Page 1 Grove TMS800E Service/Maintenance Manual...
Page 3: Table Of Contents
TMS800E TABLE OF CONTENTS SECTION 1 ........Introduction Description .
Page 4 TABLE OF CONTENTS TMS800E Description............2-13 Maintenance .
Page 5 TMS800E TABLE OF CONTENTS Maintenance ............2-52 .
Page 6 TABLE OF CONTENTS TMS800E Relay Panel Component Replacement ....... . . 3-14 Instrument Replacement .
Page 7 TMS800E TABLE OF CONTENTS Installing/Removing 5 m (16 ft) Sections ........4-40 Installing the 5 m (16 ft) Sections .
Page 8 TABLE OF CONTENTS TMS800E Mounting the Counterweight ......... 5-11 Stowing the Counterweight .
Page 9 TMS800E TABLE OF CONTENTS Installation............7-19 ISX Engine Diesel Particulate Filter/Selective Catalyst Reduction Assembly .
Page 10 TABLE OF CONTENTS TMS800E Wheels and Tires ........... . . 8-19 Description.
Page 11 TMS800E TABLE OF CONTENTS ALL Weather Package & Lubricants ........9-1 Standard Lubricants Package .
Page 12 TABLE OF CONTENTS TMS800E TOC-10...
Page 13 An untrained operator subjects himself and others to death or serious injury. Do not operate this crane unless: • You are trained in the safe operation of this crane. Manitowoc is not responsible for qualifying personnel. • You read, understand, and follow the safety and operating recommendations contained in the crane manufacturer’s manuals and...
Page 14 CALIFORNIA PROPOSITION 65 WARNING Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. CALIFORNIA PROPOSITION 65 WARNING Battery posts, terminals, and related accessories contain chemical lead and lead compounds, chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.
Page 15: Section 1
TMS800E SERVICE MANUAL SECTION 1 INTRODUCTION TABLE OF CONTENTS Description ......1-1 Shims.
Page 16: List Of Specifications
INTRODUCTION TMS800E SERVICE MANUAL List Of Specifications Seventh ......1.00 Sixth......1.38 Fifth .
Page 17: Brakes
TMS800E SERVICE MANUAL INTRODUCTION Rear Pump #2 (QSM Engine) Type ....Single reduction tandem Type ....... . . Gear Ratio .
Page 18 INTRODUCTION TMS800E SERVICE MANUAL Published 01-29-2014, Control # 496-00...
Page 19 TMS800E SERVICE MANUAL INTRODUCTION Item Description Rear View Mirror Crane Cab Counterweight Outrigger Float Outrigger Jack Cylinder 6561-3 Rear View FIGURE 1-1 GROVE Published 01-29-2014, Control # 496-00...
Page 20 INTRODUCTION TMS800E SERVICE MANUAL Left Side View FIGURE 1-1 continued Published 01-29-2014, Control # 496-00...
Page 21 TMS800E SERVICE MANUAL INTRODUCTION Right Side View FIGURE 1-1 continued Item Description Item Description Folding Jib Auxiliary Boom Nose Boom Carrier Cab Stinger Center Front Stabilizer Outrigger Stabilizer Cylinder Front Axles Removable Counterweights Outrigger Beam Auxiliary Hoist Outrigger Main Hoist Hydraulic Oil Cooler Boom Pivot Rear Axles...
Page 22 INTRODUCTION TMS800E SERVICE MANUAL Table 1-1: Axle Weight Distribution CG to CL WEIGHT FRONT AXLE REAR AXLE DESCRIPTION REAR BOGIE kg (lb) kg (lb) kg (lb) cm (in) Maximum Tire & Wheel Loads Allowed 22317 (49200) 27216 (60000) Maximum Axle Loads Allowed 23224 (51200) 27216 (60000) Carrier 8 x 4 x 4 (w/O/R Beams)
Page 23 TMS800E SERVICE MANUAL INTRODUCTION CG to CL WEIGHT FRONT AXLE REAR AXLE DESCRIPTION REAR BOGIE kg (lb) kg (lb) kg (lb) cm (in) Add: 1814 kg (4000 lb) counterweight on 473.43 (186.39) 1820 (4013) 1533 (3379) 288 (634) carrier deck (with pins) Add: 2722 kg (6000 lb) counterweight on -298.73 (-117.61) 2727 (6013)
Page 24: General Maintenance
INTRODUCTION TMS800E SERVICE MANUAL GENERAL MAINTENANCE When raising a portion of a crane or a complete crane, ensure the crane is blocked securely and the weight is These general suggestions should be helpful in following the supported by blocks rather than by lifting equipment. i ns t r u c t io n s i n th i s m a nu a l .
Page 25: Wires And Cables
TMS800E SERVICE MANUAL INTRODUCTION 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 pre-loaded must have a film of oil over the Always use new locking devices on components which have entire assembly to obtain accurate pre-loading.
Page 26: Hydraulic Systems
Loctite® are specified throughout the Service Manual.The following types of Loctite® brand adhesives are Fatigue of Welded Structures available from the Manitowoc Crane Care Parts Department or your local Grove Manitowoc distributor. Experience has shown that highly stressed welded structures when repeatedly subjected to varying stresses Application of Medium Strength Loctite®...
Page 27: Fasteners And Torque Values
• Torque wrenches must be those specified and forces must be applied at the handle grip. The use of handle The torque tables are provided by Manitowoc for reference extensions will change applied torque to the bolt. when performing maintenance.
Page 28 INTRODUCTION TMS800E SERVICE MANUAL • Multiplier bar handles must be propped or supported Torque Values within the outer 1/4 of the handle length, or serious The following tables list the torque values for both ASME under or over tightening will occur. standard and metric fasteners.
Page 29 TMS800E SERVICE MANUAL INTRODUCTION NOTE: Studs shall be torqued using capscrew values when grade is known. Table 1-4: Metric Fasteners, Coarse Thread, Zinc-Flake Coating Bolt Diameter - Metric Torque Values (Nm) Grade 21.6 42.4 73.1 1195 1608 2072 10.9 12.5 31.5 62.0 1325...
Page 30: Weld Studs
INTRODUCTION TMS800E SERVICE MANUAL Table 1-7: Metric Fasteners, Fine Thread, Untreated Bolt Diameter - Metric Torque Values (Nm, Maximum/Minimum) Grade M8x1 M10x1 M10x1.25 M12x1.5 M14x1.5 M16x1.5 M18x1.5 M20x1.5 M22x1.5 M24x2 M27x2 M30x2 M33x2 M36x3 1225 1661 — — 1130 1534 —...
Page 31: Wire Rope
ANSI/ASME B30.5, federal During fabrication, ropes receive lubrication; the kind and regulations, and Manitowoc Crane Group. The inspection amount depends on the rope’s size, type, and anticipated interval shall be determined by a qualified person and shall use.
Page 32: Wire Rope Inspection (Running Ropes And Pendant Cables)
• Number, distribution and type of broken wires. fittings use only pre-assembled lengths of wire rope as supplied from Manitowoc Crane Care. Do not build • Evidence of core failure. lengths from individual components.
Page 33: Wire Rope Replacement (All Wire Rope)
National Consensus Standard as referenced by Federal Government Agencies and as recommended by Grove Manitowoc Crane Group. All wire rope will eventually deteriorate to a point where it is no longer usable. Wire rope shall be taken out of service when any of the following conditions exist: •...
Page 34: Installing 35X7 Wire Rope
INTRODUCTION TMS800E SERVICE MANUAL permanent damage to the rope.) Then lay the rope on the ground in direct line with the boom. This helps release any twist in the rope. Attach rope’s end to drum. Pull the rope over the point sheave and attach the end to the drum.
Page 35 TMS800E SERVICE MANUAL INTRODUCTION It is because of this that the following procedures for cutting NOTE: The outer strands must not be allowed to move and preparing 35x7 must be followed: with respect to the inner strands. The fused end must not exceed the diameter of the rope.
Page 36 INTRODUCTION TMS800E SERVICE MANUAL 1-22 Published 01-29-2014, Control # 496-00...
Page 37: Section 2
TMS800E SERVICE MANUAL HYDRAULIC SYSTEM SECTION 2 HYDRAULIC SYSTEM TABLE OF CONTENTS Description ....... 2-2 Swing Brake Pedal .
Page 38: Description
HYDRAULIC SYSTEM TMS800E SERVICE MANUAL Cylinders ....... . 2-54 Outrigger Extension Cylinder ....2-70 General .
Page 39 TMS800E SERVICE MANUAL HYDRAULIC SYSTEM 10. Disconnect the return lines from a pair of outrigger 19. Repeat Steps 17 and 18 for the auxiliary hoist as stabilizer cylinders and the center front stabilizer cylinder necessary. and activate the cylinders to their maximum down 20.
Page 40 HYDRAULIC SYSTEM TMS800E SERVICE MANUAL FIGURE 2-1 Published 01-29-2014, Control # 496-00...
Page 41 TMS800E SERVICE MANUAL HYDRAULIC SYSTEM FIGURE 2-2 GROVE Published 01-29-2014, Control # 496-00...
Page 42: Removing Air From The Hydraulic System
HYDRAULIC SYSTEM TMS800E SERVICE MANUAL Removing Air From the Hydraulic System Air entering the hydraulic oil will normally be removed automatically by passage of the hydraulic oil over the baffles WARNING in the hydraulic reservoir. If a component has been replaced, Extreme care must be used when removing any plugs or the reservoir level is too low, or a leak develops in the suction restrictions from a hydraulic system suspected to have...
Page 43: Supply Pressure And Return Circuit
TMS800E SERVICE MANUAL HYDRAULIC SYSTEM properly adjusted, and the component is not at fault, check of hose assemblies, refer to your Manitowoc Crane Care the valve for scored or worn parts. Scoring is a sign of the Parts Manual. number one problem in hydraulics - contamination (external...
Page 44 HYDRAULIC SYSTEM TMS800E SERVICE MANUAL pump. Refer to Swing System, page 6-1 for description and The hydraulic oil filter (see Figure 2-4) is located in the rear maintenance instructions for the 6-port hydraulic swivel. of the reservoir. It bolts to the top of the reservoir. The filter housing contains a replaceable filter element.
Page 45 TMS800E SERVICE MANUAL HYDRAULIC SYSTEM 6979 FIGURE 2-3 Item Description Item Description Reservoir Access Cover Return Filter Filler Cap Return Manifold Inlet Drain Plug (Not Shown) Sight Gauge (Oil Level Gauge) Thermometer GROVE Published 01-29-2014, Control # 496-00...
Page 46: Maintenance
HYDRAULIC SYSTEM TMS800E SERVICE MANUAL Maintenance Troubleshooting Symptom Probable Cause Solution No hydraulic oil Low hydraulic oil level. Check system for leaks. Make repairs flows in systems. as needed. Fill reservoir. b. Reservoir-to-pump suction lines b. Clean, repair, or replace lines as broken or restricted.
Page 47 TMS800E SERVICE MANUAL HYDRAULIC SYSTEM Return Filter Assembly Element Installation Element Removal Install a new O-ring between the head and the bowl (housing). Install the new element and the smaller diameter spring into the bowl (housing). Ensure the spring seats CAUTION properly.
Page 48 HYDRAULIC SYSTEM TMS800E SERVICE MANUAL 6602 FIGURE 2-4 Item Description Item Description Head O-ring Gasket Bowl Filter Element Bypass Spring Spring Bypass Valve O-ring 2-12 Published 01-29-2014, Control # 496-00...
Page 49: Oil Cooler
TMS800E SERVICE MANUAL HYDRAULIC SYSTEM OIL COOLER signal to the CAN controller. The controller will turn the fans on and off based on that signal. Description Maintenance An air cooled hydraulic oil cooler (see Figure 2-5) is mounted on the superstructure below the hoist platform. The oil cooler Removal consists of a radiator, two electric motors, and two fans.
Page 50 HYDRAULIC SYSTEM TMS800E SERVICE MANUAL 1, 2, 3, 4 FIGURE 2-5 Item Description Item Description Bolt Hex Nut Fans Spring Lockwasher Electric Motors Flatwasher 2-14 Published 01-29-2014, Control # 496-00...
Page 51: Hydraulic Pumps
TMS800E SERVICE MANUAL HYDRAULIC SYSTEM HYDRAULIC PUMPS Remove carrier parts as needed to gain access to the pump. Description QSM Cranes Tag the supply lines to the pump and tag the distribution lines from the pump, then disconnect them from the The No.
Page 52 HYDRAULIC SYSTEM TMS800E SERVICE MANUAL side of the pump is plugged. Fill housing full of Ensure the reservoir is filled with the proper hydraulic hydraulic oil through “T1” port. Re-install the plastic fluid to the high level mark on the reservoir sight gauge. cap and then install the pump.
Page 53 TMS800E SERVICE MANUAL HYDRAULIC SYSTEM Remove carrier parts as needed to gain access to the the 3/8-16 bolt and its washer to move or remove the pump. It is bolted to the engine. pump support plate. Tag the supply lines to the pump and tag the distribution CAUTION lines from the pump, then disconnect them.
Page 54 HYDRAULIC SYSTEM TMS800E SERVICE MANUAL No. 2 Pump Installation Remove all pump outlet hoses. Fill pump outlet port of each pump section with as much hydraulic oil as it can Remove the drive pad cover. take. Connect all pump outlet hoses again. Apply gasket compound (Spec.
Page 55: Maintenance Isx Cranes
TMS800E SERVICE MANUAL HYDRAULIC SYSTEM Maintenance ISX Cranes Remove the cap screws, nuts and washers (2) connecting the PTO driveline to the engine. Remove the Pump/PTO Clutch Replacement driveline. CAUTION Damage could occur! Absolute cleanliness is essential when working on the hydraulic pumps.
Page 56 HYDRAULIC SYSTEM TMS800E SERVICE MANUAL Disassembly Using a short Allen wrench or a tool, made by locking nuts on a 7/16 bolt, inserted into the socket head cap screws, and held with a wrench, remove the socket head cap screws, nuts and washers (3, Figure 2-9) that secures the front support plate to the clutch.
Page 57: Pump/Pto Clutch Assembly
TMS800E SERVICE MANUAL HYDRAULIC SYSTEM PUMP/PTO CLUTCH ASSEMBLY The pump PTO clutch is used on cranes with the ISX engine to engage/disengage pump 1 from the engine to aid in starting, especially in cold weather, and to prevent the pumps from over-speeding while traveling the crane.
Page 58: Valves
HYDRAULIC SYSTEM TMS800E SERVICE MANUAL VALVES to the Valve Usage Table. Refer to Figure 2-13 for valve locations. The description of each valve given here is for the General valve itself. For information on how each valve functions in the individual circuits, refer to the description and operation This subsection provides descriptive information for all the procedures of that circuit.
Page 59 TMS800E SERVICE MANUAL HYDRAULIC SYSTEM 6550-5 CARRIER 6551 FIGURE 2-13 SUPERSTRUCTURE Item Description Item Description Turntable Motor Control Manifold Accessory Manifold with Swing Directional Valve Charge Oil Cooler Control Manifold Pilot Operated Check Valve (Cab Tilt) Rear Outrigger Control Manifold Counterweight Removal/Cab Tilt Directional Front Outrigger Control Manifold Control Valve...
Page 60: Pressure Setting Procedures
HYDRAULIC SYSTEM TMS800E SERVICE MANUAL PRESSURE SETTING PROCEDURES • ORFS reducers as required to attach work port hoses to the gauge. The following procedures should be used to properly check, NOTE: When checking the directional control valve relief adjust and set the hydraulic system pressures. settings, unless otherwise specified, start with the The following equipment is required for checking the engine at idle RPM and move the controller to its...
Page 61: Procedure A - For Checking/Setting The Main Directional Control Valve For Hoist(S) And Boom Lift
TMS800E SERVICE MANUAL HYDRAULIC SYSTEM Pressure Tolerance Gauge Port (GPX) and Adjustment Valve To Be Set Setting bar (PSI) Location bar (PSI) Pump Differential Pressure Setting (ISX ± 4 (50) GP2 Carrier mounted piston pump Engine) (375) (see Figure 2-21) Center Front Stabilizer Relief Setting 10 - 20 Not Adjustable...
Page 62: Procedure B - For Checking/Setting The Outrigger/Swing Pressures
HYDRAULIC SYSTEM TMS800E SERVICE MANUAL 17. If the lift cylinder is not installed, plug the extend hose Procedure D - For Checking/Setting the (the larger of the two). If lift cylinder is installed, omit this Front Steer Pressure step and continue to step 18. Install a pressure check diagnostic quick disconnect with 18.
Page 63: Procedure G - For Checking/Setting The Piston Pump (Isx Engine)
TMS800E SERVICE MANUAL HYDRAULIC SYSTEM gauge pressure of 28 - 31 bar (400 - 450 psi) is achieved 300 psi) is achieved (see Figure 2-22). This valve is not (see Figure 2-14). adjustable. Stop engine. Remove diagnostic couplers Stop engine. Remove diagnostic couplers. reconnect plumbing.
Page 64: Procedure J- For Setting Threshold On Electronic Controllers
HYDRAULIC SYSTEM TMS800E SERVICE MANUAL Procedure J- For Setting Threshold on Electronic Controllers Attach test fitting and pressure gage in the pilot end caps Enter the value for the Main Hoist Up and select SET one at a time at GPA for Main Hoist Up, GPB for Aux and change the Main Hoist Down value with the same Hoist Up, GPC Tele Retract, GPD Lift Down, GPA, and setting.
Page 65 TMS800E SERVICE MANUAL HYDRAULIC SYSTEM J.). Arrange windows so you can view the EPROM psi). Then raise the counts up to reach 17.2 bar (250 window & Output Window values psi).To set swing brake solenoid threshold. Slowly depress swing brake pedal down until you reach 1.7 bar Set swing brake center percentage X &...
Page 66 HYDRAULIC SYSTEM TMS800E SERVICE MANUAL Procedure A Tele Extend Port Relief Procedure A Load Sense Relief Valve Procedure A Telescope Extend 6601-2 Procedure A FIGURE 2-15 Tele Retract Port Relief Procedure A Cab Tilt/Counterweight Removal Load Sense Relief Valve 6601-2 FIGURE 2-16 2-30 Published 01-29-2014, Control # 496-00...
Page 67 TMS800E SERVICE MANUAL HYDRAULIC SYSTEM Procedure C Air Conditioning Circuit Relief Relief Valve Pressure Port A Port GP FIGURE 2-17 Procedure B Outrigger and Swing Relief Valve FIGURE 2-18 6601-6 GROVE Published 01-29-2014, Control # 496-00 2-31...
Page 68 HYDRAULIC SYSTEM TMS800E SERVICE MANUAL 6601-7a Procedure E Priority Flow Relief Adjustment 6601-7b FIGURE 2-19 Disconnect hose from tube. Plug hose. FIGURE 2-20 2-32 Published 01-29-2014, Control # 496-00...
Page 69 TMS800E SERVICE MANUAL HYDRAULIC SYSTEM 6601-9 Procedure G & I Procedure A Piston Pump Differential Pressure Setting Piston Pump P Max Setting FIGURE 2-21 FIGURE 2-22 GROVE Published 01-29-2014, Control # 496-00 2-33...
Page 70: Directional Control Valves
HYDRAULIC SYSTEM TMS800E SERVICE MANUAL DIRECTIONAL CONTROL VALVES Connect the hydraulic lines to the valves as tagged during removal. Description Counterweight Removal/Cab Tilt Valve Bank Removal The directional control valves direct and control hydraulic oil Tag and disconnect the hydraulic lines from the valves. flow from the pumps to the boom lift and telescope cylinders, Cap or plug the lines and ports.
Page 71 TMS800E SERVICE MANUAL HYDRAULIC SYSTEM 6839-1 6839-2 FIGURE 2-23 GROVE Published 01-29-2014, Control # 496-00 2-35...
Page 72 HYDRAULIC SYSTEM TMS800E SERVICE MANUAL Item Description Item Description Main Hoist Directional Valve Load Sense Outlet (Not Shown) Auxiliary Hoist Directional Valve Inlet Port (P1) (Not Shown) Telescope Directional Valve Main Hoist Up (A Port) Lift Directional Valve Main Hoist Down (B Port) Thermal Relief Valve Auxiliary Hoist Up (A Port) Pilot Drain Port (PD)
Page 73 TMS800E SERVICE MANUAL HYDRAULIC SYSTEM 6554-1 2500 6554-2 FIGURE 2-24 Item Description Item Description Inlet Cab Tilt Up (A Port) Load Sense Port (LS) Cab Tilt Down (B Port) Outlet Port 2B (To L H Cwt Removal Cylinder (Retract) Load Sense Relief Port 2A (To L H Cwt Removal Cylinder (Extend) Counterweight Removal Directional Valve Port 1B (To R H Cwt Removal Cylinder (Retract)
Page 74: Check Valves
HYDRAULIC SYSTEM TMS800E SERVICE MANUAL CHECK VALVES Maintenance Removal Description Tag and disconnect the hydraulic lines from the valve. There are three check valves utilized in the crane hydraulic Cap or plug the lines and ports. system. The check valves are used to block flow in one direction and allow free or restricted flow in the opposite Installation direction.
Page 75: Outrigger Selector Valve
TMS800E SERVICE MANUAL HYDRAULIC SYSTEM OUTRIGGER SELECTOR VALVE Remove the bolts and washers securing the outrigger selector valve to the crane. Remove the valve as a Description complete assembly. Installation The outrigger selector valve (see Figure 2-25) directionally controls the outrigger circuit. The valve is mounted on the Attach the outrigger selector valve to the frame.
Page 76 HYDRAULIC SYSTEM TMS800E SERVICE MANUAL 6546-2 FIGURE 2-25 continued Item Description Item Description Gauge Port (GP7) Inlet Port (P) Port B (To Front and Rear Outrigger Tank Port (T) Outrigger Control Manifolds Solenoid Valve (Extend) Relief Valve Solenoid Valve (Pressure Beyond) Pressure Beyond Port (PB) Directional Control Valve (Retract - Extend) Port A (To Stabilizer Cylinders)
Page 77: Outrigger Control Manifold
TMS800E SERVICE MANUAL HYDRAULIC SYSTEM OUTRIGGER CONTROL MANIFOLD Inspection 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 utilized on the cracks or breaks.
Page 78 HYDRAULIC SYSTEM TMS800E SERVICE MANUAL 6544-2 6544-1 FIGURE 2-27 Item Description Item Description Solenoid Valve (Right Rear Extension Outlet Port (Right Rear Extension Cylinder) Cylinder) Outlet Port (Right Rear Stabilizer Cylinder) Solenoid Valve (Right Rear Stabilizer Outlet Port (Left Rear Stabilizer Cylinder) Cylinder) Outlet Port (Left Rear Extension Cylinder) Solenoid Valve (Left Rear Stabilizer...
Page 79: Pilot Operated Check Valve
TMS800E SERVICE MANUAL HYDRAULIC SYSTEM PILOT OPERATED CHECK VALVE Lubricate the check valve and O-rings with clean hydraulic oil. Description A pilot operated (PO) check valve (see Figure 2-28) is CAUTION located in each outrigger stabilizer cylinder port block. The Do not damage the O-rings during installation of the check check valve functions as a holding valve for the stabilizer valve.
Page 80: Cab Tilt Double Pilot Operated Check Valve
HYDRAULIC SYSTEM TMS800E SERVICE MANUAL CAB TILT DOUBLE PILOT OPERATED Tag and disconnect the hydraulic lines running to the valve. Cap or plug all openings. CHECK VALVE Remove the capscrews and lockwashers securing the Description valve to the plate and remove the valve. The cab tilt double pilot operated (PO) check valve (see Installation Figure 2-29) is located on the left side of the superstructure...
Page 81: Holding Valves
TMS800E SERVICE MANUAL HYDRAULIC SYSTEM HOLDING VALVES Description A bolt-on manifold style holding valve is installed on the boom lift cylinder. A cartridge style holding valve is used in each of the two telescope cylinders. The holding valve installed on the outlet of the cylinder provides meter out control, will lock the cylinder in place, prevents a load from running ahead of the oil supply, and relieves excess pressure caused by thermal...
Page 82 HYDRAULIC SYSTEM TMS800E SERVICE MANUAL CAUTION CAUTION Do not damage the O-rings during installation of the Do not damage the O-rings during installation of the holding valve. If the holding valve turns freely then gets holding valve. If the holding valve turns freely then gets hard to turn, then easy to turn;...
Page 83: Accessory Manifold With Swing Directional Control Valve
TMS800E SERVICE MANUAL HYDRAULIC SYSTEM ACCESSORY MANIFOLD WITH SWING Installation DIRECTIONAL CONTROL VALVE Install the manifold on turntable and secure with bolts, flatwashers and spring lockwashers. Torque bolts refer Description to Fasteners and Torque Values, page 1-13. The accessory manifold with swing directional valve (see Connect the hydraulic lines to the manifold as tagged Figure 2-33) is located on the right side of the turntable.
Page 84 HYDRAULIC SYSTEM TMS800E SERVICE MANUAL 6609 Swing Swing Pilot Brake Brake Supply Release 60 PSI D4 D5 D6 TANK MESH 6609-5 FIGURE 2-33 2-48 Published 01-29-2014, Control # 496-00...
Page 85 TMS800E SERVICE MANUAL HYDRAULIC SYSTEM TANK 6609-6 Bottom View FIGURE 2-33 continued Item Description Item Description Pilot Supply Relief Valve (450 psi) Drain Port D4 (Swing Motor Pilot Supply) Gauge Port (QP4A) Drain Port D6 (Hoist/Tele/Lift Valve Pilot Supply) Swing Brake Relief Valve (250 psi) Drain Port D7 (Swing Brake Lift Cylinder Solenoid Valve (Swing Brake) Pilot)
Page 86: Motor Control Manifold
HYDRAULIC SYSTEM TMS800E SERVICE MANUAL MOTOR CONTROL MANIFOLD Maintenance Removal Description Tag and disconnect the hydraulic lines from the valve. The motor control valve manifold (see Figure 2-34) is Cap or plug all openings. installed in the center of the frame. The purpose of the valve is to provide simultaneously proportional control of the oil Remove the bolts and washers securing the valve to the c o o l e r m o t o r a n d a c o n s t a n t f l o w t o t h e o p t i o n a l...
Page 87: Swing Power Brake Valve
TMS800E SERVICE MANUAL HYDRAULIC SYSTEM SWING POWER BRAKE VALVE Engage the swing lock. Install the brake valve and secure in place with the four Description bolts, flat washers, lockwashers, and nuts. The swing power brake valve (Figure 2-35) is used to Attach the hydraulic lines to the brake valve as tagged provide hydraulic pressure to the piston of the swing brake to during removal.
Page 88: Swing Brake Release Valve (Optional)
HYDRAULIC SYSTEM TMS800E SERVICE MANUAL SWING BRAKE RELEASE VALVE Maintenance (OPTIONAL) Removal Description Tag and disconnect the hydraulic lines from the swing brake release valve. Cap or plug all openings. The swing brake release valve (Figure 2-36) is used when the crane is equipped with the trailing boom option.
Page 89: Needle Valve (Optional)
TMS800E SERVICE MANUAL HYDRAULIC SYSTEM NEEDLE VALVE (OPTIONAL) opens the valve to allow the normal boom lift operation and clockwise rotation closes the valve for trailing boom mode. Description Maintenance The two lift cylinder mounted needle valves (1, Figure 2-37) are used to connect the rod and piston sides of the boom lift Removal cylinder together to allow the boom to float when the boom is...
Page 90: Cylinders
It is recommended that all exposed cylinder rods be CAUTION protected using Boeshield® T-9 Premium Metal Protectant. Manitowoc Crane Care has Boeshield® T-9 Premium Metal Ensure pressure is applied to the retract (rod) side of the Protectant available in 12 oz. cans that can be ordered cylinder only and that the extend hose is capped.
Page 91 TMS800E SERVICE MANUAL HYDRAULIC SYSTEM reoccur unless the system is drained, thoroughly movement, of the boom may be undetected by the operator cleaned, and filled with clean, filtered hydraulic oil. unless a load is suspended for a long period of time. If a load and the boom is allowed to remain stationary for a Temperature Effects on Hydraulic Cylinders period of time and the ambient temperature is cooler than the...
Page 92 HYDRAULIC SYSTEM TMS800E SERVICE MANUAL Table 2-5Boom Drift Chart (Cylinder length change in millimeters) 0.000774 (1/ °C) Coeff. = STROKE Temperature Change (°C) 5.81 11.61 17.42 23.22 29.03 34.83 40.64 46.44 52.25 58.05 63.86 11.61 23.22 34.83 46.44 58.05 69.66 81.27 92.88 104.49...
Page 93: Lift Cylinder
TMS800E SERVICE MANUAL HYDRAULIC SYSTEM LIFT CYLINDER CAUTION Description When removing seals and rings, avoid scratching the The lift cylinder (see Figure 2-38) has a bore of 30.48 cm grooved and gland surfaces. (12.0 in). The retracted length of the cylinder from the center of the barrel bushing to the center of the rod bushing is 438.7 Remove the two hydrolock seals from the outside of the cm (72.75 in).
Page 94 HYDRAULIC SYSTEM TMS800E SERVICE MANUAL 4, 5 6541 FIGURE 2-38 Item Description Item Description Backup Ring Barrel Backup Ring Holding Valve Head Screw O-ring Washer Backup Ring Tube Buffer Seal Adapter Rod Seal Setscrew (Not Shown) Backup Ring Seal Assembly Capscrew Piston Retaining Ring...
Page 95 TMS800E SERVICE MANUAL HYDRAULIC SYSTEM Assembly 10. Install the replacement hydrolock seals on the outside of the piston. Make sure the “vees” on the two hydrolock seals point at each other (see Figure 2-40). CAUTION 11. Lubricate all parts freely with clean hydraulic oil. When installing new seals and rings, avoid stretching seals or scratching the grooved or gland surfaces.
Page 96: Lower Telescope Cylinder
HYDRAULIC SYSTEM TMS800E SERVICE MANUAL LOWER TELESCOPE CYLINDER Remove the guide lock ring from the piston to gain access to the setscrew. Description Remove the setscrew and unscrew the piston from the rod. The boom lower telescope cylinder (see Figure 2-44) has a 16.5 cm (6.5 in) bore, a 13.9 cm (5.50 in) hollow rod, and is Remove the remaining guide lock ring and hydrolock internally ported.
Page 97 TMS800E SERVICE MANUAL HYDRAULIC SYSTEM Install the O-rings and backup rings in the inside of the piston. CAUTION NOTE: Use a new setscrew. Improper seal installation can cause faulty cylinder Screw the piston onto the outer rod and secure with a operation.
Page 98 HYDRAULIC SYSTEM TMS800E SERVICE MANUAL 6540-1 2, 3 FIGURE 2-44 Item Description Item Description Dowel Guidelock Ring Bolt Lok-T Seal Flatwasher Seal Retainer Retaining Plate O-ring Backup Ring 2-62 Published 01-29-2014, Control # 496-00...
Page 99 TMS800E SERVICE MANUAL HYDRAULIC SYSTEM Item Description Item Description Wear Ring Piston Retaining Ring Setscrew Wiper Ring Guidelock RIng Buffer Seal Seal Assembly Rod Seal Backup Ring Backup Ring O-ring Barrel Spacer Holding Valve Piston Wear Ring Polyseal Ring Head O-ring O-ring Backup Ring...
Page 100: Upper Telescope Cylinder
HYDRAULIC SYSTEM TMS800E SERVICE MANUAL UPPER TELESCOPE CYLINDER Remove the O-ring and backup rings from the inside of the piston. Description Remove the spacer from the rod and the wear rings from the spacer. The upper boom telescope cylinder (see Figure 2-45) has a 16.5 cm (6.50 in) bore and is internally ported (rod ported).
Page 101 TMS800E SERVICE MANUAL HYDRAULIC SYSTEM 6538-1 FIGURE 2-45 Item Description Item Description Holding Valve Backup RIng Plug Rod Seal Buffer Seal Capscrew Wear Ring Fastener Head Retaining Ring Backup Ring Wiper O-ring GROVE Published 01-29-2014, Control # 496-00 2-65...
Page 102 HYDRAULIC SYSTEM TMS800E SERVICE MANUAL Screw the piston onto cylinder rod and secure with a Item Description new setscrew. Wear Ring Install the guide lock rings and hydrolock seals onto the Spacer outside of the piston, see Figure 2-47. Backup Ring O-ring Hydrolock Piston Seals Setscrew...
Page 103: Maintenance
TMS800E SERVICE MANUAL HYDRAULIC SYSTEM STEER CYLINDER Description CAUTION The steer cylinders (see Figure 2-48) are mounted on the Do not use air pressure to remove the rod. Use only a front axles. The steer cylinders each have 5.08 cm (2.0 in) source of controlled hydraulic oil pressure if the rod is diameter bores.
Page 104 HYDRAULIC SYSTEM TMS800E SERVICE MANUAL 6845 FIGURE 2-48 Inspection Item Description Clean all parts with solvent and dry with compressed air. Inspect for damaged or worn parts and replace as Barrel required. Rod Head CAUTION Piston Clean all surfaces and remove all burrs and nicks before installing new seals and rings.
Page 105 TMS800E SERVICE MANUAL HYDRAULIC SYSTEM Assembly Install the seal on the outside of the piston. Lubricate all parts freely with clean hydraulic oil. CAUTION When installing new seals and rings, clean all surfaces CAUTION and carefully remove burrs and nicks. Parts displaying Exercise extreme care when handling the rod.
Page 106: Maintenance
HYDRAULIC SYSTEM TMS800E SERVICE MANUAL OUTRIGGER EXTENSION CYLINDER Remove the two wear rings and seal from the outside of the piston. Description NOTE: Arranging discarded seals and rings in the order of disassembly will aid in installation of new seals and The four extension cylinders (see Figure 2-49) have 6.4 cm rings.
Page 107 TMS800E SERVICE MANUAL HYDRAULIC SYSTEM 22 21 6578 FIGURE 2-49 Item Description Item Description Setscrew Spacer Seal O-ring Wear Ring Backup Ring Piston Head O-ring Wear Ring Locknut Seal Cotter Pin Wiper Ring Washer GROVE Published 01-29-2014, Control # 496-00 2-71...
Page 108 HYDRAULIC SYSTEM TMS800E SERVICE MANUAL Install the wiper ring in the spacer. Item Description Install the seal, and wear rings in the inside of the Roller cylinder head. Make sure the seals are assembled properly and installed the correct direction. Barrel Install the replacement O-ring and backup ring on the outside of the head.
Page 109 TMS800E SERVICE MANUAL HYDRAULIC SYSTEM Install the wiper ring, seal and wear rings on the inside of Remove the cover from the barrel. Insert the rod and the head. Make sure the seals are assembled properly attached part into the barrel with a slight twisting motion. and in the correct direction.
Page 110: Outrigger Stabilizer Cylinder
HYDRAULIC SYSTEM TMS800E SERVICE MANUAL OUTRIGGER STABILIZER CYLINDER With the ports open, extend the rod assembly with a hoist enough to access the top of the head with spanner Description wrench. Do not extend completely. Turn the head counterclockwise with a fitted spanner The four outrigger stabilizer cylinders (see Figure 2-51) each wrench until the threads disengage.
Page 111 TMS800E SERVICE MANUAL HYDRAULIC SYSTEM 6846-1 FIGURE 2-51 Item Description Item Description Barrel Plug Wiper Ring Head Seal Piston Seal Spacer Wear Ring Check Valve O-ring Set Screw Backup Ring Insert Seal Plug O-ring Backup Ring GROVE Published 01-29-2014, Control # 496-00 2-75...
Page 112 HYDRAULIC SYSTEM TMS800E SERVICE MANUAL Inspect the barrel carefully for scoring. If barrel is scored, it must be repaired or replaced. Thoroughly rinse parts, allow to drain, and wipe with a lint-free rag. Inspect all parts for serviceability. CAUTION Before installing new seals and rings, clean all surfaces and carefully remove burrs and nicks.
Page 113 TMS800E SERVICE MANUAL HYDRAULIC SYSTEM Install the setscrew in the piston until hand tight. Install the seal assemblies onto the piston. Remove the cover from the barrel. CAUTION Exercise extreme care when handling the rod. Damage to the rod surface may cause unnecessary maintenance and expense.
Page 114: Center Front Stabilizer Cylinder
HYDRAULIC SYSTEM TMS800E SERVICE MANUAL CENTER FRONT STABILIZER CYLINDER Turn the head counterclockwise with a fitted spanner wrench until the threads disengage. Description Extend the rod assembly slowly until the piston is free of the barrel assembly. Place the rod assembly horizontally The center front stabilizer cylinder (see Figure 2-53) has a on a workbench taking care not to damage the surface 8.9 cm (3.5 inch) bore.
Page 115 TMS800E SERVICE MANUAL HYDRAULIC SYSTEM 6846-1 FIGURE 2-54 Item Description Item Description Barrel Plug Wiper Ring Head Seal Piston Seal Spacer Wear Ring Check Valve O-ring Set Screw Backup Ring Insert Seal Plug O-ring Backup Ring GROVE Published 01-29-2014, Control # 496-00 2-79...
Page 116 HYDRAULIC SYSTEM TMS800E SERVICE MANUAL Inspect the barrel carefully for scoring. If barrel is scored, it must be repaired or replaced. Thoroughly rinse parts, allow to drain, and wipe with a lint-free rag. Inspect all parts for serviceability. CAUTION Before installing new seals and rings, clean all surfaces and carefully remove burrs and nicks.
Page 117 TMS800E SERVICE MANUAL HYDRAULIC SYSTEM Install the setscrew in the piston until hand tight. Install the seal assemblies onto the piston. Remove the cover from the barrel. CAUTION Exercise extreme care when handling the rod. Damage to the rod surface may cause unnecessary maintenance and expense.
Page 118: Counterweight Removal Cylinder
HYDRAULIC SYSTEM TMS800E SERVICE MANUAL COUNTERWEIGHT REMOVAL CYLINDER NOTE: Arranging discarded seals and rings in the order of disassembly will aid in installation of new seals and Description rings. Pay attention to how each seal and ring is installed to avoid installing replacement seals and The counterweight cylinder (see Figure 2-57) has a 8.9 cm rings improperly.
Page 119 TMS800E SERVICE MANUAL HYDRAULIC SYSTEM 6466 FIGURE 2-57 Item Description Item Description O-ring Washer Piston Capscrew O-ring Seal Wiper Ring Wear Ring Seal Locknut O-ring Bleeder Plug Head Barrel Wear Ring Holding Valve Backup Ring GROVE Published 01-29-2014, Control # 496-00 2-83...
Page 120 HYDRAULIC SYSTEM TMS800E SERVICE MANUAL Clean all oil from the threads of the head. Coat the threads with Loctite 271. Using a spanner wrench, screw the head into place in the barrel. Check the inside of the port block for any sharp edges or burrs and remove as necessary with emery cloth.
Page 121: Cab Tilt Cylinder
TMS800E SERVICE MANUAL HYDRAULIC SYSTEM CAB TILT CYLINDER Place protective padding around the rod near the head to prevent damaging the chrome during head Description removal. b. Insert a spanner wrench into the 1/4 in holes The cab tilt cylinder (see Figure 2-59) is mounted beneath provided.
Page 122 HYDRAULIC SYSTEM TMS800E SERVICE MANUAL 6577 FIGURE 2-59 Item Description Item Description Wiper Seal Retainer Ring O-ring Locknut O-ring Barrel Backup Ring Seal Head Seal Piston Wear Ring 2-86 Published 01-29-2014, Control # 496-00...
Page 123 TMS800E SERVICE MANUAL HYDRAULIC SYSTEM Inspection d. If possible, the head/seal assembly should sit for at least one hour to allow the seals to elastically Inspect the rod. There should be no scratches or pits restore. deep enough to catch the fingernail. Pits that go to the base metal are unacceptable.
Page 124 HYDRAULIC SYSTEM TMS800E SERVICE MANUAL can be accelerated by pushing the piston/seal Brush piston seals and head seals with hydraulic oil. assembly through a honed or polished tube with an inside diameter equal to the nominal cylinder bore to CAUTION plus 0.25 mm (0.010 in).
Page 125: Description
TMS800E SERVICE MANUAL ELECTRIC SYSTEM SECTION 3 ELECTRIC SYSTEM TABLE OF CONTENTS Description ....... 3-1 Diagnostic Lights .
Page 126: Carrier Cab Power Panel
ELECTRIC SYSTEM TMS800E SERVICE MANUAL 35A fuse all of which are explained in greater detail in Carrier Fuses 7 through 8 are energized when the batteries are Fuse and Relays, page 3-8. connected and the carrier cab key switch is in the “ignition” or “start”...
Page 127 TMS800E SERVICE MANUAL ELECTRIC SYSTEM 6613-1 Carrier Cab FIGURE 3-1 Item Description Item Description Carrier Frame Center Module Carrier Frame Front Module Carrier Frame Rear Module Engine Diagnostic Connector Carrier Cab Console Module Master Control Module GROVE Published 01-29-2014, Control # 496-00...
Page 128 ELECTRIC SYSTEM TMS800E SERVICE MANUAL Superstructure Right Side Superstructure Left Side Superstructure Cab FIGURE 3-2 Item Description Item Description Right Side Control Module CL-305 Control Module CL-306 Control Module IO Module Published 01-29-2014, Control # 496-00...
Page 129 TMS800E SERVICE MANUAL ELECTRIC SYSTEM Carrier Cab Item Description Fuse Panel K1 and K2 Relays Terminal Strip (2) Buzzer Crane USB Diagnostics Connector FIGURE 3-3 Ground Tab FIGURE 3-4 GROVE Published 01-29-2014, Control # 496-00...
Page 130 ELECTRIC SYSTEM TMS800E SERVICE MANUAL Superstructure Cab FIGURE 3-5 Item Description Item Description RCL Override Switch Fuse Panel Relay and Diode Module Buzzer Relay K101 (on back side) Crane USB Diagnostics Connector Relay K102 (on back side) Published 01-29-2014, Control # 496-00...
Page 131 TMS800E SERVICE MANUAL ELECTRIC SYSTEM Carrier Relay/Fuse Panel #2 FIGURE 3-8 QSM Carrier Relay/Fuse Panel #1 FIGURE 3-6 ISX Carrier Relay/Fuse Panel #1 FIGURE 3-7 Superstructure Cab Fuse Panel FIGURE 3-9 GROVE Published 01-29-2014, Control # 496-00...
Page 132: Carrier Fuse And Relays
ELECTRIC SYSTEM TMS800E SERVICE MANUAL FIGURE 3-10 Table 3-3 Item Description Relay Relay Assignment Battery Wiper Battery Disconnect Switch Heater Control Valve 100 Amp Fuse Carrier Fuse and Relays Battery Hold Down The carrier has 5 large ANL type fuses, (2) Fuse and Relay Power Relay Modules containing 14 ATO mini style fuses and 7 relays, all 250 Amp Fuse...
Page 133: Superstructure Fuse And Relay Panel
TMS800E SERVICE MANUAL ELECTRIC SYSTEM F303 (35A) is energized while the battery disconnect switch Fuses F105 through F106 are energized when the batteries is closed and protects the electrical circuits supplying power are connected and the superstructure key switch is in the ignition (RUN) position.
Page 134: General Troubleshooting
ELECTRIC SYSTEM TMS800E SERVICE MANUAL If the component proves faulty, replace it with a known working component. If wiring proves faulty, replace it with wiring of equal diameter. CAUTION After troubleshooting, test and verify the repaired circuit When possible ensure the batteries are disconnected works properly.
Page 135 TMS800E SERVICE MANUAL ELECTRIC SYSTEM Table 3-5 Amp Crimping Tool Table Description Amp Part Number Grove Part Number Tool Tool 14 to 12 gauge wire 69710-1 90145-1 9-999-100177 10 to 8 gauge wire 69710-1 90140-1 9-999-100177 9-999-100178 4 to 9 circuit 69710-1 90306-1 9-999-100177...
Page 136: Diagnostic Lights
Service tool components and software master module. When this lamp is on, an engine fault may be obtained by contacting Manitowoc Crane Care. condition is active. The engine's fault code(s) may be obtained by the Engine Stop Lamp and Warning Lamps as...
Page 137: Starter Replacement
TMS800E SERVICE MANUAL ELECTRIC SYSTEM Removal Check Run engine. Verify reading of voltmeter on front console CAUTION is 24 volts or greater. Make repairs as needed. To prevent damage to electronics, in order: Ensure Continue troubleshooting charging system as needed if keyswitch has been off 2 minutes, Battery disconnect is in replacement of alternator did not correct problem in the off position, Remove ECM power fuse, Remove...
Page 138: Battery Replacement
ELECTRIC SYSTEM TMS800E SERVICE MANUAL Battery Replacement Relay Panel Component Replacement Removal Accessory Relay Replacement CAUTION CAUTION To avoid possible engine fault codes and undesirable To avoid possible engine fault codes and undesirable operation, ensure the keyswitch has been off 2 minutes operation, ensure the keyswitch has been off 2 minutes before disconnecting batteries.
Page 139: Instrument Replacement
TMS800E SERVICE MANUAL ELECTRIC SYSTEM Verify proper installation by operating all components Disconnect the electrical connector from the switch. involved with the replacement relay and verifying they all Depress the plastic tabs on top and bottom of switch and work. pull the switch through the front of the console panel to remove it.
Page 140 ELECTRIC SYSTEM TMS800E SERVICE MANUAL Disconnect the washer hose on the wiper arm (also Inspect the wiper arm and parts of the linking component called the pantograph arm assembly) from the washer kits (pantograph adapter kit, pivot shaft kit, wiper motor nozzle fitting assembly (Figure 3-11).
Page 141: Windshield Washer Assembly Replacement
TMS800E SERVICE MANUAL ELECTRIC SYSTEM 6620 FIGURE 3-11 Windshield Washer Assembly Replacement Item Description Removal Motor Arm Drive CAUTION To prevent possible engine fault codes and undesirable Pivot Shaft operation, in order: Ensure keyswitch has been off 2 Wiper Arm minutes, Battery disconnect is in the off position.
Page 142: Skylight Wiper Assembly Replacement
ELECTRIC SYSTEM TMS800E SERVICE MANUAL Inspection Remove mounting screw and nylon flat washer from outside cab roof. Visually check the pump for evidence of cracks, leaks, or Clean any sealing material from around holes in cab other damage. Replace pump if damaged. roof.
Page 143: Section 4
TMS800E SERVICE MANUAL BOOM SECTION 4 BOOM TABLE OF CONTENTS Description ....... 4-2 Lifting Limit Switch on the Lattice Extension .
Page 144: Description
BOOM TMS800E SERVICE MANUAL DESCRIPTION Boom Retraction One boom is available on the crane; a four section, full The upper telescope cylinder retracts the tele 2 and two power, sequenced and synchronized, boom (see Figure 4- retract cables pull the tele 3 section in at the same time. 1).
Page 145: Boom Disassembly
TMS800E SERVICE MANUAL BOOM Block the lift cylinder. Take up the slack on the boom lifting device. 10. Remove the capscrews, washers and end plate DANGER securing the upper lift cylinder shaft to the boom base A secure fixture that will prevent damage to the boom is section.
Page 146 BOOM TMS800E SERVICE MANUAL 16. Tag and disconnect the hydraulic hoses and tubes from 32. Remove the capscrews and washers securing each the telescope cylinders and the two cam valves. Cap or retract cable sheave mount in the rear of tele 2. Remove plug all openings.
Page 147 TMS800E SERVICE MANUAL BOOM 43, 44 41, 42 41, 42 41, 42 41, 42 35 33 53 52 45, 46, 47 43, 44 6605-6 View A 14, 15, 16 6605-1 See View B 9, 10, 11, 12, 13 18, 19, 20, 21 24, 14, 15, 16, 17 9, 10, 11, 12, 13 18, 19, 20, 21...
Page 148 BOOM TMS800E SERVICE MANUAL Item Description Item Description Base Section Keeper Plate Tele 1 Shim Tele 2 Lower Wear Pad Nose To Tele 3 Section Front Upper Pad Retract Cables Top Front Pad Support Cable Retainer Pin Capscrew Sheave Assembly Flatwasher Anti-Two Block Plate Capscrew...
Page 149 TMS800E SERVICE MANUAL BOOM See View C 6605-3 See View D See View B 80, 81, 82 78, 79 73, 74, 75 70, 71 63, 64 60, 61 58, 59 6605-2 View B 62, 83 FIGURE 4-1 continued GROVE Published 01-29-2014, Control # 496-00...
Page 150 BOOM TMS800E SERVICE MANUAL Item Description Item Description Wear Pad Cable Anchor Capscrew Swivel Nut Sheave Mount Hex Nut Cable Retainer Retract Cable Capscrew Cotter Pin Washer Washer Capscrew Pin Cylinder Mount Washer Bolt Plate Cylinder Support Capscrew Capscrew Washer Washer Sheave Assembly Plate Cover...
Page 151 TMS800E SERVICE MANUAL BOOM 110, 111 94, 95, 96, 97 94, 95, 96, 97 84, 85 101, 102, 103 98, 99, 100 102, 103 102, 103 6605-4 98, 99, 100 105, 106 FIGURE 4-1 continued View D Item Description Item Description Capscrew Elbow...
Page 152: Boom Nose Sheaves
BOOM TMS800E SERVICE MANUAL 55. If necessary, remove the grease fittings, connectors, Item Description and grease lines from the rear of the tele 3 section. Capscrew 56. If necessary, remove the capscrews and washers Washer securing the skid pad to the cylinder mount and remove the skid pad.
Page 153: Assembly
TMS800E SERVICE MANUAL BOOM Ensure that top spacer and sheaves are in proper NOTE: Apply medium strength threadlocking adhesive/ orientation to lower sheaves. sealant to the threads of all attaching hardware except cable ends and cable lock nuts. NOTE: The lockwasher can be used more than once but must be replaced if not in good condition.
Page 154 BOOM TMS800E SERVICE MANUAL 27. Using tape or ty-wraps, fasten the extend cable ends to the telescope cylinder to aid in assembly. 28. Place the retract cable sheave mounts in the rear of the DANGER tele 3 section to aid in assembly. Ensure the telescope cylinders are securely blocked and 29.
Page 155 TMS800E SERVICE MANUAL BOOM 44. Install the bottom rear wear pad on tele 1 with the 61. Position the front end of the base at the rear of tele 1/tele capscrews and washers. Torque the capscrews. 2/tele 3/telescope cylinder assembly. 45.
Page 156: Installation
BOOM TMS800E SERVICE MANUAL Installation 10. Lower the jack after making sure it is properly supported. 11. Remove the boom lifting device. NOTE: The following procedure applies to a boom totally removed from the crane. 12. Activate the hydraulic system and remove the boom and lift cylinder blocking devices.
Page 157: Cam Operated Check Valve Adjustment
TMS800E SERVICE MANUAL BOOM Front Upper Pad Adjustment Using setscrews, adjust front upper wear pads so that CAUTION the wear pad is just touching or is no more than 2 mm When extending and retracting the boom during (0.079 in) away from contacting the next outer section at alignment, movement should be stopped if a restriction is the side surfaces, and is 4 mm to 6 mm (0.16 in to 0.24 encountered, and wear pads adjusted as necessary to...
Page 158: Adjustment
BOOM TMS800E SERVICE MANUAL Adjustment (1.0 in) above the lower leg of the cable retainer bars on the sheave mount on the upper telescope cylinder. At near fully extended boom length, during sudden extension Retract the boom approximately 25 mm (1.0 in) to after retracting the boom some distance, and with high relieve tension on the extension cables.
Page 159: Telescope Circuit
TMS800E SERVICE MANUAL BOOM TELESCOPE CIRCUIT A holding valve is threaded into a port block on the rod end of the upper telescope cylinder. The holding valve for the Description second stage of the lower telescope cylinder is mounted into the port block on the barrel end of the second stage barrel.
Page 160 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 161 Reduce load. (Refer to load chart). d. Inoperative check valve. d. Replace check valve. Clogged hose and fittings. Replace hose or fittings. (Refer to Manitowoc Crane Care Parts Manual). Broken valve spool. Replace valve section. g. Broken piston(s). g. Replace piston(s) and all cylinder seals.
Page 162: Lift Circuit
BOOM TMS800E SERVICE MANUAL LIFT CIRCUIT The holding valve is a balanced poppet type hydraulic valve. It is threaded into the port block which is an integral portion of Description the lift cylinder barrel. The holding valve functions when booming up (cylinder rod extended), booming down (cylinder The boom lift circuit consists of the lift electric controller, lift rod retracted), or holding (cylinder rod stationary).
Page 163 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 with in the Feather controls to obtain desired same control valve bank assembly.
Page 164 BOOM TMS800E SERVICE MANUAL Symptom Probable Cause Solution Boom will not Low hydraulic oil. Check for leaks. Repair any found. lower. Replenish hydraulic oil to proper level. b. Main relief valve or circuit relief valve b. Repair or replace relief valve. damaged.
Page 165 TMS800E SERVICE MANUAL BOOM Apply medium strength threadlocking compound (Spec. M20 capscrew, refer to Fasteners and Torque Values, 6829012418) to the four M10 capscrews and to the M20 page 1-13. Torque the M10 capscrews. capscrew. Remove the lifting and supporting devices from the Attach the end plate to the lift cylinder upper pivot shaft boom and lift cylinders.
Page 166: Auxiliary Boom Nose
BOOM TMS800E SERVICE MANUAL AUXILIARY BOOM NOSE cable usage. The rooster sheave is installed on the main boom nose and is secured by attach pins that pass through Description the rooster sheave and the main boom nose. The auxiliary boom nose (rooster sheave) (see Figure 4-3) is used on the boom to simplify single part and maximum part Item Description...
Page 167: Installing The Bi-Fold Manual Jib
TMS800E SERVICE MANUAL BOOM INSTALLING THE BI-FOLD MANUAL JIB is folded up at the side of the main boom for transportation or is completely removed for transportation. DANGER To prevent serious injury or death, always wear personal DANGER protective equipment; that is, a hard hat, eye protection, gloves and metatarsal boots.
Page 168 BOOM TMS800E SERVICE MANUAL 6510-3 6510-7 6510-8 6916-1 Item Description Item Description Stinger Bumper Pad Front Mount Holding Plate Upper Hangar Lower Support Rear Hangar Carrier Bracket FIGURE 4-5 4-26 Published 01-29-2014, Control # 496-00...
Page 169: Jib Erecting And Stowing Procedure
TMS800E SERVICE MANUAL BOOM JIB ERECTING AND STOWING PROCEDURE The counterweight required according to the lifting capacity chart for the planned operation with the General Warnings lattice extension is rigged. The crane is supported with the outriggers prescribed for operation with the erected lattice extension according to the lifting capacity chart.
Page 170 BOOM TMS800E SERVICE MANUAL Crane should be set up on outriggers using normal If not using the bi-fold 7 m (23 ft) section, remove pin setup procedures Figure 4-6. Refer to Section 3 - from the locking bar. Move locking bar to the base OPERATING CONTROLS and PROCEDURES, in the section attachment bar and install pin.
Page 171 TMS800E SERVICE MANUAL BOOM Remove retainer clip from the pin attaching the 7 m (23 10. Use the controller to pivot the jib so that lugs on jib align ft) section to the base section Figure 4-10. with the holes in the lugs on the boom nose (Figure 4-13).
Page 172 BOOM TMS800E SERVICE MANUAL 13. Extend the boom approximately 61 cm (2 ft) to move NOTE: Step 17 is with the 7 m (23 ft) section stowed on extension off of the ramp (Figure 4-16). boom. 17. While maintaining control with the tag line, swing extension into position on boom nose.
Page 173 TMS800E SERVICE MANUAL BOOM Dummy Plug 6642-20 FIGURE 4-22 Install cable end connector from jib where dummy Connecting plug was removed Figure 4-23. Points Cable End Connector Installed 6642-45 FIGURE 4-20 19. Connect RCL cables: Remove RCL cable end connector from extension and route through jib Figure 4-21.
Page 174: Stowing Procedure
BOOM TMS800E SERVICE MANUAL 56 ft (17 m) Jib NOTE: Do not lower boom until stinger has been completely swung in front of the 10 m (33 ft) Secure tag line to stinger nose Figure 4-25. section. Lower the boom. Remove pin from swingaway.
Page 175 TMS800E SERVICE MANUAL BOOM Lower boom below horizontal. Using tag line to control movement of stinger, swing stinger into stowed position Figure 4-33. Attach tag line to stinger nose Figure 4-30. Tag Line To Stinger FIGURE 4-33 6642-29 FIGURE 4-30 6642-23 Raise boom slightly above horizontal.
Page 176 BOOM TMS800E SERVICE MANUAL Disconnect RCL Cable. Remove retainer clips and remove pins attaching the jib to the left side of boom nose. Stow the pins in the jib pin Remove connector from junction box on boom nose holders and install the retainer clips Figure 4-39. Figure 4-36.
Page 177 TMS800E SERVICE MANUAL BOOM Raise the boom to ensure wear pad rests against boom such that the lugs on the 7 m (23 ft) section bumper plate on ramp (Figure 4-41). align with rear stowage bracket. 10. Completely retract boom so that the jib stows on the ramp and front stowage brackets Figure 4-41.
Page 178: Raising And Lowering The Hydraulic Jib
BOOM TMS800E SERVICE MANUAL • Press the top push-button to raise the lattice extension (1). Install Pin • Press the bottom push-button to lower the lattice extension (2). During Operation During operation the lattice extension is raised or lowered from the crane cab. The lattice extension can be raised or lowered, only when the power for the lattice extension is switched on.
Page 179: Lifting Limit Switch On The Lattice Extension
TMS800E SERVICE MANUAL BOOM Lifting Limit Switch on the Lattice Extension On the 17 m (56 ft) Two-Stage Swingaway Lattice Extension The functions raise hoist, extend main boom and lower main boom are monitored during operation with the lattice extension by the lifting switch on the lattice extension and are switched off when the lifting limit switch is actuated.
Page 180: Positioning/Remove The Hoist Cable
BOOM TMS800E SERVICE MANUAL On the 10 m (33 ft) section, there is a deflection sheave at Positioning/Remove the Hoist Cable the rear (1) Figure 4-49. Fold out the deflection sheave if the jib offset angle is 20° or 40°. NOTE: For zero (0) degree offset, leave the mast DANGER...
Page 181 TMS800E SERVICE MANUAL BOOM 6622-1 6622-2 FIGURE 4-51 Pin Assembly Mast Assembly Shown At 0° Offset 6568-2 To obtain maximum degree offset, remove pin Offset and stow in lug. Link Offset Link 6568-4 Shown At 20 ° Offset Shown At 40 ° Offset 6568-3 FIGURE 4-52 GROVE...
Page 182: Removing The Bi-Fold Manual Jib
BOOM TMS800E SERVICE MANUAL Slowly lower the boom until the pressure is relieved Attach auxiliary crane sling to bi-fold swingaway on the offset link pins. extension. NOTE: For 20 or 40 degree offset, make sure the mast is in the raised position. b.
Page 183: Removing The 5 M (16 Ft) Sections
For technical reasons a crane may only be set with one jib. If you wish to use the jib on several Manitowoc/Grove cranes, the parts of the jib must be adjusted for these cranes and labeled with all of the respective serial numbers.
Page 184: Electrical Connection At The Jib
BOOM TMS800E SERVICE MANUAL w3351a FIGURE 4-55 The designation 10 m (33 ft) section, 7 m (23 ft) section, and 5 m (16 ft) section have been adjusted to these lengths.The total length of the individual sections is greater or smaller. (See FIGURE 4-55.) Electrical Connection at the Jib The following describes the electrical connections at the 5 m (16 ft) sections.
Page 185: Unfolding/Folding The Deflection Sheave On The 5 M (16 Ft) Section
TMS800E SERVICE MANUAL BOOM Disconnecting • Detach the electrical connection between the 10 m (33 ft) and front 5 m (16 ft) section. • Detach the electrical connection between the two 5 m (16 ft) sections. • Detach the electrical connection between the rear 5 m (16 ft) section and the main boom head.
Page 186: Positioning/Removing The Hoist Cable
BOOM TMS800E SERVICE MANUAL Folding In Deflection Sheave Positioning Hoist Cable • Remove the hoist rope holding rollers and rods (1) Figure 4-60. • Guide the hoist rope via the deflection sheaves (3) and via the head sheave (2) on the 10 m (33 ft) section or on the 7 m (23 ft) section.
Page 187: Traveling With Manually Offsettable Jib And/Or Inserts Erected
Operate the crane only with the auxiliary single-sheave boom nose that has the identical serial number. If you wish to use the auxiliary single-sheave boom nose on several Manitowoc/Grove cranes, it needs to be adapted to the corresponding crane and marked with all the serial numbers.
Page 188: Removing The Auxiliary Single-Sheave Boom Nose
BOOM TMS800E SERVICE MANUAL • Use an auxiliary crane to couple the holding device to the connection eyes (3) on the auxiliary boom nose and lift it to the left onto the main boom head. • Align the auxiliary single-sheave boom nose so that the bearing point (2) lines up to the front bore holes in the holding device.
Page 189: Rigging In Working Position
TMS800E SERVICE MANUAL BOOM • Using the thin pin (1), fasten the auxiliary single-sheave boom nose to the bearing point (2) Figure 4-67. • Secure the pin with a retaining pin. • The auxiliary single-sheave boom nose is now in transport position.
Page 190: Attaching And Removing Hoist Cable
BOOM TMS800E SERVICE MANUAL • When reeving, guide the hoist cable over the left hand upper sheave of the main boom. • Insert the rope holding rod into the appropriate bore holes and secure them with the corresponding retaining pins. •...
Page 191: Raising And Setting Down The Main Boom With Rigged Lattice Extension
TMS800E SERVICE MANUAL BOOM During Transport TELESCOPING WITH RIGGED LATTICE EXTENSION • Insert the plug of the connecting cable into the dummy socket (2) Figure 4-73 • Wind the connecting cable onto the holders (3). CAUTION • Plug the short-circuit plug into the socket (1). The main boom may become overloaded! If you telescope the main boom with a rigged lattice extension or jib.
Page 192: Monthly Maintenance Work
BOOM TMS800E SERVICE MANUAL NOTE: information Table applies malfunctions during operation with the 10/17 m (33/ 56 ft) lattice extension. Table 4-2 Malfunction Cause Remedy No function of the lifting limit switch Lifting limit switch not connected Connect the lifting limit switch. Electrical connection between the boom head and lattice extension and Establish electrical connection.
Page 193: Hookblock
For hook blocks and other load handling devices not for the crane. The hook block utilizes a one-piece pivot block manufactured by Manitowoc Cranes, Inc.; follow the and the hook is equipped with a safety latch. The hook block manufacturer’s inspection and testing recommendations to is the quick reeve design.
Page 194 BOOM TMS800E SERVICE MANUAL 4-52 Published 01-29-2014, Control # 496-00...
Page 195: Maintenance
TMS800E SERVICE MANUAL HOIST AND COUNTERWEIGHT SECTION 5 HOIST AND COUNTERWEIGHT TABLE OF CONTENTS Description ....... 5-1 Maintenance .
Page 196: Removal
HOIST AND COUNTERWEIGHT TMS800E SERVICE MANUAL be operated at low speeds, forward and reverse, several Tag and disconnect the electrical wires to the hoist times to prime all lines with warm hydraulic oil, and to rotation indicator sensor. circulate gear lubricant through the planetary gear sets. Tag and disconnect the electrical wires to the hoist hi- speed solenoid valve.
Page 197: Functional Check
TMS800E SERVICE MANUAL HOIST AND COUNTERWEIGHT Add shims to satisfy any existing gaps. Altering the shim thickness to fit a tapering gap is acceptable. Install the Item Description capscrews, washers and nuts and tighten, refer to Main Hoist Fasteners and Torque Values, page 1-13. Auxiliary Hoist Remove the lifting device from the hoist.
Page 198: Hoist To Boom Alignment
HOIST AND COUNTERWEIGHT TMS800E SERVICE MANUAL HOIST TO BOOM ALIGNMENT center point of adjustment to check the fleet angle of the cable. Preparation All the cable must be removed from the hoist drum to check the fleet angle. Using mason cord or cat gut Boom alignment must be completed before attempting hoist fishing line you will be able to pull the line tight to make alignment.
Page 199 TMS800E SERVICE MANUAL HOIST AND COUNTERWEIGHT MAIN HOIST IS ALIGNED TO THE RIGHT HAND SHEAVE LOCATING CENTERLINE WITH SQUARE 6019 AUXILIARY HOIST IS ALIGNED TO THE CENTER SHEAVE FIGURE 5-2 Elevate the boom above 45 degrees boom angle to check if the hoist is level. Reposition the hoist drum and CAUTION tighten the cord so you can have the cord in the center of the protractor at the 90 degree mark.
Page 200: Piston Motor And Control Valve
HOIST AND COUNTERWEIGHT TMS800E SERVICE MANUAL PISTON MOTOR AND CONTROL VALVE Place the motor and motor control valve in a clean, dry suitable work area. Description Installation The piston motor is a bent axis, bidirectional, variable NOTE: Care must be taken to assure the primary thrust displacement heavy-duty motor.
Page 201: Idler Drum And Cable Follower
TMS800E SERVICE MANUAL HOIST AND COUNTERWEIGHT IDLER DRUM AND CABLE FOLLOWER Disassemble the cable follower roller 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 202 HOIST AND COUNTERWEIGHT TMS800E SERVICE MANUAL 3.0 cm (1.21 inch) Item Description 6395-2 Pivot Bracket Drum Follower Roller Spring Spring Adjusting Rod Lever Idler Roller Bracket Rotation Sensor Hydraulic Motor 6395-1 FIGURE 5-3 Published 01-29-2014, Control # 496-00...
Page 203 TMS800E SERVICE MANUAL HOIST AND COUNTERWEIGHT With one layer of cable on the hoist drum, adjust the Remove the idler drum and cable follower assembly bolts on the front of each side plate (that push from the hoist. against each arm) so the roller applies pressure on If necessary to completely disassemble or remove any the layer of cable, and does not interfere with filler/ part of the assembly, refer to the applicable paragraphs...
Page 204: Hoist Drum Indicator System
HOIST AND COUNTERWEIGHT TMS800E SERVICE MANUAL HOIST DRUM INDICATOR SYSTEM Proper circuit operation can be checked for each individual electrical component. If a malfunction occurs within the Description system, repairs should be limited to finding and replacing the faulty component(s). To determine which component is at The hoist drum rotation indicator system (see Figure 5-4) is an electrically operated system that provides the operator fault, refer to the troubleshooting section of your CAN-bus...
Page 205: Hoist Control Valves
TMS800E SERVICE MANUAL HOIST AND COUNTERWEIGHT HOIST CONTROL VALVES Maintenance Cylinders Description Removal NOTE: For more detailed information, refer to Valves, page 2-22. Set the counterweight on the carrier deck. Hoist Motor Control Valve Tag and disconnect the hydraulic lines from the cylinder. Cap or plug all openings.
Page 206: Stowing The Counterweight
HOIST AND COUNTERWEIGHT TMS800E SERVICE MANUAL Push in on the pins and turn to lock pin in the notch. Stowing the Counterweight Insert the long pins into the bottom of the counterweight. Position the crane on a firm level surface. Fully extend Push in on the pins and turn to lock pin in the notch.
Page 207 TMS800E SERVICE MANUAL HOIST AND COUNTERWEIGHT NOTE: It may be necessary to jog the counterweight with the removal control panel to remove the weight of Item Description the counterweight from the upper attach pins. Counterweight Removal Cylinder Using the counterweight removal control panel, raise the counterweight cylinders to relieve weight on the upper Spacer attach pins.
Page 208 HOIST AND COUNTERWEIGHT TMS800E SERVICE MANUAL 5-14 Published 01-29-2014, Control # 496-00...
Page 209: Description
TMS800E SERVICE MANUAL SWING SYSTEM SECTION 6 SWING SYSTEM TABLE OF CONTENTS Description ....... 6-1 Description.
Page 210: Swing Brake
SWING SYSTEM TMS800E SERVICE MANUAL the control to neutral and depressing the brake pedal will top switch), the swing brake release valve blocks the flow to stop the swing. the brake release port and spring pressure in the swing brake applies the brake. When the swing brake selector Swing Brake switch is positioned to off, the flow is directed to the brake release port, overcoming the brake spring pressure and...
Page 211 TMS800E SERVICE MANUAL SWING SYSTEM Item Description Item Description Plug Breather Plug Plug Plug Motor Elbow Gearbox and Brake Pipe Plug Breather Pinion Plug Dipstick GROVE Published 01-29-2014, Control # 496-00...
Page 212: Maintenance
TMS800E SERVICE MANUAL MAINTENANCE Troubleshooting NOTE: CAN-bus service tool should be used to aid troubleshooting. Service tool can be ordered through the Manitowoc Technical Training Center. Symptom Probable Cause Solution Superstructure Low engine rpm Increase engine rpm to obtain smooth swing operation swing operation.
Page 213 TMS800E SERVICE MANUAL SWING SYSTEM 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 214 Inspect connectors and wiring. d. Improperly lubricated swing bearing. d. Lubricate bearing recommendations. Improper size hose and/or fittings Refer to the Manitowoc Crane Care installed. Parts Manual. Clogged or restricted hydraulic hoses Clean or replace damaged parts. or fittings. g. Worn...
Page 215 TMS800E SERVICE MANUAL SWING SYSTEM Symptom Probable Cause Solution Swing brake drags. Damaged swing brake release valve. Replace cartridge. b. Internal damage to the swing brake b. Repair or replace affected parts. assembly. Loose or restricted brake lines or Tighten or replace brake lines and fittings.
Page 216: Swing Motor
SWING SYSTEM TMS800E SERVICE MANUAL SWING MOTOR Remove the capscrews securing the motor and lift the swing motor free of the motor support plate. Remove Description and discard the O-ring from the groove in the swing brake. The swing motor is mounted on the swing brake housing and Installation drives the swing gearbox through the brake assembly.
Page 217: Swing Gearbox And Brake
TMS800E SERVICE MANUAL SWING SYSTEM SWING GEARBOX AND BRAKE Installation Install a new O-ring onto the brake housing. Description Place motor support plate on brake housing. The swing gearbox and brake, used in conjunction with the Apply Loctite® 270 to socket capscrews. Install motor swing motor, rotates and stops the superstructure.
Page 218 SWING SYSTEM TMS800E SERVICE MANUAL If necessary, remove the swing motor according to the Flush the case with a light flushing oil. procedures found in this Section under SWING MOTOR NOTE: Cleaning of the gearbox with a solvent is REMOVAL. recommended to prevent an accumulation of grit If necessary, remove the swing brake according to the and grime.
Page 219: Swing Bearing
TMS800E SERVICE MANUAL SWING SYSTEM SWING BEARING Description DANGER The swing bearing is an anti-friction roller bearing that mates It is mandatory that bearing attaching bolts be inspected the Superstructure to the Carrier. The bearing inner race is for lack of torque and retorqued, as required, after the first bolted to the Superstructure and the outer race is bolted to 300 hours of crane operation.
Page 220 SWING SYSTEM TMS800E SERVICE MANUAL The inner race of the bearing is secured to the turntable by Inner Race Torquing 72, M24 Grade 10.9 bolts. The outer race of the bearing is Extend and set the outriggers. Fully elevate the boom. secured to the carrier frame by 72, M24 Grade 10.9 bolts.
Page 221 Orders for special tools 1. M24 Socket 3/4” Drive 9-999-101798 shall be referred to: 2. 4 to 1 Torque Multiplier (1/2” Input 3/4” Output) 9-999-100134 Manitowoc 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 5.
Page 222 SWING SYSTEM TMS800E SERVICE MANUAL NOTE: The bearing weighs approximately 704 kg (1886 lb) depending on the bearing. Ensure the bearing lifting device is capable of supporting the weight. DANGER 16. Place an adequate lifting device under the bearing and Ensure the lifting device is capable of fully supporting the remove the 72 bolts and washers securing the turntable weight of the superstructure.
Page 223 TMS800E SERVICE MANUAL SWING SYSTEM • Using shims, set backlash by moving the swing drive assemblies toward the bearing in order to mesh the Maximum Eccentricity Point Pinion pinion with the ring gear teeth (see Figure 6-5). • Check tooth engagement squareness and vertical tooth engagement.
Page 224: Swivels
SWING SYSTEM TMS800E SERVICE MANUAL SWIVELS lugs with bolts and jam nuts. This allows the spool to remain stationary with the carrier as the case rotates with the Description superstructure. The water swivel case is engaged to the hydraulic case by The swivel assembly (see Figure 6-6) consists of an 8-port four dowel pins causing the water swivel to rotate with the hydraulic swivel, a 2 port water swivel, and a 20 conductor...
Page 225 TMS800E SERVICE MANUAL SWING SYSTEM 3, 4 5, 6 12, 13 8, 9, 10 5, 6, 11 FIGURE 6-6 GROVE Published 01-29-2014, Control # 496-00 6-17...
Page 226: Hydraulic Swivel
SWING SYSTEM TMS800E SERVICE MANUAL Measure distance from top of the lift cylinder to base of boom section where the lift cylinder attaches. Cut two Item Description pieces of 10 x 10 cm (4 x 4 in) oak to fit. Hydraulic Swivel NOTE: It might be necessary to raise the boom slightly to...
Page 227: Integral W/Hydraulic Water Swivel
TMS800E SERVICE MANUAL SWING SYSTEM Table 6-1 Test Pressure Port # Function bar (psi) 50 (725) Case Drain (Hydraulic Fluid) 300 (4350) Hydraulic Fluid Inlet 300 (4350) Hydraulic Fluid Inlet 300 (4350) Swing (Hydraulic Fluid) 50 (725) Hydraulic Fluid Return 50 (725) Hydraulic Fluid Return 250 (3625)
Page 228: Installation
SWING SYSTEM TMS800E SERVICE MANUAL Disassembly Install new seals and rings on the spool. NOTE: Any maintenance requiring disassembly of the water swivel should include replacement of all CAUTION seals and rings. Proper alignment when installing the case is required. Do Remove the case.
Page 229: Maintenance
TMS800E SERVICE MANUAL SWING SYSTEM Maintenance Installation If removed, install the spacer bushing on the center post. Removal Route the collector core wiring harness through the Perform steps 1 through 4 of HYDRAULIC SWIVEL - center of the hydraulic and water swivels. REMOVAL in this section.
Page 230: Swing Lock Pin
SWING SYSTEM TMS800E SERVICE MANUAL 10. Connect the batteries. • Select the Info icon. Verify the angle indicated on the console does not exceed ± 1.0 degree. CAUTION It is imperative that the slew encoder be adjusted anytime SWING LOCK PIN work is done to the electrical swivel.
Page 231 TMS800E SERVICE MANUAL SWING SYSTEM lock assembly completely out of the gear teeth when the foot pedal is up. Verify the linkage can put the blade of the swing lock assembly as far as possible between the gear teeth when the foot pedal is down. Verify all attaching hardware is Swing Lock secure and undamaged.
Page 232 SWING SYSTEM TMS800E SERVICE MANUAL Published 01-29-2014, Control # 496-00 6-24...
Page 233: Description
TMS800E SERVICE MANUAL POWER TRAIN SECTION 7 POWER TRAIN TABLE OF CONTENTS Description ....... 7-1 Winter Front Grill Cover .
Page 234: Removal
POWER TRAIN TMS800E SERVICE MANUAL The superstructure cab foot throttle pedal and the increment/ Tag the starting aid (ether) tubing. Disconnect the tubing decrement switch are active while in craning mode (the from the injector nozzle on the engine intake manifold. superstructure key switch is in the ignition “RUN”...
Page 235 TMS800E SERVICE MANUAL POWER TRAIN FIGURE 7-1 QSM Engine GROVE Published 01-29-2014, Control # 496-00...
Page 236: Description
POWER TRAIN TMS800E SERVICE MANUAL FIGURE 7-1 continued QSM Engine Item Description Item Description Starter Alternator Turbocharger Oil Filter Engine Oil DIpstick Air Compressor Transmission Piston Pump Rear Engine Lift Bracket IMS (Internal Magnetic Solenoid) Published 01-29-2014, Control # 496-00...
Page 237 TMS800E SERVICE MANUAL POWER TRAIN FIGURE 7-2 ISX Engine GROVE Published 01-29-2014, Control # 496-00...
Page 238 POWER TRAIN TMS800E SERVICE MANUAL FIGURE 7-2 continued ISX Engine Item Description Item Description Starter Alternator Turbocharger Oil Filter Engine Oil DIpstick Air Compressor Transmission Piston Pump Rear Engine Lift Bracket IMS (Internal Magnetic Solenoid) Published 01-29-2014, Control # 496-00...
Page 239: Installation
TMS800E SERVICE MANUAL POWER TRAIN 20. Tag and disconnect all lines to the radiator and air Connect all linkages and cables to the engine, engine cooler. Remove the radiator assembly and fan. Cap or components, and transmission as tagged during removal.
Page 240: Engine Drive Belts
POWER TRAIN TMS800E SERVICE MANUAL 24. Connect the battery. NOTE: Belt tension is maintained with an automatic belt tension device. 25. Position the start relay and the max speed relay on the inside of the hood. Secure them with the bolts, washers, The engine drive belt should be inspected visually lockwashers, and nuts.
Page 241: Engine Control System
TMS800E SERVICE MANUAL POWER TRAIN ENGINE CONTROL SYSTEM Engine Control System Switches and Indicator Lights Engine Idle/Increment-Decrement Switch Description The Engine Diagnostic/Idle Switch, located on the left side of The engine control system is an electronically operated fuel the carrier cab console, is a two position maintained on/off injection system that optimizes fuel economy and reduces rocker switch used to access the engine fault codes or exhaust emissions.
Page 242: Fuel System
POWER TRAIN TMS800E SERVICE MANUAL speed as needed. The cycle will take approximately 20 minutes. Engine Stop Light The engine stop light is located at the top left side of the front console in the carrier cab. It is a red indicator light that illuminates to signify a serious engine problem that requires the vehicle and the engine to be stopped as soon as safely possible.
Page 243 TMS800E SERVICE MANUAL POWER TRAIN Connect the two lines to the fittings on the tank in supplied with the new filter.) Remove the filter element accordance with the identification marks made during from the filter body by pulling upward and twisting slightly.
Page 244 POWER TRAIN TMS800E SERVICE MANUAL FIGURE 7-5 Item Description Item Description Fuel Return From Fuel Cooler Filler Cap Fuel Level Sending Units Mounting Straps Tank Vent Fuel Tank Brackets Fuel Tank Fuel Supply To Engine Fuel Return (ISX-Back Side) Fuel Return (QSM) Published 01-29-2014, Control # 496-00 7-12...
Page 245: Air Intake System
TMS800E SERVICE MANUAL POWER TRAIN AIR INTAKE SYSTEM in performance before the element must be cleaned or replaced. Description A gauge connected to the air cleaner housing will indicate when the filter needs to be cleaned. Reset the gauge each The engine air intake system (see Figure 7-8) consists of an time the air cleaner is serviced.
Page 246 POWER TRAIN TMS800E SERVICE MANUAL complete a tight seal, apply pressure at the outer rim of the filter, not the flexible center. No cover pressure is required to hold the seal (Figure 7-8). FIGURE 7-6 b. AVOID DISLODGING DUST FROM THE FILTER. Gently pull the filter off the outlet tube and out of the housing.
Page 247 TMS800E SERVICE MANUAL POWER TRAIN FIGURE 7-10 Item Description Item Description Air Cleaner (See Figure 7-11) Tube Air Inlet Hood End Cap Plug Mounting Band Capscrew Service Indicator Washer Reducing Elbow Lock Washer Intake Tube Hex Nut Clamp Clamp T-bolt Clamp Adapter GROVE Published 01-29-2014, Control # 496-00...
Page 248 POWER TRAIN TMS800E SERVICE MANUAL element service life. The valve lips must point straight down and be kept free from debris to operate effectively. Mud and CAUTION chaff can lodge in these lips periodically and hold them open during engine operation. Do not touch the inside of the filter with a bare light bulb.
Page 249 TMS800E SERVICE MANUAL POWER TRAIN FIGURE 7-11 Item Description Item Description Body Assembly Wing Nut Large Air Filter Element Clip Safety Air Filter Element Cotter Pin Vacuator Valve Air Cleaner Gasket GROVE Published 01-29-2014, Control # 496-00 7-17...
Page 250: Qsm Engine Muffler
POWER TRAIN TMS800E SERVICE MANUAL QSM ENGINE MUFFLER Remove muffler clamp. Remove exhaust connector assembly. Removal Remove muffler from mounting bands. Remove capscrews, lock washers, flat washers, and nuts to free muffler mounting bands from muffler mount. CAUTION Do not touch muffler or exhaust parts until they are at ambient temperature.
Page 251: Installation
TMS800E SERVICE MANUAL POWER TRAIN Installation Item Description Install muffler mounting bands on muffler mount Engine Exhaust Tube Square Cap Install muffler to mounting bands. Muffler Clamp Install exhaust connector assembly. Capscrew As needed, install a replacement exhaust wrap around the exhaust tube.
Page 252 POWER TRAIN TMS800E SERVICE MANUAL FIGURE 7-13 Item Description Item Description Muffler Mount Weldment Diesel Particulate Filter (DPF) Assembly Cover Weldment Selective Catalytic Reduction (SCR) Assembly Muffler Guard Decomposition Pipe Assembly Cover Exhaust Tube Muffler Support 90° Elbow Exhaust Cover Adapter Tube Muffler Support Exhaust Tube...
Page 253: Installation
TMS800E SERVICE MANUAL POWER TRAIN Installation Install the DPF and secure with the mounting bands. Connect the elbow and decomposition tube to the DPF Install SCR to the muffler mount weldment with the and adapter tube with the appropriate gaskets and V- mounting bands.
Page 254: Diesel Exhaust Fluid (Def) Tank
POWER TRAIN TMS800E SERVICE MANUAL DIESEL EXHAUST FLUID (DEF) TANK Remove the hardware holding the tank straps in place. Remove the tank. Description Installation This engine uses a Selective Catalytic Reduction (SCR) system. SCR is a technology that uses a urea based DEF Place the DEF tank onto the location on the frame.
Page 255: Water Cooling System
TMS800E SERVICE MANUAL POWER TRAIN WATER COOLING SYSTEM core and is cooled by air from the fan. This process of removing heat from water as it circulates holds the engine to Description its efficient operating temperature. The following paragraphs point out several facts about The cooling system consists of the radiator, coolant recovery cooling system components, the effects of cooling system tank, engine cooling circuit, and the connecting hoses...
Page 256 POWER TRAIN TMS800E SERVICE MANUAL Rust Prevention check the coolant additive concentration in the cooling system). To keep engines operating at newness efficiency, all forms of If SCA levels are less than 1.2 Units/Gal, add Cummins rust formation must be prevented. The formation of rust in DCA4 to maintain desired level.
Page 257 TMS800E SERVICE MANUAL POWER TRAIN Place a clean drain pan to catch the overflow, and use it Flush the heaters following the same procedure as for to maintain the level in the radiator. Do not spill the the radiator core. solution on the vehicle paint.
Page 258 POWER TRAIN TMS800E SERVICE MANUAL whether or not tubes are clean. Another good test is to doubts about a hose doing its job, replacement should be feel the core for cold spots. made. The clamps should be inspected to make sure they are strong enough to hold a tight connection.
Page 259: Winter Front Grill Cover
TMS800E SERVICE MANUAL POWER TRAIN washers between the radiator and the mounts to adjust 10. Position the front cowl on the frame and secure with the radiator height properly. attaching hardware Position the fan guards on the shroud and secure with 11.
Page 260 POWER TRAIN TMS800E SERVICE MANUAL QSM Engine Radiator/Charge Air Cooler Assembly Item Description Radiator/Charge Air Cooler Recovery Tank Drain Cock Left Hand Baffle Right Hand Baffle Top Radiator Tube (QSM) Bottom Radiator Tube (QSM) Cold CAC Tube (QSM) Hot CAC Tube (QSM) Radiator Mount Fan Guards Coolant Recovery Hose...
Page 261 TMS800E SERVICE MANUAL POWER TRAIN ISX Engine Radiator/Charge Air Cooler Assembly Item Description Radiator/Charge Air Cooler Recovery Tank Drain Cock Left Hand Baffle Right Hand Baffle Top Radiator Tube (ISX) Bottom Radiator Tube (ISX) Cold CAC Tube (ISX) Hot CAC Tube (ISX) Radiator Mount Fan Guards Coolant Recovery Hose...
Page 262: Pump/Pto Clutch Assembly (Isx Engine)
POWER TRAIN TMS800E SERVICE MANUAL PUMP/PTO CLUTCH ASSEMBLY (ISX ENGINE) The pump PTO clutch is used to engage/disengage pump 1 from the engine to aid in starting, especially in cold weather, and to prevent the pumps from over-speeding while traveling the crane.
Page 263 TMS800E SERVICE MANUAL POWER TRAIN Remove the four cap screws, nuts and washers (3, Remove the three cap screws, nuts and washers (3) that Figure 7-17) securing the clutch mounting bracket (4) to secure the mounting plate (4) to the mounting bracket (5).
Page 264: Air Valve Replacement
POWER TRAIN TMS800E SERVICE MANUAL Air Valve Replacement The air valve is used to control the air to the PTO clutch. 11 mm FIGURE 7-21 Torque hardware (4, Figure 7-19), refer to Fasteners FIGURE 7-22 and Torque Values, page 1-13. Connect the electrical connectors and hoses to the Removal pumps as tagged during removal.
Page 265: Drive Train
TMS800E SERVICE MANUAL POWER TRAIN DRIVE TRAIN Removal Support the drive line being removed so it does not fall Description when disconnected. The drive train consists of the manual transmission, clutch, Remove the bolts from the bearing cap on each end of and drive lines.
Page 266 POWER TRAIN TMS800E SERVICE MANUAL TORQUE 149 to 163 Nm 110 to 120 ft-lb) TORQUE 149 to 163 Nm (110 to 120 ft-lb) TORQUE 149 to 163 Nm (110 to 120 ft-lb) TORQUE 149 to 163 Nm (110 to 120 ft-lb) View A TORQUE TORQUE...
Page 267: Clutch
TMS800E SERVICE MANUAL POWER TRAIN CLUTCH The 39.4 cm (15-1/2 in) clutch flywheel ring (cover) is attached to the engine flywheel by eight 7/16-inch Description capscrews. The pressure plate is driven by driving lugs The clutch is a 39.4 cm (15-1/2 in), 2-plate, pull-type heavy extending into mating slots in the flywheel ring (cover).
Page 268 POWER TRAIN TMS800E SERVICE MANUAL Clutch Assembly Adjusting Lever Governor Spring Pilot Bearing Crank Lockwasher Bolt Clutch Release Shaft and Parts 6, 7 4749 Clutch Installation Published 01-29-2014, Control # 496-00 7-36...
Page 269: Maintenance
TMS800E SERVICE MANUAL POWER TRAIN Maintenance Troubleshooting SYMPTON PROBABLE CAUSE SOLUTION Loose, broken, or worn engine Chatter. Tighten or replace mounts. mounts. Loose or cracked clutch Tighten or replace. housing. Rear axle attach bushings Replace bushings. worn. Misalignment. Align. Install new facings or disc Oil or grease on facings.
Page 270 POWER TRAIN TMS800E SERVICE MANUAL SYMPTON PROBABLE CAUSE SOLUTION Pressure plate return springs Replace springs. bent or stretched. Insufficient amount of release Adjust for proper release travel. travel. Lever nose out of groove in Disassemble and repair as release sleeve retainer. necessary.
Page 271 TMS800E SERVICE MANUAL POWER TRAIN SYMPTON PROBABLE CAUSE SOLUTION Replace damaged intermediate Broken intermediate plate. plate driven disc assembly. Intermediate plate lugs should Intermediate plate sticking on have 0.1524 mm (0.006 in) cover. clearance in driving slots of flywheel ring (cover). Warped or bent driven disc Replace.
Page 272 POWER TRAIN TMS800E SERVICE MANUAL Removal Use a marker or soapstone to mark the high and low points. Remove the transmission following the procedures Total difference between high and low points should not under Removal of the Transmission, page 7-48. exceed 0.203 mm (0.008 in).
Page 273 TMS800E SERVICE MANUAL POWER TRAIN Installation Put the rear driven disc on the aligning tool with the side stamped “pressure plate” facing the pressure plate. 4863-4 Insert two 12.7 cm (5 in) long 7/16 inch - 14 UNC guide 4863-6 studs into the two upper mounting holes of the flywheel.
Page 274 POWER TRAIN TMS800E SERVICE MANUAL NOTE: Ensure the adjustment mechanism will be aligned with the opening in the bell housing of the FLUSH transmission. 4863-10 PROTRUDING Position the clutch over the guide studs and slide it 4863-8 forward until contact is made with the flywheel surface. Positive Separator (Roll) pins should be flush on the The clutch assembly weighs approximately 68 kg (150 clutch side, protruding on flywheel side.
Page 275: Clutch Adjustment Procedure
TMS800E SERVICE MANUAL POWER TRAIN - Remove rust and contamination from input shaft. 9.53-15.88 mm - Replace the shaft if any wear is noticed. The clutch 0.375-0.625 in won’t release if the shaft is notched. - Do not coat the shaft with grease or never seize. If greater than 15.88 mm (0.625 in), check fly- Install discs dry or wipe on a light coat of oil.
Page 276: General Maintenance
POWER TRAIN TMS800E SERVICE MANUAL b. Turning the bolt 2-1/3 rotations changes the General Maintenance adjustment 3.175 mm (0.125 in). The Kwik-Adjust Never underestimate the necessity of perfect clutch will re-engage at a quarter of a turn. The flat of the balance.
Page 277: Manual Transmission
TMS800E SERVICE MANUAL POWER TRAIN Removal Connect the nylon tubing to the splitter valve. Shift the transmission to neutral. Bleed the air reservoirs MANUAL TRANSMISSION and tag and disconnect the nylon tubing at the range shift valve on the gearshift lever. Tag and disconnect the Description tubing at the splitter valve.
Page 278 POWER TRAIN TMS800E SERVICE MANUAL SYMPTON PROBABLE CAUSE SOLUTION Noise (from other sources). Fan bent or out of balance. Replace fan. Damaged vibration damper. Replace damper. Check balance. Replace flywheel if Flywheel out of balance. necessary. Check clutch and clutch housing for Unbalanced clutch assembly.
Page 279 TMS800E SERVICE MANUAL POWER TRAIN SYMPTON PROBABLE CAUSE SOLUTION Linkage and rods between shift lever Check and adjust linkage and rods to and auxiliary transmission not properly make sure transmission is shifting full adjusted. into gear. Clutch gear teeth worn tapered. Replace worn parts.
Page 280 POWER TRAIN TMS800E SERVICE MANUAL SYMPTON PROBABLE CAUSE SOLUTION Air lines crossed between control valve on shift lever and air valve on Range shift inoperative or Disconnect crossed air lines and transmission (steady leakage from malfunctioning. connect properly. exhaust port on range shift control valve with button in the up position).
Page 281: Lubrication
TMS800E SERVICE MANUAL POWER TRAIN Move the fourth-fifth speed sliding clutch gear forward to Thus, all parts will be amply lubricated if these procedures contact the end of the input shaft in the hub of the drive are closely followed. gear.
Page 282: Transmission Shift Air System
POWER TRAIN TMS800E SERVICE MANUAL • Air System and Connections. Check for leaks, worn TRANSMISSION SHIFT AIR SYSTEM air lines, loose connections, and capscrews. Description • Clutch Housing Mounting. Check all capscrews in the bolt circle of the clutch housing for looseness. The shift air system controls the selection of the transmission ranges and is comprised of an air valve, air regulator, air •...
Page 283: Front Axle And Suspension
TMS800E SERVICE MANUAL UNDERCARRIAGE SECTION 8 UNDERCARRIAGE TABLE OF CONTENTS Front Axle and Suspension ....8-1 Automatic Slack Adjuster (Rear) ... . . 8-39 Description .
Page 284: Maintenance
UNDERCARRIAGE TMS800E SERVICE MANUAL Each front axle is bolted to the walking beam of the General suspension system. Each axle is anchored against forward, Proper preventive maintenance will help control repair costs rearward, and side ways movement by adjustable torque and downtime.
Page 285 TMS800E SERVICE MANUAL UNDERCARRIAGE 9, 10 9, 10 6569 FIGURE 8-1 Item Description Item Description Power Steering Gear Vertical Socket Pittman Arm Pin Weld Cotter Pin Shim Drag Link Bolt Steering Shaft Lockwasher Vertical Socket Flatwasher Vertical Socket Cotter Pin GROVE Published 01-29-2014, Control # 496-00...
Page 286 UNDERCARRIAGE TMS800E SERVICE MANUAL from the air bag connections. Cap all hoses and Cotter Pin openings. Slotted Nut Tag and disconnect the hydraulic lines from the steer Grease Fitting cylinders. NOTE: Do not change the torque rod or vertical socket drag links’...
Page 287 TMS800E SERVICE MANUAL UNDERCARRIAGE NOTE: Figure shown for reference only. DIM. C Frame, axles and steer cylinder locations vary for each model. King Pin Center King Pin Center Centerline Of First Front Axle Centerline Of Front Bogie String Line King Pin Center Centerline Of Last Front Axle King Pin Center Longitudinal Measurement...
Page 288 UNDERCARRIAGE TMS800E SERVICE MANUAL Remove the saddle assemblies from the walking beams to 136 to 170 Nm (100 to 125 lb-ft). Tighten to nearest by removing bolts and flatwashers from each pivot block cotter pin hole and insert cotter pin. cap.
Page 289 TMS800E SERVICE MANUAL UNDERCARRIAGE measurements to the first front axle. If the diagonal distance from one side to the other is not within 6.35 mm (0.25 in), check the location of the suspension hangers and air bag hangers and adjust as necessary. Air Ride Adjustment NOTE: This model is equipped with an air ride front and...
Page 290 UNDERCARRIAGE TMS800E SERVICE MANUAL Toe-In Adjustment Adjust drag link (Detail #7) so that a 8.3 mm (0.33 in) rig pin can be installed through the rear relay arm mounting bracket and the rear relay arm. Tire front distance is less than tire rear distance as measured on the axle center line.
Page 291 TMS800E SERVICE MANUAL UNDERCARRIAGE axles. Adjust drag links (Detail #5) to fit between the relay arms (Details #8 and #9) and the axle steer arms. Check the position of the pitman arm on the steering gearbox and adjust if necessary. Attach drag link (Detail #6) to the pitman and adjust its length as needed to fit between the pitman arm and the front relay arm (Detail #9) while keeping the pitman arm position fixed.
Page 292 UNDERCARRIAGE TMS800E SERVICE MANUAL If greased plates are not available, raise the crane 3.75 cm (1.5 in) from the static height by lowering the CAUTION outrigger jack cylinders. This will allow adjustment of the drag links without damage, but will require rechecking Do not attempt to adjust the axle drag links or the tie rod the alignment after the axles are fully loaded ends while the full weight of the crane is on the axles...
Page 293 TMS800E SERVICE MANUAL UNDERCARRIAGE Partially extend the outrigger beams. Attach a string line pressure; it should not exceed 62 bar (900 psi). to front and rear outrigger beams as shown in (Figure 8-9) Figure 8-2. Ensure the string line is taut and level. If the pressure is too high or the axle stop is not making Refer to Figure 8-2 and ensure that Dimension C equals contact with the axle, adjust the front plunger so the axle...
Page 294: Steering System
UNDERCARRIAGE TMS800E SERVICE MANUAL STEERING SYSTEM provides for full time hydraulic steering, but still allows for manual steering in the event of a system malfunction. Description The steering system is comprised of the steering gearbox, steer pump, and two steer cylinders. The steering gearbox Maintenance Table 8-1Troubleshooting Symptom...
Page 295 TMS800E SERVICE MANUAL UNDERCARRIAGE Table 8-1Troubleshooting Symptom Probable Cause Solution b. Caster degree incorrect. b. Correct to specified degree. 11. Wheel turns hard in one direction. Metal or foreign material in Remove and clean relief valve relief ball seat in piston of seats or replace damaged steering gear.
Page 296: Functional Check
UNDERCARRIAGE TMS800E SERVICE MANUAL Table 8-1Troubleshooting Symptom Probable Cause Solution d. Low oil flow. d. Idle speed to slow or supply pump not to specifications. Pump cavitation. Correct pump supply. Overheating. Correct cause of overheating. NOTE: For more information on steering column and steering wheel maintenance, refer to Shop Reference and Maintenance Guide.
Page 297 TMS800E SERVICE MANUAL UNDERCARRIAGE remove or wind out the plungers to a depth of less than 4 degrees, double check the center of travel and mm (0.16 in) (Figure 8-9). timing mark alignment. Position the gearbox on the mounting and secure with Install the retainer nut, friction washer and tab washer eight screws and washers.
Page 298: Steer Cylinder
UNDERCARRIAGE TMS800E SERVICE MANUAL STEER CYLINDER blocks to carrier mounted brackets. The air bags and shock absorbers are bolted to the rear of the saddle assemblies Description and to carrier mounted brackets. A walking beam center is attached to each saddle assembly with the ends attached to The steer cylinders are double acting hydraulic cylinders and each rear axle.
Page 299 TMS800E SERVICE MANUAL UNDERCARRIAGE for a lowering in the hanger and distorted or frayed rubber. A inside walls of the tires to rub on the suspension saddle gap on each side of the visible rubber at the lower end of the assemblies during turns.
Page 300 UNDERCARRIAGE TMS800E SERVICE MANUAL Shock Absorbers Remove the nut securing each lateral torque rod to the axle brackets. Remove the torque rod(s). Check the shock absorbers for leakage and wear. Remove each shock absorber from the suspension NOTE: For more information on the axles, refer to Volume saddle assembly by removing the bolt and flatwashers 2 - S e r v i c e M a i n t e n a n c e M a n u a l o r t h e securing each.
Page 301: Wheels And Tires
TMS800E SERVICE MANUAL UNDERCARRIAGE Installation Position the axle and suspension assembly under the CAUTION carrier. Do not mix tires or rims from different manufacturers. Raise the assembly into position under the carrier aligning the saddle assemblies pivot blocks and air bags Tires are designed to operate with a certain sidewall with the mounting brackets on the carrier.
Page 302 UNDERCARRIAGE TMS800E SERVICE MANUAL Place the wheel assembly on the mounting studs. Take antiseize compound or synthetic lubricant with care not to damage the studs. teflon. Do not lubricate wheel or axle faces. Install hub cover if applicable. Raise the crane on outriggers so the rear wheels are off the ground.
Page 303: Brakes
TMS800E SERVICE MANUAL UNDERCARRIAGE carbon. Current regulations do not cover non-asbestos fibers. Medical experts do not agree about the possible long term risks of working with and breathing non-asbestos fibers. But some experts think that long term exposure to some non- asbestos fibers could cause pneumoconiosis, fibrosis, and cancer.
Page 304 UNDERCARRIAGE TMS800E SERVICE MANUAL Troubleshooting Table 8-2 Symptom Probable Cause Solution Brakes are poor or do not apply. Insufficient air pressure. Check for the correct pressure at the compressor and brake air chambers. b. Restriction or leak in lines, b. Check all lines, valves, etc., valves, etc.
Page 305: Front Brakes
TMS800E SERVICE MANUAL UNDERCARRIAGE FRONT BRAKES Disassembly Description The front brakes are air actuated brakes which are cam DANGER operated and that employ shoe and lining assemblies. Do not work under a crane supported by only outrigger Automatic slack adjusters maintain the proper adjustment for jacks.
Page 306 UNDERCARRIAGE TMS800E SERVICE MANUAL Pry the roller retainer loops out of the shoe web holes. Pivot the roller retainer to swing the loops clear of shoe Item Description webs (Figure 8-14). Cast Brake Spider Push down on the bottom brake shoe. Pull on the brake Chamber Bracket Seal shoe roller retainer clip to remove the bottom roller (Figure 8-15).
Page 307 TMS800E SERVICE MANUAL UNDERCARRIAGE 14. Use the correct bushing driver tool to remove the anchor Inspect the shoes for rust, expanded rivet holes, broken pin bushings from the spider. welds and correct alignment. Replace a shoe with any of the conditions listed in steps 2 through 5. 15.
Page 308 UNDERCARRIAGE TMS800E SERVICE MANUAL 13. Check the grease seals and replace if nicked, cut, or distorted. At cam head end, recess bushing 7.1 mm (0.281 in) 14. Check the air chamber bracket for a bent, broken, or cracked arm and welds. Replace as necessary. 15.
Page 309 TMS800E SERVICE MANUAL UNDERCARRIAGE Assembly Rotate the lower brake shoe forward. Install a new brake shoe return spring with the open end of the Position the spider on the axle flange and install spring hooks toward the camshaft (Figure 8-22). attaching bolts and nuts.
Page 310: Rear Brakes
UNDERCARRIAGE TMS800E SERVICE MANUAL Camshaft Installation Tighten capscrews correct torque (Figure 8-25). Check the camshaft for cracks, wear and corrosion. Check the cam head, bearing journals and splines. Replace worn or damaged camshafts Install new camshaft bushings and seals whenever you install a new camshaft.
Page 311 TMS800E SERVICE MANUAL UNDERCARRIAGE Spring Brake Actuator Item Description The upper part of the brake air chamber containing the large spring is not serviceable; however, the lower part of the Brake Air Chamber assembly is serviceable. Axle No. 3 Torque Rod Drive Shaft WARNING Stabilizer Beam...
Page 312 UNDERCARRIAGE TMS800E SERVICE MANUAL Item Description Clamp Diaphragm Push Rod Spring Shield Cover Mounting Nut Jam Nut Position the diaphragm over the push rod (see Figure 8-30). Push the lower cover assembly into the spring brake chamber and secure with the clamp. FIGURE 8-29 Rear Brake Shoe Removal Item...
Page 313: Automatic Slack Adjuster (Front)
TMS800E SERVICE MANUAL UNDERCARRIAGE Rear Brake Shoe Installation Install the lower brake shoe in position on the spider. Use a hammer and brass drift to install the anchor pin. If necessary, align the groove on the anchor pin with the holes in the spider and bushing.
Page 314: Maintenance
UNDERCARRIAGE TMS800E SERVICE MANUAL This motion rotates the worm, worm wheel, and the S-cam CAUTION shaft resulting in adjustment of the brakes. Always replace used clevis pin retainer clips with new Maintenance ones when you service an automatic slack adjuster. Do not reuse retainer clips.
Page 315 Manitowoc Crane Care, as apply service brakes and hold brakes on. Do not pump the piggyback spring brake cannot be manually the brakes.
Page 316 UNDERCARRIAGE TMS800E SERVICE MANUAL Using a 3/4 inch hand wrench turn the release-nut clockwise until 8.2 cm (3.25 in) length of bolt extends above the nut (Figure 8-41). Do not use an impact wrench. 7092-3 FIGURE 8-39 If not absolutely sure of correct bolt-to-piston engagement, repeat step 5 until sure.
Page 317 TMS800E SERVICE MANUAL UNDERCARRIAGE CAUTION There are no serviceable parts inside the spring brake Disengage a pull pawl chamber. Never attempt to disassemble the spring brake chamber as serious personal injury could result from accidental sudden release of the high energy spring. 11.
Page 318: Installation
UNDERCARRIAGE TMS800E SERVICE MANUAL Block wheels to prevent crane from moving. Ensure Apply anti-seize to clevis pin. Install and secure with system tank pressure is above 6.8 bar (100 psi). cotter pin. Use a wrench to turn the manual adjusting nut 10.
Page 319 If after adjustment the requirements in step 7 cannot be CAUTION met, contact your Manitowoc Crane Care distributor. The crane can not be driven on public roads until For easier turning of the release bolt, apply 6.5 to 8.6 bar repaired.
Page 320 UNDERCARRIAGE TMS800E SERVICE MANUAL 7093-1 7093-2 FIGURE 8-47 FIGURE 8-48 CAUTION CAUTION Do not exceed the length stated in step 3 and do not exceed 68 Nm (50 lb) torque on release bolt at any time or There are no serviceable parts inside the spring brake damage may occur which could prevent any further chamber.
Page 321: Automatic Slack Adjuster (Rear)
TMS800E SERVICE MANUAL UNDERCARRIAGE Rotate the adjusting hex approximately 1/8 turn in the anchor bracket, rotate indicator as required and direction required and re-measure the stroke. Continue retighten fastener. this process until the stroke is within limits. A minimum of 10.
Page 322 UNDERCARRIAGE TMS800E SERVICE MANUAL 6600 FIGURE 8-51 Item Description Item Description Housing Retainer Clip Bushing Boot Gasket Clevis Pin Pull Pawl Assembly Actuator Rod Worm Gear Retaining Ring Manual Adjusting Nut Roller Pin Retaining Ring Actuator Piston Worm Grease Seal Adjusting Sleeve Grease Fitting Retainer Clip...
Page 323: Maintenance
TMS800E SERVICE MANUAL UNDERCARRIAGE Maintenance Extend the coils of the ring. Use pliers to unwind the ring and pull it out of the groove. Use a new ring when you Removal assemble the slack adjuster (Figure 8-53). Pull ring out CAUTION Push ring down You must disengage a pull pawl before rotating the...
Page 324 UNDERCARRIAGE TMS800E SERVICE MANUAL 6600-5 6600-7 FIGURE 8-56 FIGURE 8-58 If the pin was removed, install it into the rod and piston Assembly (Figure 8-59). Use grease to lubricate the gear bore in the housing. Lubricate the seal with grease. Press the seal into its groove.
Page 325 TMS800E SERVICE MANUAL UNDERCARRIAGE 10. Check to ensure that the ring is installed correctly in the Then back off the adjusting nut in the opposite direction groove. You cannot pull the piston out of the actuator if 1/2 turn for drum brakes. the retaining ring is installed correctly.
Page 326 UNDERCARRIAGE TMS800E SERVICE MANUAL Measure Push Rod Travel or Adjusted Chamber Stroke Use the following procedure to check in-service push rod travel or adjusted chamber stroke on vehicle brakes. DIsengage The engine must be off. If the brake has a spring Pull Pawl chamber, follow the procedure to release the spring.
Page 327 TMS800E SERVICE MANUAL UNDERCARRIAGE Mark push rod here to measure stroke. Spring brakes released. Service brakes not applied. Step 2 Stroke Step 3 6.2-6.9 bar (90-100 psi) in air tank- engine off Spring brakes released. Service brakes applied. FIGURE 8-64 7822 Table 8-3 Standard-Stroke Clamp- Type Brake Measure the push rod travel or adjusted chamber stroke...
Page 328: Air System
UNDERCARRIAGE TMS800E SERVICE MANUAL brake and spring brake control valves. Air to the service Table 8-4Long- Stroke Clamp- Type Brake Chamber brakes on axles #3, and #4 is supplied by the primary Data reservoirs. The secondary reservoirs provide the supply for Outside Brake Brake...
Page 329 TMS800E SERVICE MANUAL UNDERCARRIAGE Leak Detection loss is 0.40 bar (6 psi) within 30 minutes. A hard to detect leak can be found by wetting the suspected area with a soap If a leak is suspected, shut off the engine and note the air solution and observing for bubbles.
Page 330: Air System Operational Test
UNDERCARRIAGE TMS800E SERVICE MANUAL Air System Operational Test NOTE: Refer to Figure 8-65 for air tank and valve installation. Park the crane on a firm level surface and apply the parking brakes. WARNING Death or injury could occur! Air pressure must not exceed 9.00 bar (130 psi). Air Suspension Switch (Inflate Position) 6906 Suspension Deflate Indicator...
Page 331 TMS800E SERVICE MANUAL UNDERCARRIAGE ABS Warning Indicator Low Pressure Indicator Automatic Traction Control Indicator 6907-1 ABS Diagnostics and Traction Control Off-Road Switch FIGURE 8-67 Record the amount of time to build air pressure from applied. Any decrease in air pressure shall not exceed 5.86 to 6.89 bar (85 to 100 psi).
Page 332: Air System Components
UNDERCARRIAGE TMS800E SERVICE MANUAL pressure in the secondary system should not drop below 11. Release the service brakes. 6.89 bar (100 psi). Emergency Brake Application Continue draining the primary reservoirs to zero (0) psi. If necessary, start the engine and charge air system to Apply the service brakes.
Page 333 TMS800E SERVICE MANUAL UNDERCARRIAGE Air Dryer 4, 5 FIGURE 8-68 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 Desiccant Cartridge...
Page 334 UNDERCARRIAGE TMS800E SERVICE MANUAL Low Pressure Indicator Switches indicator on the front console in the cab. Observe the dual air pressure gauge to determine which system is low. The The low pressure indicator switches (Figure 8-69) are used switch contacts close when the pressure in the system to warn the operator of low pressure in the air systems.
Page 335 TMS800E SERVICE MANUAL UNDERCARRIAGE Release Exhaust Port FIGURE 8-71 Pressure Protection Valve Pressure The purpose of the pressure protection valve (Figure 8-72) is Regulating to isolate one system from the other by closing at a preset Spring pressure. One valve isolates the primary system from the secondary system, one valve isolates the auxiliary system from the primary system, and the other isolates the tire inflation system from the primary system.
Page 336 UNDERCARRIAGE TMS800E SERVICE MANUAL Item Description Service Port Supply Port Delivery FIGURE 8-73 Dual Brake Valve Spring Brake Control Valve The spring brake control valve Figure 8-74 is located on the The dual brake valve is a suspended, pedal operated brake rear of the carrier frame.
Page 337: Maintenance
TMS800E SERVICE MANUAL UNDERCARRIAGE Maintenance Operational Test Start the engine and pressurize the system. Check the governor cut-out pressure with either the panel gauge or a test gauge 8.96 bar (130 psi). At the cut-out pressure, the WARNING compressor is unloaded and the air dryer is purged. Death or injury could occur! Leakage Test Depressurize both air systems completely before...
Page 338 UNDERCARRIAGE TMS800E SERVICE MANUAL conditions can also cause water accumulation and Test all lines and fittings leading to and from the air dryer should be considered before changing the desiccant. with a soap solution for leaking. An outside air source has been used to charge the Reservoirs system that has not been passed through a drying Removal...
Page 339 TMS800E SERVICE MANUAL UNDERCARRIAGE Installation arrow (secondary) should begin to climb. Both arrows should level off at about 7.60 bar (110 psi). Screw the switch into the fitting and connect the electrical leads. Safety Valve Preventive Maintenance Removal Every 16,000 km (10,000 mi) or monthly do the procedures Chock the wheels and completely depressurize the as outlined under Operating and Leakage Checks above.
Page 340 UNDERCARRIAGE TMS800E SERVICE MANUAL Leakage Test Operating Test Apply a soap solution around the cap of the valve with Chock the wheels and pressurize both systems. Adjust the system pressurized and observe for bubbles. A 25 the brakes. mm (1 in) bu bble in three s econds or longe r is Apply and release the brakes several times and check acceptable.
Page 341 TMS800E SERVICE MANUAL UNDERCARRIAGE Place parking control valve in “release” position. Installation Observe that spring brake actuators release fully. Position the brake valve and pedal assembly onto the With parking control valve in “release” position, note studs under the front console and secure with the nuts, gauge pressure reading.
Page 342: Outriggers
UNDERCARRIAGE TMS800E SERVICE MANUAL Disassemble the brake valve and clean and inspect all parts. crane and its maximum load capacity. The outriggers consist of inverted stabilizer (jack) cylinders with outrigger beams to Park Brake Control Valve allow for fully retracted, partial extension, and fully extended oper at io n.
Page 343 TMS800E SERVICE MANUAL UNDERCARRIAGE NOTE: The park brake in the carrier cab must be set pressure from the pressurized retract line unseats the before the outrigger controls will operate. cylinder check valve allowing oil to flow from the piston side through the open solenoid valve to the integrated outrigger The outrigger extend/retract momentary switch located on valve.
Page 344: Maintenance
UNDERCARRIAGE TMS800E SERVICE MANUAL Maintenance Troubleshooting Symptom Probable Cause Solution Slow erratic operation Low hydraulic oil level. Check for leaks. Make any outrigger extension cylinders. needed repairs. Fill reservoir to proper level. b. Damaged relief valve. b. Remove relief valve; clean or replace.
Page 345 TMS800E SERVICE MANUAL UNDERCARRIAGE Symptom Probable Cause Solution S l o w o r e r r a t i c o p e r a t i o n o f Cracked or damaged piston. Replace rod weld and all outrigger extension cylinders.
Page 346 UNDERCARRIAGE TMS800E SERVICE MANUAL Symptom Probable Cause Solution Outrigger vertical jack cylinder m. Main hydraulic pump m. Replace or tighten hose and slow or erratic. (continued) cavitation. fittings. n. Worn or damaged hydraulic n. Repair replace pump pump section. section. Outrigger stabilizer cylinder...
Page 347: Outrigger Beam
TMS800E SERVICE MANUAL UNDERCARRIAGE OUTRIGGER BEAM Remove the cotter pin and clevis pin securing the rod of the extension cylinder to the outrigger housing. Description After attaching a suitable lifting device of straps or belts instead of chains to prevent nicking the bottom edges of The outrigger beam assembly (see Figure 8-75) consists of the outrigger beam, pull the outrigger beam out of the an outrigger beam, a 13.9 cm (5.50 in) stabilizer (jack)
Page 348 UNDERCARRIAGE TMS800E SERVICE MANUAL Slide the extension cylinder from the jack beam being Remove clamps, nuts, washers, careful not to damage the two hoses. lockwashers securing each tube assembly to the top inside of the jack beam. Remove the tube assemblies. Tag and disconnect the hoses from the tubes in the top of the jack beam.
Page 349 TMS800E SERVICE MANUAL UNDERCARRIAGE 1, 2, 3 4, 5 12, 13 9, 10, 11 6170-4 1.5 mm (0.06 inch Wear Pad Gap 20, 21, 22, 23 1.5 mm (0.06 inch Wear Pad Gap 1.5 mm (0.06 inch Wear Pad Gap 17, 18, 19 View A - A FIGURE 8-75...
Page 350 UNDERCARRIAGE TMS800E SERVICE MANUAL Assembly NOTE: The mid beam and the jack beam are shimmed as Item Description a matched set and are identified by the stamped serial number ending in ‘A’ for the mid beam and ‘B’ for the jack beam. If one or the other is replaced, then the shims will have to be replaced and Washer tolerances rechecked.
Page 351: Extension Cylinder
TMS800E SERVICE MANUAL UNDERCARRIAGE Slide the beam into the outrigger housing and align the point during full extension. Install and lock setscrews cylinder rod with the mounting hole. against wear pads. Secure the cylinder rod to the housing with the clevis pin Adjust outrigger box side wear pads until a gap of 1.5 and cotter pin.
Page 352: Outrigger Monitoring System (Optional-Standard In North America)
UNDERCARRIAGE TMS800E SERVICE MANUAL Secure the hoses in place with the bolts, pipe clamps Remove the mounting hardware. and bolt inserts. Remove OMS string potentiometer from inside outrigger Install the shaft securing the rod end of the extension beam. cylinder to the outrigger beam. Install the outrigger beam.
Page 353: Maintenance
TMS800E SERVICE MANUAL UNDERCARRIAGE Maintenance NOTE: Refer to Cylinders, page 2-54 for Disassembly and CAUTION Assembly of the cylinders. Make sure that the piston side of all outrigger cylinders are connected to the solenoid valve bank. Reversal of Removal port connection of the rod and piston sides could result in Extend the outrigger beam slightly for improved access severe damage to the cylinders as very high pressure to the stabilizer cylinder.
Page 354: Outrigger System Valves
UNDERCARRIAGE TMS800E SERVICE MANUAL Outrigger Stabilizer Cylinder Internal Leak Test b. If oil continues to flow out the rod port, the cylinder’s internal piston seal is leaking. Use the following procedure to troubleshoot and diagnose an After determining the condition of the cylinders internal internal leak, a leaking pilot operated check valve or a piston seal, leave the rod side hose disconnected and thermal contraction on an outrigger stabilizer cylinder.
Page 355: Center Front Stabilizer Cylinder
TMS800E SERVICE MANUAL UNDERCARRIAGE solenoid directional control valve that controls outrigger Remove the washers and nuts securing the cylinder extend and retract. tube cap to the cylinder cap bracket. Tag, disconnect, and cap the hydraulic lines to the Outrigger Control Manifold cylinder.
Page 356 UNDERCARRIAGE TMS800E SERVICE MANUAL 6512 FIGURE 8-79 Item Description Item Description Stabilizer Cylinder Capscrew Cotter Pin Flatwasher Cylinder Retaining Pin Plug Cylinder Head Wear Ring Capscrew Piston Wear Ring Locknut Stabilizer Pad (Float Pad) Flatwasher Bushing Cylinder Tube Cap Hex Nut Washer Lockwasher Acorn Nut...
Page 357 TMS800E SERVICE MANUAL UNDERCARRIAGE Functional Check CAUTION CAUTION When installing cylinder retaining pin, orient it so that when cotter pins are installed they will be horizontal. Extend and set the four main outriggers before extending the center front stabilizer. Lower the jack until the holes in the cylinder rod align with the holes in the tube.
Page 358 UNDERCARRIAGE TMS800E SERVICE MANUAL 8-76 Published 01-29-2014, Control # 496-00...
Page 359: General
Grove distributor or Manitowoc Crane Care. the lubrication points, the frequency of lubrication, and other NOTE: All fluids and lubricants may be purchased by information.
Page 360: Standard Lubricants Package
LUBRICATION TMS800E SERVICE MANUAL Axles and Swing Box - Spec 6829014058: • Fleetguard DCA4 • Petro- Canada Traxon E Synthetic 75W-90 • Fleetguard DCA2 • CITGO, Synthetic Gear Lube 75W-90 • Penray Pencool 3000 • Eaton, Roadranger EP75W-90 STANDARD LUBRICANTS PACKAGE •...
Page 361: Environmental Protection
Dispose of waste properly! Improperly disposing of waste can threaten the environment. • Texaco: Meropa 150 Potentially harmful waste used in Manitowoc cranes includes Grease - Spec 6829003477: — but is not limited to — oil, fuel, grease, coolant, air •...
Page 362: Lubrication Points
It is recommended that all exposed cylinder rods be lead to a shorter lifetime. protected using Boeshield® T-9 Premium Metal Protectant. Manitowoc Crane Care has Boeshield® T-9 Premium Metal On sealed U-joints, care must be exercised to prevent Protectant available in 12 oz. cans that can be ordered rupturing seals.
Page 363: Carrier Lubrication
TMS800E SERVICE MANUAL LUBRICATION Table 9-2 Lube Description Lubrication Description Lube Specification 50/50 Fully Formulated Anti-Freeze Coolant A6-829-101130 Engine Oil SAE 15W40-ISX Engine A6-829-104182 Engine Oil SAE 15W40-QSM Engine A6-829-003483 Extreme Pressure Multi-Purpose Grease A6-829-003477 Synthetic Gear Lube A6-829-013433 Hydraulic Oil A6-829-006444 Semi-Synthetic Gear Lube A6-829-012964...
Page 364 LUBRICATION TMS800E SERVICE MANUAL Pump Drive Shaft Front Aluminum Wheel Pilots U-Joints Lube Type - ASC Lube Type - EP-MPG Lube Interval - When wheels are removed for service. Lube Interval - 250 hours Lube Amount - Generously coat the wheel pilot or hub pads with anti-seize (ASC) compound.
Page 365 TMS800E SERVICE MANUAL LUBRICATION 15. Rear Aluminum Wheel Pilots Lube Type - ASC Lube Interval - When wheels are removed for service. Lube Amount - Generously coat the wheel pilot or hub pads with anti-seize (ASC) compound. Do not apply anti-seize compound to the face of the wheel of the hub.
Page 366 LUBRICATION TMS800E SERVICE MANUAL 6556-4 FIGURE 9-2 Published 01-29-2014, Control # 496-00...
Page 367: Hydraulic Lubrication
TMS800E SERVICE MANUAL LUBRICATION 21. Jack Cylinder Support Tubes Item Description Lube Type - EP-MPG Engine Crankcase Lube Interval - 500 hours Engine Cooling System Lube Amount - Brush on inside diameter of jack cylinder support tubes and wear bands before installing jack Transmission cylinders.
Page 368: Superstructure Lubrication
. S h o u l d y o u h a v e a n y questions, please contact your local Grove Lube Type - SSGL-5 distributor or Manitowoc Crane Care. Lube Interval - Check and fill every 50 hours. Drain and 23. Hydraulic Reservoir fill after first 250 hours and every 500 hours or 12 months thereafter, whichever interval occurs first.
Page 369: Boom, Jib, And Boom Accessories Lubrication
TMS800E SERVICE MANUAL LUBRICATION BOOM, JIB, AND BOOM ACCESSORIES NOTE: Should boom chatter or rubbing noises in the boom occur, it will be necessary to lubricate the telescope LUBRICATION cylinder wear pads. By adding an extension NOTE: To service the boom at boom lengths longer than adapter to a grease gun the wear pads and wear 36.6 m (120 ft) (to access grease fittings, grease areas can be reached through the lubrication...
Page 370: Wire Rope Lubrication
NOTE: Wire rope may be purchased by contacting the Lube Interval - 250 hours or 3 months, whichever Manitowoc Crane Care Parts Department. interval occurs first For more detailed information concerning the lubrication and Lube Amount - Until grease extrudes inspection of wire rope, refer to Wire Rope, page 1-17.
Page 371 TMS800E SERVICE MANUAL LUBRICATION Item Description Turntable Gearbox Turntable Gear and Drive Pinion Turntable Bearing Main Hoist Auxiliary Hoist Boom Pivot Shaft Extend Cable Sheaves Retract Cable Sheaves Telescope Cylinder Wear Pads Internal Side and Bottom Wear Pads (Internal Sections) Boom Section Upper Wear Pads Boom Section Upper and Lower Wear Pads Upper Boom Nose Sheaves...
Page 372 LUBRICATION TMS800E SERVICE MANUAL FIGURE 9-3 9-14 Published 01-29-2014, Control # 496-00...
Page 373: Carwell® Rust Inhibitor
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 374: Inspection And Repair
Cover all bare metal with a primer that is compatible with necessary. the original paint finish and allow to dry thoroughly. Please contact Manitowoc Crane Care should you have any • Prepare the surface prior to applying the finish coat of questions.
Page 375 TMS800E SERVICE MANUAL LUBRICATION unpainted fasteners and hardware, valves, slew ring • All hardware, clips, pins, hose connections not painted fasteners and all bare metal surfaces. will have treatment applied. • Boom application areas are; pivot pins, hose end and fittings, jib pins and shafts, all bare metal surfaces, headache ball pins/ hook block pins and fasteners.
Page 376 LUBRICATION TMS800E SERVICE MANUAL 7650-21 FIGURE 9-4 9-18 Published 01-29-2014, Control # 496-00...
Page 377 TMS800E SERVICE MANUAL LUBRICATION Item Description All Hardware, Clips, Pins, Hose Connections Item Description not painted O/R Pins, Clips Hoist Hose Connections Powertrain Hardware inside compartment Jib Pins, Clips O/R Pins, Clips Valve Bank Entire underside of unit Hose Connections inside turntable Turntable Bearing Fasteners Jib Hanger Hardware Counterweight Pins...
Page 378 LUBRICATION TMS800E SERVICE MANUAL THIS PAGE BLANK 9-20 Published 01-29-2014, Control # 496-00...
Page 379 TMS800E SERVICE MANUAL ALPHABETICAL INDEX ALPHABETICAL INDEX 360° Swing Lock Control (Positive Lock Type) (Optional) ..... . . 6-22 Accessory Manifold with Swing Directional Control Valve..... . . 2-47 Air Intake System.
Page 380 ALPHABETICAL INDEX TMS800E SERVICE MANUAL Lift Cylinder............2-57 Lower Telescope Cylinder .

Manitowoc Grove TMS800E Service And Maintenance Manual

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