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Manitowoc Grove TMS9000-2 Series, Service Manual

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Manitowoc Grove TMS9000-2 Series Service Manual Download Page 233

Grove

Published 01-14-2021 Control # 707-01

7-1

TMS9000-2 SERVICE MANUAL

POWER TRAIN

7

SECTION 7

POWER TRAIN

SECTION CONTENTS

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-1

Description  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-1

Maintenance  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-2

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-2
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-4
Engine Drive Belts  . . . . . . . . . . . . . . . . . . . . . . . .  7-4

Engine Control System  . . . . . . . . . . . . . . . . . . . . .  7-5

Description  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-5
Functional Operation  . . . . . . . . . . . . . . . . . . . . . .  7-5
Engine Control System Switches and 

Indicator Lights . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-6

Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-6

Description  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-6
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-7

Air Intake System . . . . . . . . . . . . . . . . . . . . . . . . . .  7-8

Description  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-8
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-9

Exhaust System  . . . . . . . . . . . . . . . . . . . . . . . . . .  7-11

Description  . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-11
Exhaust System Removal. . . . . . . . . . . . . . . . . .  7-11
System Installation . . . . . . . . . . . . . . . . . . . . . . .  7-11
Slip Joint Exhaust Connectors . . . . . . . . . . . . . .  7-12
Exhaust System  . . . . . . . . . . . . . . . . . . . . . . . . .  7-12

After-Treatment Diesel Exhaust Fluid (DEF)  . . .  7-13

DEF Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-13
DEF Dosing Unit Filter  . . . . . . . . . . . . . . . . . . . .  7-14

Water Cooling System . . . . . . . . . . . . . . . . . . . . .  7-16

Description  . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-16

Maintenance  . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
Component Inspection. . . . . . . . . . . . . . . . . . . . . 7-19
Radiator Assembly Removal and Installation  . . . 7-20

Drive Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22

Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22

Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22

Drive Lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22

Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24

Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24
Theory Of Operation  . . . . . . . . . . . . . . . . . . . . . . 7-24
Maintenance  . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26
Clutch Adjustment Procedure  . . . . . . . . . . . . . . . 7-33
General Maintenance  . . . . . . . . . . . . . . . . . . . . . 7-33

Gearshift. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-33

Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-33
Maintenance  . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34

Manual Transmission . . . . . . . . . . . . . . . . . . . . . . 7-34

Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34
Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . 7-34
Maintenance  . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-38
Preventive Maintenance  . . . . . . . . . . . . . . . . . . . 7-39

Transmission Shift Air System  . . . . . . . . . . . . . . 7-39

Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-39
Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . 7-39

Pump / PTO Assembly  . . . . . . . . . . . . . . . . . . . . . 7-40

Pump / PTO Replacement. . . . . . . . . . . . . . . . . . 7-40

ENGINE

Description

The engine is a Cummins X12 on-highway engine.

This Service Manual does not include detailed information
on this individual engine. A separate manual, as prepared in
detail by the engine manufacturer, is supplied with this

S e r v i c e   M a n u a l

. However, a short description and

maintenance of certain components of the fuel system, air
intake system, and water cooling system are provided in this
section. 

Engine speed is controlled from the carrier cab by a foot
throttle pedal connected electronically to the engine ECM.
Speed is electronically controlled in the same manner from
the superstructure cab by either a foot throttle pedal or hand
throttle. The control module is the control center of the
system. It processes all of the inputs and sends commands
to the vehicle and engine control devices.

The engine and its components are enclosed within a hood
assembly. The hood has openings in the front and rear to
allow for adequate air flow over the engine. A door on the top
left and right side of the hood may be opened to provide
easier access to the engine.

Fo

r

 

Reference

 

Only

Summary of Contents for Grove TMS9000-2 Series

Page 1: ...Service Manual Grove TMS9000 2 F o r R e f e r e n c e O n l y ...

Page 2: ...more information go to www P65warnings ca gov diesel Batteries battery posts terminals and related accessories can expose you to chemicals including lead and lead compounds which are known to the State of California to cause cancer and birth defects or other reproductive harm Wash hands after handling For more information go to www P65warnings ca gov California Spark Arrestor Operation of this equ...

Page 3: ...ed operator subjects himself and others to death or serious injury Do not operate this crane unless You are trained in the safe operation of this crane Manitowoc is not responsible for qualifying personnel You read understand and follow the safety and operating recommendations contained in the crane manufacturer s manuals and load charts your employer s work rules and applicable government regulat...

Page 4: ...This Page Blank F o r R e f e r e n c e O n l y ...

Page 5: ...un out 0 060 maximum Note For Runout Tolerances Use the 30 60 90 Rule 0 000 0 030 Excellent 0 031 0 060 Good 0 061 0 090 Use 3R s Rotate tire 180 degrees Re lubricate tire and wheel Re inflate with tire laying flat 5 psi max 0 091 Higher Inspect all wheel end components Ride Height both tandems 1 80 open 0 50 max 0 50 difference on any one tandem Steer and Drive axles offset 0 00 0 19 Steer and Dr...

Page 6: ...omer should fill out a Field Alignment Worksheet attached to this document and submit it to Crane Care for evaluation and instruction STEP 2 Crane Care will evaluate the worksheet and provide a list of adjustments that are required STEP 3 The customer s service department will make the required adjustments per the instructions on the following pages and test the machine to validate improved perfor...

Page 7: ...t adjustable Crane Care is to advise remedy Adjust steer wheel end toe Position s Adjust drive axle thrust Adjust drive axle parallelism X Test and report result to Manitowoc Crane Care Tools other than miscellaneous wrenches Camber Caster alignment tool if available Dial Indicator s Thrust alignment tool if available 4 foot level or straight edge Trammel bar if available Can of white spray paint ...

Page 8: ...traight into inspection site at least 3 full tire rotations to ensure it s straight into site Driving into and backing out of the work area several times will ensure the vehicle s suspension components remain relaxed to achieve proper measurements For final positioning shift transmission to neutral and allow vehicle to roll forward to a stop without using the brakes Engage parking brake Note Outri...

Page 9: ...t on the same tandem Note Calibrate zero digital angle gauges to the bottom frame rail positioned in the same orientation that each is being applied on the suspension Prepare for toe adjustment if it is required Raise the machine on outriggers until the tires are just off the ground Prepare the steer tires for toe measurement by highlighting white spray paint a section row of tread around each tir...

Page 10: ...ifferent Measure to edge of tread Adjust side to side using lateral torque rods Re torque bolts 2 to 3 turns into the locking feature of the nut Note Machine should be on outriggers to perform this adjustment Adjust each axle using the lateral torque rod Lower the machine to the ground Back out and drive straight into the work area several times to ensure the vehicle s suspension components remain...

Page 11: ...ve the axle toward the rear Slight adjustments might be achieved by adjusting shims on one side of the axle Larger adjustments will be achieved by adjusting both sides in opposite directions Re torque hardware to 450 600 lbf lb 610 813 N m Note Raise the machine on outriggers to take weight off the suspension in order to reposition the mounting shims A Porta Power can be used to support the suspen...

Page 12: ...g shims on one side of the axle Larger adjustments will be achieved by adjusting both sides in opposite directions Re torque hardware to 450 600 lbf ft 610 813 N m Note Raise the machine on outriggers to take weight off the suspension in order to reposition the mounting shims A Porta Power can be used to support the suspension Be sure to lift the outriggers and put full weight on the suspension pr...

Page 13: ...64 in 0 8 mm rig pin or drill bit Adjust the intermediate drag link to center the rear relay arm and pin it with a Ø 21 64 in 0 8 mm rig pin or drill bit Apply Loctite 243 to clamp bolts and re torque to 110 130 lbf ft 149 176 N m pin Adjust intermediate Driver side front steer axle drag link F o r R e f e r e n c e O n l y ...

Page 14: ...aight ahead Using a 4 ft 1 2 meter or longer straight edge measure the front steer axle driver s side tire front and rear to the frame side plate Adjust front steer axle drag link until front and rear measurements are equal Apply Loctite 243 to clamp bolts and re torque to 50 60 lbf ft 68 81 N m Front steer axle drag link F o r R e f e r e n c e O n l y ...

Page 15: ...raight ahead Using a 4 ft 1 2 m or longer straight edge measure rear steer axle driver side tire front and rear to the frame side plate Adjust rear steer axle drag link until front and rear measurements are equal Apply Loctite 243 to clamp bolts and re torque to 110 130 lbf ft 149 176 N m Rear steer axle 2 drag link F o r R e f e r e n c e O n l y ...

Page 16: ... Miter and rotate until the steering wheel is straight ahead Slide the coupling back onto the Miter and retighten the bolt Splined coupling For minor fine adjustment of the steering wheel loosen the clamp bolts and rotate the steering link to orient the steering wheel straight ahead Apply Loctite 243 to clamp bolts and re torque to 50 60 lbf ft 68 81 N m Steering link Remove rig pins from relay ar...

Page 17: ... steer axle only Note steer tires should still be on alignment turntables for this step Steering stop Steering gearbox relief plungers should actuate 1 16 in 1 6 mm prior to contact with steering stops Steering gearbox Left turn relief Right turn relief Screw in to decrease travel Screw in to decrease travel Screw out to increase travel Screw out to increase travel F o r R e f e r e n c e O n l y ...

Page 18: ...aster tool if available otherwise place a digital angle gauge calibrated zeroed to the bottom frame rail on the bottom of the king pin housing longitudinally Caster gauge Digital angle gauge Adjust the longitudinal torque rods to achieve this Re torque clamp bolts to 2 to 3 turns into the locking feature of the nut Adjust longitudinal torque rod F o r R e f e r e n c e O n l y ...

Page 19: ... wheel end camber is not adjustable Camber should be 1 16 3 16 if camber is out of tolerance it s a sign of a part defect wear or improper installation Manitowoc Crane Care will provide direction F o r R e f e r e n c e O n l y ...

Page 20: ...ation for toe adjustment at hub height on the rear of the tires and then on the front of the tires Subtract the front value from the rear Positive result is toe in and negative is toe out The use of a toe bar provides greater accuracy Adjust the front steer axle tie rod to achieve this Apply Loctite 243 to clamp bolts and re torque to 115 125 lbf ft 156 169 N m Repeat this process for the rear ste...

Page 21: ...e shim s to the front of the bar pin to move the axle forward or to the back of the bar pin to move the axle toward the rear Slight adjustments might be achieved by adjusting shims on one side of the axle Larger adjustments will be achieved by adjusting both sides in opposite directions Re torque hardware to 450 600 lbf lb 610 813 N m Note Raise the machine on outriggers to take weight off the sus...

Page 22: ...axle forward or to the back of the bar pin to move the axle toward the rear Slight adjustments might be achieved by adjusting shims on one side of the axle Larger adjustments will be achieved by adjusting both sides in opposite directions Re torque hardware to 450 600 lbf lb 610 813 N m Note Raise the machine on outriggers to take weight off the suspension in order to reposition the mounting shims...

Page 23: ...ht line test for acceptable tracking Perform a road test to assess steering performance and ride comfort If necessary re adjust to achieve desired performance and retest Advise Manitowoc Crane Care that the adjustments did or did not resolve your issues F o r R e f e r e n c e O n l y ...

Page 24: ...F o r R e f e r e n c e O n l y ...

Page 25: ...1 8 Fasteners and Torque Values 1 8 Torque Wrenches 1 9 Torque Values 1 9 Weld Studs 1 23 SECTION 2 Hydraulic System Description 2 2 Maintenance 2 4 Draining and Flushing 2 4 Removing Air from the Hydraulic System 2 5 Parts Replacement 2 6 Supply Pressure and Return Circuit 2 6 Description 2 6 Hydraulic Reservoir and Filter 2 6 Pump Distribution 2 7 Maintenance 2 9 Troubleshooting 2 9 Return Hydra...

Page 26: ...e Piston Pumps Cut Off Differential Pressures 2 50 B Procedure for Checking Setting the Pilot Supply Pressure 2 52 C Procedure for Checking Setting the Main Directional Control Valve Load Sense Lift and Telescope Pressures 2 53 D Procedure for Checking Setting Cab Tilt Raise and Lower Pressures 2 58 E Procedure for Checking Setting Counterweight CWT Raise and Lower Pressures 2 58 F Procedure for C...

Page 27: ...Battery Charger 3 22 Remote Controller Battery 3 23 Jump Starting the Crane 3 23 Charging 3 23 SECTION 4 Superstructure Description of Maintenance Work on the Superstructure 4 1 Hoist 4 1 Boom Removal 4 9 Boom Installation 4 11 Functional Check 4 13 Boom Nose Sheaves 4 13 Boom Nose Sheaves Removal 4 13 Boom Nose Sheaves Installation 4 17 Boom Disassembly 4 17 Boom Assembly 4 18 Telescope Section 5...

Page 28: ...r 300 Operating Hours 5 000 6 000 km 3 100 3 730 mi 5 6 Maintenance Plan M 6 Every 6 Months After 500 Operating Hours 10 000 12 500 km 6 210 7 770 mi 5 6 Maintenance Plan M 12 Every 12 Months After 1 000 Operating Hours 20 000 25 000 km 12 430 15 530 mi 5 7 Maintenance and Inspection Plan Y 2 Every 24 Months After 100 000 125 000 km 62 150 77 800 mi 5 7 Maintenance and Inspection Plan Y 3 Every 36...

Page 29: ...ine Control System 7 5 Description 7 5 Functional Operation 7 5 Engine Control System Switches and Indicator Lights 7 6 Fuel System 7 6 Description 7 6 Maintenance 7 7 Air Intake System 7 8 Description 7 8 Maintenance 7 9 Exhaust System 7 11 Description 7 11 Exhaust System Removal 7 11 System Installation 7 11 Slip Joint Exhaust Connectors 7 12 Exhaust System 7 12 After Treatment Diesel Exhaust Fl...

Page 30: ...aintenance 8 2 General 8 2 Removal 8 5 Disassembly 8 5 Assembly 8 5 Installation 8 6 Axle Alignment Procedure 8 6 Steering System 8 12 Description 8 12 Maintenance 8 13 Steering Pump 8 15 Description 8 15 Steering Gearbox 8 15 Maintenance 8 15 Steer Cylinder 8 16 Description 8 16 Maintenance 8 16 Wheels and Tires 8 17 Description 8 17 Maintenance 8 17 Rear Axle and Suspension 8 17 Rear Axle 8 17 S...

Page 31: ...agnostic Trouble Codes Traction Control Valves 8 69 Power Supply Tests 8 71 Troubleshooting Diagnostic Trouble Codes J1939 Serial Communications 8 71 Miscellaneous Troubleshooting 8 73 Troubleshooting Wiring 8 74 Special Tools 8 78 Tests Repair and Adjustment 8 78 Component Removal and Installation 8 80 Outriggers 8 83 Description 8 83 Theory Of Operation 8 84 Maintenance 8 84 Extension Cylinder 8...

Page 32: ...ng Lubrication 9 13 Axle Lubrication 9 13 Outrigger Lubrication 9 17 Miscellaneous Lubrication 9 18 Turntable Cab Tilt Lubrication 9 19 Hoist Lubrication 9 21 Turntable Central Lubrication 9 22 Boom Lubrication 9 23 Monthly Lubrication Work 9 28 Carwell Rust Inhibitor 9 29 Protecting Cranes From Corrosion 9 29 Cleaning Procedures 9 29 Inspection and Repair 9 30 Application 9 30 Areas of Applicatio...

Page 33: ...sonnel are required to have relevant specialized knowledge of proper safety procedures Read this section carefully before beginning maintenance work SAFETY MESSAGES General The importance of safe operation and maintenance cannot be overemphasized Carelessness or neglect on the part of operators job supervisors and planners rigging personnel and job site workers can result in their death or injury ...

Page 34: ...ea around oil filler inspection and drain openings and lubricating nipples When changing the oil let the oil run out at operating temperature Ensure that only oils and lubricants specified in the Lubrication Section are used Replace all filters within the specified period if cleaning is not explicitly permitted Replace all seals before assembly Clean the sealing surfaces Only tighten loose screw c...

Page 35: ...nance work unless you are authorized to do so Use personal protective equipment when performing maintenance e g safety shoes gloves safety glasses hard hats fall protection etc Observe all safety and warning signs on the truck crane Observe all safety instructions contained in this maintenance manual Familiarize yourself with the conditions under which the superstructure may be slewed and the boom...

Page 36: ...g effect of battery acid in mind Note the fire alarm and fire fighting facilities on the site Return the truck crane to proper working order once maintenance work is completed Inform the crane operator accordingly HANDLING SUBSTANCES WHICH ARE HARMFUL TO THE ENVIRONMENT What do Environmentally Harmful Substances Include When you carry out maintenance work on the truck crane you will occasionally w...

Page 37: ...ve collected environmentally harmful substances disposed of by disposal companies which are approved by the national or regional authority responsible OVERVIEW OF THE OPERATING AND DISPLAY ELEMENTS NOTE Refer to the Operator Manual for the operating and display elements F o r R e f e r e n c e O n l y ...

Page 38: ...m Extensions 10 5 17 6 m 34 5 57 6 ft Manual Bi fold Boom Extension 572 90 225 55 1529 3370 1557 3433 29 63 10 5 17 6 m 34 5 57 6 ft Hydraulic Bi fold Boom Extension 585 88 230 66 1603 3535 1671 3683 67 148 10 5 17 6 m 34 5 57 6 ft Manual Integrated Heavy Duty Bi fold Boom Extension 584 23 230 01 1640 3615 1704 3756 64 141 10 5 17 6 m 34 5 57 6 ft Hydraulic Integrated Heavy Duty Bi fold Boom Exten...

Page 39: ...nt bumper 942 34 371 00 294 648 493 1086 199 438 10 9 t 12 USt Overhaul Ball Swivel in stowage tray 830 58 327 00 253 558 374 824 121 266 10 9 t 12 USt Overhaul Ball Swivel tied to front bumper 942 34 371 00 253 558 424 935 171 377 26 t 29 USt Hookblock 1 sheave tied to front bumper 955 04 376 00 323 712 548 1209 225 497 45 t 50 USt Hookblock 3 sheave tied to front bumper 955 04 376 00 560 1235 95...

Page 40: ...nth or as required If the sections are pressure washed caution should be used to not damage the paint Never point the nozzle at electrical equipment relay and control boxes suction and venting filters or control elements and lubricated surfaces NOTE The components specified in section Overview of the Components that are Easily Damaged when Cleaning page 1 8 are to be cleaned with particular care A...

Page 41: ...always necessary When marked as a high strength bolt grade 5 8 etc the mechanic must be aware that he she is working with a highly stressed component and the fastener should be torqued accordingly NOTE Some special applications require variation from standard torque values Reference should always be made to component overhaul procedures for recommendations Special attention should be given to the ...

Page 42: ...plication of excessive or improper torque ALWAYS use a slow even movement and STOP when the predetermined value has been reached When using step wrenches calculated wrench settings are valid only when the following conditions are met Torque wrenches must be those specified and forces must be applied at the handle grip The use of handle extensions will change applied torque to the bolt All handles ...

Page 43: ...14 UNC 5 38 4 37 4 36 5 8 54 3 52 9 51 5 1 2 13 UNC 5 58 6 57 1 55 7 8 82 8 80 7 78 6 9 16 12 UNC 5 84 5 82 4 80 3 8 119 4 116 5 113 5 5 8 11 UNC 5 116 6 113 7 110 8 8 164 8 160 7 156 6 3 4 10 UNC 5 206 8 201 7 196 5 8 292 3 284 9 277 6 7 8 9 UNC 5 333 8 325 4 317 1 8 471 6 459 8 448 0 1 8 UNC 5 500 3 487 8 475 3 8 707 0 689 3 671 6 1 1 8 7 UNC 5 624 0 608 4 592 8 8 1001 4 976 4 951 4 1 1 4 7 UNC ...

Page 44: ... 8 93 3 90 9 88 6 9 16 18 UNF 5 94 3 91 9 89 6 8 133 2 129 9 126 6 5 8 18 UNF 5 132 1 128 8 125 5 8 186 7 182 0 177 3 3 4 16 UNF 5 231 0 225 2 219 4 8 326 4 318 2 310 1 7 8 14 UNF 5 367 7 358 5 349 3 8 519 6 506 6 493 6 1 12 UNF 5 547 4 533 7 520 0 8 773 5 754 2 734 8 1 1 8 12 UNF 5 700 0 682 5 665 0 8 1123 5 1095 4 1067 3 1 1 4 12 UNF 5 975 0 950 6 926 2 8 1564 8 1525 7 1486 5 1 3 8 12 UNF 5 1314...

Page 45: ...8 5 164 1 10 9 253 8 247 4 241 1 12 9 296 9 289 5 282 1 M18x2 5 8 8 246 2 240 1 233 9 10 9 350 7 341 9 333 2 12 9 410 4 400 1 389 9 M20x2 5 8 8 348 0 339 3 330 6 10 9 495 6 483 2 470 8 12 9 580 0 565 5 551 0 M22x2 5 8 8 474 4 462 6 450 7 10 9 675 7 658 8 641 9 12 9 790 7 770 9 751 2 M24x3 8 8 601 3 586 3 571 3 10 9 856 4 835 0 813 6 12 9 1002 2 977 1 952 1 M27x3 8 8 881 6 859 6 837 5 10 9 1255 7 1...

Page 46: ...10 9 62 0 60 4 58 9 12 9 72 5 70 7 68 9 M12x1 0 8 8 79 5 77 5 75 5 10 9 116 7 113 8 110 9 12 9 136 6 133 2 129 8 M12x1 25 8 8 76 2 74 2 72 3 10 9 111 8 109 0 106 3 12 9 130 9 127 6 124 3 M12x1 5 8 8 72 9 71 1 69 2 10 9 107 1 104 4 101 7 12 9 125 3 122 1 119 0 M14x1 5 8 8 120 2 117 2 114 2 10 9 176 5 172 1 167 7 12 9 206 6 201 4 196 2 M16x1 5 8 8 184 4 179 8 175 2 10 9 270 9 264 1 257 3 12 9 317 0 ...

Page 47: ...51 4 927 6 903 8 10 9 1355 0 1321 1 1287 2 12 9 1585 6 1546 0 1506 3 M30x1 5 8 8 1369 2 1334 9 1300 7 10 9 1950 0 1901 3 1852 5 12 9 2281 9 2224 9 2167 8 M30x2 8 8 1324 6 1291 5 1258 4 10 9 1886 6 1839 4 1792 2 12 9 2207 7 2152 5 2097 3 M33x2 8 8 1784 5 1739 9 1695 3 10 9 2541 6 2478 0 2414 5 12 9 2974 2 2899 8 2825 4 M36x2 8 8 2340 1 2281 6 2223 1 10 9 3332 8 3249 5 3166 2 12 9 3900 2 3802 6 3705...

Page 48: ...e not recommended Table 1 6 Inch Series Screws of STAINLESS STEEL 300 18 8 with Coarse Threads Torque Values for fasteners with lubrication these torque and preload values result in an 80 utilization of the yield strength Stainless steel fasteners tend to gall while being tightened To reduce this risk lubricate the threads and torque at low speeds without interruptions Do not use excessive pressur...

Page 49: ...reads per Inch and Series Designation Grade Torque ft lb Maximum Nominal Minimum 5 8 11 UNC 8 234 225 216 5 8 18 UNF 8 250 240 230 3 4 10 UNC 8 385 370 355 7 8 9 UNC 8 615 591 567 1 8 UNC 8 929 893 857 1 1 4 7 UNC 8 2043 1964 1885 Nominal Size Threads per Inch and Series Designation Grade Torque Nm Maximum Nominal Minimum M20X2 5 12 9 756 727 698 M24X3 10 9 1089 1047 1005 M27X3 10 9 1591 1530 1469...

Page 50: ... 24 3 8 16 5 32 31 30 8 48 46 44 7 16 14 5 52 50 48 8 73 70 67 1 2 13 5 78 75 72 8 120 115 110 9 16 12 5 114 110 106 8 161 152 143 5 8 11 5 156 150 144 8 234 225 216 3 4 10 5 270 259 5 249 8 385 370 355 7 8 9 5 416 400 384 8 615 591 567 1 8 5 606 583 560 8 929 893 857 1 1 8 7 5 813 782 751 8 1342 1288 1234 1 1 4 7 5 1141 1097 1053 8 2043 1964 1885 1 3 8 6 5 1519 1461 1403 8 2496 2396 2296 1 1 2 6 ...

Page 51: ...53 51 49 7 16 20 5 57 55 53 8 85 82 79 1 2 20 5 88 84 5 81 8 125 120 115 9 16 18 5 126 121 116 8 177 170 163 5 8 18 5 182 174 5 167 8 250 240 230 3 4 16 5 312 299 5 287 8 425 409 393 7 8 14 5 458 439 5 421 8 672 646 620 1 12 5 658 632 606 8 1009 970 931 1 14 5 670 644 5 619 8 945 908 5 872 1 1 8 12 5 882 848 814 8 1500 1440 1380 1 1 4 12 5 1251 1203 1155 8 2092 2008 5 1925 1 3 8 12 5 1704 1638 157...

Page 52: ...12 9 19 18 17 M8x1 25 8 8 27 26 25 10 9 38 36 5 35 12 9 45 43 5 42 M10x1 5 8 8 53 51 49 10 9 75 72 69 12 9 89 86 83 M12x1 75 8 8 93 89 85 10 9 130 125 120 12 9 156 150 144 M14x2 8 8 148 142 136 10 9 212 203 5 195 12 9 248 238 228 M16x2 8 8 230 221 212 10 9 322 310 298 12 9 387 372 357 M18x2 5 8 8 319 306 5 294 10 9 455 436 5 418 12 9 532 511 490 M20x2 5 8 8 447 430 413 10 9 629 605 581 12 9 756 72...

Page 53: ...NS 1 M27x3 8 8 1134 1090 1046 10 9 1591 1530 1469 12 9 1910 1836 5 1763 M30x3 5 8 8 1538 1479 1420 10 9 2163 2080 1997 12 9 2595 2495 2395 M36x4 8 8 2681 2578 5 2476 10 9 3964 3812 3660 12 9 4639 4461 4283 Size Property Class Torque Nm Maximum Nominal Minimum F o r R e f e r e n c e O n l y ...

Page 54: ...1 8 8 101 97 5 94 10 9 150 144 138 12 9 175 168 161 M12X1 25 8 8 100 96 92 10 9 147 141 5 136 12 9 172 165 5 159 M12x1 5 8 8 100 96 92 10 9 140 135 130 12 9 168 162 156 M14x1 5 8 8 160 153 5 147 10 9 229 220 211 12 9 268 257 246 M16x1 5 8 8 248 238 5 229 10 9 348 335 322 12 9 418 402 386 M18x1 5 8 8 345 331 5 318 10 9 491 471 451 12 9 575 552 529 M20X1 8 8 471 453 435 10 9 694 667 5 641 12 9 812 7...

Page 55: ...718 1652 5 1587 12 9 2063 1983 5 1904 M30x1 5 8 8 1530 1471 5 1413 10 9 2253 2166 5 2080 12 9 2637 2536 2435 M30x2 8 8 1661 1597 5 1534 10 9 2336 2246 5 2157 12 9 2800 2695 2590 M33x2 8 8 2141 2059 1977 10 9 3155 3034 2913 12 9 3692 3550 5 3409 M36x2 8 8 2795 2688 2581 10 9 4118 3960 3802 12 9 4818 4634 4450 Size Property Class Torque Nm Maximum Nominal Minimum F o r R e f e r e n c e O n l y ...

Page 56: ...teners with Oil Lubrication NOTE Stainless steel fasteners tend to gall while being tightened To reduce this risk lubricate the threads with oil or molybdenum disulfide and torque at low speeds without interruptions Do not use excessive pressure Impact wrenches are not recommended Weld Studs Unless otherwise specified the following grade 2 torque values 10 apply Table 1 15 Weld Stud Torque Values ...

Page 57: ...r Extension Cylinder 2 34 Description 2 34 Maintenance 2 34 Outrigger Jack Cylinder 2 37 Description 2 37 Maintenance 2 37 Center Front Stabilizer Cylinder 2 41 Description 2 41 Maintenance 2 41 Lift Cylinder 2 44 Description 2 44 Maintenance 2 44 Counterweight Cylinder 2 47 Description 2 47 Telescope Cylinder 2 48 Description 2 48 Pressure Setting Procedures 2 49 Objective 2 49 Equipment 2 49 Val...

Page 58: ...ions of the supply pressure and return hydraulic circuit hydraulic pumps all hydraulic valves and all hydraulic cylinders Detailed descriptions and operation of individual hydraulic circuits are discussed within their individual sections as applicable A complete hydraulic system schematic showing all options is at the back of this manual Figure 2 1 provides A N S I graphical symbols and Figure 2 2...

Page 59: ...Grove Published 01 14 2021 Control 707 01 2 3 TMS9000 2 SERVICE MANUAL HYDRAULIC SYSTEM 2 FIGURE 2 1 F o r R e f e r e n c e O n l y ...

Page 60: ...ecause of a failure that might allow metal or abrasive particles to enter the system all systems must be thoroughly checked drained and flushed 1 Remove the reservoir drain plug Allow about three minutes after hydraulic oil stops flowing from the drain port for the side walls to drain 2 Clean and install the reservoir plug and fill the reservoir with a 50 50 mixture of fuel oil and clean hydraulic...

Page 61: ... port A of the axle lockout valve 20 Using a jack under the rear wheel on one side of the crane jack up the wheel to maximum travel 21 Connect the line to port A of the axle lockout valve and disconnect the line from Port B 22 Repeat step 19 using the other rear wheel 23 Connect the line to port B of the axle lockout valve Energize the axle lockout valve Replenish the reservoir hydraulic oil level...

Page 62: ...oute hydraulic oil from the hydraulic pumps to the directional control valves for the individual operating circuits The supply pressure and return circuit consists of the reservoir and integral filter two hydraulic pumps a hydraulic oil cooler and a 6 port hydraulic swivel Refer to Hydraulic Pumps page 2 12 in this section for descriptions and maintenance instructions for each hydraulic pump The s...

Page 63: ...functions to allow the hydraulic oil to bypass the filter element and flow into the reservoir through the bypass outlet instead Hydraulic Reservoir Filling Breather Filter This element filters the air in and out of the oil reservoir as the level changes Remove the breather 2 Figure 2 3 to add oil The breather incorporates a filter to strain the oil when adding to the tank The breather should be re...

Page 64: ...VICE MANUAL 9234 10 1 5 4 7 2 8 3 7 9 6 FIGURE 2 3 8 8 Item Description Item Description 1 Reservoir 6 Return Manifold 2 Breather 7 Straps 3 Magnetic Plug 8 Mounting Bracket 4 Thermistor 9 Access Cover 5 Temperature Switch 10 Return Filter F o r R e f e r e n c e O n l y ...

Page 65: ...lace pump Slow response Low hydraulic oil level Fill reservoir Hydraulic oil temperature too high watery thin oil or too low thick sluggish oil If too low warm up system As needed troubleshoot cooler circuit If too high troubleshoot cooler circuit Likely suspects are in line check valve and related hydraulic circuits Faulty pump section s Repair or replace pump section s or entire pump Software se...

Page 66: ...the cap assembly 3 Install the cap assembly on the filter head and secure the cap assembly to the filter head with the lockwashers and capscrews 4 Activate the hydraulic system and check for leaks Make repairs as needed Specific hydraulic system lift hoist telescope swing not working Leak in system Repair leak Faulty electric controls signals Adjust or replace controls signals Faulty directional c...

Page 67: ...AL HYDRAULIC SYSTEM 2 6966 1 5 6 3 7 8 9 10 4 2 11 FIGURE 2 4 Item Description Item Description 1 Cap Assembly 7 Element 2 Filter Head 8 Bypass Valve 3 Filter Bowl 9 Spacer 4 Restriction Indicator 10 Capscrew 5 O ring 11 Capscrew 6 Gasket F o r R e f e r e n c e O n l y ...

Page 68: ...1 pump on the front cover accessory drive with capscrews and flatwashers Make sure gear teeth mesh properly Torque capscrews according to Torque Values page 1 9 3 Connect the distribution and supply lines as tagged during removal 4 Install the hydraulic tank hose to the pump and secure with the capscrews flatwashers and O ring Torque capscrews according to Torque Values page 1 9 5 Assemble the two...

Page 69: ...ording to Torque Values page 1 9 Pump Priming Tool The Pump Priming Tool Figure 2 7 P N 80030367 available from Manitowoc Crane Care is used to prime the pumps after they have been removed from the crane Gear Pump Inlet Port Air Purge Bleed Ensure the hydraulic reservoir is filled to the proper level and that the fluid is not aerated aerated appearance foamy white tint with bubbles If so let the u...

Page 70: ...ediately 4 Slowly increase the engine speed to approximately 1500 rpm and hold for no longer than 1 minute and make the same checks as outlined previously 5 Slowly increase engine speed to full RPM and hold for no longer than 1 minute while making the same checks as outlined previously 6 At full engine RPM cycle all functions fully extending and retracting the cylinders to their stop position to v...

Page 71: ...same checks as outlined previously 6 At full engine RPM cycle all functions fully extending and retracting the cylinders to their stop position to verify operation and that the pump stays quiet and does not become excessively hot 7 Proceed to the pressure setting procedure 9237 1 FIGURE 2 8 1 1 CAUTION Pump or Reservoir Damage If the pump displays either excessive noise or vibration it is probably...

Page 72: ...2 16 Published 01 14 2021 Control 707 01 HYDRAULIC SYSTEM TMS9000 2 SERVICE MANUAL Pump No 2 Assembly FIGURE 2 9 8 9235 F o r R e f e r e n c e O n l y ...

Page 73: ...valve functions in the individual circuits refer to the description and operation procedures of that circuit For information on the superstructure hydraulic components refer to Figure 2 16 VALVE USAGE TABLE Valve Name Circuit Used In Physical Location Outrigger Selector and A C manifold Valve Outrigger On front face of carrier frame front cross member forward of hydraulic swivel Outrigger Control ...

Page 74: ...SYSTEM TMS9000 2 SERVICE MANUAL FWD 9238 1 2 4 3 2 1 FIGURE 2 10 4 3 Item Description Item Description 1 Outrigger Selector and AC Valve 3 Front Outrigger Manifold Valve 2 Rear Outrigger Manifold Valve 4 Swing Steer Valve F o r R e f e r e n c e O n l y ...

Page 75: ...pressure setting procedure for specific pressures The A C circuit contains a pressure reducing valve and two position two way flow control valve The pressure reducing valve protects the A C circuit in the event that a high pressure outrigger function is activated while the A C circuit is also on Activation of the A C will energize the solenoid operated relief valve and the solenoid operated two wa...

Page 76: ...CE MANUAL 3 2 1 4 5 4 3 2 5 1 9239 9239 1 FIGURE 2 11 Item Description Item Description 1 Solenoid Relief Valve 4 4 way Solenoid Pilot Valve 2 Adjustable Pressure Reducing Valve 5 4 way Outrigger Directional Valve 3 Solenoid Flow Control Valve F o r R e f e r e n c e O n l y ...

Page 77: ...he solenoid valves cap all lines and openings 2 Tag and disconnect the electrical connectors 3 Remove the capscrews nuts and washers securing the manifold to the outrigger box remove the manifold Inspection Visually inspect the valves and hydraulic connections for any evidence of leaks or other damage Check security of the electrical connections Inspect the wiring for any evidence of cracks or bre...

Page 78: ... 6 5 4 3 7 9240 9240 1 2 1 FIGURE2 12 8 1 9 Item Description Item Description 1 In Port 5 Left Front Jack Cylinder 2 Out Ports 6 Right Front Jack Cylinder 3 Center Front Jack Cylinder 7 Right Front Extension Cylinder 4 Left Front Extension Cylinder 8 Check Valve 9 Tank F o r R e f e r e n c e O n l y ...

Page 79: ...DRAULIC SYSTEM 2 6544 2 6544 1 2 2 2 2 1 3 4 5 6 2 3 4 5 6 1 FIGURE2 13 Item Description Item Description 1 In Port 4 Left Rear Jack Cylinder 2 Out Ports 5 Right Rear Jack Cylinder 3 Left Rear Extension Cylinder 6 Right Rear Extension Cylinder F o r R e f e r e n c e O n l y ...

Page 80: ... check valve Test PO Check Valve For Leakage Remove the piston side hose from the port block of the cylinder See Figure 2 14 A small amount of oil will flow out and then stop If oil stops flowing the cylinder s PO check valve is sealing properly If oil continues to flow out the piston port the cylinder s PO check valve is leaking If oil flow is not noticed from either port then the cylinder and PO...

Page 81: ...9 Nm 100 110 lb ft 5 Test the check valve and port block by operating the affected outrigger s jack cylinder Verify it extends and retracts without problems verify there is no leaking Make repairs as needed WARNING Projectile Hazard There must not be any load on the jack cylinder when removing check valve to prevent the valve from becoming a projectile CAUTION Damage Could Occur Do not damage the ...

Page 82: ...HYDRAULIC SYSTEM TMS9000 2 SERVICE MANUAL SUPERSTRUCTURE VALVES Turntable Hydraulic Valves 1 2 3 9244 FIGURE 2 16 Item Description 1 Assy Main Directional Valve 2 Assy Access Manifold 3 Assy Case Drain Manifold F o r R e f e r e n c e O n l y ...

Page 83: ...cing valve Main hoist up 8 Solenoid operated pressure reducing valve Main hoist down 3 Solenoid operated pressure reducing valve Lift up 9 Solenoid operated pressure reducing valve Lift Down 4 Solenoid operated pressure reducing valve Tele extend 10 Solenoid operated pressure reducing valve Tele Retract 5 Not Used 11 Non Adjustable port relief Lift Down 6 Adjustable port relief Tele extend 12 Adju...

Page 84: ... Position 3 Way Solenoid Valve Tele Pinning 7 Adjustable Pressure Reducing Valve 3 Solenoid Operated Proportional Relief 8 Adjustable Pressure Reducing Valve Pilot Supply 4 2 Position 3 Way Solenoid Valve CWT Lower 9 Adjustable Pressure Relief Valve Tele Pinning 5 Solenoid Operated Proportional Flow Control Valve 10 2 Position 3 Way Solenoid Valve Pilot Supply 9 9244 1 6 1 7 3 2 FIGURE 2 18 5 4 8 ...

Page 85: ...hen it is installed onto the piston as applicable or head In addition each wear ring gap is to be located as follows Divide 360 degrees by the number of wear rings on the component The resulting value is the number of degrees each wear ring gap is to be located with respect to each other The approximate wear ring gaps are as follows Leakage Check A hydraulic cylinder should not be disassembled unl...

Page 86: ...il temperature verses the ambient temperature Thermal contraction coupled with improper lubrication or improper wear pad adjustments may under certain conditions cause a stick slip condition in the boom This stick slip condition could result in the load not moving smoothly Proper boom lubrication and wear pad adjustment is important to permit the boom sections to slide freely Slow movement of the ...

Page 87: ...1 29 2 58 3 87 5 16 6 45 7 74 9 03 10 32 11 61 12 90 30 1 55 3 10 4 64 6 19 7 74 9 29 10 84 12 38 13 93 15 48 35 1 81 3 61 5 42 7 22 9 03 10 84 12 64 14 45 16 25 18 06 40 2 06 4 13 6 19 8 26 10 32 12 38 14 45 16 51 18 58 20 64 45 2 32 4 64 6 97 9 29 11 61 13 93 16 25 18 58 20 90 23 22 50 2 58 5 16 7 74 10 32 12 90 15 48 18 06 20 64 23 22 25 80 55 2 84 5 68 8 51 11 35 14 19 17 03 19 87 22 70 25 54 ...

Page 88: ...w cylinder to drain WARNING Injury Could Occur Do not use air pressure to remove the rod Use only a source of controlled hydraulic oil pressure if the rod is hard to move CAUTION Damage Could Occur Exercise extreme care when handling or setting down the rod Damage to the rod surface may cause unnecessary maintenance and expense 1 4 5 7 2 6 10 8 9 3 11 6845 FIGURE 2 19 Item Description Item Descrip...

Page 89: ...y with compressed air any parts that have been stoned and polished Assembly NOTE Lubricate seals and rings with clean hydraulic oil 1 Install the replacement wiper ring into the head 2 Install the rod seal in the inside of the head Make sure the lips of the seal face the piston 3 Install the O ring and backup ring onto the outside of the head 4 Install the O ring in the inside of the piston 5 Lubr...

Page 90: ...ch seal and ring is installed to avoid installing replacement seals and rings improperly 5 Loosen and remove the locknut securing the piston Remove the piston from the rod 6 Remove the O ring from the inside of the piston 7 Remove the spacer from the rod 8 Remove the head from the rod 9 Remove the O ring backup ring and retaining ring from the outside of the head Remove the rod seal wiper and O ri...

Page 91: ...E 2 20 Item Description Item Description 1 Barrel 16 Retaining Ring 2 Upper Rod 17 Piston Seal 3 Lower Rod 18 Wear Ring 4 Head 19 O ring 5 Head 20 O ring 6 Piston 21 O ring 7 Piston 22 Backup Ring 8 Spacer 23 Rod Seal 9 Spacer 24 Rod Seal 10 Manifold Tube 25 Wiper 11 Roller Bearing 26 Wiper 12 Nut 27 Plug 13 Clevis Pin 28 O ring 14 Washer 29 O ring 15 Cotter Pin F o r R e f e r e n c e O n l y ...

Page 92: ...ide of the piston 4 Install the spacer onto the rod 5 Install the head onto the rod 6 Lubricate the rod with clean hydraulic oil 7 Lubricate the piston seals and head seals with clean hydraulic oil 8 Remove the cover from the barrel Insert the rod and attached parts into the barrel with a slight twisting motion 9 Using a chain wrench or spanner wrench screw the head into the cylinder barrel CAUTIO...

Page 93: ...Place protective padding around the rod near the head to prevent damaging the chrome Using a spanner wrench unscrew the head from the barrel 2 Secure cylinder barrel in a chain vise in the vertical position with the rod assembly up NOTE Oil or oil air mixture may rapidly exit out of the ports during rod extension Shield the work area from the exiting oil 3 With the ports open extend the rod assemb...

Page 94: ...ttention to how each seal and ring is installed to avoid installing replacement seals and rings improperly 1 2 4 3 5 6 7 8 9 10 11 12 13 9262 FIGURE 2 21 Item Description Item Description 1 Barrel Assy 8 Plug SAE 6 2 Rod Assy 9 Capscrew 3 Piston Assy 10 O ring 4 Head Assy 11 Valve Check PO 5 Locknut 12 Capscrew Socket Head 6 Plug O ring 13 Spacer Limiter 7 Valve Body Assy F o r R e f e r e n c e O...

Page 95: ...d the diameter should be checked for out of roundness 5 Inspect the barrel carefully for scoring If barrel is scored it must be repaired or replaced 6 Thoroughly rinse parts allow to drain and wipe with a lint free rag Inspect all parts for serviceability 7 Stone out minor blemishes and polish with a fine crocus cloth 8 Clean with solvent and dry with compressed air any parts that have been stoned...

Page 96: ...rrel 9 Place a spanner wrench on the head and turn counterclockwise until the thread clicks then reverse direction to clockwise and thread in until there is no gap between the head shoulder and top of barrel 10 Slowly lower the rod down to the fully retracted position Item Description Item Description 1 O ring 5 Rod Seal 2 Backup Ring 6 Wiper Ring 3 Wear Ring 7 O ring 4 Buffer Seal 9262 2 1 2 3 FI...

Page 97: ...ent rolling NOTE Excessive wear due to side load or binding is a possibility Mark or note the piston and head relationship to the rod and barrel 4 Position the rod mount with the ports facing down Use a means of collecting the oil remove the port plugs and the check valve and allow cylinder to drain 5 Support the rod with a hoist sling and pull the rod to full extension to remove additional oil Ke...

Page 98: ... 11 15 16 21 20 1 6963 10 FIGURE2 24 Item Description Item Description 1 Barrel 12 Rod Seal 2 Rod 13 Buffer Seal 3 Head 14 Wear Ring 4 Piston 15 O ring 5 Spacer 16 Backup Ring 6 Check Valve 17 Seal 7 Setscrew 18 O ring 8 Insert 19 Backup Ring 9 Plug 20 Setscrew 10 Plug 21 Insert 11 Wiper Ring F o r R e f e r e n c e O n l y ...

Page 99: ...f any of these conditions exist Assembly NOTE Lubricate new seals and rings with clean hydraulic oil For head and piston seal installation refer to figures titled Head Seal Installation and Piston Seal Installation 1 Using round nose pliers or special installation tools twist the dual lip u cup seal into a C shape and allow it to snap into groove 2 Use a similar technique to install the wiper 3 In...

Page 100: ...cylinder completely retract and extend three times under pressure 6 When testing is complete relieve pressure on working ports Slowly open ball valve on PC port to relieve trapped oil pressure Plug the extend port marked EXT and retract the cylinder with air using a regulator at the RET port and a return line connected to the PC port Reclaim all oil Carefully bleed off air pressure once cylinder i...

Page 101: ...m Description 1 Rod Assy 13 Plug 4 SAE 2 Nylon Set 14 Plug 12 SAE 3 Piston Assy 15 Grease Fitting 4 Head Assy 16 Valve Assy Sequence 5 Bushing 17 Valve Assy Overcenter 6 Cover 18 Plug 2 SAE 7 Barrel Assy 19 Plug 16 SAE 8 Circlip Ring 20 Set Screw 9 Bushing Copper 21 Set Screw 10 Plug 8 SAE 22 Set Screw 11 Valve Assy Cart Flow Control 23 Bearing 12 Plug 6 SAE F o r R e f e r e n c e O n l y ...

Page 102: ... wear rings onto the head 2 Install O ring and retainer ring into the head 3 Install the replacement O ring and backup ring in the inside of the head 4 Install the replacement O ring wear rings and seal rings in the inside of the piston 5 Lubricate the rod with clean hydraulic oil 6 Slide the head onto the rod 7 Screw the piston onto the rod tightly Secure the piston with the setscrew 8 Lubricate ...

Page 103: ... 55 in Its stroke is 49 cm 19 3 in A wiper ring prevents foreign material from entering the cylinder O rings and other seals prevent internal and external leakage The cylinder weighs approximately 88 kg 194 lb wet 19 14 15 23 22 3 16 17 1 2 18 19 6 7 24 25 13 10 12 9 11 4 21 20 21 5 F I G U R E2 2 6 Item Description Item Description 1 Barrel 14 Wiper 2 Rod 15 Rod Seal 3 Head 16 Step Seal 4 Piston ...

Page 104: ... Relief Valve 2 Cylinder Head 13 Stop Brake Valve 3 Gasket 14 Stop Brake Valve 4 Approximate Switch 15 O ring 5 Control Unit 16 O ring 6 Approximate Switch 17 Cartridge Valve 7 Piping Unit 18 O ring 8 Valve 19 Gasket 9 Valve 20 O ring 10 Back Pressure Valve 21 Retaining Slip Ring 11 Excess Pressure Valve 22 O ring 5 5 6 4 3 1 6 9 8 7 2 10 22 21 20 18 15 16 10 19 14 11 12 13 FIGURE 2 27 F o r R e f...

Page 105: ...ulic schematic PRESSURE TO BE CHECKED GAUGE PRESSURE PSI bar TOLERANCE PSI bar PROCEDURE Pump section 1 differential pressure 475 525 33 36 See Range A Pump section 2 differential pressure 525 575 36 40 See Range A Pilot supply pressure 600 41 50 4 B Load sense max system pressure 4300 296 50 4 C Lift down pressure 2350 162 150 10 C Tele extend pressure 2900 200 100 7 C Tele retract pressure 3250 ...

Page 106: ...ch function can be found in the Crane Service Tool in the menu bar under Tools EEprom View Parameters Next select the function which needs adjusted Cab tilt is shown here Main crane functions can be found under Proportional Valves and Carrier functions can be found under Cabin A Procedure for Checking Setting the Piston Pumps Cut Off Differential Pressures 1 With engine off install a pressure chec...

Page 107: ... it does not adjust the differential pressure adjustment screw See Figure 2 14 on pump 1 in to increase or out to decrease so that a gauge reading is achieved 4 With the engine still at idle Adjust the differential pressure adjustment screw See Figure 2 14 on pump 2 in to increase the pressure until the gauge reads 525 575 PSI 36 40 bar FIGURE 2 30 Main directional valve GP port Lift down relief T...

Page 108: ...urn it in until it softly seats or bottoms out Then back the adjusting screw out turn and lock in place with the jam nut Perform this step on both pumps B Procedure for Checking Setting the Pilot Supply Pressure 1 With the engine off install pressure check diagnostic quick disconnect Parker PD240 with gauge onto test FIGURE 2 31 Differential pressure adjustment screw Piston pump 1 9266 Cut off pre...

Page 109: ...ed to do lift up and lift down functions if the hoses are attached to the cylinder in order to assure that cylinder can reach full stroke in either direction Make sure the machine is parked on a firm level surface the park brake is set the boom is fully retracted and positioned over the side away from the cab or engine cover 4 Lift Up Start engine and idle Feather into the lift up function until f...

Page 110: ... accelerate the engine to full RPM The reading at GPLS should be 2350 150 PSI 162 10 bar this pressure is non adjustable 5 Turn the RCL override switch to it s normal position Stop engine Remove diagnostic couplers Tele Extend and Retract Relief Pressures 1 With the engine off install pressure check diagnostic quick disconnect Parker PD240 with gauge onto test the nipple at GPLS port of the Access...

Page 111: ...ot unlock the cylinder using the cylinder unlock button and the jog dial selector b Use the joystick and retract cylinder 1 until the length reads 0 mm 6 Make sure that S2111N is green FIGURE 2 34 Change G to H Check box 9266 4 FIGURE 2 35 S2111N Cylinder 1 length 9266 5 Cylinder unlock button Lock button F o r R e f e r e n c e O n l y ...

Page 112: ...ease until the reading is achieved 8 Tele Retract Feather into the tele retract function until the cylinder is dead headed and hold Slowly accelerate the engine to full RPM The reading at GPLS should be 3250 100 PSI 224 7 bar if it is not adjust the Tele retract relief Figure 2 13 in to increase or out to decrease until the reading is achieved 9 Make sure that cylinder is fully retracted length re...

Page 113: ...ct the OK box Navigate to each boom section and enter 0 for the pinning position NOTE If the boom is not fully retracted enter appropriate pinning position for each section Select the OK button 11 Stop engine Remove diagnostic couplers FIGURE 2 37 9266 7 OK box Change P to L FIGURE 2 38 9266 8 OK box Boom section position F o r R e f e r e n c e O n l y ...

Page 114: ...ols EEprom View Parameters Super Cab Tilt Tilt Up Pressure params row increase the value to increase the pressure or decrease the value to decrease the pressure adjustment by 10 mA increments is suggested Make sure to write column to active settings Repeat this step until the pressure is achieved If the value needs adjusted by more than 100 mA there may other issues in the circuit b Once the press...

Page 115: ...rements is suggested Make sure to write column to active settings Repeat this step until the pressure is achieved If the value needs adjusted by more than 100 mA there may other issues in the circuit b Once the pressure is achieved make sure to Save active to customer and Save active to factory 5 Stop engine Remove diagnostic couplers F Procedure for Checking Setting Swing Pressure 1 With the engi...

Page 116: ... sure to Save active to customer and Save active to factory 4 Outrigger Jack Extend Pressure Start engine and idle Extend any outrigger jack until full stroke of the cylinder is achieved and hold Slowly accelerate the engine to full RPM The reading at G2 should be 3000 50 PSI 207 4 bar if it is not use the service tool as follows to adjust a In the Tools EEprom View Parameters Cabin Solenoid PWM C...

Page 117: ...rrectly remove the cover and check the shaft speed Figure 2 42 with a photo tach The shaft speed should be 1800 to 2000 rpm when the unit is running If the shaft is not in this range use the service tool as follows to adjust NOTE While doing this step the gauge from Step 2 should also be installed and if the pressure gets out of the acceptable range Step 2 will need to be repeated once the RPMs ar...

Page 118: ...g Setting the Front Steer Pressure 1 With the engine off install a pressure check diagnostic coupler Parker PD240 with gauge onto the diagnostic nipple at the GP port of the power steering gear box Figure 2 44 2 Disconnect and plug one steer hose and cap the fitting Figure 2 44 3 Start engine and throttle up to full RPM Fully turn the steering wheel to the left or right The reading at GP should be...

Page 119: ... control screen selectable curves Follow the steps listed below for any function which the operator feels the meter in dead band in the controller is either too fast or slow or if the max function speed is verified to be slower or faster than designed see flows show on system schematic For meter in too fast lower Imin setting For meter in too slow raise Imin setting For low function flow raise Ima...

Page 120: ...ons save the EE configuration to the controller s Factory and Customer settings area This is done by selecting Tools Calibration and Adjustment EEPROM and pressing the Save active to Customer and Save active to Factory buttons 6 Next save the configuration to a file by right clicking on the Active column and Write Write column to file from the context menu Save the file in a folder under the model...

Page 121: ...ttery 3 23 Jump Starting the Crane 3 23 Charging 3 23 DESCRIPTION Carrier General The electrical system is 24 volt operation with 24 volt starting consisting of a 24 volt alternator and four 12 volt lead acid batteries Electrical power is transferred to and from the carrier and superstructure through the electrical slip ring assembly Alternator A 140 ampere 24 volt alternator is mounted on the eng...

Page 122: ...power panel Figure 3 3 contains 5 relays and a buzzer Refer to Power Panel and Power Panel Decal illustrations Relays The carrier has 5 relays which control many of its functions The relays are located on the power panel in the carrier cab When any relay coil is energized its contacts either open or close This allows power to go to or be removed from the related circuits For any relay coil to ener...

Page 123: ... when the headlights on switch contacts are closed The coil of horn relay K103 is energized when the horn button is depressed The coil of the marker lights relay K106 is energized when the headlight switch is in the park light or ON position The coil of the steering wheel relay K107 is energized when the contacts of ignition control relay K101 are closed Fuse and Fuse Relay Panels Refer to Figure ...

Page 124: ...3 4 Published 01 14 2021 Control 707 01 ELECTRICAL SYSTEM TMS9000 2 SERVICE MANUAL FIGURE 3 4 9280a 9280b 9280d 9280c F o r R e f e r e n c e O n l y ...

Page 125: ...shed 01 14 2021 Control 707 01 3 5 TMS9000 2 SERVICE MANUAL ELECTRICAL SYSTEM 3 Superstructure Fuse and Relay Panel FIGURE 3 5 F304 F305 F306 F303 8338 2 F302 F301 FIGURE 3 6 9280e F o r R e f e r e n c e O n l y ...

Page 126: ...3 6 Published 01 14 2021 Control 707 01 ELECTRICAL SYSTEM TMS9000 2 SERVICE MANUAL FIGURE 3 7 9280f FIGURE 3 8 9280g F o r R e f e r e n c e O n l y ...

Page 127: ...nit ECU The ABS ECU 1 Figure 3 9 is located inside the cab behind the seat ABS wiring is combined with the main cab and engine harnesses Diagnostic Connector The 9 pin on board diagnostic connector 1 Figure 3 10 is located below the control panel on the left side of the dash FIGURE 3 9 1 FIGURE 3 10 1 9281 F o r R e f e r e n c e O n l y ...

Page 128: ...fifth optional camera that is mounted on the rear of the optional trailing boom dolly and it displays on the carrier monitor Camera Alignment Carrier Right Side 1 Press the camera select button Figure 3 12 2 Press the or button to select the full screen view of Right camera 3 Horizontal The right side camera should be adjusted horizontally so that the full length of the right side edge of the carr...

Page 129: ...ights and panel lights to verify the batteries have at least some charge If none of these lights comes on suspect the batteries Charge batteries as needed or jump start the crane from another crane Refer to Jump Starting the Crane page 3 23 If the batteries will not take a charge replace them 4 If you hear the starter relay clicking repeatedly power is reaching the starter but not enough Suspect t...

Page 130: ... in the charging system are in good repair and are connected properly 2 Verify the alternator belt is properly installed and is under proper tension 3 Verify the batteries put out 24 volts minimum Charge battery as needed so the battery can supply a minimum excitation voltage to the engine s charging system 4 Verify there is a minimum of 24 volts at the alternator from the batteries and that the a...

Page 131: ...1 Amp Extraction Tool Table Table 3 2 Amp Crimping Tool Table Table 3 3 Deutsch Extraction Tool Table Table 3 4 Deutsch Crimping Tool Table Description Amp Part Number Grove Part Number 14 gauge wire connectors 305183 9 999 100176 12 to 8 gauge wire connectors 91019 3 9 999 100175 4 to 9 circuit in line connectors 453300 1 N A 15 circuit in line connectors 458944 1 N A Description Amp Part Number ...

Page 132: ...onnections When servicing electrical connections on Cranes you should reapply Di Electric Grease per the instructions below Check connection for moisture before application of the grease If moisture is found please clean replace connector accordingly Apply material immediately prior to connection Make sure that there is coverage to all terminal sockets Procedure Required Material Manitowoc P N 900...

Page 133: ...05 FA06 FA08 and FA09 lamps grounds Gauge lights CB01 HEADLIGHTS switch FA09 lamps grounds Turn signal lights FA05 turn signal switch lamps grounds Suspect turn signal switch if hazard light circuit functions properly Hazard lights Hazard lights switch lamps grounds Suspect hazard lights switch if turn signal lights circuit functions properly Stop lights FD01 stop light switches turn signal switch...

Page 134: ...ssure switch on cab front console control valve ground Steering wheel horn FD02 Horn relay K103 coil horn switch ground Parallel branch from horn relay contacts horn ground Tire inflation on indicator F11 to indicator or buzzer to the normally open pressure switch on the cab front console control valve to ground Troubleshooting the Crane Control System CCS The Crane Control System CCS monitors the...

Page 135: ...ts normal position 8 Remove the four bolts attaching the alternator to the mounting bracket Remove the alternator Installation 1 Inspect the belt Verify it has no cracks or other damage Replace damaged belt as needed 2 Place the alternator on the mounting bracket Secure the alternator with the bolts Torque mounting bolts Refer to Torque Values page 1 9 3 Install the belt on all engine pulleys exce...

Page 136: ...gear hasn t disengaged from the flywheel after the ignition switch is in the ignition run position or some other problem Install starter properly as needed Battery Replacement Removal 1 Make sure that the key switch has been in the OFF position for 2 minutes 2 Turn the battery disconnect switch 1 Figure 3 24 to the OFF position 3 Remove the ECM power fuse 4 Remove the negative battery cables 4 Fig...

Page 137: ...ect position and all key switches are in the OFF position 4 Connect cables to the battery terminals starting with the positive terminals 5 Close the battery box cover 6 Install the ECM power fuse 7 Turn the battery disconnect switch to ON 8 Verify replacement batteries work by starting crane s engine and operating various crane components 1 2 3 9284 4 4 5 FIGURE 3 24 9284 1 Item Description Item D...

Page 138: ...ptacle 4 Install the cover 5 Verify proper installation by operating all components involved with the replacement relay and verifying they all work Instrument Replacement Removal 1 Make sure that the key switch has been in the OFF position for 2 minutes 2 Turn the battery disconnect switch to the OFF position 3 Remove the hardware securing the console cover and remove the cover 4 Tag and disconnec...

Page 139: ...3 Remove the hardware securing the console cover and remove the cover 4 Tag and disconnect the electrical leads from the switch 5 On the front of the console panel remove the nut securing the switch to the panel As necessary remove the knob from the switch first 6 Remove the switch from the hole in the panel Inspection 1 Visually check the switch for evidence of cracks damaged connections or other...

Page 140: ...embly s adapter to the cab exterior Remove the pantograph arm assembly s adapter and gasket 9 Remove attaching hardware to free the windshield wiper motor bracket from the cab interior Remove the bracket with motor and pivot shaft connected from the cab NOTE You may have to remove or move other parts to get the bracket and attached parts around the steering column Take care not to damage any parts...

Page 141: ...cure the wiper arm to the pivot shaft with the pivot shaft s own tapered sleeve washer and cap nut 7 Connect the wiper arm s washer hose to the washer nozzle fitting assembly 8 Connect the electrical leads to the wiper motor as marked before removal 9 Turn the battery disconnect switch to the ON position Check 1 Squirt some cleaning fluid onto the windshield with the windshield washer 2 Operate th...

Page 142: ... the four screws holding the receiver to the panel 3 Remove the receiver Installation 1 Align the receiver s four mounting holes with the holes in the panel 2 Install the four screws and tighten 3 Connect the cables as tagged during removal Battery Charger Removal 1 Unplug the wire from the battery charger 2 Loosen the screw securing the battery charger clip 5 3 Loosen the nuts securing the batter...

Page 143: ...he charging leads have been connected to the battery s Also if the battery s are found to be frozen do not attempt to charge them Remove the battery s from the crane allow them to thaw and then charge the battery s to full capacity Slow charging is preferred to fast charging Fast charging saves time but risks overheating the battery s Slow charging at six 6 amps or less develops less heat inside t...

Page 144: ...3 24 Published 01 14 2021 Control 707 01 ELECTRICAL SYSTEM TMS9000 2 SERVICE MANUAL This Page Blank F o r R e f e r e n c e O n l y ...

Page 145: ...Cable Drum 4 52 Lubricating the Swing Angle Sensor 4 54 Superstructure Air Conditioning System Additional Equipment 4 55 Checking Hoses 4 55 Other Maintenance Work 4 55 Checking for Correct Operation of the Auxiliary Heater Additional Equipment 4 55 Lubricating the Piston Rod of the Lifting Cylinder 4 55 DESCRIPTION OF MAINTENANCE WORK ON THE SUPERSTRUCTURE Hoist Description One standard hoist is ...

Page 146: ...d Installing Cable On Hoist NOTE To install synthetic rope refer to the K100 manual Refer to Figure 4 1 NOTE Straighten cable before installing on hoist drum 1 Place cable 1 over boom nose sheave and route to hoist drum 2 2 Rotate hoist drum so cable slot located on left side of drum is easily accessible 3 Insert cable through slot 3 and wedge block 4 Slowly wind the drum and rope tail in the hois...

Page 147: ...b 3 Secure the hoist assembly to the superstructure using the capscrews and washers Torque the capscrews refer to Torque Values page 1 9 for proper torque value 4 Install the bearing support assembly 8 to the drum shaft with grease fittings at the 11 o clock position Align and install the six long capscrews into the threaded turntable holes Install the three short capscrews into the blind holes To...

Page 148: ...r 2 Cotter Pin 11 Hoist Roller 20 Flat Washer 3 O Ring 12 Roll Pin 21 Narrow Flat Washer 4 Cable Wedge 13 Capscrew 22 O Ring 5 Limit Switch Assembly 14 Capscrew 23 Lockwasher 6 2 Speed Motor Piston 15 Capscrew 24 Sight Glass 7 Shaft 16 Capscrew 25 Socket Head Cap Screw 8 Bearing Support 17 Straight Thread Adapter 26 Washer 9 Motor Control Valve Assy 18 Pin 27 Lockwasher 28 Nut F o r R e f e r e n ...

Page 149: ...aintenance The following should be carried out following instructions in Lubrication page 9 1 and or manufacturers instructions 1 Pre Use or Daily Inspection refer to the Operator Manual 2 Quarterly Inspection every three months Must include but is not limited to the following inspections that must be performed by a qualified crane operator or qualified crane technician Perform pre use inspection ...

Page 150: ...ion of accelerated component wear allows the scheduling of corrective maintenance Prepare hoist by cleaning drain area to obtain an uncontaminated sample Operate hoist in both directions for one or two minutes to thoroughly mix the gear oil Take sample from midstream flow of oil to obtain an accurate representation of the oil condition After taking the oil sample continue with oil change or refill...

Page 151: ...ol valve from the brake cylinder and brake clutch which are in the motor control valve gearbox Remove the motor and motor control valve as a unit Discard the O ring 5 Cover the motor opening in the brake cylinder to protect drive components inside the hoist drum As needed secure the brake clutch from inside the brake cylinder Installation 1 Uncover the motor opening in the gearbox Verify these par...

Page 152: ...se and extend boom 4 Lower hook block until three wraps of rope remain on hoist drum 5 Remove four screws and cover from switch 6 Rotate adjustment screw 2 until switch activates Service software may be used to monitor an indicator light on the appropriate display 7 Raise hook block until there are ten rope wraps on hoist drum 8 Lower hook block to verify lower limit switch actuates with a minimum...

Page 153: ... and disconnect the telescopic hydraulic lines from the compact block if equipped also disconnect the hydraulic boom extension hydraulic lines from the compact block NOTE At this point you can continue to remove the boom or choose to remove the equipment that is attached to the boom to prevent it from being damaged You can also choose to remove the attached equipment after the boom has been remove...

Page 154: ...out that the cylinder 3 Figure 4 8 will clear it Tag and remove the shims and bushing plates on the pin 18 Reach in access hole at top of boom remove pins on stop plates Figure 4 9 9286 FIGURE 4 7 9286 1 9286 7 FIGURE 4 8 1 2 3 WARNING Crushing Hazard Make sure that the lifting device is capable of supporting the boom assembly Severe injury or death may result F o r R e f e r e n c e O n l y ...

Page 155: ...get caught up during lowering into the turntable 3 Lower the rear of the boom into position Align the boom pivot mounting holes with mounting holes in the turntable Make sure that all hydraulic and electrical cables are out of the way so they will not be damaged 4 Lubricate the pivot bushings in the turntable NOTE The boom may need to be raised or lowered to aid in the installation of the boom piv...

Page 156: ...in 2 Figure 4 13 far enough out that the cylinder 3 Figure 4 13 will clear it Install shim and bushing plate on the pin 12 Have an operator in the crane extend the lift cylinder until aligned with boom mounting holes NOTE This should be carefully controlled If the lift cylinder rod is extended too far it cannot be retracted using the main directional control valve NOTE This may take a combination ...

Page 157: ...ins 16 Figure 4 16 from the cable retainer pins 15 20 21 Figure 4 16 and remove the cable retainer pins from the upper and lower part of the boom nose 2 Remove the two hex head screws 5 Figure 4 16 securing the cover plate 4 Figure 4 16 to the upper boom nose axle 2 Figure 4 16 Remove the cover plate NOTE The boom nose sheave shafts weigh approximately 12 5 kg 27 5 lb each The boom nose sheaves we...

Page 158: ...4 14 Published 01 14 2021 Control 707 01 SUPERSTRUCTURE TMS9000 2 SERVICE MANUAL FIGURE 4 16 9516 Telescope Section 5 Assembly F o r R e f e r e n c e O n l y ...

Page 159: ...Grove Published 01 14 2021 Control 707 01 4 15 TMS9000 2 SERVICE MANUAL SUPERSTRUCTURE 4 FIGURE 4 16 continued 9517 37 73 Telescope Section 5 Assembly Continued F o r R e f e r e n c e O n l y ...

Page 160: ...CH WEIGHT ASSEMBLY 32 SHCS M8x50 8 8 33 HEX NUT M8 8 34 CABLE CLIP 35 LOCKING UNIT ASSY 36 LOCKING UNIT ASSY 37 WEAR PAD TELE 5 ASSY 38 PLATE 39 CAP SCREW 40 STRIP 41 SLIDER SUSTAGLIDE 42 PLATE 43 PLATE 44 SLIDER SUSTAGLIDE 45 PLATE 46 PLATE 47 GUIDE PILOT 48 SLIDER SUSTAGLIDE 49 FILL PLATE 50 FILL PLATE 51 SFS M10X16 52 WEAR PAD SUSTAGLIDE 53 WASHER 12 FLAT 54 SHCS M10X50 55 SHCS M12x35 8 8 56 CA...

Page 161: ... 4 24 continued 2 5 Remove the sliders holders strips and plates 30 31 32 33 66 37 38 Figure 4 24 continued 2 6 Remove Tele Section 1 from the Base Section 1 Figure 4 24 7 Remove the tele power plug 1 Figure 4 18 8 Remove the tele power cable strain relief 2 Figure 4 18 9 Remove the Tele cylinder 10 Remove the wear pads plates and strips 29 30 32 62 Figure 4 23 as necessary 11 Remove the sliders f...

Page 162: ...2 43 44 45 46 47 48 49 50 and 52 Figure 4 16 Tag the plates sliders fill plates and wear pads as to their location for reassembly BOOM ASSEMBLY Do not attempt to work on the boom without experienced supervision NOTE Apply Loctite 243 to the threads of all attaching hardware except cable ends and cable lock nuts Apply multipurpose grease MPG to all wear surfaces Use standard torque values specified...

Page 163: ...nsert Section 5 into Section 4 just far enough to measure the gaps between the sliders and wear pads and Section 4 The gaps should be no greater than 1 52 mm 0 06 in Adjust the gaps by adding or removing plates or using thicker or thiner sliders and wear pads 13 Insert Section 5 into Section 4 half way FIGURE 4 19 9518 F o r R e f e r e n c e O n l y ...

Page 164: ...4 20 Published 01 14 2021 Control 707 01 SUPERSTRUCTURE TMS9000 2 SERVICE MANUAL FIGURE 4 20 9519 Telescope Section 4 Assembly F o r R e f e r e n c e O n l y ...

Page 165: ...Grove Published 01 14 2021 Control 707 01 4 21 TMS9000 2 SERVICE MANUAL SUPERSTRUCTURE 4 FIGURE 4 20 continued 9519 1 Telescope Section 4 Assembly Continued F o r R e f e r e n c e O n l y ...

Page 166: ...SELESS TELE 4 4 WEAR PAD GREASELESS TELE 4 5 WEAR PAD GREASELESS TELE 4 6 WEAR PAD GREASELESS TELE 4 7 WEAR PAD GREASELESS TELE 4 8 HOLDER 9 HOLDER 10 STRIP T 11 11 STRIP T 10 12 PLATE 13 PLATE 14 PLATE 15 WASHER 12 FLAT 16 HHCS M12x35 8 8 17 HEX NUT M12 18 HEXAGON HEAD BOLT 19 WASHER 20 SHCS M10X35 8 8 21 SHCS M10X30 8 8 22 HEXAGON HEAD SCREW 23 HEXAGON THIN NUT 24 SPACER 25 SOCKET HEAD SCREW 26 ...

Page 167: ...es 53 54 55 58 and connect to the wear pads 29 59 20 Attach the thin nuts 57 and pipe unions 56 to the lubrication hoses and secure the hoses to the tabs inside the section 21 Install the locking unit assemblies 26 27 22 Insert Section 5 completely into Section 4 23 Insert Section 4 into Section 3 just far enough to measure the gaps between the sliders and wear pads and Section 3 The gaps should b...

Page 168: ...4 24 Published 01 14 2021 Control 707 01 SUPERSTRUCTURE TMS9000 2 SERVICE MANUAL FIGURE 4 21 continued 9521 1 59 Telescope Section 3 Assembly Continued F o r R e f e r e n c e O n l y ...

Page 169: ...ESS TELE 3 8 HOLDER 9 HOLDER 10 STRIP T 11 11 STRIP T 10 12 PLATE 13 PLATE 14 PLATE 15 WASHER 12 FLAT 16 HHCS M12x35 8 8 17 HEX NUT M12 18 HEXAGON HEAD BOLT 19 WASHER 20 SHCS M10X35 8 8 21 SHCS M10X30 8 8 22 HEXAGON HEAD SCREW 23 HEXAGON THIN NUT 24 SPACER 25 SOCKET HEAD SCREW 26 LOCKING UNIT ASSY 27 LOCKING UNIT ASSY 29 WEAR PAD TELE 3 ASSY 30 PLATE 31 CAP SCREW 32 STRIP T 11 33 SLIDER 34 FILE PL...

Page 170: ...d 29 with the plate 30 18 Install the opposite wear pad 59 strips 32 and plate 30 19 Assemble the lubrication hoses 53 54 55 58 and connect to the wear pads 29 59 20 Attach the thin nuts 57 and pipe unions 56 to the lubrication hoses and secure the hoses to the tabs inside the section 21 Install the locking unit assemblies 26 27 22 Insert Section 3 into Section 2 just far enough to measure the gap...

Page 171: ...Grove Published 01 14 2021 Control 707 01 4 27 TMS9000 2 SERVICE MANUAL SUPERSTRUCTURE 4 FIGURE 4 22 continued 9522 1 Telescope Section 2 Assembly Continued F o r R e f e r e n c e O n l y ...

Page 172: ...AD GREASELESS TELE 2 6 WEAR PAD GREASELESS TELE 2 7 WEAR PAD GREASELESS TELE 2 8 HOLDER 9 HOLDER 10 STRIP T 11 11 STRIP T 10 12 PLATE 13 PLATE 14 PLATE 15 WASHER 12 FLAT 16 HHCS M12x35 8 8 17 HEX NUT M12 18 HEXAGON HEAD BOLT 19 WASHER 20 SHCS M10X35 8 8 22 HEXAGON HEAD SCREW 23 HEXAGON THIN NUT 24 SPACER 25 SOCKET HEAD SCREW 26 LOCKING UNIT ASSY 27 LOCKING UNIT ASSY 29 WEAR PAD TELE 2 ASSY 30 PLAT...

Page 173: ...osite wear pad 59 strips 32 and plate 30 19 Assemble the lubrication hoses 53 54 55 58 and connect to the wear pads 29 59 20 Attach the thin nuts 57 and pipe unions 56 to the lubrication hoses and secure the hoses to the tabs inside the section 21 Install the locking unit assemblies 26 27 22 Insert Section 2 into Section 1 just far enough to measure the gaps between the sliders and wear pads and S...

Page 174: ...4 30 Published 01 14 2021 Control 707 01 SUPERSTRUCTURE TMS9000 2 SERVICE MANUAL FIGURE 4 23 continued 9523 1 Telescope Section 1 Assembly Continued F o r R e f e r e n c e O n l y ...

Page 175: ...ER 12 FLAT 15 WASHER 12 FLAT 16 HHCS M12x35 8 8 17 HEX NUT M12 18 HEXAGON HEAD BOLT 19 WASHER 21 SHCS M10X30 8 8 22 HEXAGON HEAD SCREW 23 HEXAGON THIN NUT 24 SPACER 25 SOCKET HEAD SCREW 26 LOCKING UNIT ASSY 27 LOCKING UNIT ASSY 29 WEAR PAD TELE 1 ASSY 30 PLATE 31 CAP SCREW 32 STRIP T 11 33 SLIDER 34 FILE PLATE 35 FILL PLATE 36 SLIDER SUSTAGLIDE 37 PLATE 38 PLATE 39 GUIDE PILOT 40 SLIDER 41 FILL PL...

Page 176: ...ad 29 with the plate 30 18 Install the opposite wear pad 62 strips 32 and plate 30 19 Assemble the lubrication hoses 53 54 55 and connect to the wear pads 29 62 20 Attach the thin nuts 57 and pipe unions 56 to the lubrication hoses and secure the hoses to the tabs inside the section 21 Install the locking unit assemblies 26 27 22 Insert the telescope cylinder assembly into Section 1 23 Install the...

Page 177: ...Grove Published 01 14 2021 Control 707 01 4 33 TMS9000 2 SERVICE MANUAL SUPERSTRUCTURE 4 FIGURE 4 24 9546 Telescope Base Section Assembly F o r R e f e r e n c e O n l y ...

Page 178: ...4 34 Published 01 14 2021 Control 707 01 SUPERSTRUCTURE TMS9000 2 SERVICE MANUAL FIGURE 4 24 continued 2 9546 1 66 30 31 32 Telescope Base Section Assembly Continued F o r R e f e r e n c e O n l y ...

Page 179: ...Grove Published 01 14 2021 Control 707 01 4 35 TMS9000 2 SERVICE MANUAL SUPERSTRUCTURE 4 9546 2 FIGURE 4 24 continued 3 Telescope Base Section Assembly Continued F o r R e f e r e n c e O n l y ...

Page 180: ...4 36 Published 01 14 2021 Control 707 01 SUPERSTRUCTURE TMS9000 2 SERVICE MANUAL 9546 3 FIGURE 4 24 continued 4 Telescope Base Section Assembly Continued F o r R e f e r e n c e O n l y ...

Page 181: ...7 COVER 8 SFS M10X16 9 BAR 10 HHCS 11 PLATE 12 PLATE 13 PLATE 14 PLATE 15 WASHER 16 WASHER 17 HEX NUT M10 18 HEXAGON HEAD SCREW 19 AXLE ASSEMBLEY 20 F WASHER 21X90X10 21 HHCS M20X30 22 PLATE 23 FLANGE 24 SHCS M10X30 8 8 25 HSS 26 HEXAGON NUT 27 ROPE PROTECTION 28 SLIDER 29 SLIDER 30 SLIDER 31 SLIDER 32 SLIDER 33 HOLDER 34 STRIP T 11 35 STRIP T 10 36 PLATE 37 PLATE 38 PLATE 39 WASHER 12 FLAT 40 HHC...

Page 182: ...sor for the linear location of the telescoping cylinder within the boom the Crane Control System commands the pinning mechanism to perform the locking operations The key component for the pinned boom then is the pinning mechanism For the TMS9000 2 this is referred to as the Mechanical Locking Head Be aware that this pinning mechanism is quite different from a past design that was referred to as Tw...

Page 183: ...6 Mechanical Locking Head Layout Item Number Description 1 I O Module 2 Valve for pinning control 3 Valve for pinning control 4 Proximity Switch S2112N 5 Double acting hydraulic actuator 6 Proximity Switch S2111N 7 Butterfly levers that engage with section pins 8 Proximity Switch S2110N 9 Actuator sliding plate 10 Left side cylinder pin that engages with boom sections 11 Proximity switch S2115N 12...

Page 184: ...7 shows these two switches and that they are located on spring loaded cylindrical bodies that can ride in and out of slots in the Boom Sections The third proximity switch is on the other side of the telescoping cylinder 16 Figure 4 26 As shown with the arrows for Items 17 and 18 in Figure 4 27 when switches S2116N and S2117N are OFF and switch S2118N is ON then the telescoping cylinder can be cons...

Page 185: ...irection from its neutral position The actuator utilizes pressure from a trombone tube or fill tube or transfer tube in the center of the hollow rod of the telescoping cylinder via a tube on the outer surface of the telescoping cylinder barrel There are two ON OFF valves 2 and 3 Figure 4 26 that control where pressure for the actuator is directed These valves are designated Y2130 and Y2131 9300 1 ...

Page 186: ...ect location for pinning operations Pinned Boom Control System Description The Pinned Boom Control System for the telescoping system manages the state of the sensors switches valves and information to from the display screens There are a number of different approaches to using the telescoping system These are referred to as the Semi Auto Mode the Manual Mode and the Emergency Mode It is important ...

Page 187: ...screws are supplied for each telescopic section Figure 4 30 125 mm 4 92 in length for telescopic section 5 140 mm 5 51 in length for telescopic section 4 170 mm 6 69 in length for telescopic section 3 200 mm 7 87 in length for telescopic section 2 270 mm 10 63 in length for telescopic section 1 You can only lock or unlock a telescopic section manually if the recess 2 Figure 4 31 in the locking pin...

Page 188: ...e telescoping cylinder for bleeding the cylinder chambers The vent screws are accessible through hand holes in the telescopic sections Prerequisites With the following requirements it is assumed that no lattice extension is rigged Park the truck crane on a level surface Support the truck crane with at least the outrigger span 7 00 m X 5 61 m 22 97 x 18 4 ft Remove the counterweight Enter the RCL r...

Page 189: ...s reaching into the manhole Carefully move the control lever for telescoping in the retract direction so that the pressure in the set of piston rings increases and the air is pushed out through the plastic hose Tighten the vent screw 1 Figure 4 32 Close the manhole again with the cover plate FIGURE 4 32 Position Number Vent For Access to Vent on Basic Section Via 1 Set of Piston Rings Manhole in T...

Page 190: ...er turns freely CHECK THE LOCKING SYSTEM Have the main boom locking system checked by your authorized Grove Crane distributor or Manitowoc Crane Care WARNING Overturning Hazard Make sure that all the Prerequisites page 4 44 are met If you do not keep to the rigging mode specified there the truck crane could overturn CAUTION Damage to Equipment Hazard Bolts in telescope slide pad are intentionally ...

Page 191: ...LL WIRE ROPE NOTE For cranes equipped with synthetic rope refer to the synthetic rope manual No precise rules can be given for determination of the exact time for replacement of wire rope since many variable factors are involved Determination regarding continued use or replacement of wire rope depends largely upon the good judgment of an appointed and qualified person who evaluates the remaining s...

Page 192: ...eplacement for the most common rope diameters NOTE The number of visible wire breaks indicated here only applies to the hoist ropes This information only applies to the initial equipment and original spare parts Number of Load Bearing Outer Wires Number of Visible Wire Breaks Regular Lay Rope 13 mm 16 mm 19 mm 22 mm 24 mm to 78 mm to 390 mm to 96 mm to 480 mm to 114 mm to 570 mm to 132 mm to 660 m...

Page 193: ...ulting from damage to the rope Replace hoist rope at the latest when the maximum permissible number of wire strand fractures according to the table are visible externally Replace hoist rope immediately if wire breakage clusters or strand breakage occur The frequency of wire breakage increases with rope age For reasons of safety it is advisable to replace the hoist rope while the number of broken w...

Page 194: ...4 36 The rope winds its way along its longitudinal axis in a way which is similar to a corkscrew The deformation is measured with the attached hook block Damage resulting from overloading Even a small amount of deformation leads to increased abrasion wire breakage and rough operation of the cable drive If deformation x at a position on the hoist rope is greater than a third of the rope diameter th...

Page 195: ...Only the inner strands continue to bear the load Corrosion or abrasion Replace hoist rope immediately Other causes The number of broken wires determines when the rope must be replaced Knot Formation 3 Figure 4 37 Repeatedly occurring knot like thickening of rope core often protrudes The strands bear on each other at thin points resulting in increased occurrence of wire breakage General wear due to...

Page 196: ...GURE 4 38 Damage Description Cause Replacement Flattening 1 Figure 4 38 Crushed areas mostly with wire breakage Mechanical damage e g due to driving over the rope Determine number of broken wires replace hoist rope immediately if serious crushing occurs Crinkle Formation Crinkle type rope deformation Loaded hoist rope was pulled over an edge Replace hoist rope immediately Kink 2 Figure 4 38 Rope d...

Page 197: ...is current free Unscrew all screws 1 Figure 4 41 and remove the casing 2 Figure 4 41 Check the seal on the casing for damage and replace it if necessary Remove any moisture in the casing with a clean lint free cloth WARNING Risk of accidents due to rope end fitting being overloaded After installing a new hoist rope the lowering limit switch must always be reset WARNING Crushing Hazard Secure the b...

Page 198: ...le Sensor Depending on the equipment on your crane there is a swing angle sensor 1 Figure 4 44 under the crane cab Remove the cover of the swing angle sensor Remove the seal 3 Figure 4 44 from the opening Remove the protective cap from the lubricating nipple 4 Figure 4 44 Clean any old grease from the lubricating nipple Use a grease gun to press 5 cm3 0 03 in3 of grease into the lubricating nipple...

Page 199: ...ollowing specifications Minimum Evacuation Time 60 minutes Refrigerant Charge Levels 2 5 pounds 0 5 oz Additional Pag Oil Required Above the 6 ounces in Compressor 5 0 ounces OTHER MAINTENANCE WORK Checking for Correct Operation of the Auxiliary Heater Additional Equipment For additional information see the section Heating and Ventilating the Superstructure Cab in the Operator Manual Lubricating t...

Page 200: ...4 56 Published 01 14 2021 Control 707 01 SUPERSTRUCTURE TMS9000 2 SERVICE MANUAL This Page Blank F o r R e f e r e n c e O n l y ...

Page 201: ... 5 000 Operating Hours 5 8 Maintenance and Inspection Plan Y 6 Every 72 Months After 6 000 Operating Hours 5 8 Periodic Inspections 5 9 Load Hook Inspection 5 9 Measures Required for Hoist Monitoring 5 10 Theoretical Service Life 5 10 Proportion of the Theoretical Service Life Used 5 10 Table Example to Determine the Remaining Theoretical Service Life on Hoist No 1 Main Hoist 5 12 SUPERSTRUCTURE M...

Page 202: ...ine are simultaneously the total operating hours of the superstructure The following table sets out the maintenance intervals for the maintenance plans NOTE Please note that the long term maintenance plans always include the short term ones Maintenance Plans Maintenance Interval Operating Hours of Diesel Engine Superstructure D daily before putting into operation W weekly M 1 monthly 100 M 3 every...

Page 203: ...em properly installed on machine Check for excess dirt grease or foreign matter Check for proper operation while operating machine 5 Boom Angle Indicator Check for proper operation while operating machine 6 Brakes Swing Foot Parking Check for proper working order Check for proper operation while operating machine 7 Brakes and Air System if equipped Check for proper working order Check for proper o...

Page 204: ...rn Check for cracked or broken glass Check for proper working order 22 Steps and Ladders Check for excess dirt grease or foreign matter Check for deterioration damage or excessive wear check for cracked or broken structures and welds 23 Tires Check for proper inflation pressure Check for excessive wear Check for excess dirt grease or foreign matter 24 Transmission Torque Converter Check for proper...

Page 205: ...ist Lubrication page 9 21 Swing Gear Check the swing gear transmission oil level page 9 18 Check the swing gear brake oil level page 9 18 Check for leaks Hydraulic System of the Superstructure Check hydraulic hoses Check for leaks with the diesel engine running Central Lubrication System on Superstructure Check the level of the grease container page 9 22 Hoist Ropes Check condition Hoist Ropes pag...

Page 206: ... the lift cylinder Other Maintenance Work Check for correct operation of the auxiliary heater additional equipment Lubricate cabin door track rollers Lubricate the connecting and socket pins Lubricate the spring latch Maintenance Work on the SUPERSTRUCTURE Every 3 Months After 300 Operating Hours Ball Swing Connection Check tightness of retaining bolts Torque Values page 1 9 Main Boom Lubricate lo...

Page 207: ...onths After 1 000 Operating Hours Main Hoist Auxiliary Hoist Oil change1 page 9 21 Check the old oil Swing Gears Oil change swing gear transmission Change the swing gear brake oil Main Boom Check the locking system Superstructure Air Conditioning System Additional Equipment Check the entire air conditioning system Maintenance Work on the SUPERSTRUCTURE Every 24 Months No maintenance work in this p...

Page 208: ...d Inspection Plan Y 6 Every 72 Months After 6 000 Operating Hours Maintenance Work on the SUPERSTRUCTURE Every 60 Months After 5 000 Operating Hours RCL Lubricate the swing angle sensor page 4 52 Maintenance Work on the Superstructure Every 72 Months After 6 000 Operating Hours Main Hoist Auxiliary Hoist Carrying Out General Inspection of Hoists page 4 2 F o r R e f e r e n c e O n l y ...

Page 209: ... etc including a special check of all welds If damage is found in the structural steelwork have qualified specialists determine the extent of the damage using the required material examination methods They should then determine what sort of repair action could be done The inspector is to write a record containing the result of the inspection and the measures taken to repair any damages Load Hook I...

Page 210: ...ch as Overloading caused by improper use of the crane Insufficient maintenance oil is not changed in the specified intervals Incorrect operation extreme acceleration or retardation of the load load drops and stops suddenly while suspended Improper maintenance using wrong oil incorrect quantity contamination during oil change Improper assembly during maintenance and repair work Leaks which were ign...

Page 211: ...tive load factor Km Graphic representation light Q 1 L 1 Power units or their parts which are subjected to highest load as an exception continuously however only very less load 10 of the operating time with highest load dead load 1 1 payload 40 of the operating time with dead load 1 3 payload 50 of the operating time only with dead load 0 125 medium Q 2 L 2 Power units or their parts which are ver...

Page 212: ...rs of the superstructure Operating hours of the superstructure since the last inspection Operating hours of the winch Operating hours of the winch since the last inspection Used proportion of the theoretical service life Remaining theoretical service life Di Di 1 Si Name of the expert Signature Note Name of the approved inspector Signature i Kmi h h h h h h h 0 10 6 90 0 0 3200 1 5 6 91 L 1 0 125 ...

Page 213: ... LOW speed Braking is accomplished by depressing a glide swing brake pedal which is a proportionate control valve that provides a controlled braking of the swing motion The swing system consists of a hydraulic remote controller swing speed switch series parallel selector valve a directional control valve the swing drives the swing brake assemblies the brake pedal and power brake valve and a swing ...

Page 214: ...sing the swing brakes Regulated flow from the pressure reducing sequence valve is also provided to the power brake valve where it is available for the activation of the swing brake when the pedal is depressed 1 FIGURE 6 1 7598 1 4 3 2 1 3 Picture May Not be Same Model as Your Machine It is for REFERENCE ONLY Item Description 1 Swing Drive 2 Axial Piston Motor 3 Turntable Bearing 4 Pinion Gear F o ...

Page 215: ...replace swing motor i Excessive overload i Reduce load Refer to load capacity chart j Restricted or partly clogged hydraulic hose or fittings j Replace hose or fittings Refer to the Manitowoc Crane Care Parts Manual k Pump cavitation in swing section k Tighten suction hose or replace any damaged fitting Check hydraulic tank level l Improperly torqued turntable bolts l Torque turntable bolts evenly...

Page 216: ...ing box and repair f Worn or damaged hydraulic pump f Replace pump section g Damaged swing directional control valve g Replace swing directional control valve h Damaged swing pinion h Replace pinion i Damaged turntable bearing i Replace turntable bearing j Excessive overload j Reduce load Refer to load capacity chart 4 Swing operation slow in either direction a Damaged relief valve a Adjust repair...

Page 217: ...e c Internal damage to the swing brake assembly c Repair or replace affected parts d Loose or restricted brake lines or fittings d Tighten or replace lines and fittings 8 Swing brake pedal is spongy a Damaged glide swing power brake valve a Repair or replace the glide swing power brake valve b Loose or restricted brake lines or fittings b Tighten or replace brake lines and fittings 9 Swing brake d...

Page 218: ...connections a Reverse port connection b Improper wiring connection b Inspect wiring and connections Make repairs as needed 13 Swing motor noisy a Air in system a Refer to Hydraulic System page 2 1 for removal of air from the system b Motor binding b Repair or replace motor Symptom Probable Cause Solution F o r R e f e r e n c e O n l y ...

Page 219: ...gear oil The hydraulic lines are only for applying or releasing the brake not providing brake or gearbox lubrication There are hydraulic lines to the swing motor these lines are also in a system sealed from gear oil The hydraulic lines are for driving the motor in the chosen rotation There is one drain plug for draining hydraulic fluid from the swing motor Swing Motor Maintenance NOTE Each swing m...

Page 220: ...to the gearbox 2 Secure the brake assembly with the socket head capscrews 3 Install the swing motor on the swing brake assembly per the procedure in this section 4 Connect the hydraulic lines to the swing motor and swing brake assembly 5 Bleed all air from the swing brake assembly Testing 1 With the Swing Brake Switch in the ON position move the swing control lever in both directions Superstructur...

Page 221: ...c 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 250 hours of operation and replaced with premium quality SGL 5 after about 500 hours of operation or each year whichever occurs first Operation in high humidity or polluted air areas will require more frequent changes to minimiz...

Page 222: ...d provide more reliable less variable readings NOTE If multipliers and or special tools are used to reach hard to get at areas ensure torque readings are accurate Torque wrenches are precision instruments and must be handled with care To ensure accuracy calibrations must be made on a scheduled basis Whenever there is a possibility that a torque wrench may have been either overstressed or damaged i...

Page 223: ...ble bolts Inner Race Torquing 1 Extend and set the outriggers Fully elevate the boom 2 Torque all bolts to 80 of the full torque value of 466 lb ft 632 Nm following star pattern sequence as shown in Figure 6 2 starting with bolt number 1 Figure 6 2 Tools used are the socket multiplier backlash adapter necessary extensions and torque wrench 3 Return to bolt 1 and torque all bolts using the same sta...

Page 224: ...Locate the connectors and ground wire that joins the swivel wiring harness to the receptacles and ground stud on the carrier 9 Disconnect the swivel wiring harness connectors from the carrier wiring receptacles Remove the ground wire from the ground stud 10 Remove the clamp securing the swivel wiring harness to the retainer plate on the bottom of the hydraulic swivel assembly 11 Coil the wiring ha...

Page 225: ...ring is to be used again align the marked teeth on the pinion shaft and the marked teeth on the bearing Installation is in the travel position Ensure the swing lock is disengaged before attempting to mate the bearing to the superstructure 1 Using an appropriate lifting device position the turntable bearing under the superstructure If the same bearing is being used position it as marked prior to re...

Page 226: ...ainers and four bolts Torque the bolts according to the specifications in Fasteners and Torque Values page 1 9 Bend all the retainer tabs to make contact with the bolt heads 7 Plug the swivel wiring harness connectors into the carrier receptacles Secure the ground wire to the ground stud using a washer lockwasher and nut 8 Install the clamp securing the swivel wiring harness to the retainer plate ...

Page 227: ...late 9 which engages the carrier frame lugs with bolts and jam nuts 10 This allows the spool to remain stationary with the carrier as the case rotates with the superstructure The spool portion of the water swivel is attached to the spool of the hydraulic swivel by four bolts The hydraulic and water swivel spools remain stationary with the carrier as the superstructure rotates The water swivel case...

Page 228: ...l 707 01 SWING SYSTEM TMS9000 2 SERVICE MANUAL 8902 1 FIGURE 6 5 6 3 4 8902 5 2 1 Item Description 1 8 Port Hydraulic AC Swivel 2 20 Conductor Slip Ring Assy 3 Bolt 4 Washer 5 Mounting Bracket 6 Harness F o r R e f e r e n c e O n l y ...

Page 229: ...oximately 236 kg 520 lb 8 On the bottom of the swivel bend the retainer tabs away from the capscrew heads Remove the eight capscrews and four capscrew retainers securing the two retainer plates to the spool Remove the retainer plates from the spool and the lugs on the carrier frame NOTE It may be necessary to remove some drive line components to remove the swivel 9 Position an adequate supporting ...

Page 230: ... appropriate pin removal tools remove the pins with wires still attached and mark each wire with the pin socket number in the connector Collect the wires and secure into one bundle Mark the bundle with the connector number For a list of the appropriate pin removal tools refer to Connector Troubleshooting page 3 11 6 Secure the connectors and wires from each of the numbered connectors so the harnes...

Page 231: ... for proper electrical termination of grounds 8 Install the clamp securing the harness to the retainer plate on the bottom of the hydraulic swivel assembly 9 Connect the batteries 10 Activate all systems cycle all functions and observe for proper operation Preventive Maintenance It is recommended that a normal inspection of the electrical swivel collector ring and brush assembly be established An ...

Page 232: ...Verify the superstructure can lock properly when the pin is applied and the superstructure can rotate without pin hangup when the pin is not applied 360 SWING LOCK CONTROL POSITIVE LOCK TYPE Description The purpose of the swing lock is to secure the superstructure in position at one of the positions in its rotation There are roughly 247 spots about 1 45 degrees apart for the superstructure to lock...

Page 233: ...34 Theory of Operation 7 34 Maintenance 7 35 Lubrication 7 38 Preventive Maintenance 7 39 Transmission Shift Air System 7 39 Description 7 39 Theory of Operation 7 39 Pump PTO Assembly 7 40 Pump PTO Replacement 7 40 ENGINE Description The engine is a Cummins X12 on highway engine This Service Manual does not include detailed information on this individual engine A separate manual as prepared in de...

Page 234: ...h an adequate lifting device and remove the aftertreatment assembly 15 Disconnect hoses from main piston pump and cap all openings 16 Unbolt driveline from piston pump coupler and lay on transmission 17 Remove piston pump assembly 18 Attach adequate lifting device to the engine and transmission sufficient to lift and support both the engine and transmission 19 Tag and disconnect the engine electri...

Page 235: ... Engine Mounts 2 Engine Oil Dipstick 3 Fan Clutch 4 Transmission 5 Alternator 6 Front Cross Member and Mounts 7 Oil Temperature Sensor 8 Oil Pressure Sensor 9 Engine Oil Filter Remote Mount 10 Transmission Oil Fill Plug 11 Gear Pump Power Steering 12 Lifting Brackets FIGURE 7 1 8326 8 F o r R e f e r e n c e O n l y ...

Page 236: ...ring removal 14 Install piston pump 15 Bolt drive line to piston pump coupler 16 Connect hoses to main piston pump NOTE Aftertreatment assembly weighs approximately 90 kg 200 pounds Ensure lifting device is sufficient to lift the aftertreatment assembly 17 Attach lifting device to and install the aftertreatment assembly 18 Install the engine hood assembly counterweight stowage frame work and the r...

Page 237: ...nputs from sensors such as the engine coolant temperature sensor and the manifold boost pressure sensor During this phase the data link is active and can be accessed by the applicable service tools The ECM opens the fuel shutoff valve so the engine is ready to be started Additionally if the key switch is turned on but the diagnostic switch remains off the indicator lights illuminate for approximat...

Page 238: ...p lights will remain on Filter Exhaust System Cleaning High Exhaust Indicator The amber filter exhaust system cleaning indicator located in the tachometer will illuminate when the exhaust system has not been able to clean under normal operating conditions and is in need of assistance in order to perform an active cleaning There are three progressive stages of need for cleaning indicated by this li...

Page 239: ...el quantity sender units 3 Connect the two lines to the fittings on the tank in accordance with the identification marks made during removal 4 Service the tank Fuel Filter Water Separator Draining The sump of the fuel filter water separator should be drained daily 30 minutes after the engine is shut down to remove any water and sediment Adhere to the following procedure 1 Place a suitable containe...

Page 240: ... front fender A service indicator designed to indicate red when servicing is required is installed at the air cleaner outlet The optional automatic cold weather starting system consists of a temperature sensor atomizer valve assembly and starting fluid bottle The quick start system is activated when 9036 5 6 7 12 2 4 3 1 8 1 Fuel Supply to Engine 2 Fuel Return From Engine 3 Tank Vent 4 Fuel Quanti...

Page 241: ... s accuracy is suspect a water manometer is the most accurate and dependable method of measuring vacuum To use the manometer hold it vertically and fill both legs approximately half full with water One of the upper ends is connected to the restriction tap on the outlet side of the air cleaner by means of a flexible hose The other end is left open to the atmosphere Maximum restriction in the air cl...

Page 242: ...gn matter that may have collected inside the air cleaner body Inspect the inside of the body for dents or other damage that would interfere with air flow or with the fins on the element or inside the body Repair any body dents being careful not to damage the sealing surfaces Be sure to clean the sealing surface of the outlet tube and the inside of the outlet tube taking care not to damage the seal...

Page 243: ...able lifting device remove the aftertreatment system 6 Inspect exhaust tubing exhaust wrap outlet sensors and wire leads and attaching hardware 7 Inspect the crane s sensor harness wiring that connects to sensor wiring of the exhaust system Repair or replace any of these components if damaged or missing System Installation 1 Install mounting bands on aftertreatment module 2 Install the aftertreatm...

Page 244: ...s Slip joint exhaust couplers require tightening to avoid exhaust leaks Perform the following procedures at the appropriate intervals After 1000 Hours or One Year Visually inspect the exhaust connector If necessary tighten the v clamps by one full turn of the nuts 2000 Hours or 2 Years Tighten the v clamps by 1 turns of the nuts 4000 Hours or 4 Years Tighten the v clamp by 1 turns of the nuts 5000...

Page 245: ...oval Refer to Figure 7 10 1 Tag and disconnect the electrical connectors on the DEF tank 2 Tag and disconnect the fluid lines on the tank 3 Remove the hardware holding the tank straps in place 4 Remove the tank Installation Refer to Figure 7 10 1 Place the DEF tank onto the location on the frame 2 Place the tank straps around the tank and secure with the hardware 3 Connect the fluid lines as tagge...

Page 246: ...dosing unit filter consists of the following components 1 Aftertreatment DEF Dosing Unit Filter Cap 2 Aftertreatment DEF Dosing Unit Filter Equalizing Element 3 Aftertreatment DEF Dosing Unit Filter Element Initial Check Inspect the area around the seal and vent of the aftertreatment DEF dosing unit filter cap for signs of leakage DEF leaks leave a white deposit If deposits are found see the Clean...

Page 247: ...d fluid has passed through the dosing system 2 Inspect the DEF filter for debris If debris is evident also check DEF tank pick up screen The aftertreatment DEF dosing unit inlet connector 3 Discard the filter element and equalizing element 4 Inspect the aftertreatment DEF dosing unit filter cap for cracks or holes that could create a DEF leak path 5 Check the condition of the threads on the aftert...

Page 248: ...er through the cooling system relies entirely upon the water pump The water pump draws water from the radiator and forces it through the water jacket and cylinder head There it accumulates heat and flows to the top radiator tank Then the water flows down through the radiator core and is cooled by air from the fan This process of removing heat from water as it circulates holds the engine to its eff...

Page 249: ...coolant filter must also be changed 1 Open cab heater line valve and SCR cooling line valves 2 Open petcocks at the Diesel Exhaust Fluid DEF Tank 1 2 Figure 7 12 to allow trapped air to bleed 3 Slowly fill the system at 11 l min 3 0 gpm to the bottom of the surge tank fill neck NOTE A fill rate faster than 11 l min 3 0 gpm can give a false reading 4 Verify a steady stream of fluid no more than 1 1...

Page 250: ...e vehicle paint 4 Replace the radiator cap and run the engine at moderate speed covering the radiator if necessary so the system reaches a temperature of 82 C 180 F or above but does not reach the boiling point Allow the engine to run at least two hours or according to recommendations of the manufacturer of the cleaning compound at 82 C 180 F so the cleaning solution may take effect Do not drive t...

Page 251: ...ve from the gasket and releases the pressure through the overflow pipe In the first stage position of the cap it should be possible to depress the cap approximately 3 mm 0 13 in The prongs on the cap can be bent to adjust this condition Care must be taken that the cap is not too loose as this would prevent proper sealing 4 Tubes are very small and can become easily clogged by rust and scale The ge...

Page 252: ...he coolant into a suitable container Dispose of the coolant in accordance with local and EPA regulations 4 Open the left and right hood access doors 5 Disconnect the hoses 12 from the coolant recovery tank 2 and remove the tank 6 Remove the hardware securing the top center hood panel to the front and rear cowls and remove the panel with doors from the crane 7 Remove the hardware securing the left ...

Page 253: ...e operate all systems and check for leaks Item Description 1 Radiator Charge Air Cooler 8 Cold CAC Tube 2 Recovery Tank 9 Hot CAC Tube 3 Drain Cock 10 Radiator Mount 4 Left Hand Baffle 11 Fan Guards 5 Right Hand Baffle 12 Coolant Recovery Hose 6 Top Radiator Tube 13 Vent Hoses 7 Bottom Radiator Tube FIGURE 7 13 1 4 6 2 8 10 7 5 3 9 11 10 13 Engine Radiator Charge Air Cooler Assembly 12 F o r R e f...

Page 254: ...onnects the rear axles MAINTENANCE Drive Lines Removal Refer to Figure 7 14 1 Support the drive line being removed so it does not fall when disconnected 2 Remove the bolts from the bearing cap on each end of the drive line Remove the drive line Installation Refer to Figure 7 14 1 Position the drive line install the bearing cap bolts and tighten bolts securely 2 Torque the bearing cap bolts on the ...

Page 255: ... TORQUE 149 to 163 Nm 110 to 120 ft lb TORQUE 149 to 163 Nm 110 to 120 ft lb TORQUE 149 to 163 Nm 110 to 120 ft lb TORQUE 149 to 163 Nm 110 to 120 ft lb TORQUE 136 Nm 100 ft lb TORQUE 149 to 163 Nm 110 to 120 ft lb Drive Line Installation View A FIGURE 7 14 F o r R e f e r e n c e O n l y ...

Page 256: ... plate is driven by driving lugs extending into mating slots in the flywheel ring cover The intermediate plate is driven by drive pins located in the engine flywheel Depressing the clutch pedal pulls the release bearing assembly toward the transmission The release bearing being connected to the release levers thus retracts the pressure plate from contact with the driven disc assembly This relieves...

Page 257: ...2 SERVICE MANUAL POWER TRAIN 7 1 Clutch Assembly 2 Adjusting Lever 3 Governor Spring 4 Pilot Bearing 5 Crank 6 Lockwasher 7 Bolt 8 Clutch Release Shaft and Parts 1 2 8 5 3 4 1 6 7 3 2 8 5 4749 Clutch Installation FIGURE 7 15 F o r R e f e r e n c e O n l y ...

Page 258: ... Use correct cover assembly Cross shaft bushings worn Replace the bushings Release levers not parallel Recheck installation Aggressive grabby Excessive backlash in the power train Worn parts Warped driven disc Install a new disc assembly Worn hub splines Install a new disc assembly Worn splines on splined shaft Replace shaft Improper facing material Install proper driven disc assembly Insufficient...

Page 259: ...ing alignment of engine and transmission Make sure driven discs slide freely on drive gear splines Internal clutch adjustment not correct Readjust clutch for standard release travel Flywheel pilot bearing fitting too tight in flywheel or on end of drive gear Free pilot bearing to a light push Fit in flywheel and on drive gear pilot If bearing is rough replace Facings gummed with oil or grease Repl...

Page 260: ...n by the shifter shaft Replace the carrier and shifter yoke Also check for proper installation to provide the best linkage operating positions Slippage Oil or grease on the facing Replace facing or install a new driven disc assembly Loose or worn facings Replace facings or install a new driven disc assembly Weak pressure springs Replace springs No free pedal Readjust clutch Release mechanism bindi...

Page 261: ...cated difference between the high and low joints must be 0 178 mm 0 007 in or less for a 35 6 cm 14 in clutch 0 203 mm 0 008 in or less for a 39 4 cm 15 5 in clutch 4 Secure a dial indicator to the crankshaft With the gauge finger against the housing pilot rotate the crankshaft Use a marker or soapstone to mark the high and low points Total difference between high and low points should not exceed ...

Page 262: ...prings need 21 7 cm 8 56 in bore 7 Springs need 24 8 cm 9 75 in bore 9 Springs need 24 8 cm 9 75 in bore Insert the aligning tool through the release bearing sleeve in the new clutch 3 Put the rear driven disc on the aligning tool with the side stamped pressure plate facing the pressure plate 4 Place the intermediate plate in the clutch cover and align the driving lugs of the plate with the slots ...

Page 263: ...y weighs approximately 68 kg 150 lb so a hoist may be required to lift it into place 8 Start the eight 7 16 inch bolts with lockwashers and tighten them finger tight 9 Tighten the bolts in the crisscross sequence to pull the clutch into its proper position in the flywheel pilot You must start with the lower left hand bolt 10 To achieve the final torque progressively tighten all bolts 61 to 69 Nm 4...

Page 264: ... or never seize Install discs dry or wipe on a light coat of oil If a clutch brake is used be sure to install it on the input shaft of the transmission at this time 12 Refer to Installation of the Transmission page 7 38 and install the transmission 4863 12 MEASURE BORE SIZE 9 53 15 88 mm 0 375 0 625 in 9 53 15 88 mm 0 375 0 625 in If greater than 15 88 mm 0 625 in check fly wheel for potential dam...

Page 265: ...e inspection plate on the bottom of the clutch housing and road test the crane for proper clutch operation Clutch Adjustment Inspection Procedure 1 Remove the inspection plate from the bottom of the clutch housing 2 Depress the clutch pedal several times and check for the 9 525 to 12 7 mm 0 375 to 0 5 in release bearing travel Readjust if necessary 3 Check the clutch pedal for 38 1 mm 1 5 in of fr...

Page 266: ...etscrews after tightening 5 Lubricate the U joints with chassis grease 6 Connect the nylon tubing to the range shift valve if disconnected 7 Connect the nylon tubing to the splitter valve MANUAL TRANSMISSION Description The transmission provides 11 forward speeds and three reverse consisting of a five speed front section and a three speed auxiliary section The auxiliary section contains the LO and...

Page 267: ...maged vibration damper Replace damper Flywheel out of balance Check balance Replace flywheel if necessary Unbalanced clutch assembly Check clutch and clutch housing for proper alignment Loose engine mountings Tighten mountings Worn U joints Replace U joints Noisy transmission in neutral Transmission misaligned Align engine and transmission assembled with rear axle so as to correct angles of U join...

Page 268: ...efill with proper grade and type of lubricant Drain back holes between bearing retainers and main case stopped up Check drain holes and gaskets to ensure openings are clean Broken gaskets Replace gaskets and use gasket cement Loose drain plug in transmission Tighten drain plug Cracked transmission housing Replace transmission Cover not properly tightened Tighten cover Noisy transmission in gear Ge...

Page 269: ...ID of the drive gear 6 Pull the input shaft forward and from the splines of the drive gear Improper adjustment of shifting linkage Worn or bent shifter rails Check and adjust linkage and rods to ensure that transmission is shifting fully into gear Insufficient lubricant Fill to proper level Range shift inoperative or malfunctioning Air lines crossed between control valve on shift lever and air val...

Page 270: ...s and washers securing the engine flywheel to the flywheel ring cover 7 Refer to Power Train page 7 1 and install the engine and transmission Lubrication General The transmission is designed so the internal parts operate in a bath of oil circulated by the motion of gears and shafts Grey iron parts have built in channels where needed to help lubricate bearings and shafts Thus all parts will be ampl...

Page 271: ...oint companion flange removed Output Shaft Check splines for wear from movement and chucking action of the universal joint companion flange Main Shaft Rear Bearing Cover Check oil seal for wear TRANSMISSION SHIFT AIR SYSTEM Description The shift air system controls the selection of the transmission ranges and is comprised of an air valve air regulator air filter range control valve a range shift c...

Page 272: ...d washers connecting the PTO driveline to the engine Remove the driveline 3 Tag disconnect and plug or cap the hydraulic hoses and ports on the pumps 4 Tag and disconnect the electrical connectors to the pumps CAUTION Damage Could Occur Absolute cleanliness is essential when working on the hydraulic pumps Always work in a clean area The presence of dirt and foreign materials in the system can resu...

Page 273: ...o the crane and loosely assemble with the cap screws nuts and washers 2 To prime the pumps add hydraulic oil to the pumps and hoses before installation 3 Connect the electrical connectors and hoses to the pumps as tagged during removal 4 Tighten the hardware connecting the mounting bracket pump to the frame Torque the hardware refer to Fasteners and Torque Values page 1 8 5 Install the driveline o...

Page 274: ...7 42 Published 01 14 2021 Control 707 01 POWER TRAIN TMS9000 2 SERVICE MANUAL This Page Blank F o r R e f e r e n c e O n l y ...

Page 275: ...ormal Braking 8 36 Vehicle Parking 8 36 Anti lock Braking Systems ABS 8 36 Automatic Traction Control 8 37 Emergency Braking 8 37 Non Asbestos Warning 8 37 Front Brakes 8 37 Description 8 37 Maintenance 8 38 Automatic Slack Adjuster 8 44 Description 8 44 Maintenance 8 44 Rear Brakes 8 52 Description 8 52 Maintenance 8 52 Rear Brake Assembly 8 55 Anti Lock Brake System ABS Automatic Traction Contro...

Page 276: ...auses the four height control valves to shift and dump all air from the suspension air bags Four pressure switches sense the air pressure in each set of air bags Low air pressure in any of the four sets of air bags will trip the respective pressure switch to illuminate the DEFLATED indicator on the side console MAINTENANCE General Proper preventive maintenance will help control repair costs and do...

Page 277: ...r road damage Check for air leaks Check tightness of nuts and bolts Torque to 41 Nm 30 lb ft Height Control Valves Check valve fittings and air lines for leaks Check actuating linkage for bent or damaged condition Shock Absorbers Check the shock absorbers for leakage and wear F o r R e f e r e n c e O n l y ...

Page 278: ...earbox 3 Vertical Socket Drag Link 4 Relay Arm 5 Torque Rod 6 Steer Axle 7 Suspension Air Bag 8 Walking Beam 9 Suspension Saddle Assembly 10 Shock Absorber 11 Steer Cylinder 12 Trunnion Tube 1 2 3 4 3 6 9 8 7 4 6 3 5 11 10 7 9 12 8 5 FIGURE 8 1 Axle and Suspension Assembly F o r R e f e r e n c e O n l y ...

Page 279: ...nd record the distance for each torque rod from center to center of the rod clevis Do not change this dimension when installing torque rods This will make wheel alignment easier when the axle is reinstalled 1 Remove the bolts hardened washers and nuts securing four torque rods to the axle brackets 2 Remove two shock absorbers from the suspension saddle assembly by removing the nut and two washers ...

Page 280: ... and nuts each apply Loctite 243 to bolt threads and torque to 295 320 Nm 217 236 lb ft 10 Install the air fittings in the inlet of the air bags Connect the air lines to the air bags and brake chambers as tagged during removal 11 Service the axles and suspension system Refer to Lubrication page 9 1 12 Build up air pressure in the systems and check for leaks Check operation of brakes and air suspen...

Page 281: ...ADDLE BLOCK DIAGONAL MEASUREMENT DIAGONAL MEASUREMENT STRING LINE STRING LINE LONGITUDINAL MEASUREMENT LONGITUDINAL MEASUREMENT KING PIN CENTER KING PIN CENTER KING PIN CENTER KING PIN CENTER C L OF FIRST FRONT AXLE C L OF LAST FRONT AXLE C L OF FRONT BOGIE FIGURE 8 2 AXLE ALIGNMENT PROCEDURE F o r R e f e r e n c e O n l y ...

Page 282: ...cure the drag link and relay arm assembly to the carrier frame with pin weldment Shim as required to obtain a max gap of 1 5 mm 0 059 in on the inside of the arm assembly and no gap on the outside Secure screw flatwasher and lockwasher to pin weldment 2 Secure the drag link Detail 7 Figure 8 8 to the rear relay arm Detail 8 Figure 8 8 with cotter pin Be sure to keep drag link clamp rotated away fr...

Page 283: ...result in poor ride quality or possible damage to suspension and axle components 1 Front Axle Ride Height 11 75 In Figure 8 5 2 Rear Axle Ride Height 15 25 In Figure 8 6 3 Adjust rod to achieve proper ride height setting Figure 8 7 and torque P clamp on P boot to 10 15 in lbs NOTE Over tightening of the P clamp will cut through the P boot Final Adjustments 1 Inflate tires to the pressure specified...

Page 284: ...red so that the distance from the string line to the front of each wheel is the same as the distance from the string line to the rear of the same wheel within 1 5 mm 0 06 in Check that the rod ends of the drag links are within limits specified in Figure 8 8 10 Remove the rig pins CAUTION Vehicle Damage Hazard Do not attempt to adjust the axle drag links or the tie rod ends while the full weight of...

Page 285: ...eft If axle stop is contacted turn front plunger in to limit wheel cut If gap to axle stop is more than 3 1 mm 0 125 inch at full turn adjust plunger to increase wheel cut Repeat for right turn rear plunger NOTE Do not attempt to set the relief pressure with the tires off the ground Plungers are fine thread and accept a small flathead screwdriver After approximately 4 wheel turns steering effort m...

Page 286: ... SCREW OUT TO INCREASE TRAVEL FRONT PLUNGER ADJUST ON LEFT HAND TURN SCREW IN TO DECREASE TRAVEL SCREW OUT TO INCREASE TRAVEL PLUNGER O RING DETAIL B DETAIL A PRIOR TO GEAR INSTALLATION WIND PLUNGER IN UNTIL IT BOTTOMS OUT IN HOUSING PRIOR TO GEAR INSTALLATION WIND PLUNGER IN UNTIL IT BOTTOMS OUT IN HOUSING 0 156 IN 4 MM MIN ACCEPTABLE PLUNGER HEAD DEPTH NOTE PLUNGER S MUST NOT BE WOUND OUT BEYOND...

Page 287: ...ungers Air leak in suction side of supply pump Reference pump servicing instruction Pump cavitation Check for restriction in pump supply Oil overheating Check for restriction in steering gear return Engine oil in power steering reservoir gear driven pump Faulty seal at pump drive shaft Repair pump Faulty seal at accessory shaft driving supply pump Repair accessory drive Lubricating oil discolored ...

Page 288: ... mount gears Linkage ball sockets seized or binding Check and repair or replace King pins seized or binding Repair or replace Oil flow rate incorrect Check and correct supply pump Darting wandering oversteering Oil flow too high Supply pump not to specifications Air trapped in steering gear Bleed system Looseness worn front end parts Check and repair as required Front end alignment not correct Ali...

Page 289: ...gine running there is a constant oil flow through the steering gear which provides an instant response and absorbs road shock There is mechanical back up steering so that the vehicle can be steered to the side of the road in the event of hydraulic pressure loss Maintenance Removal 1 Tag and disconnect the hydraulic lines from the steering gearbox Cap or plug all openings 2 Remove the steering shaf...

Page 290: ...h the steering column to the steering gearbox input shaft 10 Connect the drag link vertical socket to the pitman arm using a slotted nut Torque the nut to 135 to 170 Nm 99 to 125 lb ft Tighten the nut to the next cotter pin hole and install the cotter pin 11 Connect the hydraulic lines to the steering gearbox as tagged during removal 12 Apply never seez compound to steering gear output shaft STEER...

Page 291: ...t lubricate wheel or axle faces 1 Position the wheel assembly on the mounting studs Install the lug nuts and tighten them until they are just snug rotating the wheel so the nut being tightened is in the top position 2 Ensure the wheel assembly is positioned properly on the hub Tighten the lug nuts in the sequence shown to a preliminary torque of 37 Nm 50 lb ft 3 Torque the lug nuts 610 to 678 Nm 4...

Page 292: ...side console Maintenance General Proper preventive maintenance will help control repair costs and downtime If a major overhaul is required remove the tandem suspension and axle assemblies from the carrier However torque rods air bags shock absorbers walking beams and other components can be removed separately as required with the axles remaining on the carrier Refer to the Lubrication page 9 1 sec...

Page 293: ...0 2 SERVICE MANUAL CARRIER 8 1 2 3 2 7 5 9 4 6 4 3 2 8 1 1 Drive Axle 2 Air Brake Chamber 3 Torque Rod 4 Lower Saddle Assembly 5 Air Bags 6 Walking Beam 7 Shock Absorber 8 Drive Line 9 Lateral Torque Rod 9 6982 FIGURE 8 12 F o r R e f e r e n c e O n l y ...

Page 294: ...emove two shock absorbers from the suspension saddle assembly by removing the bolt and two washers securing each Remove the shock absorber s 5 Remove each axle from the walking beams by removing the two bolts washers and nuts securing each end of the axles to the walking beam end bushings Remove the axle s 6 Remove the saddle assemblies from the walking beams by removing two bolts and washers from...

Page 295: ...12 Install the tire and wheel assemblies and reinstall the wheel speed sensor harness tie strap harness every 150 mm Refer to WHEELS AND TIRES in this Section 13 Retract the outriggers and check the axles for proper operation WHEELS AND TIRES Description One size of tire is available on the rear axle 315 80R22 5 NOTE Always replace tires with the same size that were factory installed this crane ha...

Page 296: ... each other so that in the event of a failure in one system air is retained in the other system By means of pressure protection valves spring brake valves a reserve of air pressure remains to operate the brakes through normal use of the brake pedal Any unusual loss of pressure should be investigated immediately and corrected so as to restore the full backup capability of the system Theory of Opera...

Page 297: ...01 14 2021 Control 707 01 8 23 TMS9000 2 SERVICE MANUAL CARRIER 8 See View B 1 1 4 2 3 2 5 3 See View A 4 4 See View C 6 7 4 10 12 9 8 3 6972 4 6972 9 6972 3 6972 1 6972 2 5 FIGURE 8 14 F o r R e f e r e n c e O n l y ...

Page 298: ...ng releasing the brakes At least 280 kPa 40 psi is required to keep the parking brake valve engaged If supply 2 12 View A 4 15 View B View C 13 15 14 16 15 15 17 6972 8 6972 6 6972 5 Figure 8 14continued Item Description Item Description 1 Air Dryer Module 10 Tractor Protection Valve 2 Supply Dump Valve 11 Cross Axle Diff Lock Solenoid Valve Opt 3 Front Service Brake Relay Valve 12 Air Suspension ...

Page 299: ...suspension deflate indicator light should illuminate when the pressure in all air bags drops below 28 14 kPa 4 2 psi 3 Raise the crane on outriggers 4 Shutdown the engine Pressure Warnings and Pressure Build up 1 Drain all reservoirs to zero 0 psi by opening the drain valves If not already applied the parking brake will be applied as the system is drained Ensure the parking brakes are applied on a...

Page 300: ... Turn engine off and allow the air pressure to stabilize for one minute 3 Release the park brakes by pushing the yellow button on the front console On units equipped with trailing boom push the yellow button and the red button Ensure the dummy glad hand is installed on the trailer supply and control disconnects before pushing red button 4 Check that all wheels turn freely 5 Simulate a full air lea...

Page 301: ...out when the pressure decreases below 138 to 207 kPa 20 to 30 psi 8 On units equipped with trailing boom the trailer emergency supply line should be exhausted between 138 to 310 kPa 20 to 45 psi Air System Components Air Compressor The air compressor Figure 8 16 is mounted on and driven by the engine It provides the source of compressed air for the operation of the air system components It is cont...

Page 302: ...iliary air devices The first reservoir in the system in air dryer module also acts as a purge tank to remove additional moisture not removed by the air dryer The reservoirs have manual drain valves 12 11 3 2 4 5 9 1 8 6 10 7 FIGURE 8 16 Item Description Item Description 1 Governor 7 Auxiliary Delivery Port Air Out 2 Unloader Control Valve 8 Inlet Port Supply From Compressor 3 Common Reservoir Pres...

Page 303: ...le calibrated from 0 to 150 psi and 100 to 1000 kPa Safety Valve A safety valve Figure 8 19 is installed in the air dryer module to protect the air system against excessive air pressure buildup The valve consists of a spring loaded ball which exhausts the system if the pressure rises above 1030 kPa 150 psi A second safety valve is installed in the tire inflation circuit and is set at 1207 kPa 175 ...

Page 304: ...ervice brakes or the parking brakes through the spring brake control valve Spring Brake Control Valve The spring brake control valve Figure 8 22 is located on the rear of the carrier frame The purpose of the valve is to supply a specific limited hold off pressure to the spring brakes and in the event of loss of primary pressure to modulate the spring brakes through use of the dual brake valve Park...

Page 305: ...d pressurize the system Check the governor cut out pressure with either the panel gauge or a test gauge 896 kPa 130 psi At the cut out pressure the compressor is unloaded and the air dryer is purged Leakage Test 1 Leakage checks on the governor are made at the exhaust port with a soap solution in both the cut in and cut out positions In the cut in position the leakage can be through either the inl...

Page 306: ...ied limits replace the purge valve housing assembly which includes the thermostat and heater Leak Tests 1 Test the outlet port check valve in the dryer by observing the pressure after the governor cuts out A rapid loss in pressure indicates a possible failed check valve in the outlet port 2 Test the purge valve by applying a soap solution to the exhaust Observe for bubbles during the loading cycle...

Page 307: ...gs 3 Install the front console cover and secure with attaching hardware Functional Check Start the engine and observe the air pressure gauge The red arrow on the gauge primary should rise first until a pressure reading of about 590 kPa 85 psi at which time the green arrow secondary should begin to climb Both arrows should level off at about 760 kPa 110 psi Safety Valve Removal 1 Chock the wheels a...

Page 308: ...wheels and pressurize both systems Adjust the brakes 2 Apply and release the brakes several times and check for prompt response of the brakes at all wheels Leakage Test 1 With dual brake valve released coat the relay valve exhaust port with a soap solution to check for inlet valve and O ring leakage A 25 mm 1 in bubble in five seconds is permissible 2 With the dual brake valve applied check the re...

Page 309: ...e brake valve and pedal assembly onto the studs under the front console and secure with the nuts washers and lockwashers 2 Connect all the air lines to the brake valve as per removal tag Operating Test 1 Check the delivery pressure of both 1 and 2 circuits with a test gauge Depress the treadle to several positions between fully released and applied Check the pressure on the gauges to see if it var...

Page 310: ...filtered air at an increased pressure from the intake manifold and compresses it The compressed air is delivered to the air dryer where water and a small amount of oil is removed The air then travels into the rear brake system reservoir and a front brake system reservoir as well as any attached trailer reservoirs For each system the air pressurizes the reservoir and the air hoses all the way to th...

Page 311: ...ers If such equipment is not available carefully clean parts and assemblies in the open air Clean brake parts and assemblies in the open air During disassembly carefully place all parts on the floor to avoid getting dust into the air Use an industrial vacuum cleaner with a HEPA filter system to clean dust from the brake drums backing plates and other brake parts After using the vacuum remove any r...

Page 312: ...ect pressure at the compressor and brake air chambers Restriction or leak in lines valves etc Check all lines valves etc for leaks or restrictions Brakes out of adjustment Adjust the brakes Leaking diaphragm Replace the diaphragm Uneven braking or uneven lining wear Ruptured diaphragm Replace the Diaphragm Brakes out of adjustment Adjust the brakes Grease on the lining Replace the lining Glazed li...

Page 313: ...discard Figure 8 24 11 Do the same for the lower return spring 12 Remove the shoes from the axle Figure 8 25 13 Remove the slack adjuster reference Slack Adjuster Removal this Section 14 Remove the camshaft by grasping the camshaft head and pulling outboard 15 Remove the bolts attaching the air chamber bracket to the spider and pull it away from the spider 16 Remove spider to axle attaching nuts a...

Page 314: ...ed without exceeding the manufacture s specifications 2 Inspect the shoes for bent or cracked webs or table broken welds loose rivets or elongated rivet holes Replace shoes if any are found 3 Check the anchor pin and cam roller contact areas in the shoe webs for elongation or wear Replace the shoe if the diameter of the roller end exceeds 21 33 mm 0 835 in or the diameter of the anchor pin end exc...

Page 315: ...Roller Camshaft Cam Head Washer Shoe Return Springs Color Grey Shoe Assembly Roller Retainer Spider Steel Stamped Dust Shield Grease Seal Camshaft Bushing Lockwasher Nut Bracket Assembly Shoe Return Springs Color Red Grease Fitting Camshaft Bushing Grease Seal Slack Adjuster Camshaft Shim Washers Camshaft Retainer Snap Ring Cast Spider Front Brake Assembly FIGURE 8 28 F o r R e f e r e n c e O n l...

Page 316: ...unting studs for looseness damaged threads or bent studs Replace as necessary 15 Check the air chamber for leaks cracked housing bent pushrod loose clamp ring clogged vent holes or loose air fittings Repair or replace as necessary 16 If the air chamber is replaced or repaired check the distance from the clevis pin hole centerline to the air chamber face Reference Automatic Slack Adjuster page 8 44...

Page 317: ...ster Reference Automatic Slack Adjuster page 8 44 6 Installation of brake shoes is as follows a Lubricate the shoe roller recess with chassis grease Do not get grease on the cam head surface b Hook the ends of the new retainer springs into the holes on both shoe webs with the hooks pointing out c Position the upper and lower shoes around the anchor pin Install a new shoe return spring d Assemble t...

Page 318: ...form the removal installation and adjustment procedures that follow If your slack adjuster is as pictured in Figure 8 42 follow the removal installation and adjustment procedures on page 8 48 Removal 1 Disengage the pull pawl Use a screwdriver or equivalent tool to pry the pull pawl at least 0 8 mm 0 0313 in to disengage the teeth from the actuator 2 Use a wrench to turn the manual adjusting nut c...

Page 319: ...chamber mounting face on each brake Refer to Dimension A in Figure 8 33 6 Starting with 621 to 689 kPa 90 to 100 psi air tank pressure in both primary and secondary systems fully apply service brakes and hold brakes on Do not pump the brakes Measure between the same points as in step 5 on each brake This is Dimension B in Figure 8 33 7 Subtract Dimension A from Dimension B for each brake position ...

Page 320: ...t bottoms out Figure 8 36 NOTE If not absolutely sure of correct bolt to piston engagement repeat step 4 until sure 5 Turn the release bolt 1 4 turn clockwise and pull the bolt out to lock the formed end into the piston If the bolt does not lock into the piston in less than 13 mm 1 2 in outward movement repeat Steps 4 and 5 until it locks 6 Holding the bolt locked into the piston install the flatw...

Page 321: ...lt flatwasher and release nut into the storage pocket apply 13 5 Nm 10 lb ft torque on nut against the flatwasher Figure 8 39 11 Measure the distance from the center of the large clevis to the air chamber mounting face with the brake fully released This is dimension X in Figure 8 40 12 Using a pry bar move the slack adjuster so that the linings contact the drum Measure the distance between the sam...

Page 322: ...r is as pictured in Figure 8 42 follow the removal installation and adjustment procedures that follow MEASURE FREE STROKE FREE STROKE Y MINUS X Drum brake free stroke must be 12 7 15 9 mm 0 5 0 625 in Disc brake free stroke must be 19 1 22 2 mm 0 75 0 875 in Y X 7092 7 FIGURE 8 40 CAUTION Damage Could Occur See Figure 8 40 and Figure 8 41 Free Stroke Measurement Pull pawl must be disengaged before...

Page 323: ...e place Rotate the control arm towards the axle until they come to a complete stop and secure in that position 11 Tighten all anchor bracket fasteners 12 Rotate the adjusting hex clockwise until the lining lightly contacts the drum 13 Back off the adjuster by turning the adjusting hex counterclockwise 1 2 of a turn Adjustment Procedures Brake Applied Stroke Measurement Make sure that the brake app...

Page 324: ...44 until the power spring is fully caged or compressed Full cage position requires approximately 22 to 23 turns for 76 mm 3 00 in stroke units 3 The dual thread release bolt which reduces the travel of the release bolt by a factor of 2 4 in a 76 mm 3 00 in stroke unit for instance the parking spring is fully caged when the release bolt is up approximately 33 mm 1 3 in from the run position Figure ...

Page 325: ...roceed to Step 7 7 Rotate the adjusting hex approximately 1 8 turn in the direction required and re measure the stroke Continue this process until the stroke is within limits A minimum of 17 6 Nm 13 lb ft of torque is required to turn the hex and overcome the internal clutch A ratcheting noise will be heard Do not use an impact wrench or internal damage will occur Figure 8 47 7093 2 FIGURE 8 45 WA...

Page 326: ...cy parking brake spring mechanism incorporated into the air brake chamber The brake chamber has an aluminum body and pressure plate with a steel nonpressure plate that houses a service emergency diaphragm piston and two springs Spring Brake Actuator The spring brake actuator which is the upper part of the air brake chamber is spring applied and air released When an air pressure of 482 kPa 70 psi o...

Page 327: ...adjustment Adjust brakes Grease on the lining Replace lining Glazed lining Replace lining Shoes are installed backwards Reverse shoes Combination linings Replace with correct style Automatic adjusters are not working Adjusting pawl installed backwards Remove and properly install pawl Pawl is collapsed or missing Replace spring Bolt is frozen in adjusting sleeve Free up or replace the bolt Detent i...

Page 328: ...rvice brake chamber to the spring brake chamber 2 Separate the lower cover from the spring brake chamber 3 If the push rod or spring needs to be removed mark the position of the clevis on the push rod Remove the clevis and jam nut 4 Remove the push rod Assembly Refer to Figure 8 50 1 Insert the push rod through the spring and cover 2 Screw on the jam nut and clevis as per removal marks 3 Position ...

Page 329: ... pawl assembly to keep the pawl teeth from being damaged b Turn the manual adjusting nut until the brake shoe is fully retracted c Install the pawl assembly into the slack adjuster 5 Remove the brake drum Brake Shoe Removal 1 Push down on the bottom brake shoe and pull on the roller retaining clip to remove the bottom cam roller Figure 8 51 2 Lift the top shoe and pull on the roller retaining clip...

Page 330: ...hing in the slack adjuster arm Replace bushing if diameter exceeds 16 6 mm 0 65 in 7 Rotate the slack adjuster adjusting nut through a 360 degree rotation about 22 turns of the adjusting nut with a torque wrench Torque must be less than 2 8 Nm 25 lb in for a new or rebuilt slack adjuster 8 Check the brake drums for cracks severe heat checking heat spotting scoring pitting and distortion 9 Measure ...

Page 331: ...shoe until its ears lock into the holes in the shoe webs Figure 8 57 5 Install the slack adjuster and adjust brakes Figure 8 58 Refer to the following Sub Section Automatic Slack Adjuster page 8 44 ANTI LOCK BRAKE SYSTEM ABS AUTOMATIC TRACTION CONTROL ATC ABS System Description The Bendix Anti Lock Braking System ABS Figure 8 59 is an electronically controlled system that continually monitors whee...

Page 332: ... ignition is turned on The operator can verify the testing by listening for the ABS modulator valves actuating twice in series To increase the sound hold down the foot brake pedal when the ignition is turned on NOTE The ECU will not perform the configuration test when the speed sensors detect that the vehicle is in motion If the indicator 1 Figure 8 61 stays on there is a problem with the ABS If t...

Page 333: ...ontrol spin out At speeds below 40 km h 25 mph both engine control and differential brake control are activated as required to control wheel slip Once triggered differential braking mode remains active regardless of vehicle speed The off road switch allows greater wheel spin more torque when activated It is intended for adverse conditions usually off highway The switch is programmed for momentary ...

Page 334: ...on on both valves The M 32 and M 32QR quick release anti lock system modulators are high capacity on off air valves that use a pair of electrical solenoids for control The solenoids provide the electro pneumatic interface between the anti lock controller electronics and the air brake system The modulator is used to control the braking function during anti lock activity The modulator consists of a ...

Page 335: ...igure 8 65 The ABS ECU is located at the rear of the cab behind the driver s seat The ABS wiring harness is combined with the main cab and engine harness Troubleshooting Blink Codes and Diagnostic Modes The EC 60 controller ECU contains self testing diagnostic circuitry that continuously checks for the normal operation of internal components and circuitry as well as external ABS components and wir...

Page 336: ...ower cycle Voltage trouble codes will clear automatically when the voltage returns within the required limits All ABS functions will be re engaged J1939 trouble codes will clear automatically when communications are re established Diagnostic Modes In order to communicate with the ECU the controller has several modes that the technician can select allowing information to be retrieved or other ECU f...

Page 337: ...ause the ECU to exit the blink code mode Reconfigure ECU Mode NOTE To enter the Reconfiguration Mode the blink code switch must be held in before the application of ignition power Once the power is supplied the switch is released and then pressed seven times System Configuration Check Mode The ABS indicator lamp will display system configuration information when the diagnostic blink code switch is...

Page 338: ...SA Right 3 PMV SA Left CMN 9 PMV DA Right CMN 15 WSS DA Left 4 PMV SA Right HLD 10 PMV DA Right HLD 16 PMV DA Left HLD 5 WSS SA Left 11 WSS SA Right 17 PMV DA Left REL 6 PMV SA Right CMN 12 PMV DA Left CMN 18 WSS DA Left Pin Designation Pin Designation Pin Designation 1 ABS ORS 6 PMV AA Left CMN 11 WSS AA Left 2 Not used 7 PMV AA Left REL 12 WSS AA Right 3 Not Used 8 Input Output 3 13 PMV AA Right...

Page 339: ...odes are 2 13 For all codes check for damaged or corroded connectors Check for damaged wiring Clear trouble codes If diagnostic trouble codes return replace the ECU Troubleshooting Diagnostic Trouble Codes Wheel Speed Sensors 12 Miscellaneous page 8 72 14 Wheel Speed Sensors page 8 65 15 Wheel Speed Sensors page 8 65 16 Pressure Modulator Valves page 8 67 17 Pressure Modulator Valves page 8 67 18 ...

Page 340: ...rs Check for corroded damaged wiring or connectors between the ECU and the wheel speed sensor 4 Loss of Sensor Signal Adjust sensor to contact exciter ring Rotate wheel and verify a minimum of 0 25 VAC sensor output at 0 5 RPS Verify condition of sensor head Verify mounting of exciter ring and condition of teeth Verify proper bearing end play Verify condition and retention of clamping sleeve Verif...

Page 341: ...e X2 18 Way 5 Left Steer Axle 8 Left Steer Axle 11 Right Steer Axle 14 Right Steer Axle 15 Left Drive Axle 18 Left Drive Axle X3 15 Way 11 Left Additional Axle 14 Left Additional Axle 12 Right Additional Axle 15 Right Additional Axle 1st Blink Code Location 7 Left Steer Axle 8 Right Steer Axle 9 Left Drive Axle 10 Right Drive Axle 16 Left Additional Axle 17 Right Additional Axle FIGURE 8 69 8 7 9 ...

Page 342: ... 4 9 to 5 5 ohms from REL to CMN and HLD to CMN and 9 8 to 11 ohms from REL to HLD Check for corroded damaged wiring or connectors between ECU and PMV 4 Hold Solenoid Shorted to Ground Verify no continuity between PMV leads and ground Verify 4 9 to 5 5 ohms from REL to CMN and HLD to CMN and 9 8 to 11 ohms from REL to HLD Check for corroded damaged wiring or connectors between ECU and PMV 5 Hold S...

Page 343: ...ght Additional Axle Common 10 Right Additional Axle Hold 13 Right Additional Axle Release 1st Blink Code Location 18 Traction Control Valve FIGURE 8 71 18 2nd Blink Code Diagnostic Trouble Code Description Repair Information 1 TCV Solenoid Shorted to Ground Verify 7 to 19 ohms between TCV and TCV common Verify no continuity between TCV leads and ground Check for corroded damaged wiring or connecto...

Page 344: ... Troubleshooting Diagnostic Trouble Codes Power Supply 4 TCV Configuration Error The ECU is not configured for TCV but has detected the presence of a TCV Verify TCV wiring Inspect for the presence of a TCV Verify ECU configuration Location Measurement TCV to TCV Common 7 to 19 Ohms Release Hold Common to Voltage or Ground Open Circuit no continuity 2nd Blink Code Diagnostic Trouble Code Descriptio...

Page 345: ...ry voltage under load Check vehicle battery and associated components Check for damaged wiring Check for damaged or corroded connectors and connections 4 Battery Voltage Open Circuit Measure battery voltage under load Check condition of fuse Check vehicle battery and associated components Check for damaged wiring Check for damaged or corroded connectors and connections 5 Ignition Voltage Too Low M...

Page 346: ...erify ECU Configuration Check for other devices inhibiting J1939 communications 3 J1939 Engine Communications Loss of communications between the E 60 controller and the engine ECU over the J1939 link Check for damaged or reversed J1939 wiring Check for corroded or damaged connectors Verify presence of engine ECU on the J1939 link Verify ECU Configuration Check for other devices inhibiting J1939 co...

Page 347: ... output of E 60 controller and voltage Verify condition and wiring of the retarder relay 6 ABS Indicator Lamp Circuit Fault Check operation of diagnostic blink code switch Check wiring of diagnostic blink code switch ABS WL and ABS WL relay frame ECUs only Verify ABS WL ground input cab ECUs only 7 PMV Common Shorted to Ground Verify no continuity between the CMN of all PMVs TCV and Diff Lock Sole...

Page 348: ...imum system robustness always use the maximum size wire supported by the wire harness connectors for battery ignition ground PMV TCV Interaxle Differential Lock and indicator lamp circuits All sensor and serial communications circuits J1587 and J1939 must use twisted pair wiring one to two twists per inch See the appropriate SAE document for additional details It is recommended that wires be route...

Page 349: ...etallic hose clamps or bow tie cable ties to prevent pinching binding or fraying Wire harness lengths MUST be carefully selected for the vehicle Harnesses that are too long increase the possibility of electrical interference and wire damage Excess lengths of wire are not to be wound to form coils instead re route repair or replace wire harness DO NOT attempt to stretch harnesses that are too short...

Page 350: ...8 76 Published 01 14 2021 Control 707 01 CARRIER TMS9000 2 SERVICE MANUAL ABS ATC Cab Wiring Schematic FIGURE 8 76 F o r R e f e r e n c e O n l y ...

Page 351: ...Grove Published 01 14 2021 Control 707 01 8 77 TMS9000 2 SERVICE MANUAL CARRIER 8 ABS ATC Frame Wiring Schematic FIGURE 8 77 F o r R e f e r e n c e O n l y ...

Page 352: ...controller in the original mounting orientation using the mounting bolts retained during removal 2 Torque the mounting bolts for frame mounted units to 7 5 to 9 Nm 66 80 in Ib Over tightening the mounting hardware can cause damage to the EC 60 controller 3 Reconnect the electrical connectors to the EC 60 controller 4 Apply power and monitor the EC 60 controller power up sequence to verify proper s...

Page 353: ...rcuit exceeds the recommended 2 psi minute apply soap solution to the exhaust port of the modulator and any other components in the respective circuit 7 The leakage at the exhaust port of most Bendix components including M 32 modulators should not exceed a 25 mm one inch bubble in three seconds If leakage at the modulator is determined to exceed the maximum limits replace the modulator Operation T...

Page 354: ... a slight angle NOTE It is not necessary to remove the wheel or drum to adjust sensors using the adjustment tool 2 Press the sensor toward the wheel hub until the sensor contacts the tooth wheel 3 Remove the sensor adjustment tool 4 Verify proper sensor adjustment by driving the vehicle This allows the ABS to perform an additional self test Once the vehicle reaches approximately 11 km h 7 mph the ...

Page 355: ...modulator Installation 1 Install all air line fittings and plugs making certain thread sealing material does not enter the valve 2 Install the assembled valve on the vehicle 3 Reconnect all air lines to the valve using the identification made during removal 4 Reconnect the electrical connector to the modulator 5 After installing the valve test all air fittings for excessive leakage and tighten as ...

Page 356: ...a sharp instrument could permanently damage the sensor DO NOT use a hammer to drive the sensor into position Hammering the sensor could permanently damage it 6 Using an ABS sensor adjustment tool adjust the sensor against the tooth wheel and install the rubber grommet 7 Install the brake lining onto the spider housing Install the return spring S cam rollers and brake drum 8 Install the wheel and t...

Page 357: ...heel and install the rubber grommet 7 Install the brake lining onto the spider housing Install the return spring S cam rollers and brake drum 8 Install the wheel and tighten nuts to a torque of 645 35 Nm 475 25 ft lb 9 Adjust the rear axle brakes 10 Remove the jack stands from under the vehicle 11 Lower the vehicle and remove the wheel blocks 12 Readjust the brakes 13 Verify proper sensor adjustme...

Page 358: ...switch is in the EXTEND position the flow continues through the open solenoid valve to the barrel side of the cylinder If a jack is to be extended the flow first unseats the check valve then extends the cylinder The oil from the rod end flows to the selector valve and through the swing bank on the way to the reservoir When the selector switch is in the RETRACT position the flow through the selecto...

Page 359: ...gger beams Clean outrigger beams Binding outrigger beam Repair or replace outrigger beam Damaged outrigger valve Repair or replace valve Damaged valve coil Replace coil Main hydraulic pump cavitation Replace or tighten hose or fittings Partially shifted hydraulic selector spool Disassemble clean and polish spool and valve housing with very fine emery cloth Insufficient voltage for operation of sol...

Page 360: ...roper level Damaged main relief valve Repair or replace valve Damaged holding valve seals Replace holding valve seals Bent cylinder rod Replace cylinder rod and seals Bent outrigger housing Repair or replace outrigger housing Damaged O rings in swivel Replace O rings Excessive material on beams Clean outrigger beams Sticking solenoid valve spool Repair or replace valve spool Damaged wiring to sole...

Page 361: ...ines or fittings Damaged relief valve or damaged control valve Repair or replace valve Outrigger system activates but selected outrigger will not stow or extend and lower as desired Clogged broken or loose hydraulic lines or fittings Clean tighten or replace lines or fittings Loose or broken wire on control switch or solenoid valve Repair or replace wiring Damaged solenoid valve Repair or replace ...

Page 362: ...draulic tube to the outrigger housing 8 Remove the cotter pin and clevis pin securing the rod of the extension cylinder to the outrigger housing 9 After attaching a suitable lifting device of straps or belts instead of chains to prevent damage to the bottom edges of the outrigger beam pull the outrigger beam out of the outrigger box re adjusting the lifting attachment to prevent the beam from tipp...

Page 363: ... lugs to the brackets on the mid beam NOTE Do not allow the end of the extension cylinder to fall when the cylinder barrel lugs are removed from the brackets Use blocking to limit the drop or an 1 Jack Cylinder 2 Jack Cylinder Hose Assy 3 Mid Extend Lock Pin Lug 4 Cylinder Clevis Pin 5 O R Jack Line Tube 6 Jack Beam 7 Shim 8 Mid Extend Lock Pin 9 Tray 10 Extension Cylinder 11 Mid Bean 12 Shim 13 W...

Page 364: ...s or other damage 2 Inspect the outrigger beams for bends evidence of cracks or other damage Check the outrigger beam internally for hydraulic fluid which may indicate a leaking cylinder or damaged hydraulic line Assembly NOTE The mid beam and the jack beam are shimmed as a matched set and are identified by the stamped serial number ending in A for the mid beam and B for the jack beam If one or th...

Page 365: ...raulic hoses are not trapped against the outrigger box when the beam is fully retracted Wear Pad Adjustment NOTE When adjusting wear pads refer to Figure 8 86 1 Adjust outrigger box side wear pads until a gap of 2 0 mm 0 08 in is obtained at the tightest point during full extension 2 Adjust the wedge type wear pad at the upper end of the outrigger until a gap of 2 0 mm 0 08 in is obtained at the t...

Page 366: ...sion cylinder to the outrigger beam 5 Install the outrigger beam Refer to paragraph Outrigger Beam with Adjustable Wear Pads page 8 87 Functional Check 1 Activate the hydraulic system extend and retract the outrigger 2 Observe the operation of the outrigger beam 3 Check the hydraulic connections for any evidence of leakage OUTRIGGER JACK CYLINDERS Description The jack cylinders have 14 0 cm 5 50 i...

Page 367: ...inder rod and a pilot operated check valve is threaded into the port block Internal seals are used within the cylinder to prevent internal and external leakage A wiper ring is mounted to the front of the cylinder barrel to wipe dirt from the rod as it is retracted The cylinder weighs approximately 42 5 kg 113 8 lb Maintenance NOTE Refer to Cylinders page 2 29 for Disassembly and Assembly of the cy...

Page 368: ...ning pin Secure the cylinder and cylinder cap retaining bracket in place with the retaining pin and cotter pins 6 Install the hydraulic lines as tagged prior to removal 7 Install the cylinder cap and secure with the washers and nuts 8 Position the float pad on the cylinder ball and secure with bolts lockwashers bushing and nuts Torque the bolts 97 6 to 105 7 Nm 72 to 78 lb ft 9 Position the plate ...

Page 369: ...Pin 3 Cotter Pin 4 Cylinder Head Wear Ring 5 Piston Wear Ring 6 Outrigger Pad 7 Bushing 8 Hex Nut 9 Lockwasher 10 Plate 11 Capscrew 12 Flatwasher 13 Plug 14 Capscrew 15 Locknut 16 Flatwasher 17 Cap 18 Washer 19 Acorn Nut 20 Cap Bracket 10 14 16 20 19 18 17 13 6 7 15 6512 FIGURE 8 87 F o r R e f e r e n c e O n l y ...

Page 370: ...ator Manual for more information OMS String Potentiometers Removal 1 Remove the rear access cover plate from outrigger box 2 Remove the OMS string potentiometer spring clip 1 Figure 8 88 from the attaching point on the outrigger beam NOTE Avoid free release of cable to prevent damage to OMS string potentiometer 3 Tag and disconnect the electrical connector and secure to avoid damage 4 Remove the m...

Page 371: ...ed to meet existing conditions For information on extreme condition lubrication contact your local Grove Cranes distributor or Manitowoc Crane Care Environmental Protection Dispose of Waste Properly Improperly disposing of waste can threaten the environment Potentially harmful waste used in Grove cranes includes but is not limited to oil fuel grease coolant air conditioning refrigerant filters bat...

Page 372: ...woc Crane Care has Boeshield T 9 Premium Metal Protectant available in 12 oz aerosol cans by ordering part number 9999101803 through the Parts Department Cylinder operation and inclement weather will remove the Boeshield protectant therefore inspect machines once a week and reapply Boeshield to unprotected rods LUBRICATION POINTS A regular frequency of lubrication must be established for all lubri...

Page 373: ...AE 40 80078954 Emgard MTF 7000 BASF Phillips 66 Triton Synthetic MTF Kendall SHP Synthetic MTF Gear Lube GL 5 6829014058 CITGO Synthetic Gear Lube 75W 90 Eaton Roadranger EP75W 90 Mobil Mobilube SHC 75W 90 Shell Spirax S 75W 90 Sunoco Duragear EP75W 90 Petro Canada Traxon E Syn thetic 75W 90 75W 90 Extended Service Interval Gear Lubricant 6829012964 Century Unigear Semi synthetic Texaco Multigear ...

Page 374: ... Ipiranga IPIFLEX LI COMP EP 2 NLGI 2 Open Gear Lube 6829102971 Fuchs Ceplattyn 300 Spray NLGI 1 2 Anti Seize Compound ASC 6829003689 Jet Lube Kopr Kote Loctite C5 A Compound Antifreeze Coolant 6829101130 Old World Industries Inc Fleet Charge SCA Caterpillar DEAC Fleetguard Complete EG Mix 50 50 Supplemental Coolant Additive SCA 6829012858 Fleetguard DCA4 Fleetguard DCA2 Penray Pencool 3000 Diesel...

Page 375: ...hillips 66 Triton Synthetic MTF Kendall SHP Synthetic MTF Gear Lube GL 5 6829014058 CITGO Synthetic Gear Lube 75W 90 Eaton Roadranger EP75W 90 Mobil Mobilube SHC 75W 90 Shell Spirax S 75W 90 Sunoco Duragear EP75W 90 Petro Canada Traxon E Syn thetic 75W 90 75W 90 Extended Service Interval Gear Lubricant 6829014058 CITGO Synthetic Gear Lube Eaton Roadranger EP75W 90 Mobil Mobilube SHC 75W 90 Shell S...

Page 376: ...Compound Antifreeze Coolant 6829101130 Old World Industries Inc Fleet Charge SCA Caterpillar DEAC Fleetguard Complete EG Mix 50 50 Supplemental Coolant Additive SCA 6829012858 Fleetguard DCA4 Fleetguard DCA2 Penray Pencool 3000 Diesel Fuel 80069407 Ultra Low Sulfur Diesel Fuel 1 D Diesel Exhaust Fluid DEF 80019225 Fleetguard StableGuard Urea 32 Premix AdBlue TerraCair Ultrapure DEF TABLE 9 2 Optio...

Page 377: ... J1165 7 Brush lubrication on I D of center front jack cylinder support tube and wear bands before installing jack cylinder 8 Use grease fittings provided 9 Fill radiator to bottom of filler neck per Engineering Specification 80029046 Run engine through 2 thermal cycles check level and refill as required 10 Fill through dipstick opening 11 Check fluid level using sight gauge on the side of the tan...

Page 378: ...e following figures Drivetrain Lubrication ITEM NUMBER LOCATION NAME APPROXIMATE CAPACITY LUBE SPEC NOTES SERVICE POINTS SERVICE SERVICE HOURS DRIVETRAIN 1 ENGINE CRANKCASE X12 6829104182 2 14 1 CHECK FILL 10 HRS DAILY WITH FILTER 47 3 L 12 5 GAL 6829104182 2 1 DRAIN FILL 750 HRS 2a ENGINE COOLING SYSTEM 6829101130 4 9 14 1 CHECK FILL 10 HRS DAILY ENGINE COOLING SYSTEM X12 70 0 L 18 5 GAL 68291011...

Page 379: ...L TRANSMISSION ONLY 6829003477 8 3 LUBE 500 HRS 7 TRANSMISSION SHIFT U JOINTS CONTROL UNIT 6829003477 8 3 LUBE 500 HRS 26 AIR CLEANER FILTER 20 1 CHANGE FILTER SEE NOTE 20 27 FUEL FILTER PRIMARY 23 1 CHANGE FILTER 1000 HRS 6 MONTHS 8 DRIVELINE SLIP 6829003477 8 14 2 LUBE 500HRS 10000 MI ITEM NUMBER LOCATION NAME APPROXIMATE CAPACITY LUBE SPEC NOTES SERVICE POINTS SERVICE SERVICE HOURS F o r R e f ...

Page 380: ...9 10 Published 01 14 2021 Control 707 01 LUBRICATION TMS9000 2 SERVICE MANUAL 8885a FIGURE 9 1 3a 3b 27 1 2 26 1 8885 1a FIGURE 9 2 6 7 5 4b 4a 4c F o r R e f e r e n c e O n l y ...

Page 381: ...s G1 on the gear display The operator can choose to follow this automated lube schedule or lubricate every 250 hours See CLUTCH RELEASE BEARING on page 9 It is important to reset the grease interval count every time the release bearing is greased Clutch Release Grease Interval Reset 1 From the OFF position turn ignition ON without cranking engine 2 Move the transmission shift lever to LOW Do not a...

Page 382: ...9 12 Published 01 14 2021 Control 707 01 LUBRICATION TMS9000 2 SERVICE MANUAL 8885 2 FIGURE 9 4 3c 8885 3 FIGURE 9 5 8 8 F o r R e f e r e n c e O n l y ...

Page 383: ...50 HRS 8885 4 FIGURE 9 6 9 10 ITEM NUMBER LOCATION NAME APPROX CAPACITY LUBE SPEC NOTES SERVICE POINTS SERVICE SERVICE HOURS FRONT AXLES 11 FRONT WHEEL PILOTS 6829003689 17 4 BRUSH ON SEE NOTE 18 12 FRONT AXLE HUBS 47 L 1 PT EACH 6829012964 2 4 CHECK FILL 250 HRS 13 FRONT AXLE TIE ROD ENDS 6829003477 8 4 LUBE 1000 HRS 14 FRONT AXLE KING PINS 6829003477 8 8 LUBE 1000 HRS 15 FRONT AXLE BRAKE SLACK A...

Page 384: ...9 14 Published 01 14 2021 Control 707 01 LUBRICATION TMS9000 2 SERVICE MANUAL 8885 5 FIGURE 9 7 11 12 8885 6 FIGURE 9 8 13 15 16 14 F o r R e f e r e n c e O n l y ...

Page 385: ...7 8 BRUSH ON SEE NOTE 18 18 FRONT REAR AXLE BOWL 6829012964 2 1 CHECK FILL 250 HRS 20 5 QTS 6829012964 2 3 13 14 1 DRAIN FILL 2 YRS 50000 MI 18b DIFFERENTIAL FILTER 22 1 CHANGE FILTER 2 YRS 50000 MI 19 REAR REAR AXLE BOWL 6829012964 2 1 CHECK FILL 250 HRS 19 5 QTS 6829012964 2 13 14 1 DRAIN FILL 2YRS 50000 MI 20 REAR AXLE BRAKE SLACK ADJUSTERS 6829003477 8 4 LUBE 1000 HRS 8885 7 FIGURE 9 9 17 F o ...

Page 386: ...9 16 Published 01 14 2021 Control 707 01 LUBRICATION TMS9000 2 SERVICE MANUAL 8885 8 FIGURE 9 10 18 18b 20 19 F o r R e f e r e n c e O n l y ...

Page 387: ...APPROX CAPACITY LUBE SPEC NOTES SERVICE POINTS SERVICE SERVICE HOURS OUTRIGGERS 22 O R BEAMS 6829015304 5 14 8 BRUSH ON 50 1 WEEK 23 CENTER FRONT JACK CYLINDER SUPPORT TUBE Not Shown 6829015304 7 5 BRUSH ON SEE NOTE 7 24 WEAR PADS 6829015304 38 14 24 BRUSH ON 50 1 WEEK 8885 9 FIGURE 9 11 24 22 22 22 23 F o r R e f e r e n c e O n l y ...

Page 388: ...US 25 HYDRAULIC RESERVOIR 507 L 134 GAL TANK ONLY 6829006444 6 11 14 1 CHECK FILL 10 HRS DAILY 95 HYDRAULIC FILTER BREATHER 39 1 CHANGE FILTER BREATHER SEE NOTE 39 28 DEF SUPPLY MODULE FILTER 1 CHANGE FILTER 4500 HRS 200000 MI 29 DIESEL EXHAUST FLUID TANK 37 9 L 10 GAL TANK ONLY 80019225 34 1 CHECK FILL 30 DEF TANK FILTER 1 CHECK FILTER 1 YEAR 8885 10 FIGURE 9 12 25 29 28 30 95 F o r R e f e r e n...

Page 389: ...T 6829014058 35 2 CHECK FILL 50 HRS 1 WEEK 0 9 L 95 QT 6829014058 14 35 2 DRAIN FILL 1000 HRS 12 MONTHS 41 TURNTABLE GEAR DRIVE PINION 6829102971 1 14 2 SPRAY ON 500 HRS 6 MONTHS 42 TURNTABLE 360 SWIVEL LOCK 6829003477 1 14 1 LUBE 500 HRS 6 MONTHS 43 TILT CYLINDER PIVOT PINS 6829003477 1 14 2 LUBE 500 HRS 3 MONTHS 44 PILLOW BEARING 6829003477 1 14 2 LUBE 500 HRS 3 MONTHS 45 CAB TRACK ROLLERS LIGHT...

Page 390: ...9 20 Published 01 14 2021 Control 707 01 LUBRICATION TMS9000 2 SERVICE MANUAL 8885 12 FIGURE 9 14 45 43 44 F o r R e f e r e n c e O n l y ...

Page 391: ...RS HOIST 46 MAIN HOIST TRANSMISSION 6829014058 2 14 1 CHECK FILL 50 HRS WEEKLY 4 0 L 1 GAL 6829014058 2 14 1 DRAIN FILL 1000 HRS 12 MONTHS 47 AUX HOIST TRANSMISSION 6829014058 2 14 1 CHECK FILL 50 HRS WEEKLY 4 0 L 1 GAL 6829014058 2 14 1 DRAIN FILL 1000 HRS 12 MONTHS 48 HOIST BRAKE MAIN AUX 01930670 2 14 1 CHECK FILL 1000 HRS 12 MONTHS 8885 13 FIGURE 9 15 47 46 48 F o r R e f e r e n c e O n l y ...

Page 392: ...TABLE SLEW BEARING INNER RACE 6829003477 37 4 LUBE AUTO 50 HRS 1 WEEK LIFT CYLINDER PINS 6829003477 37 1 LUBE AUTO 50 HRS 1 WEEK BOOM PIVOT PIN 6829003477 37 4 LUBE AUTO 50 HRS 1 WEEK MAIN HOIST GEARS 6829003477 37 1 LUBE AUTO 50 HRS 1 WEEK AUX HOIST GEARS 6829003477 37 1 LUBE AUTO 50 HRS 1 WEEK 50 HOIST LOWER LIMIT SWITCH 01373458 2 LUBE 250 HRS 3 MONTHS 49 FIGURE 9 16 50 49 8885 15 F o r R e f e...

Page 393: ... as required The operator has the option to grease the boom if they so choose All of the grease fittings still exist in the boom However from that point forward the boom will always need to be greased on a typical interval LUBRICATION OF TELE SECTION TO GREASE TELE 5 TO GREASE TELE 4 TO GREASE TELE 3 TO GREASE TELE 2 TO GREASE TELE 1 TELE 1 0 0 0 50 100 TELE 2 0 0 50 100 0 TELE 3 0 50 100 0 0 TELE...

Page 394: ...8 14 27 28 34 40 1 BRUSH ON 500 HRS 6 MONTHS 82 DERRICKINGCYL PIVOT PIN 6829003477 1 8 14 2 LUBE 100 HRS MONTHLY 83 ADAPTER SECTION PIVOT PIN 6829003477 1 8 14 2 LUBE 100 HRS MONTHLY 84 BOOM EXTENSION SHEAVE 6829003477 1 2 LUBE DURING REPAIR 85 MAST SHEAVE 6829003477 1 2 LUBE DURING REPAIR 86 BOOM NOSE SHEAVES 6829003477 1 7 LUBE DURING REPAIR 87 AUX BOOM NOSE SHEAVE 6829003477 1 1 LUBE DURING REP...

Page 395: ...t wear pads of Tele 2 b Grease the rear upper wear pads of Tele 3 on both sides at the grease fittings 1 Figure 9 17 through the openings in Tele 2 c Grease locking pins on both sides 2 Figure 9 17 NOTE To grease the rear upper wear pads of Tele 3 at the 50 or 92 pinning locations extend and lock Tele 3 to these pinning locations and repeat Step 4b greasing 5 While in the horizontal position first...

Page 396: ... base section c Grease locking pins on both sides 2 Figure 9 17 NOTE To grease the rear upper wear pads of Tele 1 at the 50 or 92 pinning locations extend and lock Tele 1 to these pinning locations and repeat Step 3b greasing 4 While in the horizontal position extend and retract Tele 1 several times to make sure that grease is properly distributed 5 When Tele 1 greasing is complete retract and loc...

Page 397: ...Published 01 14 2021 Control 707 01 9 27 TMS9000 2 SERVICE MANUAL LUBRICATION 9 81 8885 18b FIGURE 9 19 8885 16a 82 82 83 84 85 87 86 86 88 FIGURE 9 20 89 8885 19a FIGURE 9 21 F o r R e f e r e n c e O n l y ...

Page 398: ...the return pulleys the retaining pins used for fastening the lattice extension sections for transport the spring latch on the run up rail NOTE The lubrication interval applies to average operation Also lubricate the pins after high pressure cleaning and generally at an interval that will prevent them getting dry 8885 20 90 8885 21 91 92 8885 22 8885 23 93 94 8885 24 FIGURE 9 22 F o r R e f e r e n...

Page 399: ...ed in the hard to reach areas Chipping or wear of paint caused by minor incidents or moving components Damage caused by personal abuse such as using the decks to transport rigging gear tools or cribbing and Exposure to harsh environmental hazards such as alkaline acids or other chemicals that can attack the crane s paint finish While the surfaces of the crane that are easily seen have the biggest ...

Page 400: ...enetrate the repair over time Application Depending upon the environment in which a crane is used and or stored the initial factory application of Carwell T32 CP 90 should help inhibit corrosion for up to approximately 12 months It is recommended that the treatment be periodically reapplied by the crane owner after that time to help continue to protect against corrosion of the crane and its compon...

Page 401: ...ICATION 9 Boom applications areas are pivot pins hose ends and fittings jib pins and shafts all bare metal surfaces overhaul ball pins hook block pins and fasteners All hardware clips pins hose connections not painted will have treatment applied F o r R e f e r e n c e O n l y ...

Page 402: ...blished 01 14 2021 Control 707 01 LUBRICATION TMS9000 2 SERVICE MANUAL 9289 1 3 4 5 2 6 7 12 9 11 8 15 6 11 17 18 9 11 10 11 9289 1 16 19 13 14 9289 2 10 13 14 16 19 FIGURE 9 23 F o r R e f e r e n c e O n l y ...

Page 403: ...train Hardware Inside Compartment 3 Valve Bank 13 O R Pins Clips 4 Hose Connections Inside Turntable 14 Entire Underside of Unit 5 Boom Extension Hanger Hardware 15 Turntable Bearing Fasteners 6 Boom Nose Pins Clips 16 Counterweight Pins 7 Hook Block Tie down Cable 17 Wire Rope 8 Overhaul Ball Hook Block 18 Tension Spring 9 Mirror Mounting Hardware 19 Outrigger Beam Wear Pad Adjustment Hardware 10...

Page 404: ...9 34 Published 01 14 2021 Control 707 01 LUBRICATION TMS9000 2 SERVICE MANUAL This Page Blank F o r R e f e r e n c e O n l y ...

Page 405: ...rs 2 29 Definitions of Stated Directions 1 2 Description of Maintenance Work on the Superstructure 4 1 Drive Train 7 22 Engine Control System 7 5 Engine 7 1 Exhaust System 7 11 Fasteners and Torque Values 1 8 Front Axle 8 2 Front Brakes 8 37 Fuel System 7 6 Gearshift 7 33 General 9 1 Handling Substances which are Harmful to the Environment 1 4 Hoist Ropes 4 47 Hydraulic Pumps 2 12 Hydraulic System...

Page 406: ...ety Messages 1 1 Safety Rules 1 3 Special Tools 8 78 Steer Cylinder 2 31 Steer Cylinder 8 16 Steering Pump 8 15 Steering System 8 12 Superstructure Air Conditioning System Additional Equipment 4 55 Superstructure Maintenance Overview 5 1 Superstructure Valves 2 26 Supply Pressure and Return Circuit 2 6 Swing Bearing 6 10 Swing Box Assemblies 6 7 Swing Lock Pin 6 20 Switch Replacement 3 18 Swivels ...

Page 407: ...F o r R e f e r e n c e O n l y ...

Page 408: ...F o r R e f e r e n c e O n l y ...

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