Manitowoc Grove TMS700E Service And Maintenance Manual

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Grove TMS700E

Service/Maintenance Manual

Table of Contents

Troubleshooting

Summary of Contents for Manitowoc Grove TMS700E

Page 1 Grove TMS700E Service/Maintenance Manual...
Page 3 DANGER An untrained operator subjects himself and others to death or serious injury. Do not operate this crane unless: Manitowoc is not • You are trained in the safe operation of this crane. responsible for qualifying personnel.
Page 4 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 5: Table Of Contents
TMS700E SERVICE MANUAL TABLE OF CONTENTS SECTION 1 ........Introduction Description .
Page 6 TABLE OF CONTENTS TMS700E SERVICE MANUAL Oil Cooler ............2-12 Description.
Page 7 TMS700E SERVICE MANUAL TABLE OF CONTENTS Description ............2-49 Maintenance .
Page 8 TABLE OF CONTENTS TMS700E SERVICE MANUAL Starter Replacement ..........3-15 Battery Replacement .
Page 9 TMS700E SERVICE MANUAL TABLE OF CONTENTS Brake Test Procedure ..........5-5 Hoist to Boom Alignment .
Page 10 TABLE OF CONTENTS TMS700E SERVICE MANUAL Maintenance ........... . . 6-20 SECTION 7.
Page 11 TMS700E SERVICE MANUAL TABLE OF CONTENTS Steering System ............8-12 Description .
Page 12 TABLE OF CONTENTS TMS700E SERVICE MANUAL Description............8-71 Maintenance .
Page 13: Section 1
TMS700E SERVICE MANUAL INTRODUCTION SECTION 1 INTRODUCTION SECTION CONTENTS Description ......1-1 Gaskets .
Page 14: List Of Specifications
INTRODUCTION TMS700E SERVICE MANUAL from the operator’s seat with the superstructure Clutch facing forward over the front of the carrier frame. Type ....2 plate pull type dry disc List Of Specifications Engine General...
Page 15: Hoists
TMS700E SERVICE MANUAL INTRODUCTION Pump #1 Sections ....... . . 1 Output - @ 1800 rpm Type .
Page 16 INTRODUCTION TMS700E SERVICE MANUAL FIGURE 1-1 continued Published 01-29-2015, Control # 512-01...
Page 17 TMS700E SERVICE MANUAL INTRODUCTION Item Description Item Description Folding Swingaway Auxiliary Boom Nose Boom Carrier Cab Section 4 Center Front cylinder Outrigger cylinder Front Axles Removable Counterweight Outrigger Beam Auxiliary Hoist Outrigger Main Hoist Hydraulic Oil Cooler Boom Pivot Rear Tandem Axles Superstructure Cab Fuel Tank Lift Cylinder...
Page 18 INTRODUCTION TMS700E SERVICE MANUAL Table 1-1 Axle Weight Distribution Table CG To CL Weight Front Axle Rear Axle Description Rear Bogie kg (lb) kg (lb) kg (lb) cm (in) Maximum Tire & Wheel Loads Allowed 23224(51200) 27216(60000) Maximum Axle Loads Allowed 23224(51200) 27216(60000) Standard Carrier Assy (8x4x4)
Page 19 TMS700E SERVICE MANUAL INTRODUCTION CG To CL Weight Front Axle Rear Axle Description Rear Bogie kg (lb) kg (lb) kg (lb) cm (in) Cribbing (in rear troughs) -35.56(-14.00) 181(400) -11(-25) 193(425) Optional Equipment Rear Mounted Pintle Hook -218.44(-86.00) 12(26) -5(-10) 16(36) Air Conditioning - Carrier 695.96(274.00)
Page 20: General Maintenance
INTRODUCTION TMS700E 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 21: Wires And Cables
TMS700E 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 preloaded must have a film of oil over the entire Always use new locking devices on components which have assembly to obtain accurate pre-loading.
Page 22: Hydraulic Systems
When removing components of a hydraulic system, cover all assemblies for correction or replacement. For replacement openings on both the component and the crane. of hose assemblies, refer to your Manitowoc Crane Care Parts Manual. If evidence of foreign particles is found in the hydraulic system, flush the system.
Page 23: Electrical System
The following types of Loctite brand adhesives are available Equipment should be periodically inspected for evidence of from the Manitowoc Crane Care Parts Department or your weld fatigue. The frequency of these inspections should be local distributor. commensurate with the age of the equipment, the severity of...
Page 24: 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 25 TMS700E SERVICE MANUAL INTRODUCTION • 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 26 INTRODUCTION TMS700E SERVICE MANUAL Table 1-4: UNF (Fine) Thread: Torque Values for Zinc-Flake Coated and Untreated Fasteners Bolt Diameter - Inches Torque Values (Pounds-Foot, Maximum/Minimum) SAE Grade 5/16 7/16 9/16 1-1/8 1-1/4 1-1/2 1654 Zinc-Flake 1109 1530 2682 1251 2288 1155 2105 Untreated...
Page 27: Weld Studs
TMS700E SERVICE MANUAL INTRODUCTION Table 1-8: Metric Fasteners, Fine Thread, Untreated Bolt Diameter - Metric Torque Values (Nm, Maximum/Minimum) Class 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 28: Wire Rope
• It should be free from acids and alkalis. following provides inspection and maintenance procedures for wire ropes used on Manitowoc products (e.g. wire rope • It should have sufficient adhesive strength to remain on used as load lines [hoisting cables], boom extension and the ropes.
Page 29: Wire Rope Inspection (Running Ropes And Pendant Cables)
• Broken or cut strands. only pre-assembled lengths of wire rope as supplied from Manitowoc Crane Care. Do not build lengths from • Number, distribution and type of broken wires. individual components. •...
Page 30: Wire Rope Replacement (All Wire Rope)
National Consensus Standard as referenced by Federal Government Agencies and as recommended by Manitowoc Cranes. 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...
Page 31: Installing 35X7 Class Wire Rope
TMS700E SERVICE MANUAL INTRODUCTION 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 32: Synthetic Hoist Rope
KZ100 Synthetic Crane Hoist Line Manual, P/N together, preventing any movement between 9828100734 available by contacting Manitowoc Crane Care. strands. NOTE: The outer strands must not be allowed to move with respect to the inner strands.
Page 33: Section 2
TMS700E SERVICE MANUAL HYDRAULIC SYSTEM SECTION 2 HYDRAULIC SYSTEM SECTION CONTENTS Description ....... 2-2 Maintenance .
Page 34: Description
HYDRAULIC SYSTEM TMS700E SERVICE MANUAL Description ......2-60 Outrigger Jack Cylinder ....2-70 Description .
Page 35 TMS700E SERVICE MANUAL HYDRAULIC SYSTEM FIGURE 2-1 Grove Published 01-29-2015, Control # 512-01...
Page 36 HYDRAULIC SYSTEM TMS700E SERVICE MANUAL FIGURE 2-1 continued Published 01-29-2015, Control # 512-01...
Page 37: Removing Air From The Hydraulic System
TMS700E SERVICE MANUAL HYDRAULIC SYSTEM 14. Connect the return line and retract the boom. Replenish Small leaks may be hard to locate. If a leak is not readily the reservoir hydraulic oil level as necessary. detectable, use the following way to check for it: 15.
Page 38: Parts Replacement
For replacement the valve for scored or worn parts. Scoring is a sign of the of hose assemblies, refer to your Manitowoc Crane Care number one problem in hydraulics - contamination (external Parts Manual.
Page 39: Supply Pressure And Return Circuit
TMS700E SERVICE MANUAL HYDRAULIC SYSTEM • Hydraulic hose assemblies operating in climate zone “C” Hydraulic oil flows through the manifold at the lower rear of are recommended to be replaced after 8000 hours of the reservoir to the three hydraulic pumps. Almost all of the return flow goes through the filter at the top of the reservoir.
Page 40 HYDRAULIC SYSTEM TMS700E SERVICE MANUAL Hydraulic oil flowing from this valve bank returns to the Section One to provide additional hydraulic force to the reservoir filter. Section One functions. Section One also supplies the swing brake and armrest Section Three of the No. 1 hydraulic pump supplies the lockout manifold and the swing power brake valve.
Page 41: Maintenance
TMS700E SERVICE MANUAL HYDRAULIC SYSTEM Maintenance Troubleshooting Symptom Probable Cause Solution No hydraulic oil Low hydraulic oil level. Check for leaks. Repair any found. flows in systems. Add hydraulic oil to proper level. b. Reservoir-to-pump suction lines b. Clean, repair, or replace lines as broken or restricted.
Page 42 HYDRAULIC SYSTEM TMS700E SERVICE MANUAL Return Hydraulic Filter Assembly Element Installation Install a new O-ring between the head and the bowl Element Removal (housing). Install the new element and the smaller diameter spring into the bowl (housing). Ensure the spring seats DANGER properly.
Page 43 TMS700E SERVICE MANUAL HYDRAULIC SYSTEM 6459 FIGURE 2-3 Item Description Item Description Head O-ring Gasket Bowl Filter Element Bypass Spring Spring Bypass Valve O-ring Grove Published 01-29-2015, Control # 512-01 2-11...
Page 44: Oil Cooler
HYDRAULIC SYSTEM TMS700E SERVICE MANUAL OIL COOLER Maintenance Description Removal and Disassembly An air cooled hydraulic oil cooler (Figure 2-4) is mounted on Tag and disconnect the hydraulic lines from the oil the left side of the carrier forward of the fuel tank. The oil cooler.
Page 45 TMS700E SERVICE MANUAL HYDRAULIC SYSTEM FIGURE 2-4 Item Description Item Description Shroud Cooler Core Fan/Motor Assembly Front Cover Grove Published 01-29-2015, Control # 512-01 2-13...
Page 46: Hydraulic Pumps
HYDRAULIC SYSTEM TMS700E SERVICE MANUAL HYDRAULIC PUMPS Discard the gasket. Clean the gasket compound and any gasket residue from the pump drive and the No. 1 Description pump. Cover the pump drive’s opening to prevent dirt from The engine PTO driven pump drive drives the No. 1 pump. entering.
Page 47: Pump Drive
TMS700E SERVICE MANUAL HYDRAULIC SYSTEM Discard the gasket. Clean the gasket compound and Start the engine and idle it for two or three minutes any gasket residue from the engine drive pad and the without running any hydraulic functions. Check for leaks; as needed, stop the engine and make repairs.
Page 48: Maintenance
HYDRAULIC SYSTEM TMS700E SERVICE MANUAL Maintenance Troubleshooting Symptom Probable Cause Solution Oil overflow from Overfilled. Drain to the proper level. the breather. b. The hydraulic pump shaft seal is b. Repair the hydraulic pump. leaking oil. Seals leaking. Overfilled. Drain to the proper level. b.
Page 49 TMS700E SERVICE MANUAL HYDRAULIC SYSTEM Place the pump drive mounting plate and attached parts Connect the electrical connectors to the air solenoids on the transmission. Secure the pump drive mounting and the indicator light switch as tagged during Removal. plate to the transmission with bolts and hardened Connect the air lines to the disconnect controls as washers.
Page 50 HYDRAULIC SYSTEM TMS700E SERVICE MANUAL 6875 FIGURE 2-5 Item Description Item Description Hydraulic Pump Transmission Shift Control Pump Drive Breather Pump Drive Shaft Pump Drive Dipstick Disconnect Lever Transmission Pump Drive Support Straps Pump Drive Upper Support Pump Drive Mounting Plate Disconnect Air Solenoids Disconnect Indicator Light Switch Disconnect Air Cylinder...
Page 51: Valves
TMS700E SERVICE MANUAL HYDRAULIC SYSTEM VALVES to the Valve Usage Table, below. Also, refer to the following table for valve locations. The description of each valve given General here is for the valve itself. For information on how each valve functions in the individual circuits, refer to the description and This subsection provides descriptive information for all the operation procedures of that circuit.
Page 52 HYDRAULIC SYSTEM TMS700E SERVICE MANUAL Valve Name Circuit Used In Physical Location Flow Control Valve Trailing boom option Boom lift cylinder Swing Brake Release Valve Trailing boom option Superstructure right side Auxiliary Cooler Flow Control Valve Auxiliary Water Jacket (Radiator) Left side of Auxiliary Cooler support Cooler brace...
Page 53 TMS700E SERVICE MANUAL HYDRAULIC SYSTEM CARRIER 8031 6790 Optional Swing Brake Release SUPERSTRUCTURE Valve may be located here FIGURE 2-6 Item Description Item Description Auxiliary Cooler Control Valve Counterweight Removal Directional Control Valve Outrigger Selector Valve Telescope/Lift/Hoist Directional Control Valve Rear Outrigger Manifold Valve Swing Brake &...
Page 54: Pressure Setting Procedures
HYDRAULIC SYSTEM TMS700E SERVICE MANUAL PRESSURE SETTING PROCEDURES pressure and flow to the swing brake/armrest lockout manifold. Description The following table and test procedures contain main and port relief valve settings. If the pressure setting of the main The hydraulic valves in the hydraulic system must be relief valve or a port relief valve is not within 3.45 bar (50 psi) properly adjusted to protect a component, a circuit, or a of the listed setting, adjustment is necessary.
Page 55 TMS700E SERVICE MANUAL HYDRAULIC SYSTEM Table 2-2 Valve Pressure Setting Table PRESSURE TOLERANCE VALVE TO BE SET SETTING ADJUSTMENT LOCATION Bar (PSI) Bar (PSI) Load Sense Relief* 276 (4000) ±4 (50) Main Control Valve Inlet Gauge Port See step #10 - Procedure For Lift Down Relief 138 (2000) +48/-0 (+700/-0)
Page 56 HYDRAULIC SYSTEM TMS700E SERVICE MANUAL Aux Hoist Down Port Relief Telescope Extend Port Relief Main Hoist Down Port Relief Load Sense Relief Test Port Load Sense Relief Pilot Supply Test Port Inlet Gauge Port Pilot Supply Pressure Reducing Cartridge Main Hoist Up Port Relief Lift Down Port Relief FIGURE 2-8 Aux Hoist Up Port Relief...
Page 57 TMS700E SERVICE MANUAL HYDRAULIC SYSTEM Test Port Pressure Reducing Valve Adjustment: Turn Clockwise To Increase Pressure 6152-2 FIGURE 2-9 Remove pressure gauge from the test port and reinstall on the counterweight directional control valve to 121 ± 4 cap. bar (1750 ± 50 psi). See Figure 2-11. Remove gauge, reconnect plumbing, and reinstall cap.
Page 58 HYDRAULIC SYSTEM TMS700E SERVICE MANUAL hold the extend switch. Then slowly accelerate the engine to the specified RPM. Read gauge and make adjustment as required. Remove cap and install pressure gauge on outrigger selector valve pressure check port labeled GP (see Figure 2-12).
Page 59 As long as the relief settings on both the outrigger and main crane functions are achievable, there is NO need to check or set it. If there is a problem with either relief setting, contact Manitowoc Crane Care for assistance. (See Figure 2-16.) Left Side Engine...
Page 60: Directional Control Valves
HYDRAULIC SYSTEM TMS700E SERVICE MANUAL Procedure For Checking Front Steering Relief Valve Pressure Install pressure check diagnostic quick disconnect with gauge on test nipple at the inlet of the power steering gear box. (See Figure 2-17) Priority Flow Relief Valve FIGURE 2-19 Stop engine.
Page 61: Maintenance
TMS700E SERVICE MANUAL HYDRAULIC SYSTEM center directional valve. It is plumbed in parallel with the Counterweight Removal Valve Bank boom lift/telescope/hoist directional control valve. The inlet Removal section contains a load sense relief valve set at 103.43 bar (1500 psi) protecting all four working sections. Tag and disconnect the hydraulic lines from the valves.
Page 62 HYDRAULIC SYSTEM TMS700E SERVICE MANUAL 10, 20 9, 28 3, 12 6468-1 25 18 19 25 16 17 25 26 27 6463-1 FIGURE 2-20 2-30 Published 01-29-2015, Control # 512-01...
Page 63 TMS700E SERVICE MANUAL HYDRAULIC SYSTEM Item Description Item Description Load Sense Gauge Port Port 4A - Lift Extend From Pump Port 4B - Lift Retract Gauge Port Restrictor Check Main Hoist Directional Valve Relief Valve - Telescope Extend Auxiliary Hoist Directional Valve Relief Valve - Telescope Retract Telescope Directional Valve Boom Lift Thermal Relief...
Page 64 HYDRAULIC SYSTEM TMS700E SERVICE MANUAL FIGURE 2-21 Item Description Item Description Port B - Swing Left Outlet Port A - Swing Right Swing Directional Valve Relief Valve Anti-Void Assembly Inlet 2-32 Published 01-29-2015, Control # 512-01...
Page 65 TMS700E SERVICE MANUAL HYDRAULIC SYSTEM 7532-1 7532-3 7532-2 Counterweight Removal Manifold FIGURE 2-22 Item Description Item Description Port P - Pressure to Directional Valve Port 1B - Solenoid Valve SV1 Port LS - Load Sense Port 2B - Solenoid Valve SV3 Port T - Tank to Swivel Port #4 Port 2A - Solenoid Valve SV4 Pressure Compensated Regulator...
Page 66: Check Valves
HYDRAULIC SYSTEM TMS700E SERVICE MANUAL CHECK VALVES Maintenance Description Armrest Control Valve Removal There are two check valves utilized in the crane hydraulic Gain access to the base of the control valve by raising system. The check valves are used to block flow in one the armrest and removing the plastic cover screwed direction and allow free flow in the opposite direction.
Page 67 TMS700E SERVICE MANUAL HYDRAULIC SYSTEM Telescope Pedal Control Valve Functional Check valve and lines for leakage. Make repairs as needed. Check (with Auxiliary Hoist Option) Start the engine and run it at normal speed. Telescope the boom the whole way out and then the whole way back in.
Page 68 HYDRAULIC SYSTEM TMS700E SERVICE MANUAL Item Description Item Description A Port - Swing Right Telescope In or Auxiliary Hoist Up B Port - Swing Left A Port - Lift Down T Port - Tank Port B Port - Lift Up P Port - Pressure Port A Port - Main Hoist Down A Port - Telescope Out or Auxiliary Hoist Down...
Page 69: Outrigger Selector Valve
TMS700E SERVICE MANUAL HYDRAULIC SYSTEM OUTRIGGER SELECTOR VALVE Maintenance Description Removal The outrigger selector valve (Figure 2-24) directionally Tag and disconnect the electrical connectors to the controls the outrigger circuit, rear steer circuit, and the pin integrated outrigger valve. cylinders that remove the front and rear outrigger boxes. The Tag and disconnect the hydraulic lines to the integrated valve is mounted on the rear face of the carrier frame front outrigger valve.
Page 70: Outrigger Control Manifold
HYDRAULIC SYSTEM TMS700E SERVICE MANUAL OUTRIGGER CONTROL MANIFOLD Inspection Visually inspect the valves and hydraulic connections for any Description evidence of leaks or other damage. Check security of the There are two outrigger control manifolds utilized on the electrical connections. Inspect the wiring for any evidence of crane, one for the front outriggers (Figure 2-25) and one for cracks or breaks.
Page 71 TMS700E SERVICE MANUAL HYDRAULIC SYSTEM 6544-1 6137-2 FIGURE 2-26 Item Description Item Description In Port Left Rear Jack Cylinder Out Ports Right Rear Jack Cylinder Left Rear Extension Cylinder Right Rear Extension Cylinder Grove Published 01-29-2015, Control # 512-01 2-39...
Page 72: Pilot Operated Check Valve
HYDRAULIC SYSTEM TMS700E SERVICE MANUAL PILOT OPERATED CHECK VALVE Lubricate the check valve and O-rings with clean hydraulic oil. Description A pilot operated (PO) check valve (Figure 2-27) is located in CAUTION each outrigger jack cylinder port block. The check valve Do not damage the O-rings during installation of the check functions as a holding valve for the jack cylinder.
Page 73: Holding Valves
TMS700E SERVICE MANUAL HYDRAULIC SYSTEM HOLDING VALVES Description A bolt-on manifold style holding valve is installed on the boom lift cylinder and a cartridge style holding valve (Figure 2-29) 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 expansion.
Page 74 HYDRAULIC SYSTEM TMS700E SERVICE MANUAL NOTE: The holding valve should turn by hand until compression of the O-rings begins. CAUTION Carefully install the holding valve into the port block until Do not damage the O-rings during installation of the fully seated. holding valve.
Page 75: Swing Brake And Armrest Lockout Valve Manifold
TMS700E SERVICE MANUAL HYDRAULIC SYSTEM SWING BRAKE AND ARMREST LOCKOUT Installation VALVE MANIFOLD Position the manifold and spacer bushings on turntable a n d s e c u r e w i t h t w o b o l t s , f l a t w a s h e r s , a n d Description lockwashers.
Page 76 HYDRAULIC SYSTEM TMS700E SERVICE MANUAL 4, 5 6401-2 6401-1 FIGURE 2-31 Item Description Item Description Pressure Reducing Valve - Swing Brake Port REG1 - Swing Brake Release Solenoid Valve - Swing Brake Release Port REG2 - Crane Function Port B Solenoid Valve - Crane Function Lockout Valve Port G - Gauge (Not Shown)
Page 77: High Speed Boost Selector Valve
TMS700E SERVICE MANUAL HYDRAULIC SYSTEM HIGH SPEED BOOST SELECTOR VALVE Maintenance Description Removal The high speed boost selector valve (Figure 2-32) is located Tag and disconnect the electrical connectors to the on port #4 of the hydraulic swivel spool. Output from pump valve.
Page 78: Front Center Jack Relief Valve
HYDRAULIC SYSTEM TMS700E SERVICE MANUAL FRONT CENTER JACK RELIEF VALVE Description The pilot operated relief valve (Figure 2-33) is installed on the right inside frame of the front outrigger box under the right bottom side rail. Its purpose is to limit the piston pressure of the front center jack not allowing it to raise the crane.
Page 79: Needle Valve
TMS700E SERVICE MANUAL HYDRAULIC SYSTEM 6874-1 6874-2 FIGURE 2-34 NEEDLE VALVE Maintenance Description Removal The two lift cylinder mounted needle valves are used to Tag and disconnect the hydraulic lines from the valve connect the rod and piston sides of the boom lift cylinder and cap or plug all openings and remove valve.
Page 80 HYDRAULIC SYSTEM TMS700E SERVICE MANUAL Installation Functional Check Start the engine and let it idle. Disengage the swing lock. DANGER Slowly swing the turntable. Engage the swing lock before installing the swing brake valve. Engage the swing lock. DANGER Engage the swing lock before adjusting the swing brake Install the brake valve and secure in place with the four valve.
Page 81: Swing Brake Release Valve (Optional)
TMS700E SERVICE MANUAL HYDRAULIC SYSTEM 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 82: Priority Flow Divider Valve
HYDRAULIC SYSTEM TMS700E SERVICE MANUAL PRIORITY FLOW DIVIDER VALVE Maintenance Description Removal The priority flow divider (Figure 2-37) is located on the right Tag and disconnect the hydraulic lines from the valve inside carrier frame forward of the front outrigger box. It and cap or plug all openings and remove valve.
Page 83: Auxiliary Water Jacket Cooler Flow Control Valve
TMS700E SERVICE MANUAL HYDRAULIC SYSTEM AUXILIARY WATER JACKET COOLER Remove the two bolt/nut assemblies that hold the valve to the support bracket. FLOW CONTROL VALVE Installation Description Position the valve on the support bracket and secure The auxiliary water jacket cooler flow control valve with the two bolt/nut assemblies.
Page 84: Cylinders
HYDRAULIC SYSTEM TMS700E SERVICE MANUAL CYLINDERS Maintenance General General This subsection provides descriptive information for all the There must be a gap between the ends of each wear ring hydraulic cylinders used on this crane. The descriptions of when it is installed onto the piston (as applicable) or head. In the cylinders given here is for the cylinder itself.
Page 85 TMS700E SERVICE MANUAL HYDRAULIC SYSTEM smoothly. Proper boom lubrication and wear pad adjustment The charts (Table 2-4 and Table 2-5) have been prepared to is important to permit the boom sections to slide freely. Slow assist you in determining the approximate amount of retraction/extension that may be expected from a hydraulic movement, of the boom may be undetected by the operator unless a load is suspended for a long period of time.
Page 86: Lift Cylinder
HYDRAULIC SYSTEM TMS700E SERVICE MANUAL LIFT CYLINDER CAUTION Description When removing seals and rings, avoid scratching the The lift cylinder (Figure 2-39) has a bore of 30.48 cm (12.0 grooved and gland surfaces. in). The retracted length of the cylinder from the center of the barrel bushing to the center of the rod bushing is 294.6 cm Remove the two hydrolock seals from the outside of the (116.0 in).
Page 87 TMS700E SERVICE MANUAL HYDRAULIC SYSTEM 6146 FIGURE 2-39 Item Description Item Description Barrel Backup Ring Piston Buffer Seal Setscrew Deep Z Rod Seal Hydrolock Seal Wiper Ring O-ring Holding Valve Backup Rings Plugs Tube Assembly Head Backup Ring Wear Ring Head Retainer Ring O-ring Socket Head Capscrew...
Page 88 HYDRAULIC SYSTEM TMS700E SERVICE MANUAL 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. 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 89: Lower Telescope Cylinder
TMS700E SERVICE MANUAL HYDRAULIC SYSTEM 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 (Figure 2-42) has a 152 mm (6 in) bore, a 127 cm (5 in) hollow rod, and is Remove the remaining guide lock ring, the hydrolock internally ported.
Page 90 HYDRAULIC SYSTEM TMS700E SERVICE MANUAL 1, 33 2, 34 20, 21 25, 26 6228 FIGURE 2-42 Item Description Item Description Rod End Bolt (Inner Rod) Wiper Ring Retaining Plate Bolt Guide Lock Ring Backup Ring Outer Rod Low Temperature O-ring Inner Rod Setscrew (Self-Locking) Backup Ring...
Page 91 TMS700E SERVICE MANUAL HYDRAULIC SYSTEM Item Description Wiper Piston Hydrolock Seal Assembly Piston Wear Ring Backup Ring Low Temperature O-ring Rod End (Inner Rod) Buffer Deep Z Rod Retaining Plate (Inner Rod) Back-Up FIGURE 2-44 Piston Install the wiper ring, backup ring, deep Z rod seal, buffer Cylinder Head seal assembly, and wear rings into the inside of the Spacer...
Page 92: Upper Telescope Cylinder
HYDRAULIC SYSTEM TMS700E SERVICE MANUAL NOTE: Align old seals in order of removal to facilitate installation of new seals. CAUTION Remove the guide lock ring at the top of the piston to Do not use air pressure to cycle the cylinder. Use only gain access to the setscrew securing the piston to the controlled hydraulic pressure.
Page 93 TMS700E SERVICE MANUAL HYDRAULIC SYSTEM FIGURE 2-46 Item Description Item Description Setscrew Buffer Seal Piston Wear Ring Backup Ring Backup Ring O-ring O-ring Guide Lock Ring Barrel Piston Hydrolock Seal Piston Wear Ring Piston Trunnion Support Block Wear Rings Backup Ring Wiper Ring Spacer Deep Z Rod Seal...
Page 94 HYDRAULIC SYSTEM TMS700E SERVICE MANUAL NOTE: When installing seals in step 2 through 4, 11. Install the wear rings on the outside of the spacer. (Figure 2-47). Install the wiper ring and wear rings on the inside of the CAUTION cylinder head.
Page 95: Steer Cylinder
TMS700E SERVICE MANUAL HYDRAULIC SYSTEM Cylinder Installed on Crane STEER CYLINDER Extend boom so that the rear of the upper tele cylinder is Description accessible through the side access hole. Stop engine. The steer cylinders (Figure 2-49) are mounted on the front Attach bleeder hoses (2X p/n 80044629) to both tele axles.
Page 96: Maintenance
HYDRAULIC SYSTEM TMS700E SERVICE MANUAL Maintenance d. Turn the head until the beveled end of the retaining ring is visible in the mill slot. Disassembly If the head is difficult to turn or moves erratically, tap the barrel adjacent to the head with a brass or NOTE: Any maintenance requiring disassembly of the plastic mallet while turning it.
Page 97 TMS700E SERVICE MANUAL HYDRAULIC SYSTEM FIGURE 2-49 Inspection Item Description Inspect the rod. There should be no scratches or pits deep enough to catch the fingernail. Pits that go to the Wiper base metal are unacceptable. Chrome should be O-ring present over the entire surface of the rod.
Page 98 HYDRAULIC SYSTEM TMS700E SERVICE MANUAL CAUTION Before installing new seals and rings, clean all surfaces and carefully remove burrs and nicks. Parts displaying excessive wear or damage should be replaced. Assembly CAUTION When installing new seals and rings, avoid stretching seals or scratching the grooved or gland surfaces.
Page 99: Maintenance
TMS700E SERVICE MANUAL HYDRAULIC SYSTEM WARNING Before testing, ensure all fittings, hoses, ball valves, and pump components are rated higher than test pressures. Do not use air pressure to cycle or pressurize the cylinder. Failure to do so could result in personal injury or death. 10.
Page 100 HYDRAULIC SYSTEM TMS700E SERVICE MANUAL present over the entire surface of the rod. If lack of chrome on rod, the rod should be replaced. CAUTION Inspect rod for straightness. Determine if it can be When removing seals and rings, avoid scratching the straightened or must be replaced.
Page 101 TMS700E SERVICE MANUAL HYDRAULIC SYSTEM 6231 FIGURE 2-52 Item Description Item Description O-ring Seal Backup Ring Spacer Retaining Ring O-ring Head Piston Seal Locknut Wiper Ring Barrel Plug Wear Ring O-ring Grove Published 01-29-2015, Control # 512-01 2-69...
Page 102: Maintenance
HYDRAULIC SYSTEM TMS700E SERVICE MANUAL Assembly Lubricate all parts freely with clean hydraulic oil. CAUTION CAUTION When installing new seals and rings, avoid stretching Exercise extreme care when handling the rod. Damage to seals or scratching the grooved or gland surfaces. Make the rod surface may cause unnecessary maintenance sure parts are clean before and during assembly.
Page 103 TMS700E SERVICE MANUAL HYDRAULIC SYSTEM Remove all dirt, grease and other contaminants from Remove the setscrews located near the top of the around the ports and the head. piston. 10. Insert a spanner wrench into the holes on the face side of the piston.
Page 104 HYDRAULIC SYSTEM TMS700E SERVICE MANUAL 6229 FIGURE 2-55 Item Description Item Description Barrel O-ring Spacer Wiper Ring Pilot Check Valve Setscrew Plug Piston Ring Seal Head Wear Ring Wear Ring O-ring Backup Ring Ring Seal O-ring 2-72 Published 01-29-2015, Control # 512-01...
Page 105 TMS700E SERVICE MANUAL HYDRAULIC SYSTEM Thoroughly rinse parts, allow to drain, and wipe with a NOTE: Lubricate seals and rings with clean hydraulic oil. lint-free rag. Inspect all parts for serviceability. For head and piston seal installation, (Figure 2-56) Flush the barrel and fluid tube. Drain and wipe dry with a and (Figure 2-57).
Page 106: Maintenance
HYDRAULIC SYSTEM TMS700E SERVICE MANUAL Place the rod on a clean table. CENTER FRONT JACK CYLINDER 10. Install the head followed by the spacer, then the piston Description onto the rod. Note proper orientation of each component. The center front jack cylinder (Figure 2-58) has a 8.9 cm (3.5 in) bore and is double acting.
Page 107 TMS700E SERVICE MANUAL HYDRAULIC SYSTEM Insert a spanner wrench into the holes provided and turn 12. Remove the wear rings and ring seal from the piston. the head counter clockwise to remove. If the head is 13. Remove the O-rings, backup ring, wear rings, ring seal difficult to remove, tap the head with a plastic mallet and wiper ring from the head.
Page 108 HYDRAULIC SYSTEM TMS700E SERVICE MANUAL 6467 FIGURE 2-58 Item Description Item Description O-ring O-ring Backup Ring Setscrew O-ring Plug Wiper Ring Plug O-ring Pilot Check Valve Seal Head Seal Spacer Wear Ring Barrel Wear Ring 2-76 Published 01-29-2015, Control # 512-01...
Page 109 TMS700E SERVICE MANUAL HYDRAULIC SYSTEM Thoroughly rinse parts, allow to drain, and wipe with a NOTE: Lubricate seals and rings with clean hydraulic oil. lint-free rag. Inspect all parts for serviceability. For head and piston seal installation, refer to Flush the barrel and fluid tube. Drain and wipe dry with a Figure 2-59 and Figure 2-60.
Page 110: Maintenance
HYDRAULIC SYSTEM TMS700E SERVICE MANUAL Place the rod on a clean table. COUNTERWEIGHT REMOVAL CYLINDER 10. Install the head followed by the spacer, then the piston Description onto the rod. Note proper orientation of each component. The counterweight cylinder (Figure 2-61) has a 8.9 cm (3.5 in) diameter bore.
Page 111 TMS700E SERVICE MANUAL HYDRAULIC SYSTEM rings. Pay attention to how each seal and ring is installed to avoid installing replacement seals and CAUTION rings improperly. Before installing new seals and rings, clean all surfaces Loosen and remove the locknut securing the piston. and carefully remove burrs and nicks.
Page 112 HYDRAULIC SYSTEM TMS700E SERVICE MANUAL FIGURE 2-61 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 2-80 Published 01-29-2015, Control # 512-01...
Page 113 TMS700E SERVICE MANUAL HYDRAULIC SYSTEM 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 114 HYDRAULIC SYSTEM TMS700E SERVICE MANUAL 2-82 Published 01-29-2015, Control # 512-01...
Page 115: Description
TMS700E SERVICE MANUAL ELECTRIC SYSTEM SECTION 3 ELECTRIC SYSTEM SECTION CONTENTS Description ....... 3-1 Troubleshooting Lights .
Page 116 ELECTRIC SYSTEM TMS700E SERVICE MANUAL NOTE: Fuse 1 is energized when the batteries are Fuse Fuse Assignment connected and the ignition switch is in the ignition Backup Lights and Alarm (RUN) and (START) positions. Fan Motor, A/C CLutch The following carrier fuse assignments (Table 3-1) apply: A/C Condensor Fans Table 3-1 Spare (3 A Max)
Page 117 TMS700E SERVICE MANUAL ELECTRIC SYSTEM FIGURE 3-1 Grove Published 01-29-2015, Control # 512-01...
Page 118: Superstructure Relay Panel And Fuse Panel
ELECTRIC SYSTEM TMS700E SERVICE MANUAL Relays The coil of the air dryer heater relay (K107) is energized when the contacts of accessory relay (K101) are closed. The carrier has 22 relays (Table 3-2) which control many of The coil of back up relay (K108) is energized when the its functions.
Page 119 TMS700E SERVICE MANUAL ELECTRIC SYSTEM Fuse Fuse Assignment Crane Function SOLS, Hyd Boost Main, Aux Hoist Rotation Indicators Heater, A/C Evap Fans, A/C Clutch Solenoid A/C Condenser Fan Motor Beacon LT, Wiper, Washer, Switch LEDS Buzzer, DEF Level Gauge Outriggers, Counterweight Solenoids FIGURE 3-2 Grove...
Page 120 ELECTRIC SYSTEM TMS700E SERVICE MANUAL NOTE: Refer to (Figure 3-2, 3-3, and 3-4), and Table 3- 3 and 3-4 for fuse and relay identification. 6871-2 Partial Rear View Of Cab 6871-1 Item Description Fuse Installation Fuse and Relay Panel Harness Connector Harness Connector RCL Cable FIGURE 3-3...
Page 121 TMS700E SERVICE MANUAL ELECTRIC SYSTEM Relays Relay Relay Assignment The superstructure has 7 relays (Table 3-4) (Figure 3-3 and Hyd Crane Function 3-4) which control many of its functions. The relays are Ignition Relay located on the superstructure relay panel assembly Heater Control (Figure 3-4).
Page 122: Maintenance
ELECTRIC SYSTEM TMS700E SERVICE MANUAL MAINTENANCE After troubleshooting, test and repair the repaired circuit. Verify the circuit works properly. General Troubleshooting Engine Starting Problems Electrical system maintenance includes troubleshooting and Verify the battery terminals are connected and clean, the replacement of damaged components. Observe standard transmission is in neutral, and the machine is fueled.
Page 123: Troubleshooting Engine Charging Problems
TMS700E SERVICE MANUAL ELECTRIC SYSTEM If the engine starts, then shuts down, suspect a If the problem remains, check the ignition switch and the faulty engine control system. Refer to the engine accessory control circuit from the ignition switch through the coil of the accessory relays K101 and K102 to manual for further instructions.
Page 124 ELECTRIC SYSTEM TMS700E SERVICE MANUAL Table 3-5 Amp Extraction Tool Table Description Amp Part Number Grove Part Number 14 gauge wire (connectors) 305183 9999100176 12 to 8 gauge wire (connectors) 91019-3 9999100175 4 to 9 circuit (in-line connectors) 453300-1 15 circuit (in-line connectors) 458944-1 Table 3-6 Amp Crimping Tool Table...
Page 125: Troubleshooting Lights
TMS700E SERVICE MANUAL ELECTRIC SYSTEM Troubleshooting Lights Table 3-10 Lights Circuit Check lamp first. Replace any damaged lamp. F1, BOOM light switch, lamps, If all lamps in a circuit do not work, suspect the fuse and Boom Flood grounds. Parallel circuit to LED switch.
Page 126: Troubleshooting Alarms, Indicators, And Emergency Components
ELECTRIC SYSTEM TMS700E SERVICE MANUAL Gauge/Meter Circuit Component Circuit F5/F9, tachometer. Meter is F6, horn relay K106 coil, horn switch, Steering Wheel Tachometer grounded. Branch from tachometer to ground. Parallel branch from horn Horn tachometer sender to ground relay contacts, horn, ground F5, gauge.
Page 127: Troubleshooting Crane Components And Accessories
TMS700E SERVICE MANUAL ELECTRIC SYSTEM Table 3-13 Table 3-14 Component Circuit Component Circuit F4 to horn relay (K4) coil to horn Windshield Wiper Motor Swing Horn switch to ground. Parallel branch from F7, wiper/washer switch, motors in horn relay contacts to horn to ground and Windshield parallel, grounds Washer Pump...
Page 128: Alternator Replacement
ELECTRIC SYSTEM TMS700E SERVICE MANUAL Table 3-15 Component Circuit Component Circuit For hoist up, F11 to RCL CPU to aux hoist switch to auxiliary hoist up Windshield solenoid valve to ground. For hoist Wiper Motor Auxiliary Hoist F18, wiper/washer switch, motors in down, CB12 to aux hoist switch to and Windshield On/Off function...
Page 129: Starter Replacement
TMS700E SERVICE MANUAL ELECTRIC SYSTEM Tag and disconnect the electrical leads from the Starter Replacement terminals on the alternator. Removal Turn the tensioner above the alternator clockwise to remove tension from the belt. Slip the belt off of the CAUTION alternator pulley, then let the tensioner return to its To prevent damage to electronics, in order;...
Page 130: Battery Replacement
ELECTRIC SYSTEM TMS700E SERVICE MANUAL Battery Replacement Turn the battery disconnect switch to ON. Verify replacement batteries work by starting crane’s Removal engine and operating various crane components. Relay Panel Component Replacement CAUTION To prevent damage to electronics, in order: Ensure key Accessory Relay and Flasher Replacement switch has been off 2 minutes, Battery disconnect is in the off position, Remove ECM power fuse, Remove negative...
Page 131: Instrument Replacement
TMS700E SERVICE MANUAL ELECTRIC SYSTEM Verify proper installation by operating all components Switch Replacement involved with the replacement relay and verifying they all work. Rocker Switch Instrument Replacement Removal Disconnect the battery. Removal Remove the hardware securing the console cover and Disconnect the battery.
Page 132: Windshield Wiper Assembly Replacement
ELECTRIC SYSTEM TMS700E SERVICE MANUAL All Other Switches Windshield Wiper Assembly Replacement Removal Removal Disconnect the battery. Disconnect the battery. Remove the hardware securing the console cover and Tag and disconnect the electrical leads from the motor. remove the cover. Disconnect the washer hose on the wiper arm (also Tag and disconnect the electrical leads from the switch.
Page 133: Windshield Washer Assembly Replacement
TMS700E SERVICE MANUAL ELECTRIC SYSTEM Secure the adapter and the gasket of the pantograph adapter assembly to the cab exterior with capscrews and lockwashers. Install the motor bracket and attached parts in the cab interior with attaching hardware. Ensure the pivot shaft sticks through the hole in the pantograph adapter assembly.
Page 134: Skylight Wiper Assembly Replacement
ELECTRIC SYSTEM TMS700E SERVICE MANUAL Inspection shaft and flat washer and smaller nylon flat washer from mounting screw. Visually check the pump for evidence of cracks, leaks, or Remove mounting screw and nylon flat washer from other damage. Replace pump if damaged. outside cab roof.
Page 135: Section 4
TMS700E SERVICE MANUAL BOOM SECTION 4 BOOM SECTION CONTENTS Description ....... 4-1 Adjustment.
Page 136: Boom Retraction
BOOM TMS700E SERVICE MANUAL control flow to the telescope cylinders. With both cylinders Remove the hook block or headache ball and wind all retracted, the check valve for the lower telescope cylinder is the wire rope onto the hoist drum. open and the check valve for the upper cylinder is closed Elevate the boom slightly to allow for withdrawal of the allowing the lower cylinder to extend.
Page 137 TMS700E SERVICE MANUAL BOOM FIGURE 4-1 Grove Published 01-29-2015, Control # 512-01...
Page 138: Disassembly
BOOM TMS700E SERVICE MANUAL Item Description Section 4 WARNING Section 3 Shut down the crane and disconnect the batteries before proceeding. Section 2 Section 1 12. Take up the slack on the boom lifting device. Upper Telescope Cylinder 13. Remove the bolt, lockwasher, nut, and retaining pin securing the boom pivot shaft.
Page 139 TMS700E SERVICE MANUAL BOOM FIGURE 4-1 continued Grove Published 01-29-2015, Control # 512-01...
Page 140 BOOM TMS700E SERVICE MANUAL NOTE: Section 2 extend cable anchor plate not shown for clarity. FIGURE 4-1 continued Item Description Item Description Bottom Wear Pad and Shims Grease Liner Rear Side Wear Pads Port A Top Rear Wear Pads Port B Retract Cable Sheave Pusher Bar Retract Cable Sheave Shaft...
Page 141 TMS700E SERVICE MANUAL BOOM 10. Remove the four bolts and hardened washers securing 27. Remove the four bolts and hardened washers securing the guide block to the inner top of Section 1. Remove the the guide block to the inner top of Section 2. Remove the guide block and shim(s), noting quantity of shims.
Page 142 BOOM TMS700E SERVICE MANUAL 44. Remove the four bolts and hardened washers securing 56. Continue to slide the telescope cylinder assembly out of each front top wear pad to Section 3. Remove the wear Section 4. Lowering the rear of Section 4 and raising the pads and shims, noting quantity, size, and location of rod end of the cylinders will aid in removal.
Page 143: Boom Nose Sheaves
TMS700E SERVICE MANUAL BOOM 72. Remove the four bolts and hardened washers securing of the sheave shafts and secure in place with the bolt, the sheave mounting assembly and the support foot to washer, and nut. the front of the telescope cylinder. Remove the sheave NOTE: If more than one shim is required, install an equal mounting assembly and the support foot.
Page 144 BOOM TMS700E SERVICE MANUAL Position the cable retainer plate on the front of the washers. Install grease fitting in each shaft and apply sheave mounting assembly and secure with two bolts grease. and lockwashers. 18. Install the lug end of each retract cable in the slots on Install the skid pad to the bottom of the lower telescope each side of the lower telescope cylinder mount.
Page 145 TMS700E SERVICE MANUAL BOOM 33. Position the guide block on the bracket at the bottom pockets of Section 3 (cutout should align with grease front of Section 3. Secure with four bolts and hardened line). Stop and install rear side wear pads and shims on Section 3 with two flat head screws each.
Page 146: Installation
BOOM TMS700E SERVICE MANUAL 62. Install the cam valves on the mounting plates on each 75. Align lower cylinder rod mounting plates holes with holes side of Section 2 using three bolts, hardened washers, in Section 1. Secure each with five bolts and hardened and nuts (early models only) each.
Page 147: Functional Check
TMS700E SERVICE MANUAL BOOM 12. Refer to Boom Extension and Retraction Cable, page 4- 14 for cable adjustments. 13. Refer to Cam Operated Check Valve Adjustment, page DANGER 4-14 for valve adjustment. Failure to properly support the boom lift cylinder may Functional Check result in death or injury to personnel.
Page 148: Cam Operated Check Valve Adjustment
Consensus standard as referenced by Federal Government Section 3 is against the stop block of Section 2. Agencies, and as recommended by Manitowoc Cranes. Access the check valves through the hole on each side All wire rope will eventually deteriorate to a point where it is of Section 1.
Page 149: Adjustment
TMS700E SERVICE MANUAL BOOM • In standing ropes, more than two broken wires in one lay Retract the boom until either Section 4 just contacts in sections beyond end connections or more than one Section 3 stop block or Section 3 just contacts Section 2 stop block.
Page 150: Theory Of Operation
BOOM TMS700E SERVICE MANUAL section at a given length, oil is trapped in the cylinder by the functions from neutral sends a pilot pressure signal to the holding valve. Refer to Hydraulic Remote Control Valve, directional control valve to shift the spool in the directional page 2-34 for a complete description of the holding valve.
Page 151 TMS700E SERVICE MANUAL BOOM SYMPTOM PROBABLE CAUSE SOLUTION Erratic operation of Low hydraulic oil level. Check for leaks. Repair any found. retracting Replenish hydraulic oil to proper level. telescoping b. Damaged relief valve. b. Repair or replace relief valve. cylinder. Air in cylinder.
Page 152: Removal And Installation
BOOM TMS700E SERVICE MANUAL SYMPTOM PROBABLE CAUSE SOLUTION Telescope cylinder Low hydraulic oil level. Check for leaks. Repair any found. will not retract. Replenish oil to proper level. b. Relief valve damaged. b. Repair or replace relief valve. Excessive load. Reduce load.
Page 153: Theory Of Operation
TMS700E SERVICE MANUAL BOOM booming up (cylinder rod extended), booming down (cylinder cylinder. Pressure is applied to the piston, forcing the rod to rod retracted), or holding (cylinder rod stationary). extend, raising the boom. When booming down, oil enters the retract port of the port Theory of Operation block and flows to the cylinder rod side.
Page 154: Maintenance
BOOM TMS700E SERVICE MANUAL Maintenance Troubleshooting Symptom Probable Cause Solution Boom raises Low hydraulic oil. Check for leaks. Repair any found. erratically. Replenish hydraulic oil to proper level. b. Low engine rpm. b. Increase engine rpm to recommended setting. Main relief valve damaged. Replace relief valve.
Page 155 Operate unit to bring oil to operating temperature. Improper hose or fittings installed. Replace hose or fittings. (Refer to Grove Manitowoc Parts Manual). g. Restriction in return hose. g. Replace return hose. h. Cylinder piston seals worn. h. Replace all cylinder seals.
Page 156 BOOM TMS700E SERVICE MANUAL Removal Disassembly and Assembly Extend and set the outriggers and level the crane. Disassembly and assembly procedures of the lift cylinder holding valve, and control valve are provided in Hydraulic Elevate the boom slightly so that the lift cylinder is System, page 2-1 under Cylinders and Valves respectively.
Page 157 TMS700E SERVICE MANUAL BOOM 2, 3, 4 7, 8, 9 7024-2 DETAIL B DETAIL A 7024-3 7024-1 FIGURE 4-3 Item Description Upper Pivot Shaft Bolt Bolts Washer Washers Thrust Washers Stop Plate Grease Fitting Lower Pivot Shaft Grease Fitting on Cylinder (ref.) Grove Published 01-29-2015, Control # 512-01 4-23...
Page 158: Swingaway Boom Extension
BOOM TMS700E SERVICE MANUAL SWINGAWAY BOOM EXTENSION NOTE: The auxiliary boom nose (rooster sheave) does not have to be removed. Description Extend the boom enough to disengage the spring loaded boom extension stop block (refer to Figure 4-4). A 9.45 m (31 ft) fixed offsettable or a 9.45 to 17.07 m (31 to 56 ft) folding offsetable swingaway boom extension is Pull down on the handle to disengage the spring loaded provided to obtain additional boom reach.
Page 159 TMS700E SERVICE MANUAL BOOM FIGURE 4-5 Grove Published 01-29-2015, Control # 512-01 4-25...
Page 160 BOOM TMS700E SERVICE MANUAL Item Description Swingaway Base Adjusting Bolt Upper Hanger Main Hanger Lower Support Lock Hitch Pin DETAIL A Item Description Swingaway Stinger Adjusting Bolts Adjusting Bolts Front Mount Hanger DETAIL B FIGURE 4-5 continued 4-26 Published 01-29-2015, Control # 512-01...
Page 161 TMS700E SERVICE MANUAL BOOM Item Description Swingaway Base Swingaway Stinger Shock Wear Pad and Shim Ramp Wear Pad and Shim DETAIL C Item Description Swingaway Base Swingaway Stinger Stinger Attach Pin and Hitch Pin Adjusting Bolts Pin Stowage Lug Upper Support Lower Mount Wear pad Pin Mount...
Page 162 BOOM TMS700E SERVICE MANUAL Item Description Swingaway Base Swingaway Stinger Stinger Sheave Cable Retainer Pin Latch Hook Spring Latch Bar DETAIL E NOTE: Offset shown at 25 degrees. To obtain 45 degree offset, remove pin (item 56) and stow in lug. Item Description Boom Nose Upper Sheaves...
Page 163 TMS700E SERVICE MANUAL BOOM 62, 63 Item Description Pusher Bar Collar Clamp Adjustment Bar Push Bar Assembly Hitch Pin 62, 63 Clip Pin FIGURE 4-5 continued NOTE: If not removing the swingaway stinger perform 12. Remove lock hitch pin securing the Swingaway Base to steps 7 thru 10.
Page 164 BOOM TMS700E SERVICE MANUAL guide ramps and stowage pins on the front and rear Install the attach pins and retainer clips to secure the stowage brackets. swingaway to the boom nose. Raise the boom, lifting the swingaway from the cribbing on which it was resting. 15.
Page 165: Boom Extension Alignment Device Adjustment
TMS700E SERVICE MANUAL BOOM 13. Pull down on the handle to disengage the spring loaded boom extension stop block. Place the end of the handle in the retainer plate. Fully retract the boom. DANGER NOTE: When the boom retracts, the handle will be Failure to maintain the proper clearance between the released allowing the stop block to engage when swingaway anchor fittings and the boom nose attach...
Page 166: Hook Block
BOOM TMS700E SERVICE MANUAL Swingaway Mounting Adjustment 14. Refer to Detail D (rear stowage bracket) and adjust stinger upper hanger and lower hanger to maintain the The following procedures may be used to adjust the existing attachment pin in a loose condition. installation or for installing a new swingaway and/or stinger.
Page 167: Description
TMS700E SERVICE MANUAL HOIST AND COUNTERWEIGHT SECTION 5 HOIST AND COUNTERWEIGHT SECTION CONTENTS Description ....... 5-1 Description.
Page 168: Installation
HOIST AND COUNTERWEIGHT TMS700E SERVICE MANUAL Tag and disconnect the electrical wires to the hoist 13. Install the cable, following the procedures outlined under rotation indicator sensor box. Installing Cable on the Hoist, in the Operator’s Manual. Tag and disconnect the electrical wires to the hoist motor Functional Check control valve.
Page 169 TMS700E SERVICE MANUAL HOIST AND COUNTERWEIGHT 6929-1 7, 8 7, 8 6929-2 FIGURE 5-2 Item Description Item Description Main Hoist Bolts for Hoist(s) Auxiliary Hoist Nuts Cable Guard Roller Washers Cable Guide Roller Counterweight Shims (different thicknesses) Bolts for Counterweight Grove Published 01-29-2015, Control # 512-01...
Page 170: Preventative Maintenance
HOIST AND COUNTERWEIGHT TMS700E SERVICE MANUAL Preventative Maintenance • Check the hoist oil level. Inspect for any oil leaks from the hoist gearbox. It is extremely important to be aware of the possibility that Every 250 hours or 3 months. deterioration of internal critical components within the hoist reduction unit can occur.
Page 171: Brake Test Procedure
TMS700E SERVICE MANUAL HOIST AND COUNTERWEIGHT correct. The function of the hoist brake should be General Guidelines for Iron Contaminant checked more often if abnormal operating conditions or Level characteristics exist. 100-500 ppm Every 10,000 hours or every ten years, it is recommended that the hoist assembly be disassembled Normal and that all major components be examined for damage...
Page 172: Hoist To Boom Alignment
HOIST AND COUNTERWEIGHT TMS700E SERVICE MANUAL Replace any parts showing excessive wear and any spring the drum at a 90 degree angle. The boom has the ability whose length is shorter than the minimum shown in the to extend, retract, and change the angle of departure applicable hoist Service Manual.
Page 173 TMS700E SERVICE MANUAL HOIST AND COUNTERWEIGHT Main Hoist is Aligned to the Right Hand Sheave Locating Centerline with Square Auxiliary Hoist is Aligned to the Center Sheave FIGURE 5-3 6019 Grove Published 01-29-2015, Control # 512-01...
Page 174: Motor And Brake
HOIST AND COUNTERWEIGHT TMS700E SERVICE MANUAL MOTOR AND BRAKE Reinstall any hoist drum rotation indicator parts removed earlier, if done. Connect electrical wires as tagged Description during removal. Torque CPU bolt according to Fasteners and Torque Values, page 1-12. Adjust sensor per Each hoist has a hydraulic motor, a brake valve, a brake instructions in Hoist Drum Indicator System, page 5-10.
Page 175 TMS700E SERVICE MANUAL HOIST AND COUNTERWEIGHT hardware. Do likewise for the cable guide roller and Secure the cable guard roller to the cable tension shaft and attaching hardware. brackets with its shaft and attaching hardware. Inspect each shaft and roller for cracks, scoring, or Attach each of the two springs to its related eyebolt and grooving.
Page 176: Description
HOIST AND COUNTERWEIGHT TMS700E SERVICE MANUAL HOIST DRUM INDICATOR SYSTEM well as providing power to the rotation sensor. It also sends a signal to the thumper solenoid proportional to the sensor. Description Thumb Thumper Solenoid The hoist drum rotation indicator system (see Figure 5-4) is The thumb thumper solenoid provides feedback proportional an electrically operated system that provides the operator to the hoist line speed by pulsing the rubber button on top of...
Page 177 TMS700E SERVICE MANUAL HOIST AND COUNTERWEIGHT off, then either the CPU is damaged or the sensor is damaged. The following should be used only after using the diagnostic LEDs. Support End Bracket Sensing End Lock Nuts 31 mm (1.21 in.) To Sensor Connects to DT3S FIGURE 5-5...
Page 178: Hoist Rotation Indicator (Hri) Display System
HOIST AND COUNTERWEIGHT TMS700E SERVICE MANUAL Hoist Rotation Indicator (HRI) Display Item Description System Button The HRI Display consists of an LED display that indicates Thumb Thumper Rotation Indicator Solenoid the direction the hoist(s) are rotating, pressure switches that monitor hydraulic pilot pressure, and a control module Measure the sensor input voltage from +10V terminal 1 mounted in the cab.
Page 179: Hoist Control Valves
TMS700E SERVICE MANUAL HOIST AND COUNTERWEIGHT wires to the display. Replace the panel and secure with the hardware. 8425-1 FIGURE 5-7 Item Description HRI Control Module To LED Indicator The control module is located in the fuse and relay panel Power and Ground behind the driver’s seat in the cab Figure 5-8.
Page 180: Maintenance
HOIST AND COUNTERWEIGHT TMS700E SERVICE MANUAL attachment to the removal cylinders and lugs to pin it under NOTE: The cylinder weighs approximately 42 kg (92 lb). the hoist mounting. The two additional slabs pin to the Remove the four bolts and lockwashers securing the standard box and to each other.
Page 181 TMS700E SERVICE MANUAL HOIST AND COUNTERWEIGHT FIGURE 5-10 Item Description Item Description CWT Removal Panel Box Attach Pin Removal Cylinder 2495 kg (5500 lb) Slabs Slab Attach Pin 2495 kg (5500 lb) Standard Box Cylinder Attach Pin Jack Screws Grove Published 01-29-2015, Control # 512-01 5-15...
Page 182 HOIST AND COUNTERWEIGHT TMS700E SERVICE MANUAL 5-16 Published 01-29-2015, Control # 512-01...
Page 183: Description
TMS700E SERVICE MANUAL SWING SYSTEM SECTION 6 SWING SYSTEM SECTION CONTENTS Description ....... . 6-1 Description .
Page 184: Swing Brake
SWING SYSTEM TMS700E SERVICE MANUAL Swing Brake blocks the regulated flow to the brake release port and spring pressure in the swing brake applies the brake. When the Hydraulic power for the swing brake control and swing brake Swing Brake selector switch is positioned to OFF, the cooling is supplied by the pilot generator capsule in the hoist/ regulated flow is directed from the pressure reducing/ telescope/lift directional control valve to the swing brake and...
Page 185 TMS700E SERVICE MANUAL SWING SYSTEM 6470-1 FIGURE 6-1 Item Description Item Description Breather Plug Level Plug Filler Plug Motor Swing Drive and Brake Pinion Hydraulic Apply Brake Port Drain Plug Hydraulic Release Brake Port Grove Published 01-29-2015, Control # 512-01...
Page 186: Maintenance
SWING SYSTEM TMS700E SERVICE MANUAL MAINTENANCE Troubleshooting Symptom Probable Cause Solution Boom swing Low engine rpm. Increase engine rpm to obtain smooth operation erratic in swing operation. either direction. b. Low hydraulic oil. b. Check for leaks. Repair any found. Replenish hydraulic oil to proper level.
Page 187 TMS700E SERVICE MANUAL SWING SYSTEM Symptom Probable Cause Solution Boom will not swing Damaged relief valve. Remove, clean, and repair or replace in either direction. relief valve. b. Damaged swing motor. b. Repair or replace swing motor. Swing brake not releasing properly. Repair as necessary.
Page 188 SWING SYSTEM TMS700E SERVICE MANUAL Symptom Probable Cause Solution Swing brake Improper brake adjustment. Adjust brake. operation erratic. b. Air in swing brake system. b. Bleed brake system. Brake pedal not fully retracted. Check brake pedal return spring; repair or replace spring. d.
Page 189: Swing Motor
TMS700E SERVICE MANUAL SWING SYSTEM SWING MOTOR Test Test swing of superstructure in each direction. Stop and Description start swing several times. The swing motor is mounted on the swing brake housing and Inspect for hydraulic leaks and repair as necessary. drives the swing gearbox through the brake assembly (see Figure 6-1).
Page 190: Swing Bearing
SWING SYSTEM TMS700E SERVICE MANUAL Bleed all air from the brake assembly. Connect the hydraulic lines to the swing brake. Testing Connect the hydraulic lines to the swing motor. Service the gearbox as indicated under Servicing. With the Swing Brake Switch in the ON position, position the swing control lever in both directions.
Page 191 TMS700E SERVICE MANUAL SWING SYSTEM Torquing Turntable Bolts Proper identification of bolt grade is important. When marked as a high strength bolt (grade 8), the serviceman must be General aware of bolt classifications and that he is installing a high strength heat-treated tempered component and the bolt must be installed according to specifications.
Page 192 SWING SYSTEM TMS700E SERVICE MANUAL Torque Values Return to bolt 1 and torque all bolts sequentially in a clockwise direction to their final torque value specified. Refer to Fasteners and Torque Values, page 1-12 for the The same tools are used as in step 2 (see Figure 6-2). torque value for the turntable bolts.
Page 193 TMS700E SERVICE MANUAL SWING SYSTEM Orders for special tools shall be referred to: 6633 Manitowoc Crane Care 1565 Buchanan Trail East FIGURE 6-3 P.O. Box 21 Shady Grove, PA 17201 Phone: 717-598-8121 Fax: 717-597-4062 Description Grove Part Number Quantity Required 1.
Page 194 SWING SYSTEM TMS700E SERVICE MANUAL Disconnect the swivel wiring harness connectors from the carrier wiring receptacles. Remove the ground wire from the ground stud. DANGER 10. Remove the clamp securing the swivel wiring harness to Ensure that any blocking material used is capable of fully the retainer plate on the bottom of the hydraulic swivel supporting the weight of the superstructure and will not assembly.
Page 195: Swivels
TMS700E SERVICE MANUAL SWING SYSTEM Using appropriate lifting device, align 10. Install the boom and lift cylinder following the procedures superstructure over the carrier in the travel position and outlined in Boom, page 4-1. carefully lower the superstructure, being careful not to 11.
Page 196 SWING SYSTEM TMS700E SERVICE MANUAL 6, 7 11, 12 18, 19, 20 25, 26 23, 24 FIGURE 6-5 6-14 Published 01-29-2015, Control # 512-01...
Page 197: Hydraulic Swivel
TMS700E SERVICE MANUAL SWING SYSTEM HYDRAULIC SWIVEL Item Description Description Hydraulic Swivel Each of the ports on the spool and case of the swivel is Water Swivel stamped with the port number (see Table 6-1). The function of each port is described below. The hydraulic swivel has Mounting Bolts four grease fittings on the case.
Page 198 SWING SYSTEM TMS700E SERVICE MANUAL Table 6-1 Test Pressure Port # Function bar (psi) 170 (2500) Air Conditioning 34 (500) Dual Return 240 (3500) Swing 240 (3500) Lift/Tele/Hoist 34 (500) Drain 2.1 (30) Heater Supply (Coolant) 2.1 (30) Heater Return (Coolant) NOTE: This blocking is to add extra support for the boom.
Page 199: Two Port Water Swivel
TMS700E SERVICE MANUAL SWING SYSTEM TWO PORT WATER SWIVEL Cleaning and Inspection Description The 2 port water swivel allows engine coolant to flow from DANGER the carrier-mounted engine to the hot water heater in the operator’s cab. Through an internally drilled passage in the 5 Cleaning solvents can be toxic, flammable, an irritant to port hydraulic swivel spool, coolant is transferred to a the skin, or give off harmful fumes.
Page 200: Electrical Swivel
SWING SYSTEM TMS700E SERVICE MANUAL ELECTRICAL SWIVEL Remove the clamp securing the wiring harness to the retainer plate on the bottom of the hydraulic swivel Description assembly. Tag each wire on the large flat connector. Using the The swivel assembly consists of a 49 conductor slip ring and appropriate pin removal tools, remove the pins, with cover assembly.
Page 201 TMS700E SERVICE MANUAL SWING SYSTEM example of this could be at approximately 100 to 150 engine operating hours. When this time limit is reached, perform the following. 6 mm (0.25 in Check the collector ring and brush assembly for any corrosion, pitting, arcing, and wear.
Page 202: Swing Lock Pin
SWING SYSTEM TMS700E SERVICE MANUAL SWING LOCK PIN CAUTION Description Do not attempt to rotate the slotted shaft in the center of T h e p u r p o s e o f t h e s w i n g l o c k p i n i s t o l o c k t h e the slew potentiometer.
Page 203 TMS700E SERVICE MANUAL SWING SYSTEM the gear teeth when the control pedal is pushed down. Verify hardware (two 5/16-18 screws and 5/16 ID lockwashers) to all attaching hardware is secure and undamaged. Make ensure the swing lock assembly stays in place and can lock adjustments as needed.
Page 204 SWING SYSTEM TMS700E SERVICE MANUAL PAGE LEFT BLANK 6-22 Published 01-29-2015, Control # 512-01...
Page 205: Section 7
TMS700E SERVICE MANUAL POWER TRAIN SECTION 7 POWER TRAIN SECTION CONTENTS Description ....... 7-1 Aftertreatment Diesel Exhaust Fluid (DEF) .
Page 206: Maintenance
POWER TRAIN TMS700E SERVICE MANUAL start solenoid is activated when the engine is started, 10. Remove the bolts, washers, lockwashers, and nuts providing an injection of starting fluid to the engine. The securing the start relay to the hood. Lay the relay with system consists of a solenoid valve, starting aid container, the harness on the engine.
Page 207 TMS700E SERVICE MANUAL POWER TRAIN 7976-1 7976-2 FIGURE 7-1 Grove Published 01-29-2015, Control # 512-01...
Page 208: Installation
POWER TRAIN TMS700E SERVICE MANUAL washers, lockwashers, nuts and bonded mounting centers from the front engine mounting support and the Item Description transmission mounting brackets. Three Section Pump 27. Carefully lift the engine assembly from the crane and move it to a clean work area. Pump Drive Prop Shaft 28.
Page 209 TMS700E SERVICE MANUAL POWER TRAIN 13. As needed, install ether cylinder if removed earlier. 19. Connect the starting aid tubing to the nozzle in the intake manifold. Verify the nozzle orifice points upstream. 14. Connect the battery cables, starting aid valve connector, and engine electrical connections as marked during 20.
Page 210: Engine Drive Belts
POWER TRAIN TMS700E SERVICE MANUAL Engine Drive Belts surfaces. A drive belt that is glazed or shiny indicates belt slippage. The proper operation of engine belt-driven components such Engine drive belt damage can be caused by various factors as the alternator, fan clutch, and water pump depend on the such as incorrect tension, incorrect belt size, misaligned proper condition and tension of the engine drive belts.
Page 211: Engine Control System
TMS700E SERVICE MANUAL POWER TRAIN ENGINE CONTROL SYSTEM During the cranking phase, with the ignition switch in the start position, the ECM commands all of the fuel needed to Description start the engine. There is no need to use the throttle pedal while cranking the engine.
Page 212 POWER TRAIN TMS700E SERVICE MANUAL Engine Stop Light code. When all codes have been flashed, the sequence will begin again. If no codes are present, both the engine The engine stop light is located at the top of the front console warning and engine stop lights will remain on.
Page 213: Fuel System
TMS700E SERVICE MANUAL POWER TRAIN FUEL SYSTEM Place a suitable container under the filter and open the drain plug. Description Drain until fuel appears. The fuel system consists of the fuel tank, fuel filter-water Close the drain plug. separator, injection fuel pump, the fuel injectors, and fuel Filter Replacement cooler.
Page 214 POWER TRAIN TMS700E SERVICE MANUAL 6781-1 FIGURE 7-4 Item Description Item Description Fuel Return Line - From Fuel Cooler (QSM Vent Tube shown) Mounting Strap Fuel Supply Line - To Engine Fuel Tank Fuel Filter-Water Separator Plug Fuel Level Senders 7-10 Published 01-29-2015, Control # 512-01...
Page 215: Air Intake System
TMS700E SERVICE MANUAL POWER TRAIN AIR INTAKE SYSTEM of water) maximum with a dirty air cleaner at maximum governed RPM. Description A service indicator on the air cleaner housing will indicate when the filter needs to be cleaned or replaced. Reset the The engine air intake system (Figure 7-8) consists of an air indicator each time the air cleaner is serviced.
Page 216 POWER TRAIN TMS700E SERVICE MANUAL INSPECT THE FILTER FOR DAMAGE. Always look for filter damage, even if a new filter element is being installed. Pay special attention to the inside of the open end (sealing area). Do not install a damaged filter.
Page 217 TMS700E SERVICE MANUAL POWER TRAIN 6786 Air Cleaner Mounting Band Air Inlet Hood Service Indicator Reducing Elbow Tube Vacuator Valve QSM AIr Intake Installation Air Cleaner Mounting Band Air Inlet Hood Service Indicator Reducing Elbow Tube Elbow ISX AIr Intake Installation Air Cleaner Body inside the air cleaner body.
Page 218 POWER TRAIN TMS700E SERVICE MANUAL surfaces. Be sure to clean the sealing surface of the outlet and reduces serviceable life. If a valve is lost or damaged, tube and the inside of the outlet tube, taking care not to replace it with a new valve of the same part number. damage the sealing area on the tube.
Page 219: Exhaust System
TMS700E SERVICE MANUAL POWER TRAIN EXHAUST SYSTEM Install the Decomposition Pipe, install new gaskets as necessary. Description Secure all exhaust tubing with appropriate clamps. The ISX exhaust system incorporates a diesel particulate Tighten the mounting hardware for all the components. filter (DPF) to remove soot, a diesel exhaust fluid (DEF) Attach the crane’s sensor harness wires, as tagged dosing section (decomposition pipe) to inject the DEF and a...
Page 220: Isx Exhaust System
POWER TRAIN TMS700E SERVICE MANUAL After 1000 Hours, or One Year 4000 Hours or 4 Years Visually inspect the exhaust connector. If necessary, tighten Tighten the V-clamp by 1 ½ turns of the nuts. the V-clamps by one full turn of the nuts. 5000 Hours or 5 Years 2000 Hours or 2 Years Remove the V-clamps and gaskets, and replace them with...
Page 221: Qsm Exhaust System
TMS700E SERVICE MANUAL POWER TRAIN QSM Exhaust System Muffler Tube Exhaust Stack Mounting Band Connector Assembly Engine Exhaust Tube Muffler Clamp Muffler Mount Exhaust Cover Muffler Cover Muffler Guard QSM Exhaust System Grove Published 01-29-2015, Control # 512-01 7-17...
Page 222: Aftertreatment Diesel Exhaust Fluid (Def)
POWER TRAIN TMS700E SERVICE MANUAL AFTERTREATMENT DIESEL EXHAUST Removal FLUID (DEF) Tag and disconnect the electrical connectors on the DEF tank. DEF Tank Tag and disconnect the fluid lines on the tank. Description Remove the hardware holding the tank straps in place. This engine uses a Selective Catalytic Reduction (SCR) Remove the tank.
Page 223: Def Dosing Unit Filter
TMS700E SERVICE MANUAL POWER TRAIN DEF Dosing Unit Filter The filter should be replaced every 200,000 miles or 4500 hours of crane operation. The DEF dosing unit filter is a 10-micron filter designed to The aftertreatment DEF dosing unit filter consists of the prevent foreign objects, that may be suspended in the DEF, following components: from entering the dosing system.
Page 224 POWER TRAIN TMS700E SERVICE MANUAL NOTE: Do not disconnect the vehicle batteries until the Inspect the aftertreatment DEF dosing unit filter cap for DEF dosing system has completed the purge cracks or holes that could create a DEF leak path. c y c l e .
Page 225: Water Cooling System
TMS700E SERVICE MANUAL POWER TRAIN WATER COOLING SYSTEM part directly responsible is not a part of the cooling system. Most of these problems can be traced to overheating; Description however, an engine that is running too cold can be just as troublesome.
Page 226 POWER TRAIN TMS700E SERVICE MANUAL Run the engine for 5 minutes and recheck the NOTE: A fill rate faster than 11 l/min (3.0 gpm) can give a antifreeze/coolant level. Refill as necessary repeating false reading. step 1. Verify a steady stream of fluid (no more than 1 l (1 qt)) at DEF tank petcocks (1 and 2) then close.
Page 227: Cleaning
Stop the engine as often as necessary to prevent boiling. normal; install non-charged filter if SCA levels are above With the engine stopped, feel the radiator core with bare normal (contact Manitowoc Crane Care for filter part hands to check for cold spots, and then observe the number).
Page 228: Component Inspection
POWER TRAIN TMS700E SERVICE MANUAL 11. Blow insects and dirt from the radiator core air Engine Water Jacket passages, using water, if necessary, to soften The water jacket permits coolant to be circulated around the obstructions. cylinder walls, combustion chamber, and valve assemblies. Some of these coolant passages are small and can easily Component Inspection become clogged, if the cooling system does not receive the...
Page 229: Radiator Assembly Removal And Installation
TMS700E SERVICE MANUAL POWER TRAIN hydrometers are not accurate enough for use with heavy Summary, page 7-22. There is a shut off valve located on the duty diesel cooling systems. coolant filter head. Turn it to the OFF position before removing the filter.
Page 230 POWER TRAIN TMS700E 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 231 TMS700E 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 232 POWER TRAIN TMS700E SERVICE MANUAL Remove the hardware securing the top center hood brackets using the mounts, hardened washers, and panel to the front and rear cowls and remove the panel nuts. with doors from the crane. Position the fan guard on the shroud and secure with Remove the hardware securing the left and right lower bolts, washers, and lockwashers.
Page 233: Drive Train
TMS700E SERVICE MANUAL POWER TRAIN DRIVE TRAIN Removal Support the drive shaft being removed so it does not fall Description when disconnected. If removing the coupling shaft assembly or the forward slip shaft assembly, support the The drive train consists of the manual transmission, clutch, other shaft also.
Page 234 POWER TRAIN TMS700E SERVICE MANUAL Torque all fasteners according to Fasteners and Torque Values on page 1- DETAIL A FIGURE 7-11 7-30 Published 01-29-2015, Control # 512-01...
Page 235: Clutch
TMS700E SERVICE MANUAL POWER TRAIN CLUTCH The driven plates rotate inside the clutch assembly but are not fastened to the clutch assembly. The driven discs’ Description splined center holes mate with the transmission input shaft, but unless the flywheel pressure plate contacts them, they The clutch (Figure 7-12) is a 15-1/2 in (39.4 cm), 2-plate, will not rotate, nor will the transmission input shaft.
Page 236 POWER TRAIN TMS700E SERVICE MANUAL 6, 7 4749 FIGURE 7-12 Item Description Item Description Clutch Assembly Lockwasher Clutch Pedal Adjusting Lever Bolt Governor Spring Clutch Release Shaft and Yoke Pilot Bearing (ref.) Throw Out Bearing Crank Throw-Out Bearing Grease Fitting 7-32 Published 01-29-2015, Control # 512-01...
Page 237: Maintenance
TMS700E SERVICE MANUAL POWER TRAIN Maintenance Troubleshooting Table 7-1 SYMPTOM PROBABLE CAUSE SOLUTION Chatter. Loose, broken, or worn engine mounts. Tighten or replace mounts. b. Loose or cracked clutch housing. b. Tighten or replace. Rear axle attach bushings worn. Replace bushings. d.
Page 238 POWER TRAIN TMS700E SERVICE MANUAL SYMPTOM PROBABLE CAUSE SOLUTION Insufficient release. Driven disc distorted or warped. Driven disc assembly must be straight (continued) within 0.38 mm (0.015 in) total indicator reading. Replace discs. Damage to driven disc can be caused by poor installation methods.
Page 239 TMS700E SERVICE MANUAL POWER TRAIN SYMPTOM PROBABLE CAUSE SOLUTION Noisy clutch. Clutch release bearings Lubricate bearing. Replace damaged. damaged. b. Flywheel pilot bearing dry or damaged. b. Lubricate bearing. Replace damaged. Clutch release bearing housing striking Adjust clutch. Also check wear on flywheel ring.
Page 240 POWER TRAIN TMS700E SERVICE MANUAL 10 Springs need 21.7 cm (8.56 in) bore. 7 Springs need 24.8 cm (9.75 in) bore. 9 Springs need 24.8 cm (9.75 in) bore. Insert the aligning tool through the release bearing sleeve in the new clutch (Figure 7-17). 4863-4 FIGURE 7-15 Move the gauge finger to contact the pilot bearing bore...
Page 241 TMS700E SERVICE MANUAL POWER TRAIN 4863-9 FIGURE 7-21 Install the front disc on the aligning tool with the side 4863-7 FIGURE 7-19 stamped “flywheel” facing the engine (Figure 7-21). NOTE: It’s imperative that the side stamped “flywheel” faces the engine and the side stamped “pressure Flush plate”...
Page 242 POWER TRAIN TMS700E SERVICE MANUAL After tapping, the pins should be flush against the flywheel (Figure 7-24). CAUTION Failure to tighten the bolts in this manner can cause permanent damage to the clutch or create an out-of- balance condition. Tighten the bolts in the criss-cross sequence to pull the clutch into its proper position in the flywheel pilot.
Page 243 TMS700E SERVICE MANUAL POWER TRAIN The release levers of new or factory exchange cover assemblies are properly adjusted and locked at assembly Clutch Housing and will not require further adjustment. However, after the transmission has been securely attached to the engine, the release sleeve must be adjusted until the correct distance between the surface of the release bearing housing and the front brake disc is obtained.
Page 244: Gearshift And Transmission Shift Air System
POWER TRAIN TMS700E SERVICE MANUAL GEARSHIFT AND TRANSMISSION SHIFT Shifting Gears AIR SYSTEM The manual transmission’s gear shift has six drive locations and the neutral locations. The gear shift has a finger switch Description (range control switch) for high range and low range, and a thumb switch (deep reduction switch) for deep reduction The remote location of the transmission from the shift lever in (Figure 7-27).
Page 245: Maintenance
TMS700E SERVICE MANUAL POWER TRAIN Maintenance Troubleshooting Table 7-2 SYMPTOM PROBABLE CAUSE SOLUTION Excessive lever Setscrews loose control shaft Tighten or replace setscrews. travel or sloppy feel universal joints or shift fingers. when shifting. Hard shifting. Bent shift transmission. Disassemble and repair as necessary Damaged cross shaft or bushings in master or slave unit.
Page 246: Manual Transmission
Troubleshooting Guide on the Roadranger web site for diagnostic procedures. If these cannot be One ratio in the front section is used only in low range as a retrieved, contact your distributor or Manitowoc starting gear. The remaining four ratios in the front section Crane Care.
Page 247 TMS700E SERVICE MANUAL POWER TRAIN SYMPTOM PROBABLE CAUSE SOLUTION Noisy transmission Transmission misaligned. Align engine transmission (in neutral). (assembled) with rear axle so as to correct angles of U-joints. b. Worn transmission pinion bearing. b. Replace bearing. Worn or scored countershaft bearing. Replace bearings.
Page 248 POWER TRAIN TMS700E SERVICE MANUAL SYMPTOM PROBABLE CAUSE SOLUTION Oil leakage. Transmission over filled. Drain to proper level. b. Breather stopped up. b. Clean breather assembly. Use of transmission oil that foams and Drain and refill with proper grade and expands when hot.
Page 249 TMS700E SERVICE MANUAL POWER TRAIN SYMPTOM PROBABLE CAUSE SOLUTION Bearing failure. Use of wrong lubricant or grade of Drain transmission; flush and refill with lubricant. proper grade and type of lubricant. b. Bearings adjusted too tight or too b. Obtain correct adjustment. loose.
Page 250 POWER TRAIN TMS700E SERVICE MANUAL clutch release yoke rides up and over the release between the release bearing and the clutch brake. The bearing (throw-out bearing) while the shaft goes into the correct distance should be 12.7-14.2 mm (0.500-.560 in) pilot bearing.
Page 251 TMS700E SERVICE MANUAL POWER TRAIN Maintain the oil level. Inspect regularly. Change the oil regularly. Use the correct grade and type of oil. Buy from a reputable dealer. Draining Oil Drain the transmission while the oil is warm. Remove the drain plug at the bottom of the case.
Page 252 POWER TRAIN TMS700E SERVICE MANUAL • Clutch Housing Mounting. Check all capscrews in the • Filler and Drain Plugs. Remove the filler plugs and bolt circle of the clutch housing for looseness. check the level of lubricant at specified intervals. Tighten the filler plug and drain plug securely.
Page 253 TMS700E SERVICE MANUAL UNDERCARRIAGE SECTION 8 UNDERCARRIAGE SECTION CONTENTS Front Axle And Suspension....8-2 Description......8-37 Description .
Page 254: Front Axle And Suspension
UNDERCARRIAGE TMS700E SERVICE MANUAL FRONT AXLE AND SUSPENSION respective pressure switch to illuminate the Deflated Indicator on the side console. Description Maintenance Front Axle General The carrier has two non-driving front steer axles (see Proper preventive maintenance will help control repair costs Figure 8-1).
Page 255 TMS700E SERVICE MANUAL UNDERCARRIAGE FIGURE 8-1 Grove Published 01-29-2015, Control # 512-01...
Page 256 UNDERCARRIAGE TMS700E SERVICE MANUAL Remove the bolts, hardened washers, and nuts securing each of the torque rods to the carrier frame. Item Description Remove the cotter pin and nut securing each vertical Steering Column socket drag link to its axle. Steering Gearbox Remove the cotter pin and nut (and washers if any) Vertical Socket Drag Link...
Page 257 TMS700E SERVICE MANUAL UNDERCARRIAGE Position the air bag(s) on the saddle assembly and (100 to 125 lb-ft). Tighten to nearest cotter pin hole and secure each with a bolt and lockwasher. insert cotter pin. Position the trunnion tube through the center bushing on Attach the four torque rods to the carrier frame using two each walking beam.
Page 258 UNDERCARRIAGE TMS700E SERVICE MANUAL DIM. C King Pin Center King Pin Center C/L Of First Front Axle C/L Of Front Bogie String Line King Pin Center C/L Of Last Front Axle King Pin Center Longitudinal Measurement Diagonal Measurement String Line Longitudinal Measurement Diagonal Measurement C/L Of Rear Axle...
Page 259 TMS700E SERVICE MANUAL UNDERCARRIAGE Toe-In Adjustment Tire front distance is less Cramp Angle than tire rear distance as measured on the axle center line. (1.5 mm or 0.06 in difference) FIGURE 8-3 3.0 mm (0.12 in) Toe-in (see Figure 8-3) is having the wheels of a steerable minimum FIGURE 8-4 axle closer together in the front than in the rear.
Page 260 UNDERCARRIAGE TMS700E SERVICE MANUAL Remove the relay arm rig pins and secure all drag links. If greased plates are not available, raise the crane 3.75 cm (1.5 in) from the static height by lowering the Check that the rod ends on all drag links are within the outrigger jack cylinders.
Page 261 TMS700E SERVICE MANUAL UNDERCARRIAGE Front Relay Arm Rig Pin Rear Relay Arm Rig Pin Drag Link (Detail #7) Rear Relay Arm (Detail #8) Drag Link (Detail #6) Steering Front Relay Arm Drag Links (Detail #5) Gearbox (Detail #9) 43.4 mm (1.71 in) 35.6 mm (1.40 in) Max.
Page 262 UNDERCARRIAGE TMS700E SERVICE MANUAL DETAIL A DETAIL B INLET GAUGE PORT FRONT PLUNGER NEWER CRANES TYPICALLY HAVE A TEST REAR PLUNGER ADJUST LEFT HAND TURN. PORT ON THE LINE TO THIS PORT WHICH ADJUST RIGHT HAND TURN. SCREW IN TO DECREASE TRAVEL. ALLOWS TESTING WITHOUT LINE SCREW IN TO DECREASE TRAVEL.
Page 263 TMS700E SERVICE MANUAL UNDERCARRIAGE Install a pressure check diagnostic quick disconnect with measuring the distance at the front and rear of the gauge on the test port upstream of the inlet gauge port of saddle assemblies. If necessary, adjust the height control valves to raise or lower the saddle assemblies the power steering gearbox.
Page 264: Steering System
UNDERCARRIAGE TMS700E SERVICE MANUAL Once all four corners are adjusted, drive the machine STEERING SYSTEM forward at a slow speed and “tap” the brake pedal to bounce the machine. Do this 3 times going forward, then Description 3 times in reverse. The steering system is comprised of the steering gearbox, Repeat steps 3 through 5 until all the trailing arms steer pump, and two steer cylinders.
Page 265 TMS700E SERVICE MANUAL UNDERCARRIAGE Symptom Probable Cause Solution Lubricating oil discolored or smells Operating temperatures too Check and correct cause of bad. high. overheating. b. Change intervals too long. b. Change oil more often. Incorrect lubricant used. Drain, flush, and refill with recommended lubricant.
Page 266 UNDERCARRIAGE TMS700E SERVICE MANUAL Symptom Probable Cause Solution King pins seized or binding. Repair or replace. Oil flow rate incorrect. Check and correct supply pump. 17. Darting, wandering, oversteering. Oil flow too high. Supply pump specifications. b. Air trapped in steering gear. b.
Page 267: Steering Pump
TMS700E SERVICE MANUAL UNDERCARRIAGE be determined by connecting a pressure gauge at the NOTE: The steering gearbox weighs approximately 79 kg pump outlet port or at the steering gear inlet port. With (176 lb). the engine running at a medium speed, turn the steering Support the weight of the gearbox.
Page 268: Steer Cylinder
UNDERCARRIAGE TMS700E SERVICE MANUAL 14.44 Degrees 14.69 Degrees FIGURE 8-9 STEER CYLINDER Removal Tag and disconnect the hydraulic lines to the cylinder. Description Cap or plug all lines and openings. The steer cylinders are double acting hydraulic cylinders and Remove the cotter pin, washer, and the retaining nut are controlled by a steering control valve located in the from each end of the cylinder.
Page 269: Rear Axle And Suspension
TMS700E SERVICE MANUAL UNDERCARRIAGE REAR AXLE AND SUSPENSION Maintenance Description General Proper preventive maintenance will help control repair costs Rear Axle and downtime. If a major overhaul is required, remove the The rear axles (see Figure 8-10) have single reduction tandem suspension and axle assemblies from the carrier.
Page 270 UNDERCARRIAGE TMS700E SERVICE MANUAL FIGURE 8-10 Item Description Item Description Drive Axle Air Bags Air Brake Chamber Walking Beam Torque Rod Shock Absorber Lower Saddle Assembly Drive Line 8-18 Published 01-29-2015, Control # 512-01...
Page 271 TMS700E SERVICE MANUAL UNDERCARRIAGE Height Control Valves Remove the drive line between the two rear axles. Remove the bolts, hardened washers, and nuts securing Check valve, fittings, and air lines for leaks. Check actuating each fore and aft torque rod to the axle brackets. linkage for bent or damaged condition.
Page 272 UNDERCARRIAGE TMS700E SERVICE MANUAL Installation p o s s i b l e d a m a g e t o s u s p e n s i o n a n d a x l e components. Position the axle and suspension assembly under the Start crane and charge the air system until the air carrier.
Page 273: Wheels And Tires
TMS700E SERVICE MANUAL UNDERCARRIAGE WHEELS AND TIRES lubricate the wheel pilot or hub pads only with an antiseize compound or synthetic lubricant with Description teflon. Do not lubricate wheel or hub faces. Raise the crane on outriggers so the front wheels are off The following tire size is available for the axles: the ground.
Page 274 UNDERCARRIAGE TMS700E SERVICE MANUAL Mounting the Wheels on the Rear Axle Tighten the lug nuts in the sequence shown to a preliminary torque of 68 Nm (50 lb-ft) (see Figure 8-14). NOTE: Do not lubricate the wheel studs or lug nuts or the Keep tightening the lug nuts in the sequence shown until wheel face or the hub.
Page 275: Brakes
TMS700E SERVICE MANUAL UNDERCARRIAGE BRAKES have vacuums with high efficiency (HEPA) filters and workmans’ arm sleeves. If such equipment is not Description available, carefully clean parts and assemblies in the open air. The front brakes (see Figure 8-15) are air actuated brakes Clean brake parts and assemblies in the open air.
Page 276: Maintenance
UNDERCARRIAGE TMS700E SERVICE MANUAL Maintenance Table 8-2 Troubleshooting 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.
Page 277 TMS700E SERVICE MANUAL UNDERCARRIAGE FIGURE 8-15 Item Description Item Description Cast Spider With Horse Collar Camshaft Shim Washers Shoe Retainer Springs (Color-Orange) Slack Adjuster Inner Washer Shoe Assembly Camshaft Bushing Cam Head Washer Shoe Return Springs (Color-Red) Camshaft Retainer Snap Ring Roller Slack Adjuster Inspection Hole Plug...
Page 278 UNDERCARRIAGE TMS700E SERVICE MANUAL Item Description Lift up the end of Camshaft Bushing the brake shoe. Grease Seal Dust Shield Retainer Roller Forged Spider Shoe Assembly Shoe Return Springs (Color-Grey) Camshaft Cam Head Washer Remove the roller with retainer spring. Spider (Steel Stamped) Retainer FIGURE 8-17...
Page 279 TMS700E SERVICE MANUAL UNDERCARRIAGE Remove all four screws Dust Shield FIGURE 8-21 19. Clean brake parts as outlined below: FIGURE 8-19 CAUTION Oxidation and dirt on the outside of brake drum acts as an 13. Remove the shoes from the axle (see Figure 8-19). insulator and may hinder heat dissipation.
Page 280 UNDERCARRIAGE TMS700E SERVICE MANUAL Check the linings and replace the shoes if contaminated, 14. Check the air chamber bracket mounting studs for cracked, or worn to less than 6.35 mm (0.25 in) looseness, damaged threads, or bent studs. Replace as thickness at any point.
Page 281 TMS700E SERVICE MANUAL UNDERCARRIAGE Install new grease seals with a piloted driver so the seals are flush with the end of the air chamber bracket tube At cam head end, recess (see Figure 8-21). bushing 7.1 mm (0.281 in) Assembly Position the spider on the axle flange and install attaching bolts and nuts.
Page 282: Automatic Slack Adjuster
UNDERCARRIAGE TMS700E SERVICE MANUAL into the web holes. Make sure that both loops are Removal engaged in the web holes. CAUTION g. Repeat steps (d) thru (f) on the upper shoe. You must disengage a pull pawl before rotating the Install the drum and axle spindle nut(s) and washers.
Page 283: Adjustment Procedures
NOTE: If the items referred to in step 3 and 4 are not stored on the chamber, they must be obtained from the vehicle tool box or Manitowoc Crane Care, as FIGURE 8-25 the piggyback spring brake cannot be manually released without them.
Page 284 UNDERCARRIAGE TMS700E SERVICE MANUAL 7092-2 FIGURE 8-27 Insert the release-bolt into the center hole of the head. 7092-4 Ensure the formed end of the bolt has entered the hole FIGURE 8-29 in the piston inside the chamber. Continue to insert the bolt until it bottoms out (Figure 8-28).
Page 285 TMS700E SERVICE MANUAL UNDERCARRIAGE To reactivate the piggyback/spring brake from its 12. Using a pry bar, move the slack adjuster so that the manually-released position, reverse the order of steps 8 linings contact the drum. Measure the distance between the same points as in step 11. This dimension is “Y” in through 1.
Page 286: Installation
UNDERCARRIAGE TMS700E SERVICE MANUAL Apply Anti-Seize type lubricant to camshaft splines. Alternative 2 Install the brake onto the camshaft with the adjusting hex pointing away from the brake chamber. NOTE: If your slack adjuster is as pictured in Figure 8-34, use the removal, installation and adjustment NOTE: Do not pull push rod out to meet the brake adjuster.
Page 287 (3.00 in) stroke units. If after adjustment the requirements in step 7 cannot be met, contact your distributor or Manitowoc Crane Care. The crane can not be driven on public roads until repaired. Brake Free Play Measurement and...
Page 288 UNDERCARRIAGE TMS700E SERVICE MANUAL CAUTION Do not exceed the length stated in step 3 and do not exceed 68 Nm (50 lb-ft) torque on release bolt at any time or damage may occur which could prevent any further correct manual release of the spring brake chamber. The dual thread release bolt which reduces the travel of the release bolt by a factor of 2.4 in a 76 mm (3.00 in) stroke unit, for instance, the parking spring is fully caged...
Page 289: Rear Brakes
TMS700E SERVICE MANUAL UNDERCARRIAGE Using a pry bar, move the slack adjuster so that the If installation indicator is not positioned properly, refer to linings contact the drum. Measure the distance between Figure 8-39. Loosen fastener holding indicator to anchor bracket, rotate indicator as required and retighten the same points as in step 4.
Page 290: Maintenance
UNDERCARRIAGE TMS700E SERVICE MANUAL Maintenance Table 8-3 Troubleshooting Symptom Probable Cause Solution Brakes are poor or do not apply. Insufficient air pressure. Check for correct pressure at c o m p r e s s o r a n d b r a k e chambers.
Page 291 TMS700E SERVICE MANUAL UNDERCARRIAGE Symptom Probable Cause Solution Brake is dragging. Low spring brake hold-off air Check for minimum spring pressure, 70 psi (482 kPa). brake pressure, 4.82 bar (70 p s i ) . C h e c k f o r p r o p e r f u n c t i o n i n g o f a i r s y s t e m components.
Page 292 UNDERCARRIAGE TMS700E SERVICE MANUAL Unbolt the air brake chamber from the mounting bracket and remove the air brake chamber (see Figure 8-40). Installation Bolt the air brake chamber to the mounting bracket. Install the pin through the clevis and slack adjuster. Check brake adjustment.
Page 293 TMS700E SERVICE MANUAL UNDERCARRIAGE Place jack stands under the frame where the wheels are to be removed. Cage the spring brake with the caging bolt provided. Fully release the slack adjuster so that the shoes retract allowing the drums to clear the linings. To retract the slack adjuster, do the following: Brake Return...
Page 294 UNDERCARRIAGE TMS700E SERVICE MANUAL Apply brake lubricant to all parts except the linings and Camshaft Installation drums to prevent rust. Check all spider bolts for the correct torque (see Figure 8-45). Inspect Parts Check the spider for expanded anchor pin holes and cracks.
Page 295: Automatic Slack Adjuster
TMS700E SERVICE MANUAL UNDERCARRIAGE the camshaft through the spider and bracket so that the Pull each shoe away from the cam to permit enough camshaft turns freely. space to install the cam rollers and retainers. Press the ears of the retainer together to permit the retainer to fit between the brake shoe webs (see Figure 8-48).
Page 296: Automatic Slack Adjuster
UNDERCARRIAGE TMS700E SERVICE MANUAL AUTOMATIC SLACK ADJUSTER Maintenance Description Removal T h e a u t o m a t i c s l a c k a d j u s t e r ( s e e F i g u r e 8 -5 0 ) NOTE: See Figure 8-51 for steps 1 through 5.
Page 297 TMS700E SERVICE MANUAL UNDERCARRIAGE Rotate the adjusting hex nut clockwise until the slack adjuster arm hole lines up with the clevis hole (see Figure 8-52). Rotate the Control Install the clevis pin without the cotter pin at this time. Arm Until it Stops CAUTION Excessive positioning force may damage control arm.
Page 298 UNDERCARRIAGE TMS700E SERVICE MANUAL Brake Adjustment Spin the wheel by hand to check for drag. Tap the drum lightly with a hammer and listen for a sharp ringing NOTE: See Figure 8-54 for adjustment procedure. sound. If drag is noted, back off the slack adjuster and recheck free stroke.
Page 299: Air System
TMS700E SERVICE MANUAL UNDERCARRIAGE AIR SYSTEM The compressor, which is mounted on and driven by the engine, is regulated by an air governor which vents the Description compressor when a pressure of 9.30 bar (135 psi) is sensed in the air system. When pressure drops to 7.90 bar (115 psi), The air system (see Figure 8-55) provides the air supply to the governor will allow the compressor to supply the air operate the service brakes, parking brakes, air suspension...
Page 300 UNDERCARRIAGE TMS700E SERVICE MANUAL 6223 VIEW E-E VIEW A-A 6473-4 VIEW D-D FIGURE 8-55 8-48 Published 01-29-2015, Control # 512-01...
Page 301 TMS700E SERVICE MANUAL UNDERCARRIAGE VIEW B-B VIEW C-C 6473-1 FIGURE 8-55 continued Grove Published 01-29-2015, Control # 512-01 8-49...
Page 302 UNDERCARRIAGE TMS700E SERVICE MANUAL The Air Pressure Low Light and warning buzzer should activate immediately. Item Description b. The red (rear primary) needle on the dual air gauge Auxiliary Reservoirs should rise to about 5.90 bar (85 psi) at which time the green (front/secondary) needle will begin to rise.
Page 303: Air System Components
TMS700E SERVICE MANUAL UNDERCARRIAGE The Air Pressure Low Light and warning buzzer will Air Dryer come on when the secondary air pressure drops below 5.17 ± 0.34 bar (75 ± 5 psi). b. The pressure in the secondary circuit should not drop below 5.90 ±0.34 bar (85 ±5 psi).
Page 304 UNDERCARRIAGE TMS700E SERVICE MANUAL Reservoirs Six air reservoirs store compressed air for braking and auxiliary air devices. The first reservoir in the system (front primary supply) also acts as a purge tank to remove additional moisture not removed by the air dryer. It contains an automatic drain valve.
Page 305 TMS700E SERVICE MANUAL UNDERCARRIAGE There are three pressure protection valves in the air system. The purpose of the pressure protection valve (see Figure 8-61) is to isolate one system from the other by closing at a preset 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 306: Maintenance
UNDERCARRIAGE TMS700E SERVICE MANUAL valves. One valve controls the front #2 axle service brakes, park brakes are disengaged. The button will pop out when one valve controls the rear axle service brakes, and the other the air pressure falls below 2.80 bar (40 psi) exhausting the valve controls the rear parking brakes.
Page 307 TMS700E SERVICE MANUAL UNDERCARRIAGE Disconnect and tag the air lines connected to the air Leakage Test compressor. Leakage checks on the governor are made at the Unbolt and remove the compressor from the engine. exhaust port with a soap solution in both the cut-in and cut-out positions.
Page 308 UNDERCARRIAGE TMS700E SERVICE MANUAL Every 900 hours, or 40,000 km (25,000 mi) check for Leak Tests moisture in the air system by opening the reservoir’s Test the outlet port check valve in the dryer by observing drain cock or automatic drain valve. the pressure after the governor cuts out.
Page 309 TMS700E SERVICE MANUAL UNDERCARRIAGE Operating and Leakage Checks Remove the hardware securing the gauge to the front console and remove the gauge. Shut down the engine and slowly reduce the pressure. Installation The switch should activate at about 5.20 bar (75 psi). The air gauges and indicators in the cab can be used to Install the air pressure gauge in the front console with test the switch.
Page 310 UNDERCARRIAGE TMS700E SERVICE MANUAL Cleaning Pressure Protection Valve Clean all metal parts in cleaning solvent. Removal Wipe clean all rubber parts and replace the filter if Chock the wheels and completely depressurize both air clogged. systems. NOTE: Do not reinstall the valve without a clean filter. Tag and disconnect the two air lines from the pressure protection valve and remove the capscrews, nuts and Replace all worn parts.
Page 311 TMS700E SERVICE MANUAL UNDERCARRIAGE Double Check Valve Relay Valve Removal CAUTION Chock the wheels and completely depressurize both air systems. Completely depressurize all reservoirs before removing the insert. Tag and disconnect the air lines connected to the double check valve. The inlet/exhaust valve assembly can be replaced without Remove the two nuts and washers securing the valve to removing the valve.
Page 312 UNDERCARRIAGE TMS700E SERVICE MANUAL Preventive Maintenance Preventive Maintenance Every 300 hours, 16,000 km (10, 000 mi), or monthly. Every 300 operating hours, 16,000 km (10,000 mi), or three months. Check the relay valve for leakage and proper operation. Clean dirt away from the heal of the treadle, plunger Every 3600 operating hours, 160,000 km (100,000 mi), or boot, and mounting plate.
Page 313 TMS700E SERVICE MANUAL UNDERCARRIAGE Operating and Leakage Check Cleaning and Inspection NOTE: Replace malfunctioning or leaking parking brake Clean all parts and inspect the threads, body, and cover valve. for damage. Chock the wheels and pressurize the air system. Inspect the exhaust seat for scratches or pitting. With the park brake valve plunger pulled out (exhaust Assembly position), coat the exhaust port and plunger stem with a...
Page 314: Outriggers
UNDERCARRIAGE TMS700E SERVICE MANUAL OUTRIGGERS Theory of Operation When the outrigger cylinder is activated, it extends or re- Description tracts the outrigger beam within the outrigger box. The jack The outriggers, when properly extended and set, provide a cylinder is mounted to the end of the beam. The jack cylinder rigid four point platform which is capable of supporting the applies force to the outrigger beam vertically.
Page 315: Maintenance
TMS700E SERVICE MANUAL UNDERCARRIAGE Maintenance Troubleshooting Symptom Probable Cause Solution Slow or erratic operation of Damaged relief valve. Remove relief valve; clean or o u t r i g g e r e x t e n s i o n replace.
Page 316 UNDERCARRIAGE TMS700E SERVICE MANUAL Symptom Probable Cause Solution Sticking spool. Dirt in the system. Change oil and flush system. b. Distortion caused by tie bolts b. Retorque tie bolts. being overtorqued. Flow in excess of valve rating. Limit flow through valve to that recommended.
Page 317 TMS700E SERVICE MANUAL UNDERCARRIAGE Symptom Probable Cause Solution Outrigger jack cylinder Damaged piston seals. Replace all cylinder seals. retracts under load. b. Damaged holding valve seals. b. Replace seals. Damaged holding valve. Replace valve assembly. d. Scored cylinder barrel. d. Repair or replace cylinder. Cracked or damaged piston.
Page 318: Outrigger Beam
UNDERCARRIAGE TMS700E SERVICE MANUAL OUTRIGGER BEAM Place blocking material under the outrigger beam (see Figure 8-66). Description Tag and disconnect the hydraulic lines at the cylinder barrel end of the extension cylinder. Cap all lines and The outrigger beam assembly (see Figure 8-65) consists of fittings.
Page 319 TMS700E SERVICE MANUAL UNDERCARRIAGE Installation Apply grease (EP-MPG) to the bottom of the outrigger CAUTION beam. Be sure that the piston side of all outrigger cylinders are connected to the solenoid valve bank. Reversal of port If removed, install the side adjustable wear pad in the connection of the rod and piston sides could result in outrigger beam.
Page 320 UNDERCARRIAGE TMS700E SERVICE MANUAL 5, 6 5, 6 14, 15 16, 17 8, 9, 10, 11 FIGURE 8-65 Item Description Item Description Lower Front Wear Pad Retainer Pin Setscrew Cotter Pin Jack Cylinder Mid Extension Lock Outrigger Box CAUTION Clevis Pin During initial start-up and checking of the outrigger operation, each control switch must be operated before Cotter Pin...
Page 321: Outrigger Extension Cylinder
TMS700E SERVICE MANUAL UNDERCARRIAGE NOTE: Rear Outrigger Shown NOTE: Outrigger removal and installation similar for both front and rear outriggers, NOTE: Lifting belts or straps should be used for lifting purposes so as to avoid nicking or scratching the FIGURE 8-66 bottom edges of the outrigger beam.
Page 322: Outrigger Monitoring System (Optional-Standard In North America)
UNDERCARRIAGE TMS700E SERVICE MANUAL plate, and for proper tracking during beam Removal extension and retraction. Extend the outrigger beam slightly for improved access and shut down the engine. 18° Remove the outer access cover plate from outrigger box. 10° Remove the OMS string potentiometer (1, Figure 8-68) connector (2) from the attaching point on the outrigger beam.
Page 323: Outrigger Jack Cylinder
TMS700E SERVICE MANUAL UNDERCARRIAGE Installation Remove the cotter pins securing the cylinder retaining pin and remove the cylinder retaining pin and cylinder Install string potentiometer inside outrigger beam. cap retaining bracket. Install the OMS string potentiometer enough to engage Jack the jack cylinder up just enough to insert the slotted hole with the mounting hardware (Figure 8-68).
Page 324 UNDERCARRIAGE TMS700E SERVICE MANUAL Checking Cylinder for Internal Piston Seal Leak Fully extend and set the outriggers. Extend Port Retract Port 15° Piston Port 15° Rod Port NOTE: Keep hydraulic fittings and hoses close to angles shown for proper tracking during extension and retraction.
Page 325: Outrigger System Valves
TMS700E SERVICE MANUAL UNDERCARRIAGE Testing Pilot Operated Check Valve for Leakage manifold consists of four 12 volt solenoid valves and assembly mounting hardware. The front manifold consists of Fully extend and set the outriggers. five 12 volt solenoid valves and assembly mounting hardware.
Page 326 UNDERCARRIAGE TMS700E SERVICE MANUAL Welded tube shown with cylinder inside and with cylinder tube cap outside fastened to cap bracket inside. Wear rings are shown inside because they keep cylinder and tube from making metal-to-metal contact. Cylinder rod end is on top and barrel end is on bottom. 6512 FIGURE 8-71 Item...
Page 327 TMS700E SERVICE MANUAL UNDERCARRIAGE Jack the jack cylinder up just enough to insert the Lower the jack until the holes in the cylinder rod align retaining pin back into the cylinder’s lugs. Insert the with the holes in the tube. Apply grease (EP-MPG) to the retaining pin.
Page 328 UNDERCARRIAGE TMS700E SERVICE MANUAL 8-76 Published 01-29-2015, Control # 512-01...
Page 329: Section 9
Dispose of waste properly! Improperly disposing of waste can threaten the environment. ALL WEATHER PACKAGE & LUBRICANTS Potentially harmful waste used in Manitowoc cranes includes Arctic Conditions Down to -40°C (-40°F) — but is not limited to — oil, fuel, grease, coolant, air...
Page 330: Standard Lubricants Package
LUBRICATION TMS700E SERVICE MANUAL operate at extreme low temperatures. We also recommend Grease - Spec 6829104275: the use of appropriately sized heaters for the hydraulic tank, • Petro-Canada Precision Synthetic EP1 engine oil pan, engine water jacket and batteries. The operator needs to follow the guide lines as stated in the •...
Page 331: Lubrication Points
TMS700E SERVICE MANUAL LUBRICATION • Petro-Canada Traxon E Synthetic CD50 Diesel Exhaust Fluid (DEF)– Spec 80019225: • Chevron Delo Transmission Fluid SAE 50 • Fleetguard StableGuard™ Urea 32 Premix • Conoco/Phillips/Union 76 Triton Synthetic Transoil 50 • AdBlue® Hydraulic Tank - Spec 6829006444: •...
Page 332 LUBRICATION TMS700E SERVICE MANUAL Table 9-1: Standard Lube Symbol Chart Symbol Description Antifreeze/Coolant - 50/50 Blended, Fully Formulated - SAE Grade J1941 Engine Oil - SAE 15W-40, API Service Classification CJ-4. (CI-4 for pre-2007 ISM engines) EP-MPG Extreme Pressure Multipurpose Grease - Lithium Soap Base, NLGI Grade 2. SGL-5 Synthetic Gear Lubricant - SAE Grade 50, API Gravity 23.
Page 333: Carrier Lubrication
TMS700E SERVICE MANUAL LUBRICATION CARRIER LUBRICATION Pump Drive Lube Type - SSGL-5 Engine Crankcase Lube Interval - Check fluid level every 100 hours or Lube Type - EO - 15W40 monthly, whichever interval occurs first. Drain and fill Lube Interval - Check fluid level every 10 hours or daily, every 500 hours.
Page 334 LUBRICATION TMS700E SERVICE MANUAL Transmission 11. Front Aluminum Wheel Pilots Shift U-Joints/Control Unit Lube Type - ASC Lube Type - EP-MPG Lube Interval - When wheels are removed for service. Lube Interval - 500 hours Lube Amount - Generously coat the wheel pilot or hub pads with antiseize compound.
Page 335 TMS700E SERVICE MANUAL LUBRICATION Side 10, 11 11, 12 15, 16 11, 12 15, 16 6772-1 6772-2 20, 21 20, 21 FIGURE 9-1 Grove Published 01-29-2015, Control # 512-01...
Page 336 LUBRICATION TMS700E SERVICE MANUAL 15. Rear Aluminum Wheel Pilots Lube Type - ASC Item Description Lube Interval - When wheels are removed for service. Engine Crankcase Lube Amount - Generously coat the wheel pilot or hub Engine Cooling System pads with antiseize compound. Do not apply antiseize Transmission compound to the face of the wheel of the hub.
Page 337 TMS700E SERVICE MANUAL LUBRICATION NOTE: Figure 9-2 pertains to the differentials and the 21. Rear Axle Brake Camshafts planetary hubs and wheel bearings. Lube Type - EP-MPG Lube Interval - 1000 hours Lube Amount - Until grease extrudes Application - 4 grease fittings 22.
Page 338: Superstructure Lubrication
. S h o u l d y o u h a v e a n y interval occurs first questions, please contact your distributor or Manitowoc Crane Care. Lube Amount - Coat all teeth After 2000 hours or 2 years of service, an oil Application - Spray on sample should be taken and laboratory analyzed.
Page 339: Boom, Boom Extension, And Boom Accessories Lubrication
TMS700E SERVICE MANUAL LUBRICATION 33. Upper Lift Cylinder Pivot Pin and the temperature is 21°C ± 6.7°C (70°F ± 20°F). Drain and fill every 1000 hours or 12 months. Lube Type - EP-MPG Lube Amount - Capacity - 14.7 l (15.5 qt) Lube Interval - 500 hours or every 3 months, whichever interval occurs first Application - Fill until level is visible in sight gauge.
Page 340 LUBRICATION TMS700E SERVICE MANUAL FIGURE 9-3 NOTE: Should boom chatter or rubbing noises in the boom occur, it will be necessary to lubricate the telescope Item Description cylinder wear pads. By adding an extension Turntable Gear Box adapter to a grease gun the wear pads and wear areas can be reached through the lubrication Turntable Gear and Drive Pinion access holes in the side of the boom and through...
Page 341: Wire Rope Lubrication
TMS700E SERVICE MANUAL LUBRICATION 44. Boom Section Upper and Lower Wear Pads 49. Auxiliary Boom Nose Sheave Lube Type - EP-MPG Lube Type - EP-MPG Lube Interval - 50 hours or 1 week, whichever occurs Lube Interval - 250 hours or 3 months, whichever first interval occurs first Lube Amount - Thoroughly coat all areas the wear pad...
Page 342 LUBRICATION TMS700E SERVICE MANUAL 6772-3 6772-4 FIGURE 9-3 continued 9-14 Published 01-29-2015, Control # 512-01...
Page 343: Carwell® Rust Inhibitor
Manitowoc Crane Group's cranes are manufactured to high quality standards, including the type of paint finish Exercise special care and increase the frequency of demanded by today's industry.
Page 344: Inspection And Repair
To the extent any damage is structural in nature, • Use of pressure pots to apply the treatment to the unit Manitowoc Crane Care must be contacted and consulted being processed is recommended. as to what repairs may be required.
Page 345: Areas Of Application
• Superstructure applications are; hose ends and fittings, Please contact Manitowoc Crane Care should you have any wire rope on hoist roller, tensioning springs on hoists, all questions. unpainted fasteners and hardware, valves, slew ring fasteners and all bare metal surfaces.
Page 346 LUBRICATION TMS700E SERVICE MANUAL 7650-21 7650-22 FIGURE 9-4 9-18 Published 01-29-2015, Control # 512-01...
Page 347 TMS700E SERVICE MANUAL LUBRICATION Item Description Hoist Hose Connections Boom Extension Pins, Clips Valve Bank Hose Connections inside turntable Boom Extension Hanger Hardware Boom Nose Pins, Clips Hook block Tiedown Cable Headache Ball/Hook block Mirror Mounting Hardware O/R Hose Connections All Hardware, Clips, Pins, Hose Connections not painted O/R Pins, Clips Powertrain Hardware inside compartment...
Page 348 LUBRICATION TMS700E SERVICE MANUAL 9-20 Published 01-29-2015, Control # 512-01...
Page 349 TMS700E SERVICE MANUAL Alphabetical Index 360° Swing Lock Control (Positive Lock Type) (Optional) ..... . . 6-20 Aftertreatment Diesel Exhaust Fluid (DEF) ........7-18 Air Intake System.
Page 350 SERVICE MANUAL TMS700E Needle Valve ............2-47 Oil Cooler .

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