Manitowoc Grove TMS9000-2 SERVICE Manual – PDF DOWNLOAD

Manitowoc Grove TMS9000-2 SERVICE Manual – PDF DOWNLOAD

FILE DETAILS:

Manitowoc Grove TMS9000-2 SERVICE Manual – PDF DOWNLOAD

Language : English
Pages :354
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Manitowoc Grove TMS9000-2 SERVICE Manual – PDF DOWNLOAD

Table of Contents 5
SECTION 1 13
General Instructions 13
Using the Service Manual 13
Safety Messages 13
General 13
Safety Alert Symbol 13
Signal Words 13
Manitowoc CraneCare Service instructions 14
Definitions of stated directions 14
Breaking in a New Crane 15
Safety Rules 15
Handling Substances Which Are Harmful to the Environment 16
What do environmentally harmful substances include? 16
Use suitable equipment 16
Filling and draining 16
Collect and store separately 16
Disposal 16
Overview of the Operating and Display Elements 17
Axle Weight Distribution Table 17
Cleaning 19
Boom Cleaning 19
Overview of the Components that are Easily Damaged when Cleaning 20
On Truck Crane 20
Fasteners and Torque Values 20
Torque Wrenches 21
Torque Values 21
Weld Studs 35
SECTION 2 37
Hydraulic System 37
Description 38
Maintenance 40
Hydraulic Oil Recommendations 40
Draining and Flushing 40
Removing Air from the Hydraulic System 41
Parts Replacement 42
Supply Pressure and Return Circuit 42
Description 42
Hydraulic Reservoir and Filter 42
Hydraulic Reservoir Thermistor and Temperature Switch 43
Pump Distribution 43
No 1 and 2 Pump 43
Maintenance 45
Troubleshooting 45
Return Hydraulic Filter Assembly 46
Element Removal 46
Element Installation 46
Hydraulic Pumps 48
Description 48
Maintenance 48
No 1 Pump 48
Removal 48
Installation 48
No 2 Pump 48
Removal 48
Installation 49
Pump Priming Tool 49
Gear Pump Inlet Port Air Purge/Bleed 49
Gear Pump Outlet Port Air Bleeding: 50
Gear Pump Start-up Procedure (Pump No 1) 50
Testing After Rebuild or Replacement 50
Piston Pump Air Purge /Bleed and Case Filling 50
Piston Pump Start-up Procedure (Pump No 2) 51
Carrier Valves 53
General 53
Outrigger Selector-A/CManifold Valve 55
Description 55
Maintenance 55
Removal 55
Installation 55
Functional Check 55
Outrigger Control Manifold 57
Description 57
Maintenance 57
Removal 57
Inspection 57
Installation 57
Functional Check 57
Pilot Operated Check Valve 59
Description 59
Internal Leak Testing 59
Check Cylinder for Internal Piston Seal Leak 60
Test PO Check Valve For Leakage 60
Maintenance 60
Removal 60
Installation 60
Superstructure Valves 62
Turntable Hydraulic Valves 62
Main Directional Valve Assembly 63
Access Manifold Assembly 64
Hydraulic system of the superstructure 64
Checking for Leaks 64
Cylinders 65
General 65
Maintenance 65
General 65
Leakage Check 65
Temperature Effects On Hydraulic Cylinders 66
Steer Cylinder 67
Description 67
Maintenance 67
Disassembly 67
Inspection 69
Assembly 69
Outrigger Extension Cylinder 70
Description 70
Maintenance 70
Disassembly 70
Upper Barrel 70
Lower Barrel 70
Inspection 70
Assembly 72
Lower Barrel 72
Upper Barrel 72
Outrigger Jack Cylinder 73
Description 73
Maintenance 73
Disassembly 73
Inspection 75
Assembly 75
Center Front Jack Cylinder 77
Description 77
Maintenance 77
Disassembly 77
Inspection 80
Assembly 80
Functional Check 81
Lift Cylinder 81
Description 81
Maintenance 81
Disassembly 81
Inspection 83
Assembly 83
Counterweight Cylinder 84
Description 84
Telescope Cylinder 84
Description 84
Pressure Setting Procedures 85
Objective 85
Equipment 85
Valve Pressure Setting Table 85
Service Tool Notes 86
A Procedure for checking/setting the piston pumps cut-off & differential pressures 87
Procedure for checking/setting the pilot supply pressure 88
C Procedure for checking/setting the main directional control valve, load sense, lift and telescope pressures 89
Load sense relief (max system pressure) 89
Lift down relief pressures 89
Tele extend and retract relief pressures 90
D Procedure for checking/setting cab tilt raise and lower pressures 94
E Procedure for checking/setting counterweight (CWT) raise and lower pressures 94
F Procedure for checking/setting swing pressure 95
G Procedure for checking/setting outrigger pressure 95
HProcedure for checking/setting Air Conditioning pressure 96
I Procedure for checking/setting the center front stabilizer pressure 97
J Procedure for checking/setting the front steer pressure 98
K Procedure for adjusting electronic controllers (meter-in dead band and/or max function speeds) 99
SECTION 3101
Electrical System101
Description101
Carrier101
General101
Alternator101
Batteries101
Carrier Power Panel and Fuse Panels102
Carrier Power Panel102
Relays102
Fuse and Fuse & Relay Panels103
Anti-Lock Brake System (ABS)104
Electronic Control Unit (ECU)104
Diagnostic Connector105
Wheel Speed Sensor and Tone Ring106
Camera System106
Camera Alignment Right Side106
Camera Alignment Reverse106
Maintenance107
General107
General Troubleshooting107
Tools for Troubleshooting107
Troubleshooting Engine Starting Problems107
Troubleshooting Engine Charging Problems108
Troubleshooting Slip Ring-Caused Electrical Problems108
Connector Troubleshooting109
Troubleshooting Lights109
Troubleshooting Gauges and Meters109
Troubleshooting Alarms, Indicators, and Emergency Components110
Troubleshooting the CCS System110
ODM error code viewer110
Troubleshooting Crane Components and Accessories111
Alternator Replacement111
Removal111
Installation111
Check111
Starter Replacement111
Removal111
Installation112
Check112
Battery Replacement112
Removal112
Installation113
Relay Panel Component Replacement114
Accessory Relay and Flasher Replacement114
Buzzer Replacement114
Plug-in Relays Replacement114
Instrument Replacement114
Removal114
Inspection114
Installation114
Check114
Switch Replacement114
Rocker Switch114
Removal114
Inspection115
Installation115
Check115
All Other Switches115
Removal115
Inspection115
Installation115
Check115
Windshield Wiper Assembly Replacement115
Removal115
Inspection117
Installation117
Check117
Windshield Washer Assembly Replacement117
Removal117
Inspection117
Installation117
Check117
Jump Starting the Crane117
SECTION 4119
Superstructure119
Description of maintenance work on the superstructure119
Hoist119
Description119
Theory of Operation119
Carrying Out Partial Inspection of Hoists119
Carrying Out General Inspection of Hoists120
Installing Cable On Hoist120
Removing/Installing the Hoist120
Removing120
Installing121
Functional Check121
Hoist Fluid Level Check121
Usage and Inspection123
Preventative Maintenance123
Oil Sampling124
General Guidelines for Iron Contaminant Level124
Brake Test Procedure125
Motor, Motor Control Valve, and Brake125
Description125
Removal125
Installation125
Hoist Rotation and Minimum Wrap Indicator System125
Description125
Maintenance126
General126
Adjusting Minimum Wrap Switch126
Hoist Control Valves126
Description126
Boom Removal127
Boom Installation129
Functional Check133
New York House Lock133
Bleeding the Telescoping Cylinders133
Prerequisites133
Bleeding Procedure133
Telescoping status134
Vent Screw Position No 1134
Vent Screw Position No 2134
Telescope Slide Pad Adjustment134
Check the locking system135
Hoist ropes136
Checking the Position of Sheaves and Rope Drums136
The recommended hook-blocks are designed to be of sufficient weight to overhaul the rope properly when using the parts of line required for the allowed load at the chosen boom length Operating with a higher number of parts of line than is necessary 137
Rated Capacity Limiter142
Maintenance of the Slip Ring Assembly of the Cable Drum142
Prerequisites143
Maintenance of the Slip Ring Assembly143
Lubricating the Swing Angle Sensor144
Superstructure Air Conditioning System (Additional Equipment)145
Checking Hoses145
Other Maintenance Work145
Checking for Correct Operation of the Auxiliary Heater (Additional Equipment)145
Lubricating the Piston Rod of the Lifting Cylinder145
SECTION 5147
Superstructure Maintenance147
Superstructure maintenance overview147
Maintenance Intervals147
Maintenance plans149
Maintenance plan D: Daily/Before Commissioning149
Maintenance plan W: Weekly150
Maintenance Plan M 1: Monthly/ After 100 Operating Hours/Approximately 2,000 km (1240 mi)151
Maintenance Plan M 3: Every 3 Months/After 300 Operating Hours/ 5 000 – 6 000 km (3,100 – 3,730 mi)152
Maintenance Plan M 6: Every 6 Months/After 500 Operating Hours/ 10 000 – 12 500 km (6,210 – 7,770 mi)153
Maintenance Plan M 12: Every 12 Months/ After 1,000 Operating Hours/ 20 000 – 25 000 km (12,430 – 15,530 mi)154
Maintenance and Inspection Plan Y 2: Every 24 Months/After 100 000 – 125 000 km (62,150 – 77,800 mi)155
Maintenance and Inspection Plan Y 3: Every 36 Months/After 3,000 Operating Hours156
Maintenance and Inspection Plan Y 5: Every 60 Months/After 5,000 Operating Hours157
Maintenance and Inspection Plan Y 6: Every 72 Months/After 6,000 Operating Hours158
Periodic inspections158
Load hook inspection159
Measures required for hoist monitoring160
Theoretical service life160
Proportion of the theoretical service life used160
Determining the operating conditions (collective load)161
Table example to determine the remaining theoretical service life on hoist no 1 (main hoist)162
SECTION 6163
Swing System163
Description163
Theory of Operation163
Swing Drive163
Swing Brake163
Maintenance165
Troubleshooting165
Swing Box Assemblies169
Description169
Swing Motor Maintenance169
Removal169
Installation169
Testing169
Swing gear brake function check169
Swing Brake Assembly Maintenance170
Removal170
Installation170
Testing170
Swing Gearbox Maintenance170
Removal170
Installation171
Servicing171
Normal maintenance should only consist of proper lubrication and a periodic check of mounting bolt torque values Lubrication consists of maintaining the gearbox oil level Oil in a new gearbox should be drained and flushed out after approximately 25171
Oil Changing171
Checking Oil Level171
Testing171
Swing Bearing172
Description172
Maintenance172
General172
Torquing Turntable Bolts172
General172
Torque Values173
Tools Required173
Inner Race Torquing173
Outer Race Torquing173
Removal174
Inspection175
Installation175
Testing176
Swivels177
Description177
Hydraulic Swivel179
Description179
Maintenance179
Removal179
Installation179
Electrical Swivel180
Description180
Theory of Operation180
Maintenance180
Removal180
Installation180
Preventive Maintenance181
Swing Lock Pin182
Description182
Maintenance182
360° Swing Lock Control (Positive Lock Type)182
Description182
Maintenance182
SECTION 7183
Power Train183
Engine183
Description183
Maintenance184
Removal184
Installation186
Engine Drive Belts186
Engine Control System187
Description187
Functional Operation187
Engine Control System Switches and Indicator Lights188
Engine Stop Indicator188
Engine Warning Indicator188
Filter Exhaust System Cleaning/High Exhaust Indicator188
Engine Idle/Diagnostic Switch188
Engine Increment/Decrement Switch188
Fuel System188
Description188
Fuel Tank188
Injection Fuel Pump188
Fuel Filter-Water Separator189
Maintenance189
Fuel Tank189
Removal189
Installation189
Fuel Filter-Water Separator189
Draining189
Filter Change Procedure189
Air Intake System191
Description191
Maintenance191
Troubleshooting191
Check For Filter Restriction191
Filter Element Replacement191
Element Cleaning192
Air Cleaner Body192
Vacuator Valve192
Duct Work192
Exhaust System193
Description193
Exhaust System Removal193
System Installation193
Slip Joint Exhaust Connectors194
After 1000 Hours, or One Year194
2000 Hours or 2 Years194
4000 Hours or 4 Years194
5000 Hours or 5 Years194
Exhaust System195
Aftertreatment Diesel Exhaust Fluid (DEF)196
DEF Tank196
Description196
Removal196
Installation196
DEF Dosing Unit Filter197
Initial Check197
Preparatory Steps197
Remove198
Clean and Inspect for Reuse198
Install198
Finishing Steps198
Water Cooling System199
Description199
Maintenance199
General199
Effects Of Cooling System Neglect199
Overheating199
Overcooling199
Rust Prevention199
Engine Antifreeze/Coolant Fill Procedure (when level is low)199
Engine Antifreeze/Coolant Fill Procedure (after a complete draining of the system)200
Antifreeze/Supplemental Coolant Additives Maintenance Summary200
Cooling System Level Check Interval200
SCA Level Check/Coolant Filter Change Interval200
Cleaning201
Pressure Flushing201
Component Inspection202
Radiator/Recovery Tank202
Engine Water Jacket202
Water Pump202
Fans and Belts202
Thermostat202
Hoses and Clamps202
Test Equipment202
Antifreeze/Coolant203
Coolant Filter203
Radiator Assembly Removal and Installation203
Removal203
Installation205
Drive Train205
Description205
Maintenance205
Drive Lines205
Removal205
Installation205
Lubrication205
Clutch207
Description207
Theory Of Operation207
Maintenance209
Troubleshooting209
Removal212
Inspection212
Installation213
Clutch Adjustment Procedure215
Clutch Adjustment Inspection Procedure216
General Maintenance216
Gearshift216
Description216
Maintenance216
Troubleshooting216
Removal217
Installation217
Manual Transmission217
Description217
Theory of Operation217
Maintenance217
Troubleshooting217
Removal of the Transmission221
Special Procedure for Changing Clutch (Input) Shaft221
General221
Disassembly221
Assembly221
Installation of the Transmission221
Lubrication221
General221
Draining Oil222
Refilling Oil222
Adding Oil222
Operating Temperature222
Proper Lubrication222
Preventive Maintenance222
Transmission Shift Air System222
Description222
Theory of Operation222
Pump/PTO Assembly223
Pump/PTO Replacement223
Removal223
Installation224
SECTION 8225
Undercarriage225
Front Axle226
Suspension226
Maintenance226
General226
Beam Center Cap Fasteners226
Beam End Connections and Bushings226
Saddle Assembly End Cap Fasteners226
Beam Center Bushings226
Beam Center Cross Tube226
Air Bags227
Height Control Valves227
Shock Absorbers227
Removal229
Disassembly229
Assembly229
Installation229
Axle Alignment Procedure230
Toe-In Adjustment232
Axle Stop Settings232
Drag Link Installation and Axle Synchronization232
Air Ride Adjustment233
Final Adjustments233
Setting Axle Stops and Steering Gear Relief Plungers235
Steering System236
Description236
Maintenance236
Troubleshooting236
Functional Check238
Steering Pump238
Description238
Steering Gearbox239
Description239
Maintenance239
Removal239
Installation239
Steer Cylinder240
Description240
Maintenance240
Removal240
Installation240
Wheels and Tires241
Description241
Maintenance241
Assemblies241
Rear Axle and Suspension241
Rear Axle241
Suspension241
Maintenance242
General242
Beam Center Cap Fasteners242
Beam End Connections and Bushings242
Saddle Assembly End Cap Fasteners242
Beam Center Bushings242
Beam Center Cross Tube242
Air Bags242
Height Control Valves242
Shock Absorbers242
Removal244
Disassembly244
Assembly244
Installation245
Wheels and Tires245
Description245
Maintenance245
Mounting the Wheels on the Axle245
Air System246
Description246
Theory of Operation246
Braking248
Maintenance249
Leak Detection249
Air System Operational Test249
Pressure Warnings and Pressure Build-up249
Air Leakage Test250
Loss of Primary (Rear) Air System250
Loss of Secondary (Front) Air System250
Emergency Brake Application251
Air System Components251
Description251
Air Compressor251
Air Governor251
Air Dryer251
Reservoirs252
Low Pressure Indicator Switches252
Maintenance255
Air Compressor255
Air Governor255
Air Dryer255
Reservoirs256
Low Pressure Indicator Switches256
Operating and Leakage Checks256
Stop Light Switch257
Air Pressure Gauge257
Safety Valve257
Tire Inflation Pressure Protection Valve257
Relay Valve258
Spring Brake Control Valve258
Dual Brake Valve259
Removal259
Installation259
Operating Test259
Leakage Test259
Preventive Maintenance259
Park Brake Control Valve260
Brakes260
Description260
Air Supply260
Normal Braking260
Vehicle Parking260
Anti-lock Braking Systems (ABS)260
Automatic Traction Control261
Emergency Braking261
Non-Asbestos Warning261
Front Brakes261
Description261
Maintenance262
Troubleshooting262
Disassembly262
Cleaning264
Inspection264
Repair/Replacement266
Assembly267
Automatic Slack Adjuster267
Description267
Maintenance267
Removal268
Installation268
Adjustment Procedures268
Brake Applied Stroke Measurement268
Brake Free Play Measurement and Adjustment269
Removal272
Installation273
Adjustment Procedures273
Brake Applied Stroke Measurement273
Brake Free Play Measurement and Adjustment274
Rear Brakes276
Description276
Brakes276
Spring Brake Actuator276
Maintenance276
Troubleshooting276
Spring Brake Actuator277
Manually Caging the Spring Brake277
Removal277
Installation278
Disassembly278
Assembly278
Rear Brake Assembly279
Disassemble Brakes279
Brake Shoe Removal279
Clean and Inspect Parts280
Inspect Parts280
Assemble Brakes280
Camshaft Installation280
Brake Shoe Installation281
Anti-Lock Brake System (ABS)/ Automatic Traction Control (ATC)281
ABS System Description281
ABS Indicator282
ATC System Description283
ATC Operation283
System Operation283
ATC Valve283
ATC Indicator284
Pressure Modulator Valves284
Acceptable Tire Sizes284
ABS Troubleshooting284
Diagnostic Connector and ABS Diagnostic Switch Location284
Troubleshooting: Blink Codes and Diagnostic Modes285
ECU Diagnostics285
Active Diagnostic Trouble Codes285
Blink Codes285
Blink Code Switch Activation285
Blink Code Timing286
Diagnostic Modes286
Diagnostic Mode Selection286
Active Diagnostic Trouble Code Mode286
Inactive Diagnostic Trouble Code Mode286
Clearing Active Diagnostic Trouble Codes287
Dynamometer Test Mode287
Reconfigure ECU Mode287
System Configuration Check Mode287
EC-60 Controller Wire Harness Connector Pin Assignments287
X1 Connector Pin Assignments288
X2 Connector Pin Assignments288
X3 Connector Pin Assignments288
Active or Inactive Diagnostic Trouble Codes: Index288
Troubleshooting Diagnostic Trouble Codes: ECU289
Troubleshooting Diagnostic Trouble Codes: Wheel Speed Sensors289
Speed Sensor Repair Tests290
ECU Wire Harness Connector: Speed Sensor Pins290
Troubleshooting Diagnostic Trouble Codes: Pressure Modulator Valves291
Pressure Modulator Valve Repair Test292
ECU Wire Harness Connector: Pressure Modulator Valves Pins292
Troubleshooting Diagnostic Trouble Codes: Traction Control Valves293
Traction Control Valve Repair Tests294
ECU Wire Harness Connector: Traction Control Valve Pins294
Troubleshooting Diagnostic Trouble Codes: Power Supply294
Power Supply Tests295
ECU Wire Harness Connector: Power Supply Pins295
Troubleshooting Diagnostic Trouble Codes: J1939 Serial Communications296
J1939 Troubleshooting Tests296
ECU Wire Harness Connector: J1939 Serial Communications Pins296
Troubleshooting Diagnostic Trouble Codes: Miscellaneous297
Miscellaneous Troubleshooting298
Stop Lamp Switch Test298
Dynamometer Test Mode (ATC Indicator Lamp Continuously Illuminated)298
ABS Indicator Lamp298
PMV Commons298
Differential Lock Solenoid298
ECU Wire Harness Connector: Miscellaneous Pins298
Troubleshooting Wiring299
ABS/ATC Wiring299
CAB ECU Wiring Harness Connectors299
ABS Wiring Requirements299
ABS/ATC Cab Wiring Schematic300
ABS/ATC Frame Wiring Schematic301
Special Tools302
Tests, Repair and Adjustment302
ABS EC-60 Controller302
Installing a New ABS EC-60 Controller302
Reconfiguring EC-60 Controllers302
ATC Valve302
ABS Modulator Valves303
Leakage Test: M-32 and M-32QR Modulator Valves303
Operation Test: M-32 and M-32QR Modulator Valves304
Electrical Tests: Modulator Valves304
ABS Sensor Adjustment304
Component Removal and Installation305
ATC Valve305
Removal305
Installation305
Leak Test: Traction Control Valve305
Traction Control Valve Component Test with Hand- Held Diagnostic Tool305
\Modulator Valves M-32, M-32QR305
Removal305
Installation305
Wheel Speed Sensor Replacement (Front)305
Removal305
Installation306
Wheel Speed Sensor, Replacement (Rear)307
Removal307
Installation307
Outriggers308
Description308
Theory Of Operation308
Maintenance308
Troubleshooting308
Outrigger Beam (with Adjustable Wear Pads)312
Removal312
Disassembly313
Inspection314
Assembly314
Installation315
Wear Pad Adjustment315
Extension Cylinder316
Description316
Maintenance316
Removal316
Installation316
Functional Check316
Outrigger Jack Cylinders316
Description316
Maintenance316
Removal316
Installation317
Functional Check317
Center Front Jack Cylinder317
Description317
Maintenance317
Removal317
Installation318
Functional Check318
Outrigger Monitoring System (Optional—Standard in North America)320
Description320
OMS String Potentiometers320
Removal320
Installation320
SECTION 9321
Lubrication321
General321
Environmental Protection321
Cummins Oil Registration List321
Arctic Conditions Below -18° C (0° F)322
Lubrication Points322
Standard Lubricants323
Cold Weather Lubricants325
Arctic Lubricants and Conditions327
Temperatures Below -9°C (15°F)327
Cold Weather Package and Lubricants327
Notes Listed in the Following Tables327
Drivetrain Lubrication328
Steering Lubrication332
Axle Lubrication332
Outrigger Lubrication335
Miscellaneous Lubrication336
Turntable & Cab Tilt Lubrication337
Hoist Lubrication340
Turntable Central Lubrication341
Boom Lubrication342
Crane Setup342
Greaseless Boom342
Monthly Lubrication Work345
Pins345
Carwell® Rust Inhibitor346
Protecting Cranes From Corrosion346
Cleaning Procedures346
Inspection and Repair347
Application347
Areas of Application347

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