maintenance281
Transmission Shift Air System282
Description282
Theory of Operation282
UnderCarriage283
Front Axle and Suspension283
Description283
Front Axle283
Suspension284
Maintenance284
General284
Beam Center Cap Fasteners284
Beam End Connections and Bushings284
Saddle Assembly End Cap Fasteners284
Beam Center Bushings284
Beam Center Cross Tube284
Air Bags286
Height Control Valves286
Shock Absorbers286
Removal286
Disassembly286
Assembly288
Installation288
Axle Alignment Procedure288
Air Ride Adjustment289
Toe-In Adjustment290
Axle Stop Settings290
Drag Link Installation and Axle Synchronization290
Final Adjustments291
Setting Axle Stops and Steering Gear Relief Plungers293
Steering System294
Description294
Maintenance294
Functional Check296
Steering Pump296
Description296
Steering Gearbox296
Description296
Maintenance296
Removal296
Installation296
Steer Cylinder298
Description298
Maintenance298
Removal298
Installation298
Rear Axle and Suspension298
Description298
Rear Axle298
Suspension298
Maintenance298
General298
Beam Center Cap Fasteners298
Beam End Connections and Bushings298
Saddle Assembly End Cap Fasteners299
Beam Center Bushings299
Beam Center Cross Tube299
Air Bags299
Height Control Valves299
Shock Absorbers300
Removal300
Disassembly300
Assembly300
Installation301
Wheels and Tires301
Description301
Maintenance301
Mounting the Wheels on the Front Axle301
Mounting the Wheels on the Rear Axle302
Brakes303
Description303
Rear Brake Spring Brake Actuator303
Maintenance303
Non-Asbestos Warning303
Front Brakes305
Description305
Disassembly305
Inspection307
Repair/Replacement308
Assembly309
Camshaft Installation310
Rear Brakes310
Description310
Disassembly310
Spring Brake Actuator311
Removal311
Installation311
Disassembly311
Assembly311
Rear Brake Shoe Removal312
Clean and Inspect Parts313
Rear Brake Assembly313
Rear Brake Shoe Installation313
Automatic Slack Adjuster (Front)313
Description313
Maintenance314
Removal314
Installation314
Adjustment Procedures314
Brake Applied Stroke Measurement314
Brake Free Play Measurement and Adjustment315
Slack Adjuster Style #2317
Installation318
Adjustment Procedures318
Brake Applied Stroke Measurement318
Brake Free Play Measurement and Adjustment319
Automatic Slack Adjuster (Rear)321
Description321
Maintenance323
Removal323
Disassembly323
Assembly324
Adjust the Brakes325
Measure Free Stroke325
Measure Push Rod Travel or Adjusted Chamber Stroke326
Air System328
Description328
Theory of Operation328
Braking328
Maintenance328
Leak Detection329
Air System Operational Test330
Pressure Warnings and Pressure Build-up330
Air Leakage Test331
Loss of Primary (Rear) Air System331
Loss of Secondary (Front) Air System332
Emergency Brake Application332
Air System Components332
Description332
Air Compressor332
Air Governor332
Air Dryer333
Reservoirs333
Low Pressure Indicator Switches334
Stop Light Switch334
Air Pressure Gauge334
Safety Valve334
Pressure Protection Valve335
Relay Valve335
Dual Brake Valve336
Park Brake Control Valve336
Antilock Modulator336
Traction Control Valve336
Maintenance337
Air Compressor337
Removal337
Installation337
Air Governor337
Removal337
Installation337
Operational Test337
Leakage Test337
Air Dryer337
Removal337
Installation337
Preventive Maintenance337
Leak Tests338
Reservoirs338
Removal338
Maintenance338
Cleaning338
Installation338
Low Pressure Indicator Switches338
Operating and Leakage Checks338
Removal338
Installation339
Preventive Maintenance339
Stop Light Switch339
Operational Test339
Leakage Test339
Removal339
Installation339
Air Pressure Gauge339
Removal339
Installation339
Functional Check339
Safety Valve339
Removal339
Installation339
Operating and Leakage Checks339
Tire Inflation Pressure Protection Valve339
Removal339
Installation339
Operational Check339
Leakage Test340
Preventive Maintenance340
Relay Valve340
Removal340
Inspection340
Installation340
Operating Test340
Leakage Test340
Preventive Maintenance340
Spring Brake Control Valve340
Removal340
Inspection340
Installation340
Operating Test340
Leakage Test341
Dual Brake Valve341
Removal341
Installation341
Operating Test341
Leakage Test341
Preventive Maintenance341
Park Brake Control Valve342
Removal342
Installation342
Operating and Leakage Check342
Preventive Maintenance342
Outriggers342
Description342
Theory of Operation342
Maintenance344
Troubleshooting344
Outrigger Beam347
Description347
Theory of Operation347
Maintenance347
Removal347
Disassembly347
Inspection350
Assembly350
Installation350
Wear Pad Adjustment351
Extension Cylinder351
Description351
Removal351
Installation351
Functional Check352
Outrigger Monitoring System (Optional—Standard in North America)352
Description352
Removal352
Installation352
Outrigger Stabilizer Cylinder352
Description352
Maintenance353
Removal353
Installation353
Functional Check353
Outrigger Stabilizer Cylinder Internal Leak Test354
Checking Cylinder for Internal Piston Seal Leak354
Testing Pilot Operated Check Valve for Leakage354
Outrigger System Valves354
Description354
Pilot Operated Check Valve354
Outrigger Selector Valve354
Outrigger Control Manifold355
Center Front Stabilizer Circuit Relief Valve355
Center Front Stabilizer Cylinder355
Description355
Maintenance355
Removal355
Installation355
Functional Check357
Lubrication359
General359
Arctic Conditions Below -15°C (5°F)359
ALL Weather Package & Lubricants359
Standard Lubricants Package360
Environmental Protection361
Lubrication Points362
Surface Protection for Cylinder Rods362
Carrier Lubrication363
Hydraulic Lubrication367
Superstructure Lubrication368
Boom, Jib, and Boom Accessories Lubrication369
Wire Rope Lubrication370
CARWELL® Rust Inhibitor373
Protecting Cranes From Corrosion373
Cleaning Procedures373
Inspection and Repair374
Application374
Areas of Application374

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