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INTRODUCTION
GENERAL MAINTENANCE
These general suggestions should be helpful in following the
i ns t r u c t io n s i n th i s m a nu a l . I n a n al y z i ng a s y s te m
malfunction, use a systematic procedure to locate and
correct the problem.
1.
Determine the problem.
2.
List possible causes.
3.
Devise checks.
4.
Conduct checks in a logical order to determine the
cause.
5.
Consider the remaining service life of components
against the cost of parts and labor necessary to replace
them.
6.
Make the necessary repair.
7.
Recheck to ensure that nothing has been overlooked.
8.
Functionally test the failed part in its system.
NOTE:
Your safety and that of others is always the number
one consideration when working around machines.
Safety is a matter of thoroughly understanding the
job to be done and the application of good common
sense. It is not just a matter of do's and don'ts. Stay
clear of all moving parts.
Cleanliness
An important item in preserving the long life of the crane is
keeping dirt out of working parts. Enclosed compartments,
seals, and filters have been provided to keep the supply of
air, fuel, and lubricants clean. It is important that these
enclosures be maintained.
Whenever hydraulic, fuel, lubricating oil lines, or air lines are
disconnected, clean the adjacent area as well as the point of
disconnect. As soon as the disconnection is made, cap, plug,
or tape each line or opening to prevent entry of foreign
material. The same recommendations for cleaning and
covering apply when access covers or inspection plates are
removed.
Clean and inspect all parts. Be sure all passages and holes
are open. Cover all parts to keep them clean. Be sure parts
are clean when they are installed. Leave new parts in their
containers until ready for assembly.
Clean the rust preventive compound from all machined
surfaces of new parts before installing them.
Removal and Installation
When performing maintenance, do not attempt to manually
lift heavy parts when hoisting equipment should be used.
Never locate or leave heavy parts in an unstable position.
1-10
When raising a portion of a crane or a complete crane,
ensure the crane is blocked securely and the weight is
supported by blocks rather than by lifting equipment.
W h e n u s i n g h o i s t i n g e q u i p m e n t , f o l l o w t h e h o i s t
manufacturers recommendations and use lifting devices that
will allow you to achieve the proper balance of the
assemblies being lifted and to ensure safe handling. Unless
otherwise specified, all removals requiring hoisting
equipment should be accomplished using an adjustable
lifting attachment. All supporting members (chains and
cables) should be parallel to each other and as near
perpendicular as possible to the top of the object being lifted.
The capacity of an eyebolt diminishes as the angle
between the supporting members and the object
becomes less than 90°. Eyebolts and brackets should
never be bent and should only have stress in tension.
Some removals require the use of lifting fixtures to obtain
proper balance. The weights of some components are given
in their respective sections of the manual.
If a part resists removal, check to be certain all nuts and bolts
have been removed and that an adjacent part is not
interfering.
Disassembly and Assembly
When assembling or disassembling a component or system,
complete each step in turn. Do not partially assemble one
part and start assembling some other part. Make all
adjustments as recommended. Always check the job after it
is completed to see that nothing has been overlooked.
Recheck the various adjustments by operating the crane
before returning it to the job.
Pressing Parts
When pressing one part into another, use an anti-seize
compound or a molybdenum disulfide base compound to
lubricate the mating surfaces.
Assemble tapered parts dry. Before assembling parts with
tapered splines, be sure the splines are clean, dry, and free
from burrs. Position the parts together by hand to mesh the
splines before applying pressure.
Parts which are fitted together with tapered splines are
always very tight. If they are not tight, inspect the tapered
splines and discard the part if the splines are worn.
Locks
Lockwashers, flat metal locks, or cotter pins are used to lock
nuts and bolts.
Published 01-29-2014, Control # 496-00
TMS800E SERVICE MANUAL
CAUTION
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