Manitowoc Grove TMS500-2 Service Manual
  1. Manuals
  2. Brands
  3. Manitowoc Manuals
  4. Construction Equipment
  5. Grove TMS500-2
  6. Service manual

Manitowoc Grove TMS500-2 Service Manual

Hide thumbs Also See for Grove TMS500-2:
Table of Contents

Advertisement

Quick Links

Download this manual
Grove TMS500-2
Service Manual
9826

Advertisement

Table of Contents
loading

Related Manuals for Manitowoc Grove TMS500-2

Summary of Contents for Manitowoc Grove TMS500-2

  • Page 1 Grove TMS500-2 Service Manual 9826...
  • Page 2 WARNING California Proposition 65 Breathing diesel engine exhaust exposes you to chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. • Always start and operate the engine in a well-ventilated area. • If in an enclosed area, vent the exhaust to the outside.
  • Page 3 SERVICE MANUAL TMS500-2 DANGER An untrained operator subjects himself and others to death or serious injury. Do not operate this crane unless: Grove is not • You are trained in the safe operation of this crane. responsible for qualifying personnel. •...
  • Page 4 THIS PAGE BLANK...

  • Page 5: Table Of Contents

    TMS500-2 TABLE OF CONTENTS TABLE OF CONTENTS SECTION 1 ........Introduction 1 Using The Service Manual.
  • Page 6 TABLE OF CONTENTS TMS500-2 Pump Distribution ..........2-6 Maintenance .
  • Page 7 TMS500-2 TABLE OF CONTENTS Superstructure Cab Fuse and Relay Panels ........3-7 Camera System (Optional) .
  • Page 8 TABLE OF CONTENTS TMS500-2 Telescope Circuit Troubleshooting ......... 4-5 Lift Circuit .
  • Page 9 TMS500-2 TABLE OF CONTENTS Tools Required ........... . . 5-7 Procedure .
  • Page 10 TABLE OF CONTENTS TMS500-2 System Installation..........7-15 Slip Joint Exhaust Connectors.
  • Page 11 TMS500-2 TABLE OF CONTENTS Description ............8-34 Maintenance .
  • Page 12 TABLE OF CONTENTS TMS500-2 Monthly Lubrication Work ......... . . 9-29 Carwell®...

  • Page 13: Section 1

    TMS500-2 SERVICE MANUAL INTRODUCTION SECTION 1 INTRODUCTION SECTION CONTENTS Using The Service Manual ....1-1 Disassembly and Assembly....1-11 Pressing Parts .

  • Page 14: Safety Messages

    INTRODUCTION TMS500-2 SERVICE MANUAL the crane, these reference locations are to be considered as protected from unauthorized operation before beginning t h o s e v i e w e d f r o m t h e o p e r a t o r ’ s s e a t w i t h t h e maintenance work.

  • Page 15: List Of Specifications

    TMS500-2 SERVICE MANUAL INTRODUCTION LIST OF SPECIFICATIONS Engine General Cummins L9 Model ..... .TMS500-2 Series Bore ......114 mm (4.5 in) Rated Capacity.

  • Page 16: Boom 102

    INTRODUCTION TMS500-2 SERVICE MANUAL Boom 102’ Section 1 ... . 78.7 L/min (20.8 gpm) Length ..9.8 to 31.0 meters (32.0 to 102.0 ft) Pump No.
  • Page 17 TMS500-2 SERVICE MANUAL INTRODUCTION FIGURE 1-1 9739 Grove Published 07-21-2020, Control # 673-02...
  • Page 18 INTRODUCTION TMS500-2 SERVICE MANUAL FIGURE 1-2 9740 Published 07-21-2020, Control # 673-02...
  • Page 19 TMS500-2 SERVICE MANUAL INTRODUCTION Main Exhaust After Hoist Superstructure treatment Auxiliary Carrier Cab Compartment Hoist Lift Cylinder Boom Nose DEF Tank 9827 Rear Outriggers Fuel Tank Front Outriggers Rear Drive Axles Counterweight Center Front Jack Steering Axle Cylinder Boom and Boom Extension 9827-1 Engine Compartment Air Cleaner...
  • Page 20 INTRODUCTION TMS500-2 SERVICE MANUAL Table 1-1: Axle Weight Distribution Table - 95’ Boom CG To CL Front Axle Rear Axle Description Weight kg (lb) Rear Bogie cm (in) kg (lb) kg (lb) (22800 (48040 Maximum Tire & Wheel Loads Allowed 10342 21791 (21500...
  • Page 21 TMS500-2 SERVICE MANUAL INTRODUCTION CG To CL Front Axle Rear Axle Description Weight kg (lb) Rear Bogie cm (in) kg (lb) kg (lb) (36 t) 40 ton Hookblock (4 sheave) - tied to 868.68 (342.00) (774) (1184) -186 (-410) front bumper (36 t) 40 ton Hookblock (4 sheave) - behind 279.40 (110.00)
  • Page 22 INTRODUCTION TMS500-2 SERVICE MANUAL CG To CL Front Axle Rear Axle Description Weight kg (lb) Rear Bogie cm (in) kg (lb) kg (lb) Boom Extension Carrier Brackets 429.26 (169.00) (256) (194) (62) Aux Boom Nose 904.54 (356.12) (105) (167) (-62) Counterweight (11994 Full Counterweight...

  • Page 23: General Maintenance

    TMS500-2 SERVICE MANUAL INTRODUCTION GENERAL MAINTENANCE raising a portion of a crane or a complete crane, make sure the crane is blocked securely and the weight is supported by The suggestions and instructions throughout this manual blocks rather than by lifting equipment. should be helpful in operating the crane.

  • Page 24: Wires And Cables

    INTRODUCTION TMS500-2 SERVICE MANUAL Flat metal locks must be installed properly to be effective. Installation Bend one end of the lock around the edge of the part. Bend Lubricate new or used bearings before installation. Bearings the other end against one flat surface of the nut or bolt head. that are to be preloaded must have a film of oil over the entire Always use new locking devices on components which have assembly to obtain accurate pre-loading.

  • Page 25: Hydraulic Systems

    Manual.The following types of Loctite brand adhesives are Experience has shown that highly stressed welded available from the Manitowoc Crane Care Parts Department structures when repeatedly subjected to varying stresses or your local Grove distributor. caused by twisting, shock, bending, and intentional and/or unintentional overloads, often become subject to weld Application of Medium Strength Loctite®...

  • Page 26: Fasteners And Torque Values

    INTRODUCTION TMS500-2 SERVICE MANUAL The following procedure covers the proper application and Use of proper torque values is extremely important. Improper curing method for medium-strength Loctite® adhesive/ torquing can seriously affect performance and reliability. sealant (Loctite® #243) and primer (Locquic Primer T7471). Identification of fastener grade is always necessary.
  • Page 27 TMS500-2 SERVICE MANUAL INTRODUCTION Grade 5 120° 120° 3 Lines 1 Line 3 Dots 3 Radial 1 Radial 1 Row Markings Spaced Spaced Lines Notched 1 Dot Line Heat 120° 120° 1 Dot Corners Treated Grade 8 60° 60° 6 Lines 1 Line 6 Radial 6 Dots...
  • Page 28 INTRODUCTION TMS500-2 SERVICE MANUAL Table 1-3 Inch Series with Coarse Threads (UNC) – Zinc Flake Coated Nominal Size, Threads per Torque (ft-lb) Inch, and Series Grade Maximum Nominal Minimum Designation 1/4-20 UNC 13.5 13.2 12.8 5/16-18 UNC 19.1 18.6 18.1 24.0 23.4 22.8...
  • Page 29 TMS500-2 SERVICE MANUAL INTRODUCTION Table 1-4 Inch Series with Fine Threads (UNF) – Zinc Flake Coated Nominal Size, Threads per Torque (ft-lb) Inch, and Series Grade Maximum Nominal Minimum Designation 1/4-28 UNF 10.6 10.4 10.1 15.0 14.6 14.2 5/16-24 UNF 21.1 20.6 20.1...
  • Page 30 INTRODUCTION TMS500-2 SERVICE MANUAL Nominal Size, Threads per Torque (N-m) Property Inch, and Series Class Maximum Nominal Minimum Designation M6x1.0 10.9 12.2 11.9 11.6 12.9 14.3 13.9 13.6 20.2 19.7 19.2 M8x1.25 10.9 29.6 28.9 28.2 12.9 34.7 33.8 33.0 40.0 39.0 38.0...
  • Page 31 TMS500-2 SERVICE MANUAL INTRODUCTION Nominal Size, Threads per Torque (N-m) Property Inch, and Series Class Maximum Nominal Minimum Designation 2089.8 2037.6 1985.3 M36x4 10.9 2976.4 2902.0 2827.6 12.9 3483.0 3395.9 3308.9 Table 1-6 Metric Series with Fine Threads – Zinc Flake Coated Nominal Size, Threads per Torque (N-m) Property...
  • Page 32 INTRODUCTION TMS500-2 SERVICE MANUAL Nominal Size, Threads per Torque (N-m) Property Inch, and Series Class Maximum Nominal Minimum Designation 386.0 376.3 366.7 M20x1.5 10.9 549.7 535.9 522.2 12.9 643.3 627.2 611.1 520.8 507.8 494.8 M22x1.5 10.9 741.7 723.2 704.7 12.9 868.0 846.3 824.6...

  • Page 33: Weld Studs

    Hoist Rope — — The Crane may be equipped with synthetic hoist rope or wire rope. Hoist rope may be purchased through Manitowoc NOTE: Stainless steel fasteners tend to gall while being Crane Care. tightened. To reduce this risk, lubricate the threads...

  • Page 34: Wire Rope

    INTRODUCTION TMS500-2 SERVICE MANUAL • Suspending loads while traveling over irregular Keeping Records surfaces, such as railroad tracks, potholes, and rough A signed and dated report of the hoist rope condition, at each terrain. periodic inspection, must be kept on file at all times. The •...

  • Page 35: Wire Rope Inspection (Running Ropes And Pendant Cables)

    • Number, distribution and type of broken wires. only pre-assembled lengths of wire rope as supplied from Manitowoc Crane Care. Do not build lengths from • Evidence of core failure. individual components. •...

  • Page 36: Wire Rope Inspection (Boom Extension And Retraction Cables)

    INTRODUCTION TMS500-2 SERVICE MANUAL Wire Rope Inspection (Boom Extension and eventually deteriorate to a point where it is no longer usable. Wire rope shall be taken out of service when any of the Retraction Cables) following conditions exist: Periodic Inspection •...

  • Page 37: Installing 35X7Class Wire Rope

    TMS500-2 SERVICE MANUAL INTRODUCTION NON-PREFORMED 6 ROPE BEFORE CUTTING DIAM. PREFORMED BEFORE CUTTING FIGURE 1-7 Method 2 AFTER CUTTING Wind a length of soft annealed wire around the wire rope at least seven times (Figure 1-8). The two ends should be FIGURE 1-9 twisted together in the center of the seizing.

  • Page 38: Procedures For Cutting And Preparing 35X7 Class Wire Rope

    INTRODUCTION TMS500-2 SERVICE MANUAL range from 1 to 2% of the rope’s minimum breaking inner and outer strands are welded together, force. preventing any movement between them. For ropes in multi-part systems: Reeve the traveling NOTE: The outer strands must not be able to move with block and boom tip sheaves so the rope spacing is respect to the inner strands.

  • Page 39: Section 2

    TMS500-2 SERVICE MANUAL HYDRAULIC SYSTEM SECTION 2 HYDRAULIC SYSTEM SECTION CONTENTS Description ....... 2-1 Accessory Manifold Assembly .
  • Page 40 HYDRAULIC SYSTEM TMS500-2 SERVICE MANUAL FIGURE 2-1 Published 07-21-2020, Control # 673-02...

  • Page 41: Maintenance

    TMS500-2 SERVICE MANUAL HYDRAULIC SYSTEM FIGURE 2-2 Maintenance Remove the reservoir drain plug. Allow about three minutes after hydraulic oil stops flowing from the drain port for the side walls to drain. Hydraulic Oil Recommendations For the hydraulic oil specifications, refer to Standard Clean and install the reservoir plug and fill the reservoir Lubricants, page 9-2.

  • Page 42: Removing Air From The Hydraulic System

    HYDRAULIC SYSTEM TMS500-2 SERVICE MANUAL 18. Connect the return line to the main hoist motor and fully hoist down, then hoist up again. Replenish the reservoir CAUTION hydraulic oil level as necessary. Hydraulic oil supply lines must be connected to the 19.

  • Page 43: Parts Replacement

    The filler cap includes a strainer for is being performed should be replaced. Refer to the catching contaminants and gaskets to prevent leaking. A Manitowoc Crane Care Parts Catalog for proper replacement breather cap (vent) is located on top of the reservoir to allow parts.

  • Page 44: Pump Distribution

    HYDRAULIC SYSTEM TMS500-2 SERVICE MANUAL A large access cover on the top of the reservoir provides Hydraulic Reservoir Temperature Sending Unit access for cleaning. The cover is secured to the top of the The Temperature Sender can be damaged by over-torquing. reservoir with a bolt clamp.
  • Page 45 TMS500-2 SERVICE MANUAL HYDRAULIC SYSTEM 9323 FIGURE 2-3 Item Description Item Description Reservoir Return Filter Filler Cap with Breather Lock Washers Magnetic Drain Plugs (Under tank) Sight Glass Access Cover Grove Published 07-21-2020, Control # 673-02...

  • Page 46: Maintenance

    HYDRAULIC SYSTEM TMS500-2 SERVICE MANUAL MAINTENANCE Troubleshooting SYMPTOM PROBABLE CAUSE SOLUTION No hydraulic oil flows in Low hydraulic oil level. Fill reservoir. systems. Clean, repair, or replace lines Reservoir-to-pump suction as necessary. Check lines for lines broken or restricted. Air security, absence of cracks, entering at suction lines.

  • Page 47: Return Hydraulic Filter Assembly

    TMS500-2 SERVICE MANUAL HYDRAULIC SYSTEM SYMPTOM PROBABLE CAUSE SOLUTION Leak in system. Repair leak. Adjust or replace controls Faulty electric controls/signals. signals. Faulty directional control valve. Replace valve. Specific hydraulic system (lift, Troubleshoot circuit with Poorly adjusted control in hoist, telescope, swing) not schematic.
  • Page 48 HYDRAULIC SYSTEM TMS500-2 SERVICE MANUAL 5, 6 6728 Item Description Item Description Capscrew Filter Head Washer Gauge O-ring O-ring Element Bypass Valve Bowl Spacer Gasket Capscrew FIGURE 2-4 2-10 Published 07-21-2020, Control # 673-02...

  • Page 49: Hydraulic Pumps

    TMS500-2 SERVICE MANUAL HYDRAULIC SYSTEM HYDRAULIC PUMPS Connect the distribution and supply lines as tagged during removal. Description Install the hydraulic tank hose to the pump and secure with capscrews, flatwashers O-Ring The engine drives the No. 1 gear pump (Figure 2-5) mounted (Figure 2-4).
  • Page 50 The Pump Priming Tool (Figure 2-6), P/N 80030367, Torque hose connections to the specified Manitowoc available from Manitowoc Crane Care, is used to prime the torque setting. (Refer to Fasteners and Torque Values, pumps after they have been removed from the crane.
  • Page 51 Touch pump to verify it has not become hot from binding. Manitowoc torque specifications. Refer to Fasteners and Listen for abnormal noises indicating low hydraulic oil Torque Values, page 1-14.).
  • Page 52 HYDRAULIC SYSTEM TMS500-2 SERVICE MANUAL 9237-2 9237-2a Item Description Port Sizes SAE J518C Code 62 1 1/4” SAE J518C Code 61 2 1/2” SAE J1926/1 ORB-12 1 1/16-12 UN-2B THD SAE J1926/1 ORB-04 7/16-20 UNF-2B THD FIGURE 2-7 2-14 Published 07-21-2020, Control # 673-02...
  • Page 53 TMS500-2 SERVICE MANUAL HYDRAULIC SYSTEM Piston Pump Start-up Procedure (Pump No. 2) Make sure the hydraulic reservoir is filled to the proper CAUTION level and that the fluid is not aerated. If it is aerated, let Pump or Reservoir Damage! the unit sit until the air has escaped and fluid is a dark solid color.
  • Page 54 HYDRAULIC SYSTEM TMS500-2 SERVICE MANUAL Pump No. 2 Assembly 9325b FIGURE 2-8 Item Description Item Description Pump, Variable Displacement Driveshaft Hydraulic Pump Outlet Port Washer 90 Deg Elbow HHCS Straight Thread Adapter Hex Nut Assy Pump Support 2-16 Published 07-21-2020, Control # 673-02...

  • Page 55: Carrier Valves

    TMS500-2 SERVICE MANUAL HYDRAULIC SYSTEM CARRIER VALVES General This subsection provides descriptive information for the hydraulic valves used on this crane. For a listing of the valves, the carrier circuit they are used in, and their physical location, refer to VALVE USAGE TABLE - CARRIER. Refer to Figure 2-9 for valve locations.
  • Page 56 HYDRAULIC SYSTEM TMS500-2 SERVICE MANUAL 9324 FIGURE 2-9 Item Description Item Description Outrigger Selector Manifold Valve Front Outrigger Manifold Valve Rear Outrigger Manifold Valve Swing/Steer Selector Valve 2-18 Published 07-21-2020, Control # 673-02...

  • Page 57: Outrigger Selector Manifold Valve

    TMS500-2 SERVICE MANUAL HYDRAULIC SYSTEM OUTRIGGER SELECTOR MANIFOLD VALVE Maintenance Description Removal of Manifold Valve Tag and disconnect the electrical connectors to the The outrigger selector manifold (Figure 2-10) directionally outrigger selector valve. controls the outrigger circuit. The valve is mounted on the rear face of the carrier frame member forward of the swivel.
  • Page 58 HYDRAULIC SYSTEM TMS500-2 SERVICE MANUAL 9326 9239b FIGURE 2-10 Item Description Item Description Solenoid Relief Valve 4-way Solenoid Pilot Valve Proportional Flow Control Valve 4-way Outrigger Directional Valve 2-20 Published 07-21-2020, Control # 673-02...

  • Page 59: Outrigger Control Manifold

    TMS500-2 SERVICE MANUAL HYDRAULIC SYSTEM OUTRIGGER CONTROL MANIFOLD Inspection of Outrigger Control Manifold Visually inspect the valves and hydraulic connections for any Description evidence of leaks or other damage. Check security of the electrical connections. Inspect the wiring for any evidence of There are two outrigger control manifolds used on the crane, cracks or breaks.
  • Page 60 HYDRAULIC SYSTEM TMS500-2 SERVICE MANUAL Fittings 5, 3, 6 Same Torque Value = 42 ft-lbs. FRONT MANIFOLD Fitting 2 Torque Value = 27 ft-lbs. 9239c FIGURE 2-11 9239d 2-22 Published 07-21-2020, Control # 673-02...
  • Page 61 TMS500-2 SERVICE MANUAL HYDRAULIC SYSTEM REAR MANIFOLD Fittings Same Torque Value = 42 ft-lbs. FIGURE 2-12 8122-3 Changing Solenoid Valves Functional Check To change the solenoid valve, Activate the hydraulic system and cycle the affected cylinder(s) several times. Observe for proper functioning of Unscrew and remove the old solenoid value.
  • Page 62 HYDRAULIC SYSTEM TMS500-2 SERVICE MANUAL 9240-2 9240-2a FIGURE 2-13 Item Description Item Description In Port Right Front Jack Cylinder Out Ports Right Front Extension Cylinder Center Front Stabilizer Check Valve Left Front Extension Cylinder Tank Left Front Jack Cylinder Gauge Port 2-24 Published 07-21-2020, Control # 673-02...
  • Page 63 TMS500-2 SERVICE MANUAL HYDRAULIC SYSTEM 6544-3 6544-3a FIGURE 2-14 Item Description Item Description In Port Left Rear Jack Cylinder Out Ports Right Rear Jack Cylinder Left Rear Extension Cylinder Right Rear Extension Cylinder Grove 2-25 Published 07-21-2020, Control # 673-02...

  • Page 64: Pilot Operated Check Valve

    HYDRAULIC SYSTEM TMS500-2 SERVICE MANUAL PILOT OPERATED CHECK VALVE Description A pilot operated (PO) check valve is located in each outrigger jack cylinder port block. The check valve functions as a holding valve for the jack cylinder. Oil flow is directed from the “V”...

  • Page 65: Maintenance

    TMS500-2 SERVICE MANUAL HYDRAULIC SYSTEM Test PO Check Valve For Leakage Remove the piston side hose from the port block of the cylinder see Figure 2-16. Piston Port CAUTION Rod Port Personal Injury Hazard! Release hose to adapter connection slowly. Trapped pressure may exit between the outrigger cylinder and the work port PO check valves in the outrigger selector valve.

  • Page 66: Superstructure Hydraulic Valves

    HYDRAULIC SYSTEM TMS500-2 SERVICE MANUAL Lubricate the check valve and O-Rings with clean NOTE: The check valve should turn by hand until hydraulic oil. compression of the O-Rings begins. Carefully install the check valve into the port block until fully seated. Torque to 136-149 N-m (100-110 lb-ft). CAUTION Test the check valve and port block by operating the Damage Could Occur!

  • Page 67: Main Directional Valve Assembly

    TMS500-2 SERVICE MANUAL HYDRAULIC SYSTEM Main Directional Valve Assembly FIGURE 2-18 Item Description Item Description Port 1A -Main Hoist Down Load Sense - Inlet Port Port 1B - Main Hoist Up Port PS - Pilot Supply Port 2A - Aux Hoist Down Gauge Port Port 2B - Aux Hoist Up Relief Valve - Telescope Extend...

  • Page 68: Accessory Manifold Assembly

    HYDRAULIC SYSTEM TMS500-2 SERVICE MANUAL Accessory Manifold Assembly 9328-1 FIGURE 2-19 9328-4 Item Description Item Description Swing Brake Release Solenoid Air Conditioning Relief Adjustment Valve - SV1 Swing Brake Release Relief Load Sense Dump Solenoid Valve - Adjustment Joystick Pilot Supply Solenoid and Swing Left Solenoid Valve - TS1 Valve - SV2 Swing Brake Solenoid Valve - EH1...

  • Page 69: Superstructure Hydraulic System

    The approximate Wear Ring Gaps are indicated in the following table: If damage cannot be rectified immediately, further damage is likely: • Inform Manitowoc Crane Care or your repair personnel. WEAR RING GAP Head (or Piston) Size Wear Ring Gap Inch Inch 1 to 4.75...
  • Page 70 HYDRAULIC SYSTEM TMS500-2 SERVICE MANUAL contraction will allow a cylinder to retract as the Leakage Check hydraulic fluid which is trapped in the cylinder cools. A hydraulic cylinder should not be disassembled unless it is The change in the length of a cylinder is proportional to the essential.

  • Page 71: Pressure Setting Procedures

    Required pressure gauge analog or digital capable of therefore, listed pressures may not match the reading 0-34.5 MPa (0-5000 psi). Diagnostic Quick values shown on the hydraulic schematic. Disconnect (Manitowoc 9999101806). Grove 2-33 Published 07-21-2020, Control # 673-02...

  • Page 72: Service Tool Notes

    HYDRAULIC SYSTEM TMS500-2 SERVICE MANUAL GAUGE PRESSURE TOLERANCE PRESSURE TO BE CHECKED PROCEDURE PSI (bar) PSI (bar) 325-400 Pump differential pressure See Range (-23-28) Pilot supply pressure 1350 (93) ± 50 (4) Load sense (max system) pressure 4000 (275) ± 50 (4) Tele extend pressure (102’...
  • Page 73 TMS500-2 SERVICE MANUAL HYDRAULIC SYSTEM Finding Menu Bar Functions 9265-2a FIGURE 2-20 Next, select the function that needs adjusted. The Main (Figure 2-21). The Carrier functions can be found under crane functions can be found under Proportional Valves Cabin also shown in Figure 2-21. Finding Main Crane Functions FIGURE 2-21 9265-1a...

  • Page 74: Procedure For Checking/Setting The Piston Pump Cut-Off And Differential Pressures

    Pressure Adjustment Screw (Figure 2-22) IN to increase or OUT to decrease so that a gauge reading is achieved. With engine off, install a pressure check diagnostic quick disconnect (Manitowoc 9999101806) with gauge onto PISTON PUMP Differential Pressure Adjustment Screw...

  • Page 75: Procedure For Checking/Setting The Pilot Supply Pressure

    With the engine off, install a pressure check diagnostic need to be active to assure that the Pilot Supply will not quick disconnect (Manitowoc 9999101806) with gauge be cut off before the cylinder can be dead headed). The onto the test nipple at the GP3 port of the accessory reading at GP3 should be 1350 ±...

  • Page 76: Procedure For Checking/Setting The Main Directional Control Valve, Load Sense, Lift And Telescope Pressures

    4000 ±50 psi (275 ± 4 bar) is With the engine off, install a pressure check diagnostic achieved (see Figure 2-24). quick disconnect (Manitowoc 9999101806) with gauge onto the test nipple at the GP2 port of the accessory Stop the engine and remove the diagnostic couplers manifold (see Figure 2-23).
  • Page 77 A, Telescope Section of the main directional control valve to the cylinder port block at With the engine off, install a pressure check diagnostic the back of the base section. quick disconnect (Manitowoc 9999101806) with gauge MAIN DIRECTIONAL VALVE BOTTOM Telescope Retract Relief...

  • Page 78: Procedure For Checking/Setting Swing Pressure

    With the engine off, install a diagnostic quick disconnect With the engine off, install a pressure check diagnostic coupler (Manitowoc 9999101806) with gauge onto the quick disconnect (Manitowoc 9999101806) with gauge test nipple at GP1 port of the accessory manifold with onto the test nipple at the GP7 port of the main swing directional control valve (see Figure 2-23).

  • Page 79: Procedure For Checking/Setting Outrigger Pressure

    With the engine off, install a pressure check diagnostic Once the pressure is achieved, make sure to "Save active to coupler (Manitowoc 9999101806) with gauge onto the customer" and "Save active to factory”. OUTRIGGER SELECTOR MANIFOLD...
  • Page 80 HYDRAULIC SYSTEM TMS500-2 SERVICE MANUAL Outrigger Beams Retract Target params Row, increase achieved. If the value needs adjusted by more than 100 the value to increase the pressure or decrease the value mA, there may be other problems within the circuit. to decrease the pressure (adjustment by 10 mA •...

  • Page 81: Procedure For Checking Air Conditioning Operation

    With the engine off, install a pressure check diagnostic (A/C). Listen to make sure that the compressor motor is coupler (Manitowoc 9999101806) with gauge onto the running or verify by removing the cover (see Figure 2-27) and looking at the shaft. The reading at GP13 should be 1350 ±50 psi (93 ±4 bar).

  • Page 82: Procedure For Checking/Setting The Center Front Stabilizer Pressure

    GP port of the outrigger 5-stack valve (see Figure 2-28). Center Front Stabilizer Pressure With the engine off, install a pressure check diagnostic coupler (Manitowoc 9999101806) with gauge onto the OUTRIGGER 5-STACK VALVE 9330-6 FIGURE 2-28 Extend the center front stabilizer to the ground and hold Stop the engine.
  • Page 83 TMS500-2 SERVICE MANUAL HYDRAULIC SYSTEM plunger out (counterclockwise) 10 full turns (see Figure 2-29). POWER STEERING GEAR BOX Right Turn Steer Plunger 9330-7a FIGURE 2-29 Start the engine and throttle up to full RPM. Fully turn the Steering stops must be in place on the axle to obtain the steering wheel to the right and hold.

  • Page 84: Procedure For Adjusting Electronic Controllers (Meter-In Dead Band And/Or Max Function Speeds)

    HYDRAULIC SYSTEM TMS500-2 SERVICE MANUAL STEER / SWING VALVE Steering Relief 9330-8 FIGURE 2-30 J. Procedure for Adjusting Electronic either too fast or slow, or if the max function speed is verified to be slower or faster than designed (see flows shown on Controllers (Meter-in Dead Band and/or Max system schematic): Function Speeds)
  • Page 85 TMS500-2 SERVICE MANUAL HYDRAULIC SYSTEM EXAMPLE ONLY - for MAIN HOIST UP FIGURE 2-31 9330-9b Adjust the Imin or Imax per the information above the Context Menu. Save the file in a folder under the (adjustment by 10 mA increments is suggested). Model Designation (TMS500-2).
  • Page 86 HYDRAULIC SYSTEM TMS500-2 SERVICE MANUAL THIS PAGE BLANK 2-48 Published 07-21-2020, Control # 673-02...

  • Page 87: Section 3

    TMS500-2 SERVICE MANUAL ELECTRICAL SYSTEM SECTION 3 ELECTRICAL SYSTEM SECTION CONTENTS Description ....... 3-1 Troubleshooting Accessories .

  • Page 88: Carrier Power Panel And Fuse Panels

    ELECTRICAL SYSTEM TMS500-2 SERVICE MANUAL CARRIER POWER PANEL AND FUSE test indicator located on the top of the battery is used to determine if the battery can be tested in case of a starting PANELS problem. Most carrier electrical circuits are protected by the fuse In addition to the batteries, the battery box also contains five panels located under the dash in the carrier cab.
  • Page 89 TMS500-2 SERVICE MANUAL ELECTRICAL SYSTEM Carrier Cab Relays Relays 9290-1 FIGURE 3-3 The coils of the accessory relay (Figure 3-3), (K101) is (K105) and Marker Lights on relay (K106) are energized energized when the ignition switch is at the RUN (1) position. when the Marker Lights and Headlights ON switch contacts The coil of Horn relay (K103) is energized when the Horn are closed.

  • Page 90: Carrier Cab Fuse And Relay Panels

    ELECTRICAL SYSTEM TMS500-2 SERVICE MANUAL Carrier Cab Fuse and Relay Panels Refer to (Figure 3-4) for carrier fuse assignments and relay box identification. Carrier Cab Fuse & Relay Identification 9280a 9280-3a 9280-1a FIGURE 3-4 Published 07-21-2020, Control # 673-02...

  • Page 91: Anti-Lock Brake System (Abs)

    TMS500-2 SERVICE MANUAL ELECTRICAL SYSTEM Battery Box Main Power Distribution F304 F305 F306 F307 F301 F302 F303 8338-3 Fuse Rating Circuit Number F304 100A Disconnect Battery + Main Carrier Cab Power Disconnect Battery + Carrier Ignition Relay F305 100A Power, Carrier ECM Relay Power and Carrier Head Lights Circuit Breaker F306 100A...
  • Page 92 ELECTRICAL SYSTEM TMS500-2 SERVICE MANUAL Console Power Panel Identification The Carrier Cab Console Power Panel (Figure 3-8) contains 1 relay (2), (Figure 3-7) and the fuse box (Figure 3-7) 9281-2 10026 FIGURE 3-6 9281-3 FIGURE 3-7 Diagnostic Connector The 9-pin on-board diagnostic connector (1), (Figure 3-7) is located below the carrier cab control panel on the left side of the dash board.

  • Page 93: Superstructure Cab Fuse And Relay Panels

    TMS500-2 SERVICE MANUAL ELECTRICAL SYSTEM SUPERSTRUCTURE CAB FUSE AND RELAY Most superstructure electrical circuits are protected by the PANELS Refer to for the Superstructure fuse assignments and relay panels as shown in (Figure 3-9) and the location on the Superstructure Cab in (Figure 3-10). Superstructure Cab Fuse &...
  • Page 94 ELECTRICAL SYSTEM TMS500-2 SERVICE MANUAL components of the fuse and relay panel (Figure 3-10) located at the rear of the superstructure cab. Access to all the fuses may be gained by removing the small plastic cover on the front of the panel. Inside the small plastic fuse cover, a fuse decal as shown in (Figure 3-9) can be found.

  • Page 95: Camera System (Optional)

    TMS500-2 SERVICE MANUAL ELECTRICAL SYSTEM CAMERA SYSTEM (OPTIONAL) (Figure 3-11). The power for the display/cameras is supplied by a 3A fuse, F16 in the carrier cab power panel as shown in There is an optional group camera package which consists (Figure 3-4) on the Carrier Fuse Identification Panel.

  • Page 96: General Troubleshooting

    ELECTRICAL SYSTEM TMS500-2 SERVICE MANUAL Using a multimeter, test the circuit for continuity if you suspect a broken circuit or for voltage if you suspect a power problem. Check the electrical schematic and WARNING wiring diagram for the most accurate wiring information. Serious Injury Could Occur! If the component proves faulty, replace it with a known working component.

  • Page 97: Jump Starting Hazard

    TMS500-2 SERVICE MANUAL ELECTRICAL SYSTEM If the starter engages but you cannot turn the engine charging at six (6) amps or less develops less heat inside the (and the lights dim, signaling power drain during battery and breaks up the sulfate on the battery plates more start attempt), check the starter’s feed circuit from efficiently to bring the battery up to full charge.

  • Page 98: Di-Electrical Grease Application

    (socket) contact.as shown in (Figure 3-12). splice. Di-electrical Grease Application Grease Application Since March 2018 Manitowoc Cranes has been using Di- Electric Grease on all electrical connectors. All of the below electrical connection received Di-Electric Grease: • All Deutsch Connectors.

  • Page 99: Troubleshooting Lights

    TMS500-2 SERVICE MANUAL ELECTRICAL SYSTEM Clean off Excess Material Excessive Paste Must be Wiped Off 6862-45 FIGURE 3-16 FIGURE 3-13 6862-42 Make sure that each socket has material. The towel with If clean-up is necessary, contact cleaner or petroleum excess material can be used to fill empty terminal distillates can be used.

  • Page 100: Troubleshooting Gauges And Meters

    ELECTRICAL SYSTEM TMS500-2 SERVICE MANUAL FA04 RH High Beam, FA05 LH Marker Lights, FA06 Park brake indicator. Indicator, normally closed park RH Marker Lights. Location: Carrier Cab. brake pressure switch on cab front console control valve, ground. Triple ID Lights: FA08. Location: Carrier Cab. Steering wheel horn.

  • Page 101: Starter Replacement

    TMS500-2 SERVICE MANUAL ELECTRICAL SYSTEM Remove the four bolts attaching the alternator to the Alternator Check mounting bracket. Remove the alternator. Run engine. Verify reading of voltmeter on front console is 24 volts or greater. Make repairs as needed. Alternator Installation Continue troubleshooting charging system as needed if Inspect the belt.
  • Page 102 ELECTRICAL SYSTEM TMS500-2 SERVICE MANUAL 9284-4 Item Description Starter Mounting to Bell Housing FIGURE 3-18 Close the engine compartment. Starter Installation Place the starter on its mounting pad. Secure the starter Starter Check with the bolts. Refer to Cummins Manual for torque Try to start the engine.

  • Page 103: Battery Replacement

    TMS500-2 SERVICE MANUAL ELECTRICAL SYSTEM Battery Replacement Battery Installation Place the batteries in the battery compartment, refer to Battery Removal (Figure 3-20). CAUTION To avoid possible engine fault codes and undesirable operation, ensure the key switch has been OFF 2 minutes before disconnecting batteries.

  • Page 104: Relay Panel Component Replacement

    ELECTRICAL SYSTEM TMS500-2 SERVICE MANUAL Relay Panel Component Replacement Buzzer Replacement Remove the cover from the relay panel. Accessory Relay Replacement Tag and disconnect the electrical leads from the buzzer. Make sure that the key switch has been in the OFF position for 2 minutes.

  • Page 105: Switch Replacement

    TMS500-2 SERVICE MANUAL ELECTRICAL SYSTEM Instrument Installation Rocker Switch Installation Put the instrument in place on the console panel and Place the switch on the console panel and secure it by secure it with the attaching hardware. pushing the switch into the panel, until it snaps into place.

  • Page 106: Windshield Wiper Assembly Replacement

    ELECTRICAL SYSTEM TMS500-2 SERVICE MANUAL Disconnect the washer hose on the wiper arm (4), Other Switch Installation (Figure 3-22) (also called the pantograph arm assembly) Place the switch through the hole in the front console from the washer nozzle fitting assembly. panel and secure to the front of the panel with the nut.
  • Page 107 TMS500-2 SERVICE MANUAL ELECTRICAL SYSTEM 6620 FIGURE 3-22 Item Description Item Description Wiper Arm or Pantograph Arm Motor Assembly Arm Drive Wiper Blade Pivot Shaft and Hardware Pantograph Adapter and Gasket Grove 3-21 Published 07-21-2020, Control # 673-02...

  • Page 108: Carrier Cab

    ELECTRICAL SYSTEM TMS500-2 SERVICE MANUAL Windshield Wiper Assembly Inspection Visually check the motor housing for evidence of cracks or other damage. Check for excessive shaft end play indicating worn or damaged bearings. Replace motor if damaged. Inspect the wiper blade for serviceability. Replace wiper blade when worn.

  • Page 109: Windshield Washer Assembly Replacement

    TMS500-2 SERVICE MANUAL ELECTRICAL SYSTEM WINDSHIELD WASHER ASSEMBLY SUPERSTRUCTURE WIPER ASSEMBLY REPLACEMENT Skylight Wiper Assembly Replacement Windshield Washer Assembly Removal Make sure that the key switch has been in the OFF position for 2 minutes. Turn the battery disconnect switch to the OFF position. Locate the windshield washer container and pump.

  • Page 110: Windshield Wiper Assembly Replacement - Superstructure Cab

    ELECTRICAL SYSTEM TMS500-2 SERVICE MANUAL WINDSHIELD WIPER ASSEMBLY shaft and flat washer and smaller nylon flat washer from mounting screw. REPLACEMENT - SUPERSTRUCTURE CAB Remove mounting screw and nylon flat washer from Windshield Wiper Assembly Removal outside cab roof. Make sure that the key switch has been in the OFF Clean any sealing material from around holes in cab position for 2 minutes.
  • Page 111 TMS500-2 SERVICE MANUAL ELECTRICAL SYSTEM 6620 FIGURE 3-25 Item Description Item Description Wiper Arm or Pantograph Arm Motor Assembly Arm Drive Wiper Blade Pivot Shaft and Hardware Pantograph Adapter and Gasket Grove 3-25 Published 07-21-2020, Control # 673-02...
  • Page 112 ELECTRICAL SYSTEM TMS500-2 SERVICE MANUAL Windshield Wiper Assembly Inspection Visually check the motor housing for evidence of cracks or other damage. Check for excessive shaft end play indicating worn or damaged bearings. Replace motor if damaged. Inspect the wiper blade for serviceability. Replace wiper blade when worn.

  • Page 113: Windshield Washer Assembly Replacement

    TMS500-2 SERVICE MANUAL ELECTRICAL SYSTEM WINDSHIELD WASHER ASSEMBLY Windshield Washer Assembly Inspection REPLACEMENT Visually check the pump for evidence of cracks, leaks, or other damage. Replace pump if damaged. Windshield Washer Assembly Removal Inspect the container for leaking. Replace pump seal if it Make sure that the key switch has been in the OFF is leaking.

  • Page 114: Computer Modules

    ELECTRICAL SYSTEM TMS500-2 SERVICE MANUAL COMPUTER MODULES available to those technicians that have attended the New Technology training course. This crane is equipped with 5 computer modules. The modules and locations are listed in the table below. The USING THE OPERATOR DISPLAY MODULE modules are susceptible to voltage / amperage surges in the (ODM) electrical system.
  • Page 115 TMS500-2 SERVICE MANUAL ELECTRICAL SYSTEM FIGURE 3-27 9479f Grove 3-29 Published 07-21-2020, Control # 673-02...
  • Page 116 ELECTRICAL SYSTEM TMS500-2 SERVICE MANUAL Remote Control Components THIS PAGE BLANK FIGURE 3-28 Table 3-3 Remote Control Components Item Component (Figure 3-28) Description Programming Port For Grove factory authorized use only Color Display Displays information for the selected function Power Button ON/OFF switch which activates and deactivates the remote control Amber, solid = remote control in boot loader mode (ready to be programmed)

  • Page 117: Receiver

    TMS500-2 SERVICE MANUAL ELECTRICAL SYSTEM Momentary buttons that activate the selected function in the display: 5a - Outrigger beams 5b - Outrigger jacks 5c - Boom lift 5d - Option: Function Selector Buttons (qty 10) 5e - Horn (activates the superstructure horn) 5f - Escape: exits the selected function screen 5g - Information (software version/revision and crane serial number) 5h - Engine...
  • Page 118 ELECTRICAL SYSTEM TMS500-2 SERVICE MANUAL THIS PAGE BLANK Published 07-21-2020, Control # 673-02...
  • Page 119 TMS500-2 SERVICE MANUAL BOOM SECTION 4 BOOM SECTION CONTENTS Description ....... 4-1 Remove the Inner Mid Section .

  • Page 120: Boom System Components

    BOOM TMS500-2 SERVICE MANUAL outer mid-section (6) and is routed around two sheaves (21) on the top front of the inner mid-section (4), and secured to the rear of the base section (13). DANGER Fly Retraction Cables To prevent serious injury or death, always wear personal protective equipment;...
  • Page 121 TMS500-2 SERVICE MANUAL BOOM 6838-1 6838-2 FIGURE 4-1 Grove Published 07-21-2020, Control # 673-02...

  • Page 122: Telescope Circuit

    BOOM TMS500-2 SERVICE MANUAL Item Description Item Description Outer Rod End of Telescope Cylinder Extend Synchronizing Cables Boom Base Section Base Section Synchronizing Cable Termination Inner Rod End Section of Telescope Cylinder Fly Retraction Cables Inner Mid Section Fly Section Retract Cable Sheaves Cylinder Barrel of Telescope Cylinder Retract Cable Termination Fly Section Outer Mid-Section...

  • Page 123: Telescope Circuit Troubleshooting

    TMS500-2 SERVICE MANUAL BOOM TELESCOPE CIRCUIT TROUBLESHOOTING Table 4-1 SYMPTOM PROBABLE CAUSE SOLUTION Erratic operation of Low hydraulic oil level. Replenish hydraulic oil to proper level. e x t e n d i n g b. Damaged relief valves. b. Repair or replace relief valves. t e l e s c o p i n g Air in telescope cylinder.

  • Page 124: Lift Circuit

    Repair or replace relief valve. Excessive load. Reduce load. d. Clogged hose and fittings. d. Replace hose or fittings. (Refer to Manitowoc Crane Care Parts Manual). Broken valve spool. Replace valve. Damaged piston seals. Replace all cylinder seals. g. Damaged piston(s).

  • Page 125: Theory Of Operation

    Operate unit to bring oil to operating temperature. Improper hose or fittings installed. Replace hose or fittings. (Refer to Manitowoc Crane Care Parts Manual). Operating two functions within the Feather controls to obtain desired same control valve bank assembly.

  • Page 126: General Maintenance Notes

    Operate unit to bring oil to operating temperature. Improper hose or fittings installed. Replace hose or fittings. (Refer to Manitowoc Crane Care Parts Manual). g. Restriction in return hose. g. Replace return hose. h. Cylinder piston seals worn. h. Replace all cylinder seals.

  • Page 127: Boom Extension Removal (Optional)

    TMS500-2 SERVICE MANUAL BOOM • To adjust the lower side wear pads, use shims so that wear pads are just in contact with the side plate of the next outer section. DANGER • To adjust the rear bottom wear pads, use shims so that Before attempting to remove the boom extension;...

  • Page 128: Boom Removal

    BOOM TMS500-2 SERVICE MANUAL Remove the retaining pin from the hitch pin (3), Attach a lifting device to the lifting lugs (1), (Figure 4-6) (Figure 4-4) that secures the boom extension to the rear on the swingaway extension taking pressure off the stowage bracket.
  • Page 129 TMS500-2 SERVICE MANUAL BOOM Turn off key and remove power using the battery disconnect. Disconnect any electrical wiring from the boom. DANGER Tag and disconnect the hydraulic lines to the telescope To prevent serious injury or death, always wear personal cylinder.
  • Page 130 BOOM TMS500-2 SERVICE MANUAL CAUTION Use extreme caution as cable reel is spring tensioned. Disconnect the cable from the Fly section (3), (Figure 4-10) and feed the cable through the cable guides (1), (Figure 4-10), and attach the cable to the Base section cable guide (2), (Figure 4-10).

  • Page 131: Remove The Base Section

    TMS500-2 SERVICE MANUAL BOOM Remove the access cover (1), (Figure 4-13) on the top rear of the base section. Slide the assembly out of the base section (1), (Figure 4-14) enough to gain access to CAUTION the top rear adjustable wear pads on the inner midsection (2), (Figure 4-14).

  • Page 132: Disconnect The Inner Mid Section

    BOOM TMS500-2 SERVICE MANUAL Raise the front of the assembly slightly and remove the wear pad mounting bolts and the wear pads from the bottom of the base section. Continue to pull the assembly until it is clear of the base section.

  • Page 133: Remove The Inner Mid Section

    TMS500-2 SERVICE MANUAL BOOM pads, keeper plates (3), (Figure 4-19) and bolts from the top of the outer mid section. FIGURE 4-18 6838-11 Remove the two nuts from the extend cable anchor plate adjusting bolts. FIGURE 4-19 6838-10 Pull the four retract cables up through the holes in the bottom of the inner mid section and lay them out to the At the top front of the inner mid section, remove the four rear.
  • Page 134 BOOM TMS500-2 SERVICE MANUAL Remove the lock nut and adjustment nut (1), (Figure 4-23) from the extend cable adjustment bolt. This will free the extend cable from the inner mid weldment. 6748-23 FIGURE 4-21 6818-15 FIGURE 4-23 10. Secure the extend cable keeper plate and adjustment Remove the screws securing each top (1), (Figure 4-22) bolt to the tele cylinder with cable ties (1), (Figure 4-24) and bottom side wear pads (2), (Figure 4-22) at the front...

  • Page 135: Remove The Outer Mid Section

    TMS500-2 SERVICE MANUAL BOOM 12. Remove the cotter pins and pins (2), (Figure 4-25) securing the four retract cables to the rear of the outer mid section. DANGER To prevent serious injury or death, always wear personal protective equipment; i.e., a hard hat, eye protection, gloves and metatarsal boots.
  • Page 136 BOOM TMS500-2 SERVICE MANUAL barrel (2), (Figure 4-27) to the rear of the outer mid Slide the fly assembly out of the outer mid section section. enough to gain access to the top rear adjustable wear pads on the fly assembly through the hole in the top of the outer mid section.

  • Page 137: Remove The Telescope Cylinder

    TMS500-2 SERVICE MANUAL BOOM wear pads, shims, and mounting angle (3), (Figure 4-31) pads and shims. Note the location of the shims for (top left side only). installation. Remove the Telescope Cylinder Do not attempt to work on the boom without experienced supervision..

  • Page 138: Boom Nose Sheaves

    BOOM TMS500-2 SERVICE MANUAL Remove sheave shaft retainer plates (3), (Figure 4-36) from the left and right sides of the sheave mount. Carefully pull the sheave shaft (4), (Figure 4-36) from the assembly, removing the spacers, and sheave (5), (Figure 4-36). Note the exact number of spacers you have for installation.

  • Page 139: Boom Nose Sheave Removal

    TMS500-2 SERVICE MANUAL BOOM Boom Nose Sheave Removal nose sheaves weigh approximately 9.4 kg (21 lb) each. Refer to Figure 4-37. Remove the hitch pin clip (3) from Carefully pull the upper boom nose sheave shaft (9) the pin and remove the pin lock hair (2) from the upper from the boom nose, removing the spacers (7, 8, 14) and lower part of the boom nose (9).
  • Page 140 BOOM TMS500-2 SERVICE MANUAL 102’ Boom Nose Assembly 6748-13a 6748-13b Item Description Item Description Sheave Assembly F Washer Pin Lock Hair L Washer Hitch Pin Clip Lock Nut Standard S-Hook End Cap Cotter Pin Spacer Chain (Not Shown) Shim Spacer HHCS Spacer Tube L Washer...

  • Page 141: Boom Assembly Procedure

    TMS500-2 SERVICE MANUAL BOOM NOTE: The lockwasher can be used more than once but that will be acceptable. It will not be necessary or must be replaced if not in good condition. desirable to remove one spacer from the first side. Install the locknut (12), washer (10), keyed washer (11), Apply a light coat of lubricant to the sheave shaft (4), and shims (15) (if necessary) onto the boom nose...
  • Page 142 BOOM TMS500-2 SERVICE MANUAL Reeve the five extend cables around the Telescope Cylinder sheave (Figure 4-40). 6862-11 FIGURE 4-41 Install cable retainer (3), (Figure 4-40) as referenced in Step 4b above. Attach a suitable lifting device to the Telescope Cylinder. 6748-33 FIGURE 4-39 Raise the Telescope Cylinder.
  • Page 143 TMS500-2 SERVICE MANUAL BOOM with the extend cable keeper plate (2), (Figure 4-44) and two bolts (3), Figure 4-44). 6838-14 FIGURE 4-44 15. Turn the cylinder rod mounting lug ends (Figure 4-45) so that they are aligned vertically to clear the mounting brackets in the outer mid section.

  • Page 144: Install The Outer Mid Section

    BOOM TMS500-2 SERVICE MANUAL adjustment weldment). The tools should extend past the wear pad adjustments as shown in (Figure 4-47). Align On This Edge 6960-15 FIGURE 4-46 19. Temporarily tie extend cables to the Telescope Cylinder to maintain proper cable alignment during assembly 6838-17 FIGURE 4-47 (Figure 4-45).
  • Page 145 TMS500-2 SERVICE MANUAL BOOM NOTE: Use grease to aid in holding the wear pad in place. CAUTION Do not allow the cables to become entangled or overlap. Cable or boom failure could result. Attach the fly retract cables to the cable anchors (1), (Figure 4-51) on the base end of the fly section on both sides.
  • Page 146 BOOM TMS500-2 SERVICE MANUAL 13. Align the cylinder mounting holes with the mounting bracket holes in the rear of outer mid section and secure with two bolts and bushings on each side. See (Figure 4-54). NOTE: It is important that the cylinder mount bolts be properly torqued.
  • Page 147 TMS500-2 SERVICE MANUAL BOOM 18. Install kickback plate hardware (1), (Figure 4-56) on the inside top of outer mid section. 6748-30a FIGURE 4-56 19. Rotate the cylinder mounting to make mounting easier into the inner mid section. (Figure 4-57) 6838-5 FIGURE 4-59 21.

  • Page 148: Install The Inner Mid Section

    BOOM TMS500-2 SERVICE MANUAL Attach both the mid-syncro cable anchor ends (1), (Figure 4-63) with the capscrews and bushings to the base end (2), (Figure 4-63) of the outer mid section. 6838-6 FIGURE 4-61 Install the Inner Mid Section Do not attempt to work on the boom without experienced supervision.
  • Page 149 TMS500-2 SERVICE MANUAL BOOM Pass the threaded end of the fly retract cables down 10. Install adjustment bolts and lock nuts to the upper though the bottom of the fly section. Lay the cables out adjustable wear pad weldment. Do not install wear pads toward the nose end of the fly section.
  • Page 150 BOOM TMS500-2 SERVICE MANUAL 13. Assemble the fly retract cable anchor weldments to the 17. Attach the mid retract cables to the outer mid section as retract cables. Thread the single nut on the cable end shown in (Figure 4-72). until there is 38 mm (1 1/2 inch) of thread showing, then install the locknut (Figure 4-70) NOTE:...
  • Page 151 TMS500-2 SERVICE MANUAL BOOM 6862-20 FIGURE 4-74 21. Continue inserting the outer mid section into the inner mid section. Stop when the upper rear adjustable wear pads on the inner mid section are accessible. 22. Install the adjustable wear pads (1), (Figure 4-75) to the top of the base end of the inner mid section.
  • Page 152 BOOM TMS500-2 SERVICE MANUAL machined into the sides of the inner mid anchor plate. 26. Carefully clamp the anchor assembly to the inner mid anchor weldment (Figure 4-78). Remove the installation bolt and replace with the standard adjustment bolt. b. Take up the slack on the anchor adjustment bolt and remove the clamps.

  • Page 153: Tensioning The Boom Extend And Retract Cables

    TMS500-2 SERVICE MANUAL BOOM 31. Install the retainer capscrew, washer, and the nut to lock the sheave assembly pins in place (1), (Figure 4-81). CAUTION Failure to properly position the port block will cause problems when mounting the boom on the crane. The crane hydraulic system will not function properly if the port block in installed incorrectly.
  • Page 154 BOOM TMS500-2 SERVICE MANUAL • To assure cables are adequately tensioned, torque In the order listed, torque the 4/3/2 retract, the 2/3/4 cables to at least the minimum torque values found in extend, the 3/2/1 retract, and the 1/2/3 extend cables to Table 4-3.
  • Page 155 TMS500-2 SERVICE MANUAL BOOM 6862-30 4-Section Boom Cable Positioning and FIGURE 4-84 Adjustment Locations Table 4-3: Minimum Torque Values for Boom Cable Tensioning Cables (Extend/Retract) Minimum Torque Values 4/3/2 retract 10.5 N-m (96 in-lb) 2/3/4 extend 40.5 N-m (360 in-lb) 3/2/1 retract 8 N-m (72 in-lb) 1/2/3 extend...

  • Page 156: Install The Base Section

    BOOM TMS500-2 SERVICE MANUAL Install the Base Section Connect the mid retract cables to the front end of the base section (Figure 4-86). Do not attempt to work on the boom without experienced supervision. DANGER To prevent serious injury or death, always wear personal protective equipment;...
  • Page 157 TMS500-2 SERVICE MANUAL BOOM 10. Adjust the cable until there is 76mm (3 inch) of threads showing past the adjustment nut (Figure 4-90). 6862-33 Test Port FIGURE 4-88 6862-35 FIGURE 4-90 Carefully guide the port block into the anchor weldment. 11.

  • Page 158: Final Boom Installation

    BOOM TMS500-2 SERVICE MANUAL FINAL BOOM INSTALLATION Do not attempt to work on the boom without experienced supervision. DANGER To prevent serious injury or death, always wear personal protective equipment; i.e., a hard hat, eye protection, gloves and metatarsal boots. NOTE: The complete boom assembly weighs are: 95’...

  • Page 159: Swingaway Extension Installation (Optional)

    TMS500-2 SERVICE MANUAL BOOM SWINGAWAY EXTENSION INSTALLATION Make sure that the lift cylinder is properly supported with a structure capable of supporting the weight of the lift (OPTIONAL) cylinder. 10. Elevate the boom slightly with the lifting device so that the lift cylinder can be extended approximately 30 cm (12 in) to allow for insertion of the lift cylinder rod end to DANGER...
  • Page 160 BOOM TMS500-2 SERVICE MANUAL 6814-4a FIGURE 4-96 6821-3b FIGURE 4-98 Be sure that the sliding portion (4), (Figure 4-98) of the rear stowage bracket is in the “OUT” position and secured in place with retaining pin(s) (5), (Figure 4-98) before Step 9. DANGER Extend the boom approximately 51 to 64 cm (20 to 25”).

  • Page 161: Boom Maintenance

    TMS500-2 SERVICE MANUAL BOOM DANGER Before performing Step 16, confirm that the extension is fully supported and secured prior to removing the attachment pins or the jib could fall. 17. Remove the attachment pins and clip pins (1), (Figure 4-96) from the anchor and attachment fittings (2), (Figure 4-96) on the right side of the boom nose and stow them in the base of the boom extension.

  • Page 162: Boom Alignment And Servicing

    BOOM TMS500-2 SERVICE MANUAL Visually inspect the telescoping sections for adequate lubrication of all wear surfaces. CAUTION Observe extended sections for evidence of cracks, When extending and retrac ti ng the boom during warping, or other damage. alignment, movement should be stopped if a restriction is Periodically check the security of the boom wear pads.

  • Page 163: Inspection

    TMS500-2 SERVICE MANUAL BOOM Inspection • In running ropes, six randomly distributed broken wires in one lay or three broken wires in one strand Do not attempt to work on the boom without experienced in one lay. supervision. • Wear of one-third the original diameter of outside individual wires.

  • Page 164: Lift Cylinder Maintenance

    BOOM TMS500-2 SERVICE MANUAL LIFT CYLINDER MAINTENANCE Pull the lower lift cylinder pivot shaft out far enough to remove the cylinder. Lift Cylinder Removal 10. Move the lift cylinder to a clean work area. Extend and set the outriggers and level the crane. Elevate the boom slightly so that the lift cylinder is extended approximately 0.3 m (1 ft).
  • Page 165 TMS500-2 SERVICE MANUAL BOOM RETAINING BOLT UPPER PIVOT SHAFT LOWER PIVOT SHAFT DETAIL A DETAIL B 6862-38 FIGURE 4-102 4-47 Grove Published 07-21-2020, Control # 673-02...
  • Page 166 BOOM TMS500-2 SERVICE MANUAL THIS PAGE BLANK 4-48 Published 07-21-2020, Control # 673-02...
  • Page 167 TMS500-2 SERVICE MANUAL HOIST AND COUNTERWEIGHT SECTION 5 HOIST AND COUNTERWEIGHT SECTION CONTENTS Description ....... 5-1 Brake Test Procedure .

  • Page 168: Maintenance

    HOIST AND COUNTERWEIGHT TMS500-2 SERVICE MANUAL MAINTENANCE Removal Remove all cable from the hoist drum. Warm-up Procedure Tag and disconnect the hydraulic lines to the hoist. Cap A warm-up procedure is recommended at each start-up and or plug all lines and openings. is essential at ambient temperatures below 4°C (+40°F).

  • Page 169: Installation

    TMS500-2 SERVICE MANUAL HOIST AND COUNTERWEIGHT Installation Remove the lifting device from the hoist. 10. Connect the hydraulic lines to the hoist making sure that Make sure that the mounting plate and hoist pads are the proper lines are connected to the correct ports as clean and free from debris and that the hoist has not marked during removal.

  • Page 170: Hoist Maintenance And Inspection

    HOIST AND COUNTERWEIGHT TMS500-2 SERVICE MANUAL HOIST MAINTENANCE AND INSPECTION turn determines appropriate intervals for inspections. The usage categories must be assigned by the crane user on a It is extremely important that the maintenance staff involved consistent crane-by-crane basis. The five crane/hoist usage with crane inspections be made aware of the possibility that categories are as follows: deterioration of internal critical components within the hoist...
  • Page 171 TMS500-2 SERVICE MANUAL HOIST AND COUNTERWEIGHT Pre-Use or Daily Inspection crane technician. The annual inspection MUST include, but not be limited, to the following: The pre-use or daily inspection must include, but is not limited to, the following inspections that will be performed Perform the pre-use/daily, quarterly and semi-annual inspections.

  • Page 172: Brake Test Procedure

    HOIST AND COUNTERWEIGHT TMS500-2 SERVICE MANUAL Information obtained from the oil analysis allows the sample. Operate the hoist in both directions for one or two maintenance technician to substitute preventive minutes to thoroughly mix the gear oil, then take the sample maintenance for more costly unscheduled down time or a far from the midstream flow of the oil to obtain an accurate more dangerous failure.

  • Page 173: Hoist To Boom Alignment

    TMS500-2 SERVICE MANUAL HOIST AND COUNTERWEIGHT HOIST TO BOOM ALIGNMENT fishing line you will be able to pull the line tight to make an accurate measurement of the fleet angle. Find the Preparation centerline of the hoist drum by using a square and drawing a line horizontal on the drum.

  • Page 174: Piston Motor And Control Valve

    HOIST AND COUNTERWEIGHT TMS500-2 SERVICE MANUAL MAIN HOIST IS ALIGNED TO THE RIGHT HAND SHEAVE LOCATING CENTERLINE WITH SQUARE AUXILIARY HOIST IS ALIGNED TO THE CENTER SHEAVE 6019 FIGURE 5-2 PISTON MOTOR AND CONTROL VALVE Place the motor and motor control valve in a clean, dry, suitable work area.

  • Page 175: Idler Drum And Cable Follower

    TMS500-2 SERVICE MANUAL HOIST AND COUNTERWEIGHT IDLER DRUM AND CABLE FOLLOWER Disassemble the cable follower drum as follows. Remove the two bolts and washers securing the Description angle to the right side of the shaft. The main and auxiliary hoists are equipped with an idler b.
  • Page 176 HOIST AND COUNTERWEIGHT TMS500-2 SERVICE MANUAL 6957-4a 6957-1 Item Description Pivot Bracket Drum Follower Roller Spring Spring Adjusting Rod Lever Idler Roller Bracket Hydraulic Motor Oil Level Oil Fill Drain Vent 6957-2 FIGURE 5-3 5-10 Published 07-21-2020, Control # 673-02...

  • Page 177: Hoist Drum Rotation Indicator System

    (9999102296). The CAN- damage to the solenoid. link service software and connection cable may be ordered from Manitowoc Crane Care. 5-11 Published 07-21-2020, Control # 673-02 Grove...
  • Page 178 HOIST AND COUNTERWEIGHT TMS500-2 SERVICE MANUAL 8479 Hoist 8478-1 Controller FIGURE 5-4 Item Description Rotation Indicator Controller Rotation Sensor Connection Two Speed Solenoid Connection 5-12 Published 07-21-2020, Control # 673-02...

  • Page 179: Counterweights

    TMS500-2 SERVICE MANUAL HOIST AND COUNTERWEIGHT COUNTERWEIGHTS Back the counterweight away from the turntable until it is clear of the crane. Configurations for counterweights follows below. 10. Replace the pin assembly in the turntable counterweight mounting lugs. Fixed Counterweight Description The Standard Counterweight is a 2268 kg (5000 lb) box 11.
  • Page 180 HOIST AND COUNTERWEIGHT TMS500-2 SERVICE MANUAL 6826-2 Item Description Item Description Counterweight Jam Nut Pin Assembly Lock Pin Capscrew Counterweight Inserts Hex Nut FIGURE 5-5 5-14 Published 07-21-2020, Control # 673-02...
  • Page 181 TMS500-2 SERVICE MANUAL HOIST AND COUNTERWEIGHT 6826-3 Item Description Item Description Weldment, Platform Hex Nut Bracket, Platform MTG. F Washer HHCS FIGURE 5-6 5-15 Published 07-21-2020, Control # 673-02 Grove...
  • Page 182 HOIST AND COUNTERWEIGHT TMS500-2 SERVICE MANUAL THIS PAGE BLANK 5-16 Published 07-21-2020, Control # 673-02...
  • Page 183 TMS500-2 SERVICE MANUAL SWING SECTION SECTION 6 SWING SECTION SECTION CONTENTS Introduction....... 6-1 Maintenance .
  • Page 184 SWING SECTION TMS500-2 SERVICE MANUAL FIGURE 6-1 6713 Item Description Item Description Plug Breather Plug Brake Apply Port Brake Release Port Motor Drain Plug for Brake Housing Gearbox and Brake Fill Plug and Oil Level Indicator Pinion Breather Published 07-21-2020, Control # 673-02...
  • Page 185 TMS500-2 SERVICE MANUAL SWING SECTION Maintenance Troubleshooting Symptom Probable Cause Solution Superstructure Damaged relief valve. Replace relief valve. swing operation b. Swing brake dragging (not releasing b. Readjust and/or replace necessary erratic in either properly). parts. direction. Low engine RPM. Increase engine RPM to obtain smooth swing operation.
  • Page 186 SWING SECTION TMS500-2 SERVICE MANUAL Symptom Probable Cause Solution Superstructure Crane not level. Level crane using outriggers. swing operation b. Turntable bearing binding due to b. Rotate machine 360 degrees in both erratic in one continuous limited swing. (Example: directions several times and lubricate direction only.
  • Page 187 TMS500-2 SERVICE MANUAL SWING SECTION Symptom Probable Cause Solution Superstructure Damaged relief valve. Remove, clean, and repair or replace swing operation valve. slow in either b. Improperly adjusted swing brake. b. Readjust. direction. Damaged electric remote control valve. Replace electric remote control valve. d.

  • Page 188: Description

    SWING SECTION TMS500-2 SERVICE MANUAL Symptom Probable Cause Solution Swing brake Damaged swing brake release valve. Replace release valve. system will not operate. Internal damage to the swing brake Repair or replace affected parts. assembly. d. Loose or restricted brake lines or d.

  • Page 189: Description

    TMS500-2 SERVICE MANUAL SWING SECTION Swing Motor Installation CAUTION Use care when removing the capscrews securing the CAUTION brake, as there is tension on the bolts due to internal Use care when engaging the swing motor drive gear, do brake springs. not force the shaft to engage.

  • Page 190: Maintenance

    SWING SECTION TMS500-2 SERVICE MANUAL Gearbox Installation Checking the Oil Level If removed, install the swing brake according to the procedures found in this Section under Swing Brake (pg Check the oil level through the level plug. 6-7). If no oil is visible on the level plug, add oil until the level If removed, install the swing motor according to the is between the min and max on the level plug.
  • Page 191 TMS500-2 SERVICE MANUAL SWING SECTION NOTE: If multipliers and/or special tools are used to reach hard to get at areas, make sure that torque CAUTION readings are accurate. Repeated re-torquing may cause bolts to stretch. If bolts Torque wrenches are precision instruments and must be keep working loose, they must be replaced with new bolts handled with care.
  • Page 192 SWING SECTION TMS500-2 SERVICE MANUAL 6750-2 FIGURE 6-2 The inner race of the bearing is secured to the turntable by Torque all outer race turntable bolts (Figure 6-2) to a final 36, 1 inch, grade 8 bolts. The outer race of the bearing is torque of 638 to 607 N-m (471 to 448 ft-lbs).
  • Page 193 Orders for Special Tools 1. 1 1/2” Socket 3/4” Drive 9-999-100143 Shall be Referred to: 2. 4 to 1 Torque Multiplier (1/2” Input 3/4” Output) 9-999-100134 Manitowoc/Grove Crane Care 3. Backlash Adapter 9-999-100141 1565 Buchanan Trail East 4. 1/2” Drive Torque Wrench 9-999-100136 Shady Grove, PA 17256-0021 5.
  • Page 194 SWING SECTION TMS500-2 SERVICE MANUAL capscrews securing the two retainer plates to the spool. NOTE: If the same bearing is to be used again, mark the Remove the retainer plates from the spool and the lugs position of the bearing on the Superstructure so on the carrier frame.
  • Page 195 TMS500-2 SERVICE MANUAL SWING SECTION NOTE: It will be necessary to rotate the Superstructure Apply Loctite 271 to the capscrews. Position the two while attached to the lifting device. Outer race bolts retainer plates on the bottom of hydraulic swivel spool, can only be installed from the swing drive side of engaging the lugs on the carrier frame, and secure them the turntable.

  • Page 196: Swivels

    SWING SECTION TMS500-2 SERVICE MANUAL SWIVELS carrier frame lugs with capscrews and hex nuts. This allows the spool to remain stationary with the carrier as the case Description rotates with the superstructure. The hydraulic and water swivel spools remain stationary with The swivel assembly (Figure 6-5) consists of a 5-port the carrier as the superstructure rotates.
  • Page 197 TMS500-2 SERVICE MANUAL SWING SECTION 7, 8 6,9,10 4, 5, 15 17, 18, 19 11, 14 6733-3 Item Description Item Description Swivel Assembly HHCS Plate Plate Slip Ring Assembly 2 Port Water Swivel HHCS, Stud Retainer Plate F Washer Hex Lock Nut Elbow Adapter HHCS...

  • Page 198: Hydraulic Swivel

    SWING SECTION TMS500-2 SERVICE MANUAL Hydraulic Swivel swivels are separate components. The function of each port is described below. Description Each of the ports on the spool and case of the swivel is stamped with the port number. The hydraulic and water Hydraulic Swivel Max Test Pressure Port #...
  • Page 199 TMS500-2 SERVICE MANUAL SWING SECTION NOTE: Do not adjust the swivel linkage rod. Rotate swivel of linkage rod as additionally shown in (Figure 6-6). to align with the mounting holes, and install the Torque the bolts (Figure 6-2). hardware (bolt, lock washer, and nut) on both ends 6733-5 Item Description...

  • Page 200: Electrical Slip Ring Assembly

    SWING SECTION TMS500-2 SERVICE MANUAL Installation The slip ring assembly cover is secured with a seal and bolts The electrical slip ring assembly also incorporates a slew NOTE: The hydraulic swivel weighs approximately 117 kg potentiometer. The potentiometer controls functions in the (258 lb).
  • Page 201 TMS500-2 SERVICE MANUAL SWING SECTION 4, 5, 6 CAUTION When withdrawing the wiring harness through the center of the hydraulic and water swivels, make sure that the wires do not get caught and damaged. 2, 3 11. Remove the electrical slip ring assembly and wiring harness from the crane.
  • Page 202 SWING SECTION TMS500-2 SERVICE MANUAL established. An example of this could be at approximately If this occurs, reposition the collar set screwed to 100 to 150 engine operating hours. When this time limit is the potentiometer shaft and repeat Steps 3 through reached, perform the following: Check the collector ring and brush assembly for any Tighten the three screws that secure the slew...
  • Page 203 TMS500-2 SERVICE MANUAL POWER TRAIN SECTION 7 POWER TRAIN SECTION CONTENTS Engine ........7-1 After-treatment Diesel Exhaust Fluid (DEF) .

  • Page 204: Engine Removal

    POWER TRAIN TMS9000-2 SERVICE MANUAL MAINTENANCE 16. Tag and disconnect the engine electrical harness connector from the carrier harness connector and the Engine Removal battery cables. 17. Tag and disconnect the transmission oil lines to the filter NOTE: If the Transmission needs to be removed from the and to the oil cooler.
  • Page 205 TMS500-2 SERVICE MANUAL POWER TRAIN Engine Installation - Right View 8326-4 Item Description Item Description Transmission Mount Alternator Engine Oil Dipstick Front Cross Member and Isolators Fan Clutch Engine Oil Filter Transmission FIGURE 7-1 Grove Published 07-21-2020, Control # 673-02...
  • Page 206 POWER TRAIN TMS9000-2 SERVICE MANUAL Engine Installation - Left View 8326-5 Item Description Item Description Lifting Bracket, Rear, Lifting Position Gear Pump Transmission Oil Fill Plug FIGURE 7-2 Published 07-21-2020, Control # 673-02...

  • Page 207: Engine Installation

    TMS500-2 SERVICE MANUAL POWER TRAIN Engine Installation Refer to (Figure 7-1), (Figure 7-2) and (Figure 7-3). With all components and fittings installed on the engine, lift the engine assembly into the crane. With the engine assembly in position, install the bolts, washers, lockwashers, nuts, and isolators on the front engine mounting support and on the transmission mounting brackets.

  • Page 208: Engine Drive Belts

    POWER TRAIN TMS9000-2 SERVICE MANUAL 21. Position the start relay and max speed relay on the The engine drive belt should be inspected visually on a daily inside of the hood and secure with the bolts, washers, basis. The drive belt should be inspected for cracks, frayed lockwashers, and nuts.

  • Page 209: Engine Control System Switches And Indicator Lights

    TMS500-2 SERVICE MANUAL POWER TRAIN power-up sequence. However, if an active fault is present, While the engine is cranking, the ECM is performing one of the lights remains illuminated, determined by the type additional diagnostic and status operations. An active fault of fault being sensed.
  • Page 210 POWER TRAIN TMS9000-2 SERVICE MANUAL Engine Control System Switches & Indicator Lights Item Description Color Cross-Axle Lock Indicator (Optional) Amber Inter-axle Locked Indicator Amber Suspension Deflated Indicator Amber ABS Traction Control Indicator Amber Tire Inflation Indicator Amber Left Turn Signal Indicator Green Marker Lights/Headlamps ON Indicator Green...

  • Page 211: Fuel System

    TMS500-2 SERVICE MANUAL POWER TRAIN • C) Flashing with Check Engine Light illuminated: Start Engine Stop Indicator cleaning immediately. Engine Stop lamp is locate d in the t op rig ht of the The high exhaust temperature indicator (28), (Figure 7-4) is speedometer (21), (Figure 7-4), which is on the right side of located in the tachometer.

  • Page 212: Maintenance

    POWER TRAIN TMS9000-2 SERVICE MANUAL removed from the fuel, are formed. The water droplets drain Place a suitable container under the filter and open the into a void between the two paper elements and to a drain plug. reservoir in the bottom of the housing, where it can be Drain until fuel appears.

  • Page 213: Air Intake System

    TMS500-2 SERVICE MANUAL POWER TRAIN 9332 Fuel Supply to Engine Fuel Return From Engine Tank Vent Fuel Quantity Sending Unit Filler Cap Fuel Tank Mounting Straps Fuel Tank Bracket FIGURE 7-5 Fuel Tank Installation AIR INTAKE SYSTEM designed to indicate red when servicing is required, is installed at the air cleaner outlet.
  • Page 214 POWER TRAIN TMS9000-2 SERVICE MANUAL evidence of dust leakage, check the following places for Make sure that the air cleaner inlet is not plugged. possible trouble. Inspect the air cleaner outlet to be sure it is not plugged NOTE: Dust that gets by the air cleaner system can often by paper, rags, etc.
  • Page 215 TMS500-2 SERVICE MANUAL POWER TRAIN INSPECT THE FILTER FOR DAMAGE. Always tube and the inside of the outlet tube, taking care not to look for filter damage, even if a new filter element is damage the sealing area on the tube. being installed.
  • Page 216 POWER TRAIN TMS9000-2 SERVICE MANUAL 8967-5 After-Treatment Module Mounting Bracket Exhaust Down Pipe V-Band Clamp Exhaust Tube Mounting Bracket - Flex Coupler Flex Coupler Gasket Tailpipe U-Bolt Clamp Exhaust Tube - Adapter Support Bracket - DEF Lines Mounting Bond FIGURE 7-6 7-14 Published 07-21-2020, Control # 673-02...

  • Page 217: Exhaust System

    TMS500-2 SERVICE MANUAL POWER TRAIN EXHAUST SYSTEM Module so that the tailpipe is vertical and the inlet aligns with the exhaust tube. Description Install the After-treatment Module and install new gaskets as necessary. The exhaust system utilizes a single module after-treatment which is comprised of a diesel oxidation catalyst (DOC), a Secure all exhaust tubing with appropriate clamps.

  • Page 218: Exhaust System

    POWER TRAIN TMS9000-2 SERVICE MANUAL Exhaust System FIGURE 7-7 8967-2 Diesel Particulate Filter (DPF) Diesel Exhaust Fluid (DEF) Dosing Module Selective Catalytic Reduction (SCR) Stack 7-16 Published 07-21-2020, Control # 673-02...

  • Page 219: After-Treatment Diesel Exhaust Fluid (Def)

    TMS500-2 SERVICE MANUAL POWER TRAIN AFTER-TREATMENT DIESEL EXHAUST Removal FLUID (DEF) Tag and disconnect the electrical connectors on the DEF tank. DEF Tank Tag and disconnect the fluid lines on the tank. Description Remove the hardware holding the tank straps in place. This engine uses a Selective Catalytic Reduction (SCR) Remove the tank.

  • Page 220: Def Dosing Unit Filter

    POWER TRAIN TMS9000-2 SERVICE MANUAL DEF Dosing Unit Filter The After-treatment DEF dosing unit filter consists of the following components: The DEF dosing unit filter is a 10-micron filter designed to (1) After-treatment DEF Dosing Unit Filter Cap. prevent foreign objects, that may be suspended in the DEF, from entering the dosing system.
  • Page 221 TMS500-2 SERVICE MANUAL POWER TRAIN NOTE: Do not disconnect the vehicle batteries until the if contaminated fluid has passed through the dosing DEF Dosing System has completed the purge system. c y c l e . B e f o r e b e g i n n i n g t o r e m o v e a n d / o r Inspect the DEF filter for debris.

  • Page 222: Water Cooling System

    POWER TRAIN TMS9000-2 SERVICE MANUAL Torque Value: 80 n-m (59 ft-lb). of the radiator. At all times, the antifreeze/coolant should be properly inhibited against corrosion. It is recommended that Finishing Steps a 50/50 fully formulated antifreeze coolant be used at all times.
  • Page 223 Refill as necessary repeating Install charged filter if SCA levels are normal or below Step 1. normal; install non-charged filter if SCA levels are above normal (contact Manitowoc Crane Care for filter part number). Grove 7-21 Published 07-21-2020, Control # 673-02...

  • Page 224: Cleaning

    POWER TRAIN TMS9000-2 SERVICE MANUAL Stop the engine as often as necessary to prevent boiling. 1 year or 1000 hours • Test antifreeze/coolant for contamination. With the engine stopped, feel the radiator core with bare hands to check for cold spots, and then observe the Condemning limits are: temperature gauge reading.

  • Page 225: Component Inspection

    TMS500-2 SERVICE MANUAL POWER TRAIN Component Inspection assemblies. Some of these coolant passages are small and can easily become clogged if the cooling system does not Radiator/Recovery Tank receive the proper maintenance. Top and Bottom Tanks - Look for leaks, particularly •...

  • Page 226: Radiator Assembly Removal And Installation

    POWER TRAIN TMS9000-2 SERVICE MANUAL regulations. Refer to Environmental Protection, page 9-1 Antifreeze/Coolant of this manual. Heavy-duty diesel engines require a balanced mixture of Open the left and right hood access doors. water and antifreeze/coolant. Fill the system with a 50/50 blended, fully formulated extended life antifreeze/coolant at Disconnect the hoses from the coolant recovery tank all times.
  • Page 227 TMS500-2 SERVICE MANUAL POWER TRAIN Engine Radiator/Charge Air Cooler Assembly 8285-1a Item Description Item Description Radiator/Charge Air Cooler Cold CAC Tube Surge Tank Hot CAC Tube Drain Cock Radiator Mount Left Hand Baffle Fan Guards Right Hand Baffle Coolant Recovery Hose Top Radiator Tube Vent Hoses Bottom Radiator Tube...

  • Page 228: Drive Train

    POWER TRAIN TMS9000-2 SERVICE MANUAL MAINTENANCE Connect the air cooler tubes to the air cooler using the bellows and clamps. Tighten the clamps to 4 to 5 N-m Drive Lines (35 to 45 in-lb). Connect the hoses to the top and bottom of the radiator. Ensure the drain cock is closed.
  • Page 229 TMS500-2 SERVICE MANUAL POWER TRAIN Drive Line Installation TORQUE TORQUE TORQUE TORQUE View A TORQUE TORQUE FIGURE 7-11 Grove 7-27 Published 07-21-2020, Control # 673-02...

  • Page 230: Electronic Clutch Actuator (Eca)

    Remove the (4) 3/8"-16 capscrews that secure the ECA 14-tooth shaft and is 1-3/4" longer. A modified input bracket. Remove the bracket. shaft (Eaton P/N 4306034 or contact Manitowoc Crane Care) can be used as an alignment tool. • Remove the (4) 3/8"-16 capscrews that secure the ECA to the housing.

  • Page 231: Mounting Transmission To Engine

    TMS500-2 SERVICE MANUAL POWER TRAIN Attach a two-point lift chain with a minimum capacity of the input shaft through the clutch and into the pilot 680 kg (1500 lbs) to the transmission. bearing. Remove the capscrews securing the transmission to the If interference is encountered, move the transmission engine.

  • Page 232: Pump/Pto Assembly

    POWER TRAIN TMS9000-2 SERVICE MANUAL PUMP/PTO ASSEMBLY Pump/PTO Replacement The PTO driveline (1), (Figure 7-12) powers the no. 2 pump (2), (Figure 7-12) in the L9 engine installation. CAUTION Damage Could Occur! Absolute cleanliness is essential when working on the hydraulic pumps.
  • Page 233 TMS500-2 SERVICE MANUAL POWER TRAIN Removal Installation De-pressurize the hydraulic system. Using the lifting device, place the mounting bracket/ pump assembly onto the crane and loosely assemble Remove the cap screws, nuts, and washers connecting with the cap screws, nuts, and washers. the PTO Driveline (1), (Figure 7-12) to the engine.
  • Page 234 POWER TRAIN TMS9000-2 SERVICE MANUAL THIS PAGE BLANK 7-32 Published 07-21-2020, Control # 673-02...

  • Page 235: Anti-Lock Brake System (Abs)

    TMS500-2 SERVICE MANUAL UNDERCARRIAGE SECTION 8 UNDERCARRIAGE SECTION CONTENTS Axles ........8-1 Rear Brakes .

  • Page 236: Maintenance

    UNDERCARRIAGE TMS500-2 SERVICE MANUAL mounting plates. The axle is built of a forged I-beam center The axle bolts conform to SAE Grade 8 specifications. Do section and heat-treated steel forged knuckle pins. not replace them with standard bolts. The rear axles have single reduction differentials. The Springs differentials have hypoid drive pinions, ring gear sets, and The two main causes of leaf spring failure are loose bolts...
  • Page 237 TMS500-2 SERVICE MANUAL UNDERCARRIAGE Front Axle Installation Alignment Position the axle under the crane. Have a qualified alignment specialist inspect the machine for compliance with the following machine specifications: Align the holes in the axle with the spring bottom mounting plate. Install the eight bolts and hardened •...
  • Page 238 UNDERCARRIAGE TMS500-2 SERVICE MANUAL 4, 5 1, 2 6861-2 FIGURE 8-1 Published 07-21-2020, Control # 673-02...
  • Page 239 TMS500-2 SERVICE MANUAL UNDERCARRIAGE Item Description Item Description Bolt Inner Bushing Washer Washer Spring Mount Hex Nut Washer Washers Hangar Link Shock Absorber Steer Arm Axle Stop Drag Link Top Plate Steering Gear Spring Steering Column Outer Bushing Miter Gear Washer Bolt Capscrew...
  • Page 240 UNDERCARRIAGE TMS500-2 SERVICE MANUAL Torque Drag Link Ball Joints 120- 170 ft-lbs. 1994 mm (78.50 in) 6958-2 FIGURE 8-3 0.794mm (1/32 inch) ± 0.794mm (1/32 inch) for 95 mm (3.75 in) 95mm (3.75 in) Loaded vehicle. Loosen the tube clamp nut and bolt on each end of 6958-3a FIGURE 8-4 the cross tube.

  • Page 241: Rear Axles

    TMS500-2 SERVICE MANUAL UNDERCARRIAGE NOTE: Do not attempt to set the relief pressure with the tires off the ground. Plungers are fine thread and Setting Axle Stops a c c e p t a s m a l l f l a t h e a d s c r e w d r i v e r. A ft e r approximately 4 wheel turns, steering may be considerable higher.
  • Page 242 UNDERCARRIAGE TMS500-2 SERVICE MANUAL lubrication intervals. Check the torque on all bolts at least Rear Tandem Removal once a year. NOTE: The axle does not have to be removed from the crane for maintenance. Beam Center Cap Fasteners Remove the hardware securing the axle limiting straps Periodically check the bolts on the saddle cap to prevent on each side of the axle and remove the straps.
  • Page 243 TMS500-2 SERVICE MANUAL UNDERCARRIAGE Remove each shock absorber from the trailing arm Remove the trailing arm assemblies from the walking assembly by removing the nut and two washers beams by removing two bolts and washers from each securing each. Remove the shock absorber(s). pivot block cap.
  • Page 244 UNDERCARRIAGE TMS500-2 SERVICE MANUAL 6861-1a Item Description Item Description Front Rear Drive Axle Air Bags Air Brake Chamber Shock Absorber Drive Line Yokes Limiting Strap Bracket Transverse Torque Rod Back Rear Drive Axle Longitudinal Torque Rod Frame Trailing Arm Assembly Walking Beam FIGURE 8-7 8-10...
  • Page 245 TMS500-2 SERVICE MANUAL UNDERCARRIAGE Attach the fore and aft torque rods to the carrier frame Axle and Suspension Assembly using two bolts and hardened washers on each. Torque As necessary, assemble the axle and suspension assembly the bolts per Table 1-3, Inch Series with Coarse Threads using the following procedures: (UNC) –...

  • Page 246: Wheels And Tires

    UNDERCARRIAGE TMS500-2 SERVICE MANUAL In addition to matching individual tire rolling radii and circumference, match the total tire circumference of one driving axle to the other driving axle.The result will be satisfactory axle lubricant temperatures. Do not over-tighten the ny- Vehicle Maintenance Schedule lock nut - rod and arm should pivot freely...

  • Page 247: Steering System

    TMS500-2 SERVICE MANUAL UNDERCARRIAGE Install the wheel assemblies on the mounting studs. Place the mounting ring and hub cover over the hub and studs. Install the lug nuts and tighten until the nuts are just snug. Position the nut that is to be tightened on top. Tighten the rear wheel lug nuts to a preliminary torque of 68 N-m (50 pounds-foot) in the sequence as shown in (Figure 8-9).
  • Page 248 UNDERCARRIAGE TMS500-2 SERVICE MANUAL Symptom Probable Cause Solution High operating temperatures. Oil flow restriction. Check back pressure. b. Oil flow too high. b. Check maximum oil flow. Excessive pump pressure with Pinched oil return line, high Relocate line. steering gear in neutral. back pressure.
  • Page 249 TMS500-2 SERVICE MANUAL UNDERCARRIAGE Symptom Probable Cause Solution 13. Darting, wandering, oversteering. Oil flow too high. Supply pump specifications. b. Air trapped in steering gear. b. Bleed system. Looseness, worn front end Check and repair as required. parts. d. Front alignment d.

  • Page 250: Steering Gearbox

    UNDERCARRIAGE TMS500-2 SERVICE MANUAL STEERING GEARBOX Turn the input shaft on the gearbox until it bottoms out. Turn the input shaft in the opposite direction while Description counting the number of turns until it bottoms out. The steering gear box (Figure 8-11) is attached to the frame and is located on the left side beneath the carrier cab.

  • Page 251: Air System

    TMS500-2 SERVICE MANUAL UNDERCARRIAGE AIR SYSTEM 11, 12 Description The air system (Figure 8-14) provides the air supply and control to operate the service brakes, parking brakes, air suspension system, inter-axle and optional cross axle differential locks, tire inflation, and the engine fan clutch solenoid valve.
  • Page 252 UNDERCARRIAGE TMS500-2 SERVICE MANUAL 6972-10a 6972-10b 6972-10c 6972-10d FIGURE 8-13 8-18 Published 07-21-2020, Control # 673-02...
  • Page 253 TMS500-2 SERVICE MANUAL UNDERCARRIAGE 6972-10g 6972-10j 6972-10h 6972-10k 6972-10i Figure 8-13 continued Grove 8-19 Published 07-21-2020, Control # 673-02...

  • Page 254: Maintenance

    UNDERCARRIAGE TMS500-2 SERVICE MANUAL Item Description Item Description Inter-Axle Differential Lock Solenoid Air Dryer Module Valve Supply Dump Valve Rear Service Brake Relay Valve Tire Inflation Solenoid Valve ABS Modulator Valve Axle 2, LEFT Service Brake Relay Valve ABS Modulator Valve Axle 2, RIGHT Secondary Tank A Traction Control Valve Air Suspension Solenoid Valve...
  • Page 255 TMS500-2 SERVICE MANUAL UNDERCARRIAGE indicator light should illuminate when the pressure in all Raise the crane on the outriggers. air bags drops below 28 ± 14 kPa (4 ± 2 psi). Shutdown the engine. Air Suspension Switch (Inflate Position) 9288 Air Suspension Switch (Deflate Position) FIGURE 8-14 should increase together until they reach their full...

  • Page 256: Air System Components

    UNDERCARRIAGE TMS500-2 SERVICE MANUAL Observe the air pressure gauge, on the front console, for pressure in the primary system should not drop below two additional minutes without the service brakes 689 kPa (100 psi). applied. Any decrease in air pressure shall not exceed Continue draining the secondary reservoirs to zero (0) one (1) psi per minute.
  • Page 257 TMS500-2 SERVICE MANUAL UNDERCARRIAGE Air Compressor 9907 FIGURE 8-15 Grove 8-23 Published 07-21-2020, Control # 673-02...
  • Page 258 UNDERCARRIAGE TMS500-2 SERVICE MANUAL Air Dryer 4, 5 6861-1e FIGURE 8-16 Item Description Item Description Governor Auxiliary Delivery Port (Air Out) Unloader Control Valve Inlet Port (Supply From Compressor) Common Reservoir Pressure Pressure Protection Valves Delivery Port Out (To Primary Safety Valve Reservoir) (Not Shown) Delivery Port Out (To Secondary...
  • Page 259 TMS500-2 SERVICE MANUAL UNDERCARRIAGE switch is installed in each system and they are electrically kPa (150 psi). A second safety valve is installed in the tire connected in parallel to illuminate the Low Air Pressure inflation circuit and is set at 1207 kPa (175 psi). indicator on the front console in the cab.
  • Page 260 UNDERCARRIAGE TMS500-2 SERVICE MANUAL Relay Valve The purpose of the two piston operated relay valves (Figure 8-21) and (Figure 8-22) is to speed up application of the service brakes. The valve is remote mounted and delivers air to the brakes in response to signals from the foot brake control valves.
  • Page 261 TMS500-2 SERVICE MANUAL UNDERCARRIAGE Maintenance WARNING Death or Injury Could Occur! Depressurize both air systems completely before disconnecting air lines or components. NOTE: For more in-depth information on Bendix system components, go to the Bendix website and download the appropriate document. Air Compressor NOTE: Detailed maintenance instructions for the air...
  • Page 262 UNDERCARRIAGE TMS500-2 SERVICE MANUAL conditions can also cause water accumulation and Operational Test for the Air Governor should be considered before changing the desiccant. Start the engine and pressurize the system. Check the governor cut-out pressure with either the panel gauge or a An outside air source has been used to charge the test gauge 896 kPa (130 psi).
  • Page 263 TMS500-2 SERVICE MANUAL UNDERCARRIAGE Reservoirs Preventive Maintenance for the Low Pressure Indicator Switches Removal of the Reservoirs Every 16,000 km (10,000 mi) or monthly do the procedures Chock the wheels and completely depressurize both as outlined under Operating and Leakage Checks above. systems.
  • Page 264 UNDERCARRIAGE TMS500-2 SERVICE MANUAL Safety Valve mm (1 in) b ubble in three second s or lon ger is acceptable. Removal of Safety Valve Disconnect the air line on the delivery side of the valve Chock the wheels and completely depressurize the and apply a soap solution to the delivery port.
  • Page 265 TMS500-2 SERVICE MANUAL UNDERCARRIAGE position. Observe that the spring brake actuators Leakage Test for the Relay Valve release fully. With dual brake valve released, coat the relay valve exhaust port with a soap solution to check for inlet valve With the parking control valve in “release” position, note and O-Ring leakage.

  • Page 266: Brakes

    UNDERCARRIAGE TMS500-2 SERVICE MANUAL Installation of the Dual Brake Valve Disassemble the brake valve and clean and inspect all parts. Park Brake Control Valve Position the brake valve and pedal assembly onto the studs under the front console and secure with the nuts, Removal of Park Brake Control Valve washers, and lockwashers.

  • Page 267: Air Supply

    TMS500-2 SERVICE MANUAL UNDERCARRIAGE Air Supply Wheel Speed Sensor and Tone Ring An ABS wheel speed sensor and tone ring (Figure 8-24) is The vehicle’s compressor, see Air Compressor, page 8-22, mounted in each monitored wheel. As the wheel spins, the takes in filtered air at an increased pressure from the intake sensor sends a fluctuating signal to the ABS ECU, which the manifold and compresses it.

  • Page 268: Front Brakes

    UNDERCARRIAGE TMS500-2 SERVICE MANUAL • Always wear a respirator approved by NIOSH or MSHA vacuum with a HEPA filter and rags soaked in water and during all brake service procedures. Wear the respirator wrung until nearly dry. Used rags should be disposed of from removal of the wheels through assembly.
  • Page 269 TMS500-2 SERVICE MANUAL UNDERCARRIAGE Disassembly of the Front Brakes CAUTION Damage Could Occur! WARNING Do not force the drum. Excessive force may damage brake components. Death or Injury Could Occur! Do not work under a crane supported by only outrigger Brake Shoe Removal jacks.
  • Page 270 UNDERCARRIAGE TMS500-2 SERVICE MANUAL remove brake dust from drums. Wipe the interior of the brake drums with a greaseless solvent to remove any Retainer Spring spilled oil. Clean all other brake parts thoroughly with a suitable shop solvent. Wipe dry with a clean, lint-free cloth. Inspection of Brakes and Parts NOTE: Refer to (Figure 8-30) for the brake components...
  • Page 271 TMS500-2 SERVICE MANUAL UNDERCARRIAGE Mount a dial indicator with the plunger on the cam After re-bushing, recheck radial play. Replace the head at the roller contact area. camshaft if play is still excessive. b. Zero the dial indicator. CAUTION Move the cam head up and down and note the Damage Could Occur! maximum reading.
  • Page 272 UNDERCARRIAGE TMS500-2 SERVICE MANUAL 21. Check air chamber clevis pin for cracks and wear. 22. Check automatic slack adjuster. Reference If more than 0.91 mm Automatic Slack Adjuster, page 8-40. (0.035 in). Replace bushings and recheck. Repair/Replacement of Camshaft Routinely replace lower cost items such as springs, seals, bushings, and heavily worn parts.
  • Page 273 TMS500-2 SERVICE MANUAL UNDERCARRIAGE Install new camshaft seals and, if required, bushings in both the spider and camshaft bracket. Use a seal driver CAUTION to install the bushings. Damage Could Occur! If the camshaft bracket was removed, install the gasket Seals must be installed with the lip side (spring side) of and bracket to the spider.

  • Page 274: Automatic Slack Adjuster

    UNDERCARRIAGE TMS500-2 SERVICE MANUAL Install the slack adjuster. Reference Automatic Slack Adjuster, page 8-40. AUTOMATIC SLACK ADJUSTER Description The automatic slack adjuster compensates for normal wear in the brake shoe linings by maintaining a nominal clearance between the lining and the drum. Rotate the lower shoe up so that the return When the brake is applied, the slack adjuster’s rotation...
  • Page 275 TMS500-2 SERVICE MANUAL UNDERCARRIAGE NOTE: Note the orientation of the slack adjuster with Removal of Slack Adjuster reference to the push rod before removal to make sure of proper orientation at installation. CAUTION Remove the slack adjuster with a suitable puller. Damage Could Occur! Installation of the Slack Adjuster You must disengage a pull pawl before rotating the...
  • Page 276 UNDERCARRIAGE TMS500-2 SERVICE MANUAL BRAKE APPLIED STROKE MEASUREMENT Applied Stroke = B minus A (Fully Retracted) (Brake Application at 621 to 689 kPa (90 - 100 psi) reservoir pressure) 7094-1 FIGURE 8-40 Starting with 621 to 689 kPa (90 to 100 psi) air tank b r a k e f u l l y r e l e a s e d .

  • Page 277: Rear Brakes

    TMS500-2 SERVICE MANUAL UNDERCARRIAGE Grove Crane distributor. The crane cannot be driven on incorporated into the air brake chamber. The brake chamber public roads until repaired. has an aluminum body and pressure plate with a steel non- pressure plate that houses a service/emergency diaphragm, REAR BRAKES piston, and two springs.

  • Page 278: Maintenance

    UNDERCARRIAGE TMS500-2 SERVICE MANUAL Maintenance Troubleshooting Rear Brakes SYMPTOM PROBABLE CAUSE SOLUTION Check for correct pressure at Brakes are poor or do not Insufficient air pressure. compressor and brake apply. chambers. Restriction or leak in lines, valves, Check all lines, valves, etc., for etc.
  • Page 279 TMS500-2 SERVICE MANUAL UNDERCARRIAGE SYMPTOM PROBABLE CAUSE SOLUTION Improper connection of the service Check and connect line to line at spring brake. proper port. Tighten connections on air lines Leaking lines or spring brake or replace spring brake unit seals. seals.
  • Page 280 UNDERCARRIAGE TMS500-2 SERVICE MANUAL Caging Bolt Spring Brake Chamber Caging Clamp Bolt Stowage Air Ports Diaphragm Clamp Push Rod Mounting Bolt Service Spring Brake Chamber Shield Push Rod 6861-1x FIGURE 8-43 Cover Mounting Nut Remove the clamp securing the service brake chamber to the spring brake chamber.
  • Page 281 TMS500-2 SERVICE MANUAL UNDERCARRIAGE BRAKE APPLIED STROKE MEASUREMENT Applied Stroke = B minus A (Fully Retracted) (Brake Application at 621 to 689 kPa (90 - 100 psi) reservoir pressure) 7094-1 FIGURE 8-45 Starting with 621 to 689 kPa (90 to 100 psi) air tank Turn the integral release bolt counterclockwise using a pressure in both the primary and secondary systems, 3/4-inch socket wrench (Figure 8-46), until the power...

  • Page 282: Rear Brake Assembly

    UNDERCARRIAGE TMS500-2 SERVICE MANUAL 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) MEASURE FREE STROKE 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 8-47).
  • Page 283 TMS500-2 SERVICE MANUAL UNDERCARRIAGE Install the pawl assembly into the slack adjuster. Remove the brake drum. Retainer Spring Brake Shoe Removal Push down on the bottom brake shoe and pull on the roller retaining clip to remove the bottom cam roller. 6862-3 FIGURE 8-51 Clean and Inspect Parts...
  • Page 284 UNDERCARRIAGE TMS500-2 SERVICE MANUAL Check the camshaft for cracks, wear, and corrosion. Camshaft Installation Check the cam head, bearing journals, and splines. Check all spider bolts for the correct torque as shown Refer to Repair/Replacement of Camshaft, page 8-38 in below.

  • Page 285: Abs System Description

    TMS500-2 SERVICE MANUAL UNDERCARRIAGE CAUTION Damage Could Occur! Webs Do not get grease on cam head surface. The cam surface must be free of oil, grease, and other contaminates for Squeeze efficient operation. Put the cam head thrust washer on the camshaft. Apply O-617-A or B chassis grease to the camshaft bushings or needle bearings and to the camshaft journals.
  • Page 286 UNDERCARRIAGE TMS500-2 SERVICE MANUAL slippery road conditions. The ABS improves the vehicle’s which sends signals to the ABS modulator valves if it detects stability and control by reducing wheel lock during braking. that a wheel has locked up or is about to lock up. The modulator valves control the pressure in the brake assembly The ABS electronically monitors the rotational speed of both air chambers.

  • Page 287: Atc System Description

    TMS500-2 SERVICE MANUAL UNDERCARRIAGE FIGURE 8-59 8861e ATC System Description control wheel slip. Once triggered, differential braking mode remains active regardless of vehicle speed. Just as ABS improves vehicle stability during braking, ATC • The off-road switch allows greater wheel spin (more improves vehicle stability and traction during vehicle torque) when activated.
  • Page 288 UNDERCARRIAGE TMS500-2 SERVICE MANUAL M-32 Port Designation Air Supply Port Air Delivery Port Treadle Port Electrical Connector FIGURE 8-60 ATC Indicator The ATC indicator (2), (Figure 8-59) is the primary indicator of the ATC status. The ATC indicator: • Lights at key-ON and turns OFF after a two second lamp check.

  • Page 289: Abs Troubleshooting

    TMS500-2 SERVICE MANUAL UNDERCARRIAGE Acceptable Tire Sizes The speed calculation for an exciter ring with 100 teeth is based on a default tire size of 510 revolutions per mile. This figure is based on the actual rolling circumference of the tires, which varies with tire size, tire wear, tire pressure, vehicle loading, etc.
  • Page 290 UNDERCARRIAGE TMS500-2 SERVICE MANUAL In addition, by operating the blink code switch as described Voltage trouble codes will clear automatically when the below, one of several diagnostic modes can be entered. voltage returns within the required limits. All ABS functions Refer to the Diagnostic Mode Selection, page 8-56 in this will be re-engaged.
  • Page 291 TMS500-2 SERVICE MANUAL UNDERCARRIAGE Inactive trouble codes, and event history, may be retrieved System Configuration Check and cleared by using a hand-held or PC-based diagnostic 4 Modulators tool. 5 Modulators Clearing Active Diagnostic Trouble Codes 6 Modulators The ECU will clear active trouble codes when the diagnostic 4th Number ABS Configuration blink code switch is depressed and released three times.
  • Page 292 UNDERCARRIAGE TMS500-2 SERVICE MANUAL X1 Connector Pin Assignments Designation Designation Designation Ground J1939 Low SAE J1587 (B) Trailer ABS Dash J1939 High SAE J1587 (A) Indicator Stop Lamp Switch Ignition Not Used Input Traction Control Wheel Speed Sensor Battery Valve - Common Drive Axle Right (+) Traction Control Wheel Speed Sensor...
  • Page 293 TMS500-2 SERVICE MANUAL UNDERCARRIAGE 1st Blink Code Number Troubleshooting Test Location Refer to No faults (Code 1, 1) Wheel Speed Sensors page 8-59 Wheel Speed Sensors page 8-59 Wheel Speed Sensors page 8-59 Wheel Speed Sensors page 8-59 Power Supply page 8-64 Pressure Modulator Valves page 8-61...
  • Page 294 UNDERCARRIAGE TMS500-2 SERVICE MANUAL 1st Blink Code Location Left Additional Axle Sensor Right Additional Axle Sensor 2nd Blink Diagnostic Trouble Code Repair Information Code Description 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. Excessive Air Gap Verify mounting of exciter ring and condition of teeth.
  • Page 295 TMS500-2 SERVICE MANUAL UNDERCARRIAGE Clear DTC after issue is corrected. The sensor DTC will ECU Wire Harness Connector: Speed Sensor Pins remain until the power is cycled to the ABS ECU and the vehicle is driven above 15 MPH or DTC was cleared using either the diagnostic blink code switch or diagnostic tool.
  • Page 296 UNDERCARRIAGE TMS500-2 SERVICE MANUAL Diagnostic Trouble Blink Repair Information Code Description Code Verify no continuity between PMV leads and ground. Verify 4.9 to 5.5 ohms from Release Solenoid Shorted to REL to CMN and HLD to CMN, and 9.8 to 11 ohms from REL to HLD. Check for Ground corroded / damaged wiring or connectors between ECU and PMV.

  • Page 297: Troubleshooting Diagnostic Trouble Codes: Traction Control Valves

    TMS500-2 SERVICE MANUAL UNDERCARRIAGE Connector PMV Location Left Steer Axle Hold Left Steer Axle Release Left Steer Axle Common Right Steer Axle Hold Right Steer Axle Common Right Steer Axle Release 18 Way Right Drive Axle Common Right Drive Axle Hold Right Drive Axle Release Left Drive Axle Common Left Drive Axle Hold...
  • Page 298 UNDERCARRIAGE TMS500-2 SERVICE MANUAL Diagnostic Location Measurement Trouble Blink Repair Information TCV to TCV Common 7 to 19 Ohms Code Code Release, Hold, Common to Description Open Circuit (no continuity) Voltage or Ground The ECU is not configured for TCV, but has detected the ECU Wire Harness Connector: Traction Control Valve presence of a TCV.

  • Page 299: Power Supply Tests

    TMS500-2 SERVICE MANUAL UNDERCARRIAGE Diagnostic Trouble Blink Repair Information Code Description Code Measure battery voltage under load. Check vehicle battery and associated Battery Voltage Too Low components. Check for damaged wiring. Check for damaged or corroded connectors and connections. Measure battery voltage under load. Ensure that battery voltage is correct for the model of ECU.
  • Page 300 UNDERCARRIAGE TMS500-2 SERVICE MANUAL Check for corroded or damaged wiring connector problems such as opens or shorts to voltage or ground. 1st Blink Code Location Check for other J1939 devices which may be loading J1939 down (inhibiting) J1939 communication. Diagnostic Trouble Blink Repair Information Code Description...

  • Page 301: Miscellaneous Troubleshooting

    TMS500-2 SERVICE MANUAL UNDERCARRIAGE Diagnostic Trouble Blink Repair Information Code Description Code Apply and release service brake. Check for brake switch input into ECU (see system wiring schematic). With service brake released, check for presence of the stop lamp bulb. With service brake applied, verify system voltage is now present at the stop lamp switch input to the ECU.

  • Page 302: Troubleshooting Wiring

    UNDERCARRIAGE TMS500-2 SERVICE MANUAL With the service brake released, check for presence of Connector PMV Location stop lamp bulb. PMV Left Steer Axle Common Dynamometer Test Mode (ATC Indicator Lamp PMV Right Steer Axle Common Continuously Illuminated) 18 Way PMV Right Drive Axle Common Clear the dynamometer test mode by depressing and PMV Left Drive Axle Common releasing the blink code switch three times (or use an off-...
  • Page 303 TMS500-2 SERVICE MANUAL UNDERCARRIAGE CAUTION All wires must be carefully routed to avoid contact with rotating elements. Wiring must be properly secured approximately every 6 to 12 inches using UV stabilized, non-metallic hose clamps or bow-tie cable ties to prevent pinching, binding or fraying.
  • Page 304 UNDERCARRIAGE TMS500-2 SERVICE MANUAL ABS/ATC Cab Wiring Schematic FIGURE 8-73 8-70 Published 07-21-2020, Control # 673-02...

  • Page 305: Special Tools

    TMS500-2 SERVICE MANUAL UNDERCARRIAGE SPECIAL TOOLS procedure. The following tools are recommended for use in the procedures described in this manual. The following tools are recommended for use in the procedures described in this manual. In some cases, use of the tool is necessary to carry out the troubleshooting / repair Description Deutsch P/N...
  • Page 306 Air Supply Port The EC-60 controller is programmed for features specific to Air Delivery Port this Grove crane. Contact your Manitowoc Cranes distributor or Manitowoc Crane Care if reconfiguring the controller is Air Exhaust Port necessary. Elec. Connector-Twist Lock ATC Valve...

  • Page 307: Component Removal And Installation

    TMS500-2 SERVICE MANUAL UNDERCARRIAGE use. (See the Service Data Sheet for the anti-lock controller for this procedure at the Bendix website. Leakage Test: M-32 and M-32QR Modulator Valves Proceed to the modulator in question and inspect its wiring Park the vehicle on a level surface and block or chock connector.
  • Page 308 UNDERCARRIAGE TMS500-2 SERVICE MANUAL Disconnect all air lines and the electrical connector. ATC Valve Remove all air line fittings and plugs. These fittings will Removal of ATC Valve be re-used in the replacement modulator. Disconnect the wiring connector (4), (Figure 8-60) from Installation the ATC valve.

  • Page 309: Outriggers

    TMS500-2 SERVICE MANUAL UNDERCARRIAGE OUTRIGGERS Verify proper sensor operation by driving the vehicle. This allows the ABS to perform a self test. Once the Description vehicle reaches approximately 11 km/h (7 mph), the ABS warning lamp will go out if the sensor is working The outriggers, when properly extended and set, provide a properly.

  • Page 310: Maintenance

    UNDERCARRIAGE TMS500-2 SERVICE MANUAL switch is moved, the selector valve shifts, allowing flow to The front jack functions similar to any of the other outrigger either the extend or retract line, as applicable. If the selector cylinders. A pressure switch is used to sense pressure in the switch is in the EXTEND position, the flow continues through barrel end of the cylinder after extension.
  • Page 311 TMS500-2 SERVICE MANUAL UNDERCARRIAGE SYMPTOM PROBABLE CAUSE SOLUTION Worn or damaged hydraulic Repair or replace pump pump section. section. Scored cylinder barrel. Repair or replace barrel. Replace piston and all cylinder Cracked or damaged piston. seals. Replace all cylinder seals and Piston loose on piston rod.
  • Page 312 UNDERCARRIAGE TMS500-2 SERVICE MANUAL SYMPTOM PROBABLE CAUSE SOLUTION Worn or damaged hydraulic Repair or replace pump pump section. section. Jack cylinder retracts under Damaged piston seals. Replace all cylinder seals. load. Damaged holding valve seals. Replace valve assembly. Damaged holding valve. Replace valve assembly.
  • Page 313 TMS500-2 SERVICE MANUAL UNDERCARRIAGE SYMPTOM PROBABLE CAUSE SOLUTION One/two outriggers will not Recycle individual Hydraulic lock. stow. outrigger(s). Individual outrigger will not set Damaged piston seals. Replace seals. or stow. Damaged check valve. Repair or replace valve. Tag and disconnect the OMS sensor cable. Outrigger Beam (with Adjustable Wear Pads) Inspection of Outrigger Beams Before Removal Tag and disconnect the hydraulic lines to the cylinder...
  • Page 314 UNDERCARRIAGE TMS500-2 SERVICE MANUAL FIGURE 8-78 6990-1c Jack Cylinder Extension Cylinder Clevis Pin Outrigger Beam Wear Pad Mid Extend Lock Pin Wear Pad Jack Cylinder Hose Assembly Extension Cylinder Clevis Pin Extension Cylinder Wear Pad Wear Pad Jam Nut Plate NOTE: outrigger beam...
  • Page 315 TMS500-2 SERVICE MANUAL UNDERCARRIAGE Connect the electrical connection to the extend cylinder for Outrigger Monitoring System (OMS). CAUTION Install the rear cover of the outrigger box. Damage Could Occur! NOTE: At installation, be sure that the outrigger jack Make sure that the piston side of all outrigger cylinders is cylinder hydraulic hoses are not trapped against connected to the solenoid valve bank.
  • Page 316 UNDERCARRIAGE TMS500-2 SERVICE MANUAL 2.0 mm (0.08 in) GAP TOP REAR WEAR PAD 3.0 mm (0.12 in) GAP SIDE WEAR PADS BOTTOM WEAR PADS 8297-2a FIGURE 8-79 8-82 Published 07-21-2020, Control # 673-02...

  • Page 317: Extension Cylinder

    TMS500-2 SERVICE MANUAL UNDERCARRIAGE Extension Cylinder Install the outrigger beam. Refer to paragraph Outrigger Beam (with Adjustable Wear Pads), page 8-79 in this Section. Description The extension cylinder is installed in the outrigger beam. The Functional Check for Extension Cylinder cylinder has a single stage.

  • Page 318: Center Front Jack Cylinder

    UNDERCARRIAGE TMS500-2 SERVICE MANUAL CENTER FRONT JACK CYLINDER CAUTION Description Damage Could Occur! The retracted length of the cylinder (Figure 8-80) from the Use a nylon strap to remove the cylinder to make sure end of the ball on the barrel to the hole in the rod is 115.6 cm that the retaining pin is not damaged.

  • Page 319: Functional Check Of Center Front Jack Cylinder

    TMS500-2 SERVICE MANUAL UNDERCARRIAGE Install the pressure switch. Installation of Center Front Jack Cylinder Install the cylinder cap and secure with the washers and Apply grease (EPMPG) to the ID of the jack cylinder nuts. support tube. Position the outrigger pad on the cylinder ball and If removed, install Wear Ring in groove in bottom of secure with bolts, bushings, flatwashers and locknuts.
  • Page 320 UNDERCARRIAGE TMS500-2 SERVICE MANUAL 6512 Cylinder Plate Capscrew Cotter Pin Flatwasher Cylinder Head Wear Plug Ring Capscrew Piston Wear Ring Locknut Outrigger Pad Flatwasher Bushing Hex Nut Washer Lockwasher Acorn Nut Cap Bracket FIGURE 8-80 8-86 Published 07-21-2020, Control # 673-02...

  • Page 321: Outrigger Monitoring System

    TMS500-2 SERVICE MANUAL UNDERCARRIAGE OUTRIGGER MONITORING SYSTEM confirm the outrigger positions and rigging code. Refer to the Operator Manual for additional information. Description OMS Linear Position Sensors The Outrigger Monitoring System (OMS) aids the operator in accurately programming the Rated Capacity Limiter (RCL) Removal by automatically identifying the position of each outrigger Remove the rear access cover plate from outrigger box.
  • Page 322 UNDERCARRIAGE TMS500-2 SERVICE MANUAL THIS PAGE BLANK 8-88 Published 07-21-2020, Control # 673-02...
  • Page 323 When filling and draining crane components, observe the extreme condition lubrication, contact your local Grove following: Cranes distributor or Manitowoc Crane Care. • Do not pour waste fluids onto the ground, down any drain, or into any source of water.
  • Page 324 LUBRICATION TMS500-2 SERVICE MANUAL quickserve.cummins.com and login with a current user name Select the one that applies to your engine to view the and password or create a new account by selecting “Create registered oils. an Account” under information, choose Limited Owners Plan Standard Lubricants and register.
  • Page 325 TMS500-2 SERVICE MANUAL LUBRICATION TABLE 9-1: Standard Lubricants/Fluids [Down to -9°C (15°F)] Recommended Lubricant Grove Lube Lubricant/Fluid Spec. # Spec. Type Grade Classification Liquid Coolant Con- Fleetguard DCA4 ditioner 6829012858 Fleetguard DCA2 Penray Pencool 3000 Diesel Exhaust Fluid Fleetguard StableGuard™ Urea (DEF) 32 Premix 80019225...
  • Page 326 -29°C (-20°F). Refer to TABLE 9-2: for a list of the bands. Therefore, always check with an authorized Grove recommended optional lubricants. distributor or Manitowoc Crane Care if in doubt of the suitability of a specific fluid or lubricant. TABLE 9-2: Optional Lubricants/Fluids [Down to -29°C (-20°F)]...
  • Page 327 TMS500-2 SERVICE MANUAL LUBRICATION TABLE 9-2: Optional Lubricants/Fluids [Down to -29°C (-20°F)] Recommended Lubricant Grove Lube Lubricant/Fluid Spec. Spec. Type Grade Classification Fully Formulated Old World Industries, Inc. Fleet Antifreeze Coolant Charge SCA 6829101130 Mix 50/50 Caterpillar DEAC Fleetguard Complete EG Liquid Coolant Con- Fleetguard DCA4 ditioner...

  • Page 328: Cylinder Rod Surface Protection

    Boeshield® T-9 Premium Metal Protectant. Manitowoc Crane Care has Boeshield® T-9 Premium Metal Grease fittings that are worn and will not hold the grease Protectant available in 12 oz. aerosol cans by ordering part gun, or those that have a stuck check ball, must be replaced.
  • Page 329 TMS500-2 SERVICE MANUAL LUBRICATION 7.Fill radiator to bottom of filler neck per engineering a.500 (0-55 PPM sulfur fuel) specification 80029046. Run engine through (2) thermal b.400 (500-5000 _PPM sulfur fuel) cycles. Check level and refill as required. c.250 (<5000 -PPM sulfur fuel. Not recommended.) 8.Fill through dipstick opening.

  • Page 330: Drivetrain Lubrication

    LUBRICATION TMS500-2 SERVICE MANUAL Drivetrain Lubrication ITEM LOCATION APPROXIMATE SERVICE LUBE SPEC NOTES SERVICE SERVICE HOURS NUMBER NAME CAPACITY POINTS ENGINE CHECK & --------------- 10 HRS/DAILY CRANKCASE L9 FILL DRAIN & WITH FILTER 5.0 GAL 500 HRS/6 MONTHS FILL CRANKCASE 60,000 MILES/2000 BREATHER ---------------...
  • Page 331 TMS500-2 SERVICE MANUAL LUBRICATION FIGURE 9-1 9577 9577-a FIGURE 9-2 Published 07-21-2020, Control # 673-02 Grove...
  • Page 332 LUBRICATION TMS500-2 SERVICE MANUAL 9834 FIGURE 9-3 FIGURE 9-4 9577-1 9-10 Published 07-21-2020, Control # 673-02...
  • Page 333 TMS500-2 SERVICE MANUAL LUBRICATION 9577-2 FIGURE 9-5 9577-3 FIGURE 9-6 9-11 Published 07-21-2020, Control # 673-02 Grove...

  • Page 334: Steering Lubrication

    LUBRICATION TMS500-2 SERVICE MANUAL Steering Lubrication APPROX. SERVICE SERVICE ITEM NUMBER LOCATION NAME LUBE SPEC NOTES SERVICE CAPACITY POINTS HOURS POWER STEERING --------------- LUBE 1000 HRS GEARBOX 9577-4 FIGURE 9-7 9-12 Published 07-21-2020, Control # 673-02...
  • Page 335 TMS500-2 SERVICE MANUAL LUBRICATION Axle Lubrication ITEM APPROX. SERVICE LOCATION NAME LUBE SPEC NOTES SERVICE SERVICE HOURS NUMBER CAPACITY POINTS FRONT WHEEL --------------- BRUSH ON SEE NOTE 15 PILOTS FRONT AXLE 0.57 L (1.2 PT) CHECK & FILL 250 HRS HUBS EACH FRONT AXLE TIE...
  • Page 336 LUBRICATION TMS500-2 SERVICE MANUAL FIGURE 9-9 9577-6 9577-22 FIGURE 9-10 9-14 Published 07-21-2020, Control # 673-02...
  • Page 337 TMS500-2 SERVICE MANUAL LUBRICATION ITEM APPROX. SERVICE LOCATION NAME LUBE SPEC NOTES SERVICE SERVICE HOURS NUMBER CAPACITY POINTS REAR WHEEL --------------- BRUSH ON SEE NOTE 15 PILOTS --------------- CHECK & FILL 250 HRS FRONT REAR 18.5 L (19.5 AXLE BOWL 1, 2, 11 DRAIN &...
  • Page 338 LUBRICATION TMS500-2 SERVICE MANUAL 9577-8 FIGURE 9-12 9-16 Published 07-21-2020, Control # 673-02...
  • Page 339 TMS500-2 SERVICE MANUAL LUBRICATION Outrigger Lubrication ITEM APPROX. SERVICE SERVICE LOCATION NAME LUBE SPEC NOTES SERVICE NUMBER CAPACITY POINTS HOURS O/R BEAMS --------------- BRUSH ON 50 HRS/1 WEEK JACK CYLINDER --------------- BRUSH ON SEE NOTE 6 SUPPORT TUBES BRUSH ON WEAR PADS --------------- (Top &...

  • Page 340: Miscellaneous Lubrication

    LUBRICATION TMS500-2 SERVICE MANUAL Miscellaneous Lubrication ITEM LOCATION APPROX. SERVICE LUBE SPEC NOTES SERVICE SERVICE HOURS NUMBER NAME CAPACITY POINTS 405 L (107 HYDRAULIC CHECK & GAL) () (TANK 5, 9 10 HRS/DAILY RESERVOIR FILL ONLY) HYDRAULIC CHANGE FILTER & --------------- --------------- FILTER &...
  • Page 341 TMS500-2 SERVICE MANUAL LUBRICATION Turntable & Cab Platform Lubrication ITEM LOCATION APPROX. SERVICE LUBE SPEC NOTES SERVICE SERVICE HOURS NUMBER NAME CAPACITY POINTS 4.0 L (4.25 CHECK & FILL 50 HRS/1 WEEK TURNTABLE GEAR BOX 4.0 L (4.25 DRAIN & FILL SEE NOTE 32 TURNTABLE GEAR &...
  • Page 342 LUBRICATION TMS500-2 SERVICE MANUAL 8885-27 FIGURE 9-16 9-20 Published 07-21-2020, Control # 673-02...
  • Page 343 TMS500-2 SERVICE MANUAL LUBRICATION Hoist Lubrication ITEM APPROX. SERVICE LOCATION NAME LUBE SPEC NOTES SERVICE SERVICE HOURS NUMBER CAPACITY POINTS --------------- 2, 14 CHECK & FILL 50 HRS / WEEKLY 5.2 L (5.5 MAIN HOIST - DRAIN & FILL SEE NOTE 32 QTS) GEARBOX 500 HRS / 6...

  • Page 344: Turntable Central Lubrication

    LUBRICATION TMS500-2 SERVICE MANUAL Turntable Central Lubrication ITEM APPROX. SERVICE LOCATION NAME LUBE SPEC NOTES SERVICE SERVICE HOURS NUMBER CAPACITY POINTS HOIST LIFT CYLINDER -------------- ------------ LUBE 500 HRS / 3 MONTHS 250 HRS / BOOM PIVOT PIN --------------- LUBE 3 MONTHS HOIST LOWER 250 HRS /...
  • Page 345 TMS500-2 SERVICE MANUAL LUBRICATION 9577-10a FIGURE 9-19 9-23 Published 07-21-2020, Control # 673-02 Grove...

  • Page 346: Boom Lubrication

    LUBRICATION TMS500-2 SERVICE MANUAL Boom Lubrication • Set boom angle at zero degrees. • Disable the swing function to engage the swing brakes, For Crane Setup: and engage the 360-swing lock, if applicable. • Machine to be set up on firm level surface with fully •...
  • Page 347 TMS500-2 SERVICE MANUAL LUBRICATION ITEM APPROX. SERVICE SERVICE LOCATION NAME LUBE SPEC NOTES SERVICE NUMBER CAPACITY POINTS HOURS 125 HRS / 3 TELE CYL WEAR PADS 14, 26, 27, 29 BRUSH ON --------------- MONTHS BOOM UPPER WEAR 50 HRS / 1 --------------- 14, 26, 27, 29 BRUSH ON...
  • Page 348 LUBRICATION TMS500-2 SERVICE MANUAL ITEM APPROX. SERVICE SERVICE LOCATION NAME LUBE SPEC NOTES SERVICE NUMBER CAPACITY POINTS HOURS BOOM EXTEND CABLE 250 HRS / 3 --------------- 1, 8, 14, 26 LUBE SHEAVES MONTHS RETRACT CABLE 250 HRS / 3 --------------- 1, 8, 14, 26 LUBE SHEAVES...
  • Page 349 TMS500-2 SERVICE MANUAL LUBRICATION NOTE: The Boom will need to be extended to line up the Exterior Access Holes. FIGURE 9-24 9893 9-27 Published 07-21-2020, Control # 673-02 Grove...
  • Page 350 LUBRICATION TMS500-2 SERVICE MANUAL 9577-14 FIGURE 9-25 ITEM APPROX. SERVICE SERVICE LOCATION NAME LUBE SPEC NOTES SERVICE NUMBER CAPACITY POINTS HOURS HOOK BLOCK - 33 TON 250 HRS / 3 (3 SHEAVE) SWIVEL --------------- 8, 14 LUBE MONTHS BEARING HOOK BLOCK - 40 TON 250 HRS / 3 (4 SHEAVE) SWIVEL ---------------...

  • Page 351: Monthly Lubrication Work

    TMS500-2 SERVICE MANUAL LUBRICATION the pins for the pin connection on the lattice extension, the retaining pins on the return pulleys, the retaining pins used for fastening the lattice extension sections for transport, NOTE: lubrication interval applies average operation. Also, lubricate the pins after high- pressure cleaning and generally at an interval that will prevent them getting dry.

  • Page 352: Carwell Rust Inhibitor

    Protecting Cranes From Corrosion minimize the harmful effects of corrosion. Manitowoc Crane Group's cranes are manufactured to high Exercise special care and increase the frequency of cleaning quality standards, including the type of paint finish if the crane is operated: demanded by today's industry.

  • Page 353: Inspection And Repair

    • Prepare the surface prior to applying the finish coat of Please contact Manitowoc Crane Care should you have any paint. questions. • Apply a finish coat of paint using accepted blending techniques.
  • Page 354 LUBRICATION TMS500-2 SERVICE MANUAL all unpainted fasteners and hardware, valves, swing • All hardware, clips, pins, hose connections not painted bearing fasteners and all bare metal surfaces. will have treatment applied. • 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.
  • Page 355 TMS500-2 SERVICE MANUAL LUBRICATION 9827-1 9826 FIGURE 9-27 9-33 Published 07-21-2020, Control # 673-02 Grove...
  • Page 356 LUBRICATION TMS500-2 SERVICE MANUAL Item Description Item Description Hoist Hose Connections O/R Hose Connections All Hardware, Clips, Pins, Hose Connections not Boom Extension Pins, Clips painted O/R Pins, Clips Valve Bank Power train Hardware Inside Compartment Hose Connections Inside Turntable Entire Underside of Unit Boom Extension Hanger Hardware Turntable Bearing Fasteners...
  • Page 357 TMS500-2 SERVICE MANUAL LUBRICATION THIS PAGE BLANK 9-35 Published 07-21-2020, Control # 673-02 Grove...
  • Page 358 LUBRICATION TMS500-2 SERVICE MANUAL 9-36 Published 07-21-2020, Control # 673-02...
  • Page 359 TMS500-2 OPERATOR MANUAL Alphabetical Index After-treatment Diesel Exhaust Fluid (DEF) ....... . . 7-17 Air Intake System.
  • Page 360 OPERATOR MANUAL TMS500-2 Non-Asbestos Warning..........8-33 Outrigger Control Manifold .

Table of Contents