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Manitowoc Grove TMS9000-2 Service Manual

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Summary of Contents for Manitowoc Grove TMS9000-2

  • Page 1 Grove TMS9000-2 Service Manual...
  • Page 2 WARNING California Proposition 65 Breathing diesel engine exhaust exposes you to chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. • Always start and operate the engine in a well-ventilated area. • If in an enclosed area, vent the exhaust to the outside.
  • Page 3 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 This Page Blank...
  • Page 5 Manitowoc Cranes 1565 Buchanan Trail East PO Box 21 Shady Grove, PA 17256-0021 T 717 597 8121 F 717 593 5999 www.manitowoc.com Information Only Service Manual Supplement Date Month/day/year Mobile Crane Distributor Service Managers Mobile Crane Field Support Personnel Subject: Rev 2 Suspension Alignment Supplement;...
  • Page 6 Page 2 January 2019 ALTERNATIVE PROCEDURE: To enable a customer’s service department to make axle and front-end alignment adjustments when suspension, tire, and/or steering performance is poor: STEP 1. When an issue with tire, suspension, and/or steering performance is identified, the customer should fill out a “Field Alignment Worksheet”...
  • Page 7 Crane Care is to advise remedy. Adjust steer wheel-end toe. Position/s: Adjust drive axle thrust. Adjust drive axle parallelism. Test and report result to Manitowoc Crane Care. Tools (other than miscellaneous wrenches): Camber/Caster alignment tool (if available) Dial Indicator/s Thrust alignment tool (if available)
  • Page 8 Page 4 January 2019 Machine Preparation: NOTE: Alignments should be performed on a level surface. Height of tire patches should be within 1/8” of each other. • For field alignment configure the machine in the most common roading condition and inflate all tires to 130 psi. •...
  • Page 9 Page 5 January 2019 Machine Preparation continued: • Adjust ride height - front and rear. Note: When setting ride height and measuring alignment settings be certain that the air system is at full system pressure; re-charge frequently. • Place wheel chocks on drive axles and release the park brake. •...
  • Page 10 Page 6 January 2019 Adjust axle offset. • Measure the distance between the frame side plate to the edge of the tire tread centered over the axle, left and right; these measurements should be within 3/16 in. (4.8 mm). Note: steering axle and drive axle measurements will be different; axle lengths and frame widths are different.
  • Page 11 Page 7 January 2019 Adjust steer axle skew. • Raise the machine on outriggers and place an alignment turntable under each of the steer tires. Lower the machine making certain not to bottom-out the turntables or put them in a bind. •...
  • Page 12 Page 8 January 2019 Adjust steer axle parallelism. • Distance between the steer axle hub centers on the left and right side of the machine should be within 1/8 in. (3.2 mm). This can be measured, or the process can be simplified by use of a Trammel bar if available. •...
  • Page 13 Page 9 January 2019 Adjust steering linkage. • Rotate the steering wheel to center the front relay arm and pin it with a Ø 21/64 in. (0.8 mm) rig pin or drill bit. • Adjust the intermediate drag link to center the rear relay arm and pin it with a Ø...
  • Page 14 Page 10 January 2019 Adjust steering linkage continued. Note: Steer tires should be on alignment turntables for this step. • Adjust the front steer axle to “straight ahead.” • Using a 4 ft. (1.2 meter) or longer straight edge measure the front steer axle driver’s side tire, front and rear, to the frame side plate.
  • Page 15 Page 11 January 2019 Adjust steering linkage continued. Note: Steer tires should be on alignment turntables for this step. • Adjust rear steer axle to “straight ahead.” • Using a 4 ft. (1.2 m) or longer straight edge measure rear steer axle driver side tire, front and rear, to the frame side plate.
  • Page 16 Page 12 January 2019 Adjust steering linkage continued. • Adjust steering wheel orientation. • For major adjustments of the steering wheel, loosen the bolt on the steering column splined coupling, slide the coupling off the steering gear 90 Miter ° and rotate until the steering wheel is straight ahead.
  • Page 17 Page 13 January 2019 Adjust steer axle turning stops. • Steering stops should be set to provide 1.00 in. (25.4 mm) of clearance to closest object for any tire. Note: steering stops are located on the front steer axle only. Note: steer tires should still be on alignment turntables for this step.
  • Page 18 Page 14 January 2019 Adjust steer wheel-end caster. Caster should be positive 3.0 +/-0.5 ° ° Note: Steer tires should be on alignment turntables for this step. • Use professional alignment caster tool if available, otherwise place a digital angle gauge, calibrated/zeroed to the bottom frame rail, on the bottom of the king pin housing, longitudinally.
  • Page 19 January 2019 Steer wheel-end camber is not adjustable. Camber should be 1/16 ; if camber is out of tolerance it’s a sign of a part ° +/- 3/16° • defect, wear, or improper installation. Manitowoc Crane Care will provide direction.
  • Page 20 Page 16 January 2019 Adjust steer wheel-end toe. • Toe should be +1/32 in. (0.8 mm) +/-1/32 in. (0.8 mm). Note: Steer tires should be on alignment turntables for this step. • On the front steer axle measure the distance between the scribed lines (see “machine preparation for toe adjustment”) at hub height on the rear of the tires and then on the front of the tires.
  • Page 21 Page 17 January 2019 Adjust drive axle thrust. • Acceptable thrust misalignment is 0.75 in. (19 mm) maximum. (Note: Machine should be driven on a straight line for approximately 3 tire rotations prior to executing this step.) • If professional alignment equipment is not available, measure drive axle thrust by mounting a laser pointer parallel to the front drive wheel with the beam directed at the rear steer wheel and measure the distance between the rear steer wheel and beam.
  • Page 22 Page 18 January 2019 Adjust drive axle parallelism. • Distance between the drive axle hub centers on the left and right side of the machine should be within 1/8 in. (3.2 mm). This can be measured, or the process can be simplified by use of a Trammel bar if available. •...
  • Page 23 • Perform a straight-line test for acceptable tracking. • Perform a road test to assess steering performance and ride comfort. • If necessary, re-adjust to achieve desired performance and retest. • Advise Manitowoc Crane Care that the adjustments did or did not resolve your issues.

  • Page 25: Table Of Contents

    Signal Words............1-1 Manitowoc CraneCare Service instructions........1-2 Definitions of Stated Directions .
  • Page 26 TABLE OF CONTENTS TMS9000-2 SERVICE MANUAL Turntable Hydraulic Valves ......... . 2-26 Main Directional Valve Assembly .
  • Page 27 TMS9000-2 SERVICE MANUAL TABLE OF CONTENTS Troubleshooting Engine Charging Problems ......3-10 Troubleshooting Slip Ring-Caused Electrical Problems .
  • Page 28 TABLE OF CONTENTS TMS9000-2 SERVICE MANUAL Bleeding Procedure ..........4-44 Telescoping Status .
  • Page 29 TMS9000-2 SERVICE MANUAL TABLE OF CONTENTS Swing Brake Assembly Maintenance ........6-8 Swing Gearbox Maintenance .
  • Page 30 TABLE OF CONTENTS TMS9000-2 SERVICE MANUAL Maintenance ........... . . 7-26 Clutch Adjustment Procedure .
  • Page 31 TMS9000-2 SERVICE MANUAL TABLE OF CONTENTS Braking ............8-24 Maintenance .
  • Page 32 TABLE OF CONTENTS TMS9000-2 SERVICE MANUAL Lubrication Points ............9-2 Standard Lubricants.

  • Page 33: Section 1

    Boom Cleaning ......1-8 Manitowoc CraneCare Service instructions..1-2 Overview of the Components that are Easily Damaged when Cleaning .

  • Page 34: Manitowoc Cranecare Service Instructions

    Tightening torques may be found in Torque Values, page 1- Please note that Manitowoc Crane Care can only uphold the warranty provided for the truck crane if the following conditions are met: O u r t r a i n i n g c e n t e r a t o u r p l a n t i n S h a d y G r o v e , Pennsylvania offers specialized training programs.

  • Page 35: Breaking In A New Crane

    TMS9000-2 SERVICE MANUAL GENERAL INSTRUCTIONS BREAKING IN A NEW CRANE Special run-in instructions must be observed, i.e. additional maintenance work must be carried out on the carrier and the Special running-in instructions must be observed for superstructure in certain intervals: individual components (hoist, gearbox, etc.) after initial start-up or after part replacement or...

  • Page 36: Handling Substances Which Are Harmful To The Environment

    GENERAL INSTRUCTIONS TMS9000-2 SERVICE MANUAL HANDLING SUBSTANCES WHICH ARE • Keep all handles, steps, landings and ladders free of dirt, grease, snow and ice. HARMFUL TO THE ENVIRONMENT • Use the proper access aids and working platforms when What do Environmentally Harmful carrying out overhead work.

  • Page 37: Overview Of The Operating And Display Elements

    TMS9000-2 SERVICE MANUAL GENERAL INSTRUCTIONS OVERVIEW OF THE OPERATING AND • Only have collected environmentally harmful substances disposed of by disposal companies which are approved DISPLAY ELEMENTS by the national or regional authority responsible. NOTE: Refer to the Operator Manual for the operating and display elements.

  • Page 38: Axle Weight Distribution Table

    GENERAL INSTRUCTIONS TMS9000-2 SERVICE MANUAL 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 23224 (51200) 27216 (60000) Allowed Maximum Axle Loads Allowed 23224 (51200) 27216...
  • Page 39 TMS9000-2 SERVICE MANUAL GENERAL INSTRUCTIONS CG To CL Weight Front Axle Rear Axle Description Rear Bogie kg (lb) kg (lb) kg (lb) cm (in) 3000 lb counterweight (pin on with -246.05 (-96.87) 1369 (3019) -599 (-1321) 1969 (4340) pins) on S/S 2000 lb counterweight (pin on) on S/ -246.05 (-96.87)

  • Page 40: Cleaning

    GENERAL INSTRUCTIONS TMS9000-2 SERVICE MANUAL CG To CL Weight Front Axle Rear Axle Description Rear Bogie kg (lb) kg (lb) kg (lb) cm (in) 360° Swing Lock 117.91 (46.42) (88) (18) (70) Substitutions and Removals REM: Main Hoist Cable (820’ of 3/4” -176.91 (-69.65) -483...

  • Page 41: Overview Of The Components That Are Easily Damaged When Cleaning

    The torque tables are provided by Manitowoc for reference The use of lubricants on zinc-flake coated parts shall be when performing maintenance. prohibited since this will change the required torque value.

  • Page 42: Torque Wrenches

    GENERAL INSTRUCTIONS TMS9000-2 SERVICE MANUAL When referring to the applicable torque charts, use values as When using step wrenches, calculated wrench settings are close as possible to the torque values shown to allow for valid only when the following conditions are met: wrench calibration tolerance.
  • Page 43 TMS9000-2 SERVICE MANUAL GENERAL INSTRUCTIONS Table 1-1 Inch Series with Coarse Threads (UNC) – Zinc Flake Coated Nominal Size, Threads per Torque (ft/lb) Inch, and Series Grade Maximum Nominal Minimum Designation 1/4-20 UNC 13.5 13.2 12.8 5/16-18 UNC 19.1 18.6 18.1 24.0 23.4...
  • Page 44 GENERAL INSTRUCTIONS TMS9000-2 SERVICE MANUAL Table 1-2 Inch Series with Fine Threads (UNF) – Zinc Flake Coated Nominal Size, Threads per Torque (ft/lb) Inch, and Series Grade Maximum Nominal Minimum Designation 1/4-28 UNF 10.6 10.4 10.1 15.0 14.6 14.2 5/16-24 UNF 21.1 20.6 20.1...
  • Page 45 TMS9000-2 SERVICE MANUAL GENERAL INSTRUCTIONS Nominal Size, Threads per Torque (Nm) Property Inch, and Series Class Maximum Nominal Minimum Designation M6x1.0 10.9 12.2 11.9 11.6 12.9 14.3 13.9 13.6 20.2 19.7 19.2 M8x1.25 10.9 29.6 28.9 28.2 12.9 34.7 33.8 33.0 40.0 39.0...
  • Page 46 GENERAL INSTRUCTIONS TMS9000-2 SERVICE MANUAL Nominal Size, Threads per Torque (Nm) Property Inch, and Series Class Maximum Nominal Minimum Designation 2089.8 2037.6 1985.3 M36x4 10.9 2976.4 2902.0 2827.6 12.9 3483.0 3395.9 3308.9 Table 1-4 Metric Series with Fine Threads – Zinc Flake Coated Nominal Size, Threads per Torque (Nm) Property...
  • Page 47 TMS9000-2 SERVICE MANUAL GENERAL INSTRUCTIONS Nominal Size, Threads per Torque (Nm) Property Inch, and Series Class Maximum Nominal Minimum Designation 386.0 376.3 366.7 M20x1.5 10.9 549.7 535.9 522.2 12.9 643.3 627.2 611.1 520.8 507.8 494.8 M22x1.5 10.9 741.7 723.2 704.7 12.9 868.0 846.3...
  • Page 48 GENERAL INSTRUCTIONS TMS9000-2 SERVICE MANUAL Table 1-5 Metric Series Screws of STAINLESS STEEL A2-70/A4-70 with Coarse Threads Size Torque (Nm) M2.5x0.45 M3x0.5 M4x0.7 M5x0.8 M6x1 M8x1.25 M10x1.5 Torque Values for fasteners with lubrication these torque values result in an 80% utilization of the yield strength. Stainless steel fasteners tend to gall while being tightened.
  • Page 49 TMS9000-2 SERVICE MANUAL GENERAL INSTRUCTIONS Table 1-7 Inch Series Bearing Bolts – Untreated (Black Finish) Nominal Size, Threads per Torque (ft/lb) Inch, and Series Grade Maximum Nominal Minimum Designation 5/8-11 UNC 5/8-18 UNF 3/4-10 UNC 7/8-9 UNC 1-8 UNC 1 1/4-7 UNC 2043 1964 1885...
  • Page 50 GENERAL INSTRUCTIONS TMS9000-2 SERVICE MANUAL Table 1-9 Inch Series with Coarse Threads (UNC) – Untreated (Black Finish) Torque (ft/lb) Size Grade Maximum Nominal Minimum 1/4-20 12.5 11.5 5/16-18 3/8-16 7/16-14 1/2-13 9/16-12 5/8-11 259.5 3/4-10 7/8-9 1 1/8-7 1342 1288 1234 1141 1097...
  • Page 51 TMS9000-2 SERVICE MANUAL GENERAL INSTRUCTIONS Table 1-10 Inch Series with Fine Threads (UNF) – Untreated (Black Finish) Torque (ft/lb) Size Grade Maximum Nominal Minimum 1/4-28 14.5 13.5 5/16-24 3/8-24 7/16-20 84.5 1/2-20 9/16-18 174.5 5/8-18 299.5 3/4-16 439.5 7/8-14 1-12 1009 644.5 1-14...
  • Page 52 GENERAL INSTRUCTIONS TMS9000-2 SERVICE MANUAL Table 1-11 Metric Series with Coarse Threads – Untreated (Black Finish) Torque (Nm) Property Size Class Maximum Nominal Minimum M4x0.7 10.9 12.9 M5x0.8 10.9 12.9 10.5 10.5 M6x1 10.9 12.9 M8x1.25 10.9 36.5 12.9 43.5 M10x1.5 10.9 12.9...
  • Page 53 TMS9000-2 SERVICE MANUAL GENERAL INSTRUCTIONS Torque (Nm) Property Size Class Maximum Nominal Minimum 1134 1090 1046 M27x3 10.9 1591 1530 1469 12.9 1910 1836.5 1763 1538 1479 1420 M30x3.5 10.9 2163 2080 1997 12.9 2595 2495 2395 2681 2578.5 2476 M36x4 10.9 3964...
  • Page 54 GENERAL INSTRUCTIONS TMS9000-2 SERVICE MANUAL Table 1-12 Metric Series with Fine Threads – Untreated (Black Finish) Torque (Nm) Property Size Class Maximum Nominal Minimum M8x1 10.9 39.5 12.9 M10x0.75 10.9 12.9 M10x1.25 10.9 12.9 97.5 M12x1 10.9 12.9 M12X1.25 10.9 141.5 12.9 165.5...
  • Page 55 TMS9000-2 SERVICE MANUAL GENERAL INSTRUCTIONS Torque (Nm) Property Size Class Maximum Nominal Minimum 803.5 M24x2 10.9 1176 1130.5 1085 12.9 1410 1356 1302 1225 1171.5 1130 M27x2 10.9 1718 1652.5 1587 12.9 2063 1983.5 1904 1530 1471.5 1413 M30x1.5 10.9 2253 2166.5 2080...

  • Page 56: Weld Studs

    GENERAL INSTRUCTIONS TMS9000-2 SERVICE MANUAL Table 1-13: UNC (Coarse) Thread: Torque Values for Torque Stainless Steel Fasteners with Oil Lubrication Value Size Torque Value Size lb-in lb-ft #5 (0.125) — #8 (0.164) — 13.0 #10 (0.190) — 27.0 — 45.0 5/16 71.1 17.5...

  • Page 57: Section 2

    TMS9000-2 SERVICE MANUAL HYDRAULIC SYSTEM SECTION 2 HYDRAULIC SYSTEM SECTION CONTENTS Description ....... 2-2 Description.

  • Page 58: Description

    HYDRAULIC SYSTEM TMS9000-2 SERVICE MANUAL DESCRIPTION operation of individual hydraulic circuits are discussed within their individual sections as applicable. T h i s s e c t i o n d e s c r i b e s t h e h y d r a u l i c s y s t e m , t h e A complete hydraulic system schematic showing all options components which make up the hydraulic system, and the is at the back of this manual.
  • Page 59 TMS9000-2 SERVICE MANUAL HYDRAULIC SYSTEM FIGURE 2-1 Grove Published 01-14-2021 Control # 707-01...

  • Page 60: Maintenance

    HYDRAULIC SYSTEM TMS9000-2 SERVICE MANUAL FIGURE 2-2 Maintenance all systems must be thoroughly checked, drained, and flushed. Hydraulic Oil Recommendations Remove the reservoir drain plug. Allow about three For the hydraulic oil specifications, refer to Lubrication, page minutes after hydraulic oil stops flowing from the drain 9-1.

  • Page 61: Removing Air From The Hydraulic System

    TMS9000-2 SERVICE MANUAL HYDRAULIC SYSTEM Cycle the crane through all functions several times. 17. Repeat Steps 15 and 16 for the rear steering cylinders. Then return the crane to its stowed position and turn the 18. Raise the crane on outriggers. front and rear wheels to the extreme left.

  • Page 62: Parts Replacement

    HYDRAULIC SYSTEM TMS9000-2 SERVICE MANUAL lines to the pumps, air can enter the system. If air becomes In the event that air entrapment should persist, bleeding of entrapped in the hydraulic oil, it may be detectable in pumps air by loosening various clamp and screw type fittings may and motor operated components such as the swing become necessary.

  • Page 63: Pump Distribution

    TMS9000-2 SERVICE MANUAL HYDRAULIC SYSTEM A sight gauge is located on the side of the reservoir to when adding to the tank. The breather should be replaced indicate hydraulic oil level. when the hydraulic oil filter is changed, 6 months or 500 hours.
  • Page 64 HYDRAULIC SYSTEM TMS9000-2 SERVICE MANUAL 9234 FIGURE 2-3 Item Description Item Description Reservoir Return Manifold Breather Straps Magnetic Plug Mounting Bracket Thermistor Access Cover Temperature Switch Return Filter Published 01-14-2021 Control # 707-01...

  • Page 65: Maintenance

    TMS9000-2 SERVICE MANUAL HYDRAULIC SYSTEM MAINTENANCE Troubleshooting SYMPTOM PROBABLE CAUSE SOLUTION No hydraulic oil flows in Low hydraulic oil level. Fill reservoir. systems. Clean, repair, or replace lines Reservoir-to-pump suction as necessary. Check lines for lines broken or restricted. Air security, absence of cracks, entering at suction lines.

  • Page 66: Return Hydraulic Filter Assembly

    HYDRAULIC SYSTEM TMS9000-2 SERVICE MANUAL SYMPTOM PROBABLE CAUSE SOLUTION Leak in system. Repair leak. Adjust or replace controls Faulty electric controls/signals. signals. Faulty directional control valve. Replace valve. Specific hydraulic system (lift, Troubleshoot circuit with Poorly adjusted control in hoist, telescope, swing) not schematic.
  • Page 67 TMS9000-2 SERVICE MANUAL HYDRAULIC SYSTEM 9, 10 6966 FIGURE 2-4 Item Description Item Description Cap Assembly Element Filter Head Bypass Valve Filter Bowl Spacer Restriction Indicator Capscrew O-ring Capscrew Gasket Grove 2-11 Published 01-14-2021 Control # 707-01...

  • Page 68: Hydraulic Pumps

    HYDRAULIC SYSTEM TMS9000-2 SERVICE MANUAL HYDRAULIC PUMPS Remove the capscrews, flatwashers and O-ring securing the hydraulic tank hose assembly to the pump. Description Tag and disconnect all other lines from the pump. Cap all lines and ports. The engine drives the No. 1 gear pump Figure 2-23 mounted directly to the front cover accessory drive.
  • Page 69 Torque capscrews according to Torque Values, page 1- The Pump Priming Tool (Figure 2-7), P/N 80030367, available from Manitowoc Crane Care is used to prime the Install the front pump to the mounting bracket. pumps after they have been removed from the crane.
  • Page 70 Testing After Rebuild or Replacement Remove the shop air supply from the Pump Priming Tool. Torque hose connections to the specified Manitowoc CAUTION torque setting. Pump Damage! Gear Pump Outlet Port Air Bleeding Do not feed hot hydraulic oil into a cold pump. This may cause the pump to seize.
  • Page 71 TMS9000-2 SERVICE MANUAL HYDRAULIC SYSTEM Slowly increase the engine speed to approximately 1500 rpm and hold for no longer than 1 minute and make the same checks as outlined previously. Slowly increase engine speed to full RPM and hold for no longer than 1 minute while making the same checks as outlined previously.
  • Page 72 HYDRAULIC SYSTEM TMS9000-2 SERVICE MANUAL Pump No. 2 Assembly 8-9235 FIGURE 2-9 2-16 Published 01-14-2021 Control # 707-01...

  • Page 73: Carrier Valves

    TMS9000-2 SERVICE MANUAL HYDRAULIC SYSTEM CARRIER VALVES General This subsection provides descriptive information for the hydraulic valves used on this crane. For a listing of the valves, the carrier circuit they are used in, and their physical location, refer to VALVE USAG E TABLE. Refer to Figure 2-10 for valve locations.
  • Page 74 HYDRAULIC SYSTEM TMS9000-2 SERVICE MANUAL 9238 FIGURE 2-10 Item Description Item Description Outrigger Selector and AC Valve Front Outrigger Manifold Valve Rear Outrigger Manifold Valve Swing Steer Valve 2-18 Published 01-14-2021 Control # 707-01...

  • Page 75: Outrigger Selector-A/C Manifold Valve

    TMS9000-2 SERVICE MANUAL HYDRAULIC SYSTEM OUTRIGGER SELECTOR-A/C MANIFOLD operated relief valve and the solenoid operated two way flow control sending a load sense pressure to the pump allowing VALVE it to supply flow to the circuit. This allows a controlled amount of flow through the two way valve at the desired pressure Description controlled by the inlet pressure reducing valve.
  • Page 76 HYDRAULIC SYSTEM TMS9000-2 SERVICE MANUAL 9239-1 9239 FIGURE 2-11 Item Description Item Description Solenoid Relief Valve 4-way Solenoid Pilot Valve Adjustable Pressure Reducing Valve 4-way Outrigger Directional Valve Solenoid Flow Control Valve 2-20 Published 01-14-2021 Control # 707-01...

  • Page 77: Outrigger Control Manifold

    TMS9000-2 SERVICE MANUAL HYDRAULIC SYSTEM OUTRIGGER CONTROL MANIFOLD Inspection Visually inspect the valves and hydraulic connections for any Description evidence of leaks or other damage. Check security of the electrical connections. Inspect the wiring for any evidence of There are two outrigger control manifolds utilized on the cracks or breaks.
  • Page 78 HYDRAULIC SYSTEM TMS9000-2 SERVICE MANUAL 9240 9240-1 FIGURE2-12 Item Description Item Description In Port Left Front Jack Cylinder Out Ports Right Front Jack Cylinder Center Front Jack Cylinder Right Front Extension Cylinder Left Front Extension Cylinder Check Valve Tank 2-22 Published 01-14-2021 Control # 707-01...
  • Page 79 TMS9000-2 SERVICE MANUAL HYDRAULIC SYSTEM 6544-1 6544-2 FIGURE 2-13 Item Description Item Description In Port Left Rear Jack Cylinder Out Ports Right Rear Jack Cylinder Left Rear Extension Cylinder Right Rear Extension Cylinder Grove 2-23 Published 01-14-2021 Control # 707-01...

  • Page 80: Pilot Operated Check Valve

    HYDRAULIC SYSTEM TMS9000-2 SERVICE MANUAL PILOT OPERATED CHECK VALVE Description CAUTION A pilot operated (PO) check valve is located in each Personal Injury Hazard! outrigger jack cylinder port block. The check valve functions as a holding valve for the jack cylinder. Oil flow is directed Release hose to adapter connection slowly.

  • Page 81: Maintenance

    TMS9000-2 SERVICE MANUAL HYDRAULIC SYSTEM Maintenance Lubricate the check valve and O-rings with clean hydraulic oil. Removal CAUTION Damage Could Occur! WARNING Do not damage the O-rings during installation of the check Projectile Hazard! valve. If the check valve turns freely then gets hard to turn, There must not be any load on the jack cylinder when then easy to turn, remove the check valve and check the removing check valve to prevent the valve from becoming...

  • Page 82: Superstructure Valves

    HYDRAULIC SYSTEM TMS9000-2 SERVICE MANUAL SUPERSTRUCTURE VALVES Turntable Hydraulic Valves 9244 FIGURE 2-16 Item Description Assy Main Directional Valve Assy Access Manifold Assy Case Drain Manifold 2-26 Published 01-14-2021 Control # 707-01...

  • Page 83: Main Directional Valve Assembly

    TMS9000-2 SERVICE MANUAL HYDRAULIC SYSTEM Main Directional Valve Assembly 9246-1 FIGURE 2-17 Item Description Item Description Solenoid operated pressure reducing Solenoid operated pressure reducing valve (Aux hoist up) valve (Aux hoist down) Solenoid operated pressure reducing Solenoid operated pressure reducing valve (Main hoist up) valve (Main hoist down) Solenoid operated pressure reducing...

  • Page 84: Access Manifold Assembly

    HYDRAULIC SYSTEM TMS9000-2 SERVICE MANUAL Access Manifold Assembly 9244-1 FIGURE 2-18 Item Description Item Description 2 Position 3 Way Solenoid Valve 3 Position 4 Way Solenoid Valve (Cab (CWT Raise) Tilt) 2 Position 3 Way Solenoid Valve (Tele Adjustable Pressure Reducing Valve Pinning) Solenoid Operated Proportional Adjustable Pressure Reducing Valve...

  • Page 85: Hydraulic System Of The Superstructure

    Divide 360 degrees by the number of wear rings on the • Inform Manitowoc Crane Care or your repair personnel. component. The resulting value is the number of degrees each wear ring gap is to be located with respect to each other.
  • Page 86 HYDRAULIC SYSTEM TMS9000-2 SERVICE MANUAL Extend the rod to its maximum stroke. Remove the larger difference in oil temperature verses the ambient retract hose from the cylinder. Cap the retract hose. temperature. Thermal contraction coupled with improper lubrication or improper wear pad adjustments may, under certain WARNING conditions, cause a “stick-slip”...

  • Page 87: Steer Cylinder

    TMS9000-2 SERVICE MANUAL HYDRAULIC SYSTEM Table 2-1 Boom Drift Chart (Cylinder Length Change in Inches) Coeff. = 0.00043 (in / °F) STROKE Temperature Change (°F) (FT.) 0.26 0.52 0.77 1.03 1.29 1.55 1.81 2.06 2.32 2.58 0.52 1.03 1.55 2.06 2.58 3.10 3.61...
  • Page 88 HYDRAULIC SYSTEM TMS9000-2 SERVICE MANUAL Clean away all dirt from the head. Place protective padding around the rod near the head to prevent CAUTION damaging the chrome during head removal. Damage Could Occur! Exercise extreme care when handling or setting down the WARNING rod.
  • Page 89 TMS9000-2 SERVICE MANUAL HYDRAULIC SYSTEM Rapidly pull the rod against the head to free it. Remove Clean with solvent and dry with compressed air any rod and attached parts from the barrel. Place the rod on parts that have been stoned and polished. a surface that will not damage the chrome or allow the Assembly rod assembly to drop.

  • Page 90: Outrigger Extension Cylinder

    HYDRAULIC SYSTEM TMS9000-2 SERVICE MANUAL 12. Pressurize and cycle the cylinder with hydraulic oil Remove the upper cylinder rod assembly from the pressure. Static test the cylinder at 24,132 kPa cylinder barrel. (3500 psi). Check for proper operation and any leakage. NOTE: Cover the barrel opening to avoid contamination.
  • Page 91 TMS9000-2 SERVICE MANUAL HYDRAULIC SYSTEM FIGURE 2-20 Item Description Item Description Barrel Retaining Ring Upper Rod Piston Seal Lower Rod Wear Ring Head O-ring Head O-ring Piston O-ring Piston Backup Ring Spacer Rod Seal Spacer Rod Seal Manifold Tube Wiper Roller Bearing Wiper Plug...
  • Page 92 HYDRAULIC SYSTEM TMS9000-2 SERVICE MANUAL Install the O-ring in the inside of the piston. Install the piston onto the rod. CAUTION Damage Could Occur! Clean all surfaces and carefully remove burrs and nicks. CAUTION Replace all damaged or worn parts. Damage Could Occur! Exercise extreme care when handling or setting down the Stone out minor blemishes and polish with fine crocus...

  • Page 93: Outrigger Jack Cylinder

    TMS9000-2 SERVICE MANUAL HYDRAULIC SYSTEM damaging the chrome. Using a spanner wrench, unscrew the head from the barrel. WARNING Death or Injury Could Occur! WARNING Do not use air pressure to cycle or pressurize the cylinder. Cylinder parts could fly apart with explosive force. Use Death or Injury Could Occur! only a source of controlled hydraulic oil pressure if the rod Do not use air pressure to remove the rod.
  • Page 94 HYDRAULIC SYSTEM TMS9000-2 SERVICE MANUAL 9262 FIGURE 2-21 Item Description Item Description Barrel Assy. Plug, SAE #6 Rod Assy. Capscrew Piston Assy. O-ring Head Assy. Valve, Check PO Locknut Capscrew, Socket Head Plug, O-ring Spacer, Limiter Valve Body Assy. NOTE: Arranging discarded seals and rings in the order of installed to avoid installing replacement seals and disassembly will aid in installation of new seals and...
  • Page 95 TMS9000-2 SERVICE MANUAL HYDRAULIC SYSTEM 10. Remove the O-ring and backup ring from the outside of the head. Remove the wear rings, buffer seal, rod seal CAUTION and wiper ring from the inside of the head. Damage Could Occur! Inspection Before installing new seals and rings, clean all surfaces and carefully remove burrs and nicks.

  • Page 96: Description

    HYDRAULIC SYSTEM TMS9000-2 SERVICE MANUAL Item Description Item Description O-ring Rod Seal Backup Ring Wiper Ring Wear Ring O-ring Buffer Seal Install the replacement wiper ring, rod seal, buffer seal Lubricate the rod with clean hydraulic oil. and wear rings in the inside of the head Figure 2-22. Slide the head onto the rod.

  • Page 97: Center Front Stabilizer Cylinder

    TMS9000-2 SERVICE MANUAL HYDRAULIC SYSTEM 11. Pressurize and cycle the cylinder with hydraulic oil pressure. Test the cylinder at 4500 psi (31,026 kPa). CAUTION Check for proper operation and any leakage. Make repairs as needed. Damage Could Occur! Exercise extreme care when handling or setting down the CENTER FRONT STABILIZER CYLINDER rod.
  • Page 98 HYDRAULIC SYSTEM TMS9000-2 SERVICE MANUAL 6963 6963 FIGURE 2-24 Item Description Item Description Barrel Rod Seal Buffer Seal Head Wear Ring Piston O-ring Spacer Backup Ring Check Valve Seal Setscrew O-ring Insert Backup Ring Plug Setscrew Plug Insert Wiper Ring 2-42 Published 01-14-2021 Control # 707-01...
  • Page 99 TMS9000-2 SERVICE MANUAL HYDRAULIC SYSTEM CAUTION CAUTION Damage Could Occur! Damage Could Occur! When removing seals and rings, avoid scratching the Before installing new seals and rings, clean all surfaces grooved and gland surfaces. and carefully remove burrs and nicks. Parts displaying excessive wear or damage should be replaced.

  • Page 100: Lift Cylinder

    HYDRAULIC SYSTEM TMS9000-2 SERVICE MANUAL 11. Torque the piston 406 to 474.5 Nm (300 to 350 lb-ft). Seal ports with port plugs to prevent contamination from entering cylinder. 12. Install the piston setscrews. LIFT CYLINDER 13. Apply anti-seize lubricant to the head outer threads. 14.
  • Page 101 TMS9000-2 SERVICE MANUAL HYDRAULIC SYSTEM 9263 FIGURE 2-25 Item Description Item Description Rod Assy. Plug, #4 SAE Nylon Set Plug, #12 SAE Piston Assy. Grease Fitting Head Assy. Valve Assy., Sequence Bushing Valve Assy., Overcenter Cover Plug, #2 SAE Barrel Assy. Plug, #16 SAE Circlip Ring Set Screw...
  • Page 102 HYDRAULIC SYSTEM TMS9000-2 SERVICE MANUAL NOTE: Cover the barrel opening to avoid contamination. Assembly CAUTION CAUTION Damage Could Occur! Damage Could Occur! When removing seals and rings, avoid scratching the When installing new seals and rings, avoid stretching grooved and gland surfaces. seals or scratching the grooved or gland surfaces.

  • Page 103: Counterweight Cylinder

    TMS9000-2 SERVICE MANUAL HYDRAULIC SYSTEM COUNTERWEIGHT CYLINDER 10. Connect the hoses to the valve block. 11. Pressurize and cycle the cylinder with hydraulic oil Description pressure. Test the cylinder at 36,107 KPa (5250 psi). Check for proper operation and any leakage. Make The counterweight cylinder (Figure 2-26) has a retracted repairs as needed.

  • Page 104: Telescope Cylinder

    HYDRAULIC SYSTEM TMS9000-2 SERVICE MANUAL TELESCOPE CYLINDER Description The telescope cylinder (Figure 2-27) is installed in the boom. FIGURE 2-27 Item Description Item Description Gasket Relief Valve Cylinder Head Stop Brake Valve Gasket Stop Brake Valve Approximate Switch O-ring Control Unit O-ring Approximate Switch Cartridge Valve...

  • Page 105: Pressure Setting Procedures

    TMS9000-2 SERVICE MANUAL HYDRAULIC SYSTEM PRESSURE SETTING PROCEDURES Valve Pressure Setting Table NOTE: Reservoir oil temperature to be approx. 120-140° F Objective (49-60° C) to check pressures. To assist personnel in properly checking, adjusting and Set pressure to nominal value to account for setting the hydraulic system pressures.

  • Page 106: Service Tool Notes

    HYDRAULIC SYSTEM TMS9000-2 SERVICE MANUAL Service Tool Notes Next select the function which needs adjusted. Cab tilt is shown here. Main crane functions can be found under Attach laptop to DIAG_1 connector in cab and make sure Proportional Valves and Carrier functions can be found CAN C is selected (position 3 on CAN selector knob.) under Cabin.
  • Page 107 TMS9000-2 SERVICE MANUAL HYDRAULIC SYSTEM Tele retract relief Lift down relief LS relief Main directional valve GP port 9266 FIGURE 2-30 Adjust the differential pressure adjustment screw (see #1 “in” to increase or “out” to decrease so that a gauge Figure 2-14) on pump #2 out “CCW”...

  • Page 108: Procedure For Checking/Setting The Pilot Supply Pressure

    HYDRAULIC SYSTEM TMS9000-2 SERVICE MANUAL Piston pump #1 Differential pressure adjustment screw Piston pump #2 Cut-off pressure adjustment screw 9266 FIGURE 2-31 B. Procedure for Checking/Setting the Pilot Stop engine and remove the diagnostic coupler. Supply Pressure Assure the piston pump “cut-off” max setting is correct. Loosen the jam nut on the cut-off pressure adjusting With the engine off, install pressure check diagnostic screw.

  • Page 109: Procedure For Checking/Setting The Main Directional Control Valve, Load Sense, Lift And Telescope Pressures

    TMS9000-2 SERVICE MANUAL HYDRAULIC SYSTEM the nipple at GPPS port of the Accessory manifold. See (Figure 2-15). Pressure reducing Pilot supply reducing valve valve GPLS GPPS Tele fill relief FIGURE 2-32 9266 If the lift cylinder is not installed, plug the lift hoses. If the the cylinder in order to assure that cylinder can reach full cylinder is installed, omit this step.
  • Page 110 HYDRAULIC SYSTEM TMS9000-2 SERVICE MANUAL The RCL override switch will need to be activated to do Tele Extend and Retract Relief Pressures lift up and lift down functions if the hoses are attached to With the engine off, install pressure check diagnostic the cylinder in order to assure that cylinder can reach full quick disconnect (Parker PD240) with gauge onto test stroke in either direction.
  • Page 111 TMS9000-2 SERVICE MANUAL HYDRAULIC SYSTEM Change “G” to “H” Check box 9266-4 FIGURE 2-34 S2111N Cylinder #1 length Lock button Cylinder unlock button 9266-5 FIGURE 2-35 Make sure cylinder #1 is at 0 mm. b. Use the joystick and retract cylinder #1 until the length reads 0 mm.
  • Page 112 HYDRAULIC SYSTEM TMS9000-2 SERVICE MANUAL If it is not, use lock button and the jog dial to lock the the engine to full RPM. The reading at GPLS should be boom and verify that S2111N is green. 2900 ±100 PSI (200 ±7 bar) if it is not adjust the Tele extend relief (Figure 2-18) “in”...
  • Page 113 TMS9000-2 SERVICE MANUAL HYDRAULIC SYSTEM Change “P” to “L” OK box 9266-7 FIGURE 2-37 Boom section position OK box 9266-8 FIGURE 2-38 Use the “jog dial” and change the word “POST” to “LOST” NOTE: If the boom is not fully retracted enter appropriate and then select the “OK”...

  • Page 114: Procedure For Checking/Setting Cab Tilt Raise And Lower Pressures

    HYDRAULIC SYSTEM TMS9000-2 SERVICE MANUAL D. Procedure for Checking/Setting Cab Tilt the value to increase the pressure or decrease the value to decrease the pressure (adjustment by 10 Raise and Lower Pressures mA increments is suggested). Make sure to write With the engine off, install pressure check diagnostic quick column to “active settings”.

  • Page 115: Procedure For Checking/Setting Swing Pressure

    TMS9000-2 SERVICE MANUAL HYDRAULIC SYSTEM In the Tools->EEprom->View Parameters->Super- nipple at the MP port of the swing control valve (see >Counterweight->Lower Pressure params row Figure 2-40). increase the value to increase the pressure or decrease the value to decrease the pressure (adjustment by 10 mA increments is suggested).

  • Page 116: Procedure For Checking/Setting Air Conditioning Pressure

    HYDRAULIC SYSTEM TMS9000-2 SERVICE MANUAL nipple at the G2 port of the outrigger selector/ A/C decrease the value to decrease the pressure manifold (Figure 2-41). (adjustment by 10 mA increments is suggested). Make sure to write column to “active settings”. Repeat this step until the pressure is achieved.

  • Page 117: Procedure For Checking/Setting The Center Front Stabilizer Pressure

    TMS9000-2 SERVICE MANUAL HYDRAULIC SYSTEM nipple at the G2 port of the outrigger selector/ A/C removing the cover (Figure 2-42) and looking at the manifold (Figure 2-41). shaft. The reading at G2 should be 1000 ±150 PSI (69 ±10 bar) if it is not use the service tool as follows to Start engine and idle.

  • Page 118: Procedure For Checking/Setting The Front Steer Pressure

    Extend the center front stabilizer to the ground and hold (Figure 2-43). switch. The gauge should read 150-300 PSI (10-21 bar). If it does not, contact your distributor or Manitowoc Crane Care for assistance as this pressure is not adjustable.

  • Page 119: Procedure For Adjusting Electronic Controllers (Meter-In Dead Band And/Or Max Function Speeds)

    TMS9000-2 SERVICE MANUAL HYDRAULIC SYSTEM • All function pressure are set correctly per this procedure • Operator has tried adjusting the function speed thru the CCS control screens • Operator has tried adjusting the function control thru the CCS control screen selectable curves Steering relief Follow the steps listed below for any function which the operator feels the meter-in dead band in the controller is...
  • Page 120 HYDRAULIC SYSTEM TMS9000-2 SERVICE MANUAL 9266-16 FIGURE 2-46 Adjust the I-min or I-max per the information above model designation (GRT8100). Name the file as follows: (adjustment by 10 mA increments is suggested). Make (Sales Sample: order number Date). (700287_2015june25). sure to write column to “active settings”. Try function again.

  • Page 121: Description

    TMS9000-2 SERVICE MANUAL ELECTRICAL SYSTEM SECTION 3 ELECTRICAL SYSTEM SECTION CONTENTS Description ....... 3-1 Troubleshooting Crane Components and Accessories .
  • Page 122 ELECTRICAL SYSTEM TMS9000-2 SERVICE MANUAL Carrier Power Panel The carrier power panel (Figure 3-3) contains 5 relays and a buzzer. Refer to Power Panel and Power Panel Decal illustrations. Relays The carrier has 5 relays which control many of its functions. The relays are located on the power panel in the carrier cab.
  • Page 123 TMS9000-2 SERVICE MANUAL ELECTRICAL SYSTEM Relays 9290-2 FIGURE 3-3 The coils of the accessory relay (K101)and charge air cooler switch is in the park light or “ON” position. The coil of the relay (K103) is energized when the ignition switch is at the steering wheel relay (K107) is energized when the contacts RUN (1) or ACC (3) position.
  • Page 124 ELECTRICAL SYSTEM TMS9000-2 SERVICE MANUAL 9280b 9280a 9280d 9280c FIGURE 3-4 Published 01-14-2021 Control # 707-01...
  • Page 125 TMS9000-2 SERVICE MANUAL ELECTRICAL SYSTEM F306 F302 F304 F305 F301 F303 FIGURE 3-5 8338-2 Superstructure Fuse and Relay Panel FIGURE 3-6 9280e Grove Published 01-14-2021 Control # 707-01...
  • Page 126 ELECTRICAL SYSTEM TMS9000-2 SERVICE MANUAL FIGURE 3-7 9280f 9280g FIGURE 3-8 Published 01-14-2021 Control # 707-01...
  • Page 127 TMS9000-2 SERVICE MANUAL ELECTRICAL SYSTEM Anti-Lock Brake System (ABS) Electronic Control Unit (ECU) The ABS ECU (1), (Figure 3-9) is located inside the cab behind the seat. ABS wiring is combined with the main cab and engine harnesses. FIGURE 3-9 Diagnostic Connector The 9-pin on board diagnostic connector (1), (Figure 3-10) is located below the control panel on the left side of the dash.
  • Page 128 ELECTRICAL SYSTEM TMS9000-2 SERVICE MANUAL Wheel Speed Sensor and Tone Ring Camera System An ABS wheel speed sensor and tone ring (Figure 3-11) is There are four cameras standard on the crane, two mounted mounted in each monitored wheel. As the wheel spins, the on the carrier and two mounted on the superstructure.

  • Page 129: Maintenance

    TMS9000-2 SERVICE MANUAL ELECTRICAL SYSTEM MAINTENANCE First, use reported symptoms to identify a problem or a suspect component. General Test the suspect component per instructions in this section. The instructions identify the fuses and Electrical system maintenance includes troubleshooting and components and guide you from the easiest and most replacement of damaged components.

  • Page 130: Troubleshooting Engine Charging Problems

    ELECTRICAL SYSTEM TMS9000-2 SERVICE MANUAL through the starter solenoid to the starter motor and Verify the batteries put out 24 volts minimum. Charge ground. Make repairs as needed. If the starter battery as needed so the battery can supply a minimum solenoid or the starter motor is faulty, replace the excitation voltage to the engine’s charging system.

  • Page 131: Connector Troubleshooting

    TMS9000-2 SERVICE MANUAL ELECTRICAL SYSTEM Connector Troubleshooting The cause of an electrical problem may be a loose or corroded connection in the pin or socket connectors. Check the connectors to ensure that the pins and sockets are properly seated and engaged. If the pins and sockets show any signs of corrosion, use a good quality electrical contact cleaner or fine sandpaper to clean them.

  • Page 132: Di-Electrical Grease Application

    Di-Electrical Grease Application Use a clean towel (or clean glove) to remove any excess Since March 2018 Manitowoc Cranes has been using Di- material from the surface of the connector, and wipe Electric Grease on all electrical connectors. All of the below...

  • Page 133: Troubleshooting Lights

    TMS9000-2 SERVICE MANUAL ELECTRICAL SYSTEM Make Sure Coverage of Rubber Seal Troubleshooting Lights Check lamp first. Replace any defective lamp. If all lamps in a circuit do not work, suspect fuse and switch. Replace fuse if blown. Check the switch and circuit for continuity problems and other problems.

  • Page 134: Troubleshooting Alarms, Indicators, And Emergency Components

    ELECTRICAL SYSTEM TMS9000-2 SERVICE MANUAL ODM Error Code Viewer condition. Repair any faulty gauge, meter or other component. Repair wiring if faulty. Open the fault list screen (Figure 3-19) or the engine Troubleshooting Alarms, Indicators, and faults screen (Figure 3-20) and highlight the fault you’re interested in getting more information about.

  • Page 135: Troubleshooting Crane Components And Accessories

    TMS9000-2 SERVICE MANUAL ELECTRICAL SYSTEM Turn the tensioner above the alternator clockwise to remove tension from the belt. Slip the belt off of the alternator pulley, then let the tensioner return to its normal position. Remove the four bolts attaching the alternator to the mounting bracket.

  • Page 136: Battery Replacement

    ELECTRICAL SYSTEM TMS9000-2 SERVICE MANUAL Battery Replacement Installation Place the starter on its mounting pad. Secure the starter Removal with the bolts. CAUTION Connect the electrical leads to the terminals as tagged during removal. To avoid possible engine fault codes and undesirable Connect the batteries.
  • Page 137 TMS9000-2 SERVICE MANUAL ELECTRICAL SYSTEM Installation Place the batteries in the battery compartment. Refer to (Figure 3-24). 9284-1 9284 FIGURE 3-24 Item Description Item Description Battery Disconnect Switch Negative Cables Battery Hold Down Batteries (4) Positive Cables Install the hold down brackets. Secure the brackets to Close the battery box cover.

  • Page 138: Relay Panel Component Replacement

    ELECTRICAL SYSTEM TMS9000-2 SERVICE MANUAL Relay Panel Component Replacement Instrument Replacement Accessory Relay and Flasher Replacement Removal Make sure that the key switch has been in the OFF Make sure that the key switch has been in the OFF position for 2 minutes. position for 2 minutes.

  • Page 139: All Other Switches

    TMS9000-2 SERVICE MANUAL ELECTRICAL SYSTEM Disconnect the electrical connector from the switch. On the front of the console panel, remove the nut securing the switch to the panel. As necessary, remove Depress the plastic tabs on top and bottom of switch and the knob from the switch first.
  • Page 140 ELECTRICAL SYSTEM TMS9000-2 SERVICE MANUAL Disconnect the washer hose on the wiper arm (also exterior. Remove the pantograph arm assembly’s called the pantograph arm assembly) from the washer adapter and gasket. nozzle fitting assembly. Remove attaching hardware to free the windshield wiper Remove the cap nut and washer securing the wiper arm motor bracket from the cab interior.

  • Page 141: Windshield Washer Assembly Replacement

    TMS9000-2 SERVICE MANUAL ELECTRICAL SYSTEM Inspection Check Visually check the motor housing for evidence of cracks Squirt some cleaning fluid onto the windshield with the or other damage. Check for excessive shaft end play windshield washer. indicating worn or damaged bearings. Replace motor if Operate the windshield wiper.

  • Page 142: Remote Controller (Optional)

    ELECTRICAL SYSTEM TMS9000-2 SERVICE MANUAL • A hand held remote transmitter (1), (Figure 3-26) Check • A receiver (2), (Figure 3-26) mounted behind the seat in Squirt some cleaning fluid onto the windshield with the the carrier cab. windshield washer. •...

  • Page 143: Remote Controller Battery

    TMS9000-2 SERVICE MANUAL ELECTRICAL SYSTEM Remote Controller Battery & transmission control) that are highly susceptible to voltage/ amperage surges in the electrical system. Remove/install the battery into the remote transmitter or The batteries should be completely disconnected from the charger by squeezing the tab on the base of the battery and crane electrical system and charged using a battery charger pulling/pushing the battery out/in.
  • Page 144 ELECTRICAL SYSTEM TMS9000-2 SERVICE MANUAL This Page Blank 3-24 Published 01-14-2021 Control # 707-01...

  • Page 145: Description Of Maintenance Work On The Superstructure

    TMS9000-2 SERVICE MANUAL SUPERSTRUCTURE SECTION 4 SUPERSTRUCTURE SECTION CONTENTS Description of Maintenance Work on the Prerequisites ......4-43 Superstructure .

  • Page 146: Superstructure

    SUPERSTRUCTURE TMS9000-2 SERVICE MANUAL to route hydraulic flow to the hoist motor or motor control Place cable (1) over boom nose sheave and route to valve. hoist drum (2). Rotate hoist drum so cable slot located on left side of drum is easily accessible.
  • Page 147 TMS9000-2 SERVICE MANUAL SUPERSTRUCTURE Slowly rotate drum and ensure cable lays immediately in Secure the hoist assembly to the superstructure using the first groove. the capscrews and washers. Torque the capscrews - refer to Torque Values, page 1-9 for proper torque value. Install remainder of cable as required.

  • Page 148: Hoist

    SUPERSTRUCTURE TMS9000-2 SERVICE MANUAL 14 19 8743 FIGURE 4-2 Hoist Shaft Flat Washer Cotter Pin Hoist Roller Flat Washer O-Ring Roll Pin Narrow Flat Washer Cable Wedge Capscrew O-Ring Limit Switch Assembly Capscrew Lockwasher 2 Speed Motor Piston Capscrew Sight Glass Shaft Capscrew Socket Head Cap Screw...
  • Page 149 Although these components are designed for long service be worn or damaged, contact your Manitowoc Cranes life, reliability can be reduced by a variety of factors such as: distributor or Manitowoc Crane Care to order a replacement. • High cycle operation.
  • Page 150 SUPERSTRUCTURE TMS9000-2 SERVICE MANUAL metallic particles, hoist must be taken out of service to severe duty applications, the gear oil should be changed undergo a tear down inspection. every six months. Use the recommended lubricants. Refer to Lubrication, page 9-1. NOTE: Oil analysis alone cannot detect or warn against a fatigue failure.
  • Page 151 TMS9000-2 SERVICE MANUAL SUPERSTRUCTURE Brake Test Procedure clutch, which are in the motor control valve gearbox. Remove the motor and motor control valve as a unit. These planetary hoists have a spring applied, hydraulically Discard the O-ring. released, multiple disc brake inside the hoist housing. This Cover the motor opening in the brake cylinder to protect brake holds a suspended load when the directional control valve is in neutral, or when hydraulic power is lost.
  • Page 152 SUPERSTRUCTURE TMS9000-2 SERVICE MANUAL system will sound a buzzer in the cab, cut-out the hoist down function, and display the minimum wrap symbol on the RCL display to indicate that a minimum number of wraps of cable remain on the respective hoist. The encoder must be properly adjusted for this system to function properly.

  • Page 153: Boom Removal

    TMS9000-2 SERVICE MANUAL SUPERSTRUCTURE Hoist Directional Control Valve The hoist directional control valve is used to control the operation of the hoist. It is a four-way, pilot operated valve and is mounted on the right side of the turntable. BOOM REMOVAL NOTE: The boom, without any boom extension, weighs about 10,577 kg (23,320 lbs).
  • Page 154 SUPERSTRUCTURE TMS9000-2 SERVICE MANUAL 9286 9286-1 FIGURE 4-7 16. Slightly lift the boom to remove weight on the pivot pins. 17. Pull lift cylinder pin (2), (Figure 4-8) far enough out that WARNING the cylinder (3), (Figure 4-8) will clear it. Tag and remove the shims and bushing/plates on the pin.

  • Page 155: Boom Installation

    TMS9000-2 SERVICE MANUAL SUPERSTRUCTURE DANGER Crushing Hazard! Make sure that blocking and lifting devices are capable of supporting the boom assembly. Block the boom before doing any work under the boom. Failure to properly support the boom and/or the lift cylinder may result in death or serious injury.
  • Page 156 SUPERSTRUCTURE TMS9000-2 SERVICE MANUAL NOTE: Install a piece of wood to prevent damaging the electrical harness as shown in the red circle (Figure 4-5). 10. Run stop/adjustable bolts (1), (Figure 4-13) on the side of the weldment completely out. 11. Pull lift cylinder pin (2), (Figure 4-13) far enough out that the cylinder (3), (Figure 4-13) will clear it.

  • Page 157: Functional Check

    TMS9000-2 SERVICE MANUAL SUPERSTRUCTURE 17. Connect the hydraulic lines as tagged before removal from the boom to the turntable. CAUTION 18. Connect the electrical cables from the boom to the turntable. Pinch Hazard! Use caution when installing pin, high pinch point risk. Functional Check Activate the hydraulic system and check for proper 14.
  • Page 158 SUPERSTRUCTURE TMS9000-2 SERVICE MANUAL Telescope Section 5 Assembly 9516 FIGURE 4-16 4-14 Published 01-14-2021 Control # 707-01...
  • Page 159 TMS9000-2 SERVICE MANUAL SUPERSTRUCTURE Telescope Section 5 Assembly (Continued) 9517 FIGURE 4-16 continued Grove 4-15 Published 01-14-2021 Control # 707-01...
  • Page 160 SUPERSTRUCTURE TMS9000-2 SERVICE MANUAL Item Item Description Description Number Number TELESCOPIC PART 5 CAP SCREW AXLE STRIP SHEAVE SLIDER SUSTAGLIDE COVER PLATE PLATE HEX HEAD SCREW PLATE SHIM,2MM SLIDER SUSTAGLIDE SPACER RING PLATE RING, SPACER PLATE SPACER RING GUIDE PILOT SHIM RING SLIDER SUSTAGLIDE SPACER RING...

  • Page 161: Boom Nose Sheaves Installation

    TMS9000-2 SERVICE MANUAL SUPERSTRUCTURE Boom Nose Sheaves Installation Climb into the base section and secure the hoses to the cylinder to keep them from being damaged when Refer to (Figure 4-16) when performing this installation. removing the tele cylinder. NOTE: This procedure can be greatly simplified if two Remove the sliders, strips and plates (28, 29, 34, 35, technicians are used.

  • Page 162: Boom Assembly

    SUPERSTRUCTURE TMS9000-2 SERVICE MANUAL 18. Remove the wear pads, plates, and strips (29, 30, 32, 59), (Figure 4-22) as necessary. 19. Remove the rope protection bar (2), (Figure 4-22). DANGER 20. Remove the guide (162), (Figure 4-22). Accident Hazard! To prevent serious injury or death, always wear personal 21.
  • Page 163 TMS9000-2 SERVICE MANUAL SUPERSTRUCTURE 12. Insert Section 5 into Section 4 just far enough to measure the gaps between the sliders and wear pads and Section 4. The gaps should be no greater than 1.52 mm (0.06 in). Adjust the gaps by adding or removing plates or using thicker or thiner sliders and wear pads.

  • Page 164: Telescope Section 4 Assembly

    SUPERSTRUCTURE TMS9000-2 SERVICE MANUAL Telescope Section 4 Assembly 9519 FIGURE 4-20 4-20 Published 01-14-2021 Control # 707-01...
  • Page 165 TMS9000-2 SERVICE MANUAL SUPERSTRUCTURE Telescope Section 4 Assembly (Continued) 9519-1 FIGURE 4-20 continued Grove 4-21 Published 01-14-2021 Control # 707-01...
  • Page 166 SUPERSTRUCTURE TMS9000-2 SERVICE MANUAL Item Item Description Description Number Number TELESCOPIC PART 4 FILL PLATE - 1 MM ROPE PROTECTION FILL PLATE - 2MM WEAR PAD - GREASELESS TELE 4 WEAR PAD SUSTAGLIDE WEAR PAD - GREASELESS TELE 4 PLATE WEAR PAD - GREASELESS TELE 4 SHCS M12x35 8.8 WEAR PAD - GREASELESS TELE 4...

  • Page 167: Telescope Section 3 Assembly

    TMS9000-2 SERVICE MANUAL SUPERSTRUCTURE 12. Install wear pads (44) and plates (45). 20. Attach the thin nuts (57) and pipe unions (56) to the lubrication hoses and secure the hoses to the tabs 13. Install sliders (36) and plates (37, 38). inside the section.
  • Page 168 SUPERSTRUCTURE TMS9000-2 SERVICE MANUAL Telescope Section 3 Assembly (Continued) 9521-1 FIGURE 4-21 continued 4-24 Published 01-14-2021 Control # 707-01...
  • Page 169 TMS9000-2 SERVICE MANUAL SUPERSTRUCTURE Item Item Description Description Number Number TELESCOPIC PART 3 SLIDER ROPE PROTECTION FILL PLATE - 1 MM WEAR PAD - GREASELESS TELE 3 FILL PLATE - 2MM WEAR PAD - GREASELESS TELE 3 SOCKET-HEAD SCREW WEAR PAD - GREASELESS TELE 3 WEAR PAD SUSTAGLIDE WEAR PAD - GREASELESS TELE 3 WEAR PAD SUSTAGLIDE...

  • Page 170: Telescope Section 2 Assembly

    SUPERSTRUCTURE TMS9000-2 SERVICE MANUAL Secure the strips and wear pads with the plates (12). 18. Install the opposite wear pad (59), strips (32) and plate (30). Install the rope protection bar (2). 19. Assemble the lubrication hoses (53, 54, 55, 58) and 10.
  • Page 171 TMS9000-2 SERVICE MANUAL SUPERSTRUCTURE Telescope Section 2 Assembly (Continued) 9522-1 FIGURE 4-22 continued Grove 4-27 Published 01-14-2021 Control # 707-01...
  • Page 172 SUPERSTRUCTURE TMS9000-2 SERVICE MANUAL Item Item Description Description Number Number TELESCOPIC PART 2 FILL PLATE - 1 MM ROPE PROTECTION FILL PLATE - 2MM WEAR PAD - GREASELESS TELE 2 SOCKET-HEAD SCREW WEAR PAD - GREASELESS TELE 2 WEAR PAD SUSTAGLIDE WEAR PAD - GREASELESS TELE 2 WEAR PAD SUSTAGLIDE WEAR PAD - GREASELESS TELE 2...

  • Page 173: Telescope Section 1 Assembly

    TMS9000-2 SERVICE MANUAL SUPERSTRUCTURE 10. Install the guide (162). 19. Assemble the lubrication hoses (53, 54, 55, 58) and connect to the wear pads (29, 59). 11. On the opposite end of Tele 2, install sliders (40) and fill plates (41, 42). 20.
  • Page 174 SUPERSTRUCTURE TMS9000-2 SERVICE MANUAL Telescope Section 1 Assembly (Continued) 9523-1 FIGURE 4-23 continued 4-30 Published 01-14-2021 Control # 707-01...
  • Page 175 TMS9000-2 SERVICE MANUAL SUPERSTRUCTURE Item Item Description Description Number Number TELESCOPIC PART 1 GUIDE PILOT ROPE PROTECTION SLIDER WEAR PAD - GREASELESS TELE 1 FILL PLATE - 1 MM WEAR PAD - GREASELESS TELE 1 FILL PLATE - 2MM WEAR PAD - GREASELESS TELE 1 SOCKET-HEAD SCREW WEAR PAD - GREASELESS TELE 1 WEAR PAD SUSTAGLIDE...
  • Page 176 SUPERSTRUCTURE TMS9000-2 SERVICE MANUAL Secure the strips and wear pads in place with the plates 18. Install the opposite wear pad (62), strips (32) and plate (13, 14). (30). Lower Tele 2. 19. Assemble the lubrication hoses (53, 54, 55) and connect to the wear pads (29, 62).

  • Page 177: Telescope Base Section Assembly

    TMS9000-2 SERVICE MANUAL SUPERSTRUCTURE Telescope Base Section Assembly 9546 FIGURE 4-24 Grove 4-33 Published 01-14-2021 Control # 707-01...
  • Page 178 SUPERSTRUCTURE TMS9000-2 SERVICE MANUAL Telescope Base Section Assembly (Continued) 9546-1 FIGURE 4-24 continued 2 4-34 Published 01-14-2021 Control # 707-01...
  • Page 179 TMS9000-2 SERVICE MANUAL SUPERSTRUCTURE Telescope Base Section Assembly (Continued) 9546-2 FIGURE 4-24 continued 3 Grove 4-35 Published 01-14-2021 Control # 707-01...
  • Page 180 SUPERSTRUCTURE TMS9000-2 SERVICE MANUAL Telescope Base Section Assembly (Continued) 9546-3 FIGURE 4-24 continued 4 4-36 Published 01-14-2021 Control # 707-01...
  • Page 181 TMS9000-2 SERVICE MANUAL SUPERSTRUCTURE Item Item Description Description Number Number BASE SECTION WASHER, 12 FLAT AXLE HHCS M12x35 8.8 PLATE HEX NUT SOCKET-HEAD SCREW M16x45 8.8 BRACKET BRACKET COTTER PIN STIRRUP COVER HEXAGON HEAD BOLT SFS, M10X16 CAP SCREW M12X90 -8.8 HEXAGON HEAD SCREW HHCS WASHER, FLAT...

  • Page 182: Pinning Boom Components

    SUPERSTRUCTURE TMS9000-2 SERVICE MANUAL Climb inside the Base Section and remove the tie straps accomplished by a pinning mechanism or pinning “head” at restraining the cylinder hoses. Route the hoses out the the near end of the barrel of the telescoping cylinder (the rod rear of the Base Section as shown in (Figure 4-25).

  • Page 183: Proximity Switch Descriptions

    TMS9000-2 SERVICE MANUAL SUPERSTRUCTURE Mechanical Locking Head Layout 9300 FIGURE 4-26 Item Number Description Item Number Description I/O Module Proximity Switch S2116N Valve for pinning control Proximity Switch S2114N Valve for pinning control Proximity Switch S2117N Proximity Switch S2112N Proximity Switch S2118N Double-acting hydraulic actuator Sample boom section plate in “foot area”...
  • Page 184 SUPERSTRUCTURE TMS9000-2 SERVICE MANUAL plate that is attached to one of the pieces that move with the that they are located on spring-loaded cylindrical bodies that sliding plate. These switches are the following: can ride in and out of slots in the Boom Sections. The third proximity switch is on the other side of the telescoping •...

  • Page 185: Hydraulic Actuator Description

    TMS9000-2 SERVICE MANUAL SUPERSTRUCTURE 9300-1 FIGURE 4-27 Hydraulic Actuator Description telescoping cylinder via a tube on the outer surface of the telescoping cylinder barrel. Item 5, (Figure 4-26), indicates the hydraulic actuator for the There are two ON/OFF valves (2 and 3, (Figure 4-26) that pinning mechanism.

  • Page 186: Precision Length Sensor Description

    SUPERSTRUCTURE TMS9000-2 SERVICE MANUAL (Figure 4-28) shows a region of a typical hydraulic schematic applied to one side or both sides (with appropriate relieving for the Mechanical Locking Head Design. In the schematic, of pressure where needed). the highlighted actuator is shown to have a piston with rods Precision Length Sensor Description at both sides for the double-acting actuator.

  • Page 187: Mechanical Emergency Unlocking And Locking Of The Telescopic Sections

    TMS9000-2 SERVICE MANUAL SUPERSTRUCTURE MECHANICAL EMERGENCY UNLOCKING AND LOCKING OF THE TELESCOPIC SECTIONS 125 mm 140 mm The mechanical emergency operation must be used (4.92 in) 170 mm (5.51 in) 200 mm whenever the telescoping cylinder can no longer be moved. (6.69 in) (7.87 in) 270 mm...

  • Page 188: New York House Lock

    SUPERSTRUCTURE TMS9000-2 SERVICE MANUAL Tighten the screw against the spring load until the (unlocked) and one for fully engaged (locked). This can be locking pin (1), (Figure 4-31) is pulled in as far as it will seen on the screen of ODM display or remote. go and is situated behind the side wall of the telescopic section.

  • Page 189: Telescoping Status

    TMS9000-2 SERVICE MANUAL SUPERSTRUCTURE Location of Vent Screws Position Vent For: Access to Vent on Basic Section Via: Number Set of Piston Rings Manhole in Top of Base Section Piston Chamber Opening in Telescopic Section 5 Left-Hand Side FIGURE 4-32 Telescoping Status •...

  • Page 190: Telescope Slide Pad Adjustment

    Have the additional maintenance work on the main boom Damage to Equipment Hazard! locking system performed by your authorized Grove Crane distributor or Manitowoc Crane Care regularly. Bolts in telescope slide pad are intentionally left loose. Do not over tighten or possible damage may occur to This prevents the complete unlocking of a telescoping equipment.

  • Page 191: Hoist Ropes

    This causes the lowering limit switch to become set incorrectly and to switch off too late or not at all. and as recommended by Manitowoc. All wire rope will Consequently the load may fall causing equipment eventually deteriorate to a point where it is no longer usable.
  • Page 192 30 rope diameters. • Severe corrosion as evidenced by pitting. • Manitowoc recommends that for cable extended booms, a single damaged wire rope assembly shall require replacement of the entire set of extension cables.
  • Page 193 TMS9000-2 SERVICE MANUAL SUPERSTRUCTURE FIGURE 4-35 Damage Description Cause Replacement Replace hoist rope at the latest when the maximum permissible number of wire strand fractures Wire Breakage General wear caused by according to the table are visible (1), (Figure 4-35) aging of the rope externally.
  • Page 194 SUPERSTRUCTURE TMS9000-2 SERVICE MANUAL FIGURE 4-36 Damage Description Cause Replacement Immediately replace hoist rope if the diameter has decreased by 15% or Structural changes. more with respect to the nominal The diameter of the Diameter diameter. rope has become Reduction (1), smaller along large Immediately replace the hoist rope if (Figure 4-36)
  • Page 195 TMS9000-2 SERVICE MANUAL SUPERSTRUCTURE FIGURE 4-37 Damage Description Cause Replacement Outer layer wires in the General wear due to aging Loop Formation form of hair pins are Immediately replace hoist rope if the of the rope or subsequent (1), protruding from the rope rope structure has been substantially damage resulting from (Figure 4-37)

  • Page 196: Rated Capacity Limiter

    SUPERSTRUCTURE TMS9000-2 SERVICE MANUAL FIGURE 4-38 Damage Description Cause Replacement Determine number of broken wires; Flattening (1), Crushed areas, mostly Mechanical damage, e.g. replace hoist rope immediately if (Figure 4-38) with wire breakage. due to driving over the rope. serious crushing occurs. Crinkle Crinkle type rope Loaded hoist rope was...
  • Page 197 TMS9000-2 SERVICE MANUAL SUPERSTRUCTURE NOTE: The following sections describe the maintenance procedure for the outer cable drum. Maintenance WARNING on the cable drum in the boom is carried out in the same way. Risk of accidents due to rope end fitting being overloaded! Prerequisites After installing a new hoist rope, the lowering limit switch...

  • Page 198: Lubricating The Swing Angle Sensor

    SUPERSTRUCTURE TMS9000-2 SERVICE MANUAL When all the cable has been wound on the drum it needs to stay on the drum while you are doing the 8 ± 1 revolutions of pre-tension on the entire reel, then start pulling the cable off to route out alongside the boom section.

  • Page 199: Superstructure Air Conditioning System (Additional Equipment)

    • Lubricate the open end (2), (Figure 4-46) of the piston • Only allow damaged hoses to be replaced by Manitowoc rod on the lifting cylinder head (1), (Figure 4-46) so that Crane Care. it is evenly covered with grease.
  • Page 200 SUPERSTRUCTURE TMS9000-2 SERVICE MANUAL This Page Blank 4-56 Published 01-14-2021 Control # 707-01...

  • Page 201: Superstructure Maintenance Overview

    TMS9000-2 SERVICE MANUAL SUPERSTRUCTURE MAINTENANCE SECTION 5 SUPERSTRUCTURE MAINTENANCE SECTION CONTENTS Superstructure Maintenance Overview ..5-1 Months/After 100 000 - 125 000 km (62,150 - 77,800 mi) ..... . . 5-7 Maintenance Intervals .

  • Page 202: Maintenance Intervals

    SUPERSTRUCTURE MAINTENANCE TMS9000-2 SERVICE MANUAL The following table sets out the maintenance intervals for the The maintenance interval which occurs first shall maintenance plans: determine when maintenance work is next due. You can call up the working hours (operating hours) of the superstructure's power units individually on the crane control display in the crane operator's cab (front instrument panel).

  • Page 203: Maintenance Plans

    TMS9000-2 SERVICE MANUAL SUPERSTRUCTURE MAINTENANCE MAINTENANCE PLANS The descriptions for certain maintenance work for the maintenance plans D, W, M 1 to M 12 and Y 2 to Y 6 are provided for in Section 8. References (chapter and page number) to the description of this maintenance work can be found after the respective maintenance work.
  • Page 204 SUPERSTRUCTURE MAINTENANCE TMS9000-2 SERVICE MANUAL Lock-out Cylinder & Slew Potentiometer: Check for proper operation while operating machine. Check for proper adjustment. Operator’s Manual: Is item properly installed on machine? Signal and Running Lights & Horn: Check for cracked or broken glass. Check for proper working order. Steps and Ladders: Check for excess dirt, grease, or foreign matter.

  • Page 205: Maintenance Plan W: Weekly

    TMS9000-2 SERVICE MANUAL SUPERSTRUCTURE MAINTENANCE Maintenance Plan W: Weekly Maintenance Work on the Superstructure Main Hoist/Auxiliary Hoist • Check the oil level. Hoist Lubrication, page 9-21 • Check for leaks • Check the hoist brake. Hoist, page 4-1 • Lubricate auxiliary hoist drives (only when auxiliary hoist is fitted as additional equipment). Hoist Lubrication, page 9-21 Swing Gear •...

  • Page 206: Maintenance Plan M 1: Monthly/After 100

    SUPERSTRUCTURE MAINTENANCE TMS9000-2 SERVICE MANUAL Maintenance Plan M 1: Monthly/After 100 Operating Hours/Approximately 2,000 km (1240 mi) Maintenance Work on the SUPERSTRUCTURE: Monthly/After 100 Operating Hours Hook Blocks • Lubrication, page 9-1 Hydraulic System of the Superstructure • Bleed the telescoping cylinders, page 4-44 •...

  • Page 207: Maintenance Plan M 12: Every 12 Months/After 1,000 Operating Hours/20 000 - 25 000 Km (12,430 - 15,530 Mi)

    TMS9000-2 SERVICE MANUAL SUPERSTRUCTURE MAINTENANCE Maintenance Plan M 12: Every 12 Months/ After 1,000 Operating Hours/20 000 - 25 000 km (12,430 - 15,530 mi) Maintenance Work on the SUPERSTRUCTURE: Every 12 Months/After 1 000 Operating Hours Main Hoist/Auxiliary Hoist •...

  • Page 208: Maintenance And Inspection Plan Y 5: Every 60 Months/After 5,000 Operating Hours

    SUPERSTRUCTURE MAINTENANCE TMS9000-2 SERVICE MANUAL Maintenance and Inspection Plan Y 5: Every 60 Months/After 5,000 Operating Hours Maintenance Work on the SUPERSTRUCTURE: Every 60 Months / After 5 000 Operating Hours • Lubricate the swing angle sensor, page 4-52 Maintenance and Inspection Plan Y 6: Every 72 Months/After 6,000 Operating Hours Maintenance Work on the Superstructure:...

  • Page 209: Periodic Inspections

    TMS9000-2 SERVICE MANUAL SUPERSTRUCTURE MAINTENANCE PERIODIC INSPECTIONS The load hook must consequently be replaced. Your truck crane was inspected before delivery. Regulations in your area may prescribe specific inspection intervals and should be reviewed and adhered to. If such regulations do not exist, an inspection should be carried out by an expert least once a year.

  • Page 210: Measures Required For Hoist Monitoring

    SUPERSTRUCTURE MAINTENANCE TMS9000-2 SERVICE MANUAL MEASURES REQUIRED FOR HOIST • Overloading caused by improper use of the crane. MONITORING • Insufficient maintenance: oil is not changed in the specified intervals. NOTE: Also observe the information on the general inspection of the hoists. •...
  • Page 211 TMS9000-2 SERVICE MANUAL SUPERSTRUCTURE MAINTENANCE circumstances, the crane can be supporting a Determining the Operating Conditions small load, whereby the hoist is actually supporting (Collective Load) a heavy load, e.g. due to insufficient reeving. The collective load of the crane is divided into groups: Therefore, the following graphic representation of (also refer to ISO 4301/1, FEM 1.001) the load spectrum refers to the hoist's wire cables.
  • Page 212 SUPERSTRUCTURE MAINTENANCE TMS9000-2 SERVICE MANUAL Table Example to Determine the Remaining Theoretical Service Life on Hoist No. 1 (Main Hoist) Crane model: TMS9000E Work number: 3045 42 06 Commissioned on: 10. 06. 1990 Serial number of the hoist in accordance with the model plate:13 301 Last general overhaul performed on: ......

  • Page 213: Section 6

    TMS9000-2 SERVICE MANUAL SWING SYSTEM SECTION 6 SWING SYSTEM SECTION CONTENTS Description ....... 6-1 Description.

  • Page 214: Description

    SWING SYSTEM TMS9000-2 SERVICE MANUAL the regulated flow is directed from the pressure reducing/ is also provided to the power brake valve where it is available sequence valve to the brake release ports, overcoming the for the activation of the swing brake when the pedal is brake spring pressures and releasing the swing brakes.

  • Page 215: Maintenance

    Reduce load. Refer to load capacity chart. Restricted or partly clogged hydraulic Replace hose or fittings. Refer to the hose or fittings. Manitowoc Crane Care Parts Manual. Pump cavitation in swing section. Tighten suction hose or replace any damaged fitting. Check hydraulic tank level.
  • Page 216 Lubricate bearing per Lubrication, page 9-1. Improper size hose and/or fittings Replace hose or fittings. Refer to your installed. Manitowoc Crane Care Parts Manual. Clogged or restricted hydraulic hoses Clean or replace damaged parts. or fittings. g. Worn damaged...
  • Page 217 TMS9000-2 SERVICE MANUAL SWING SYSTEM Symptom Probable Cause Solution Swing operation Crane not level. Level crane. slow in one b. Damaged hydraulic remote control b. Replace hydraulic remote control direction only. valve. valve. Damaged swing directional control Replace the swing directional control valve.
  • Page 218 SWING SYSTEM TMS9000-2 SERVICE MANUAL Symptom Probable Cause Solution 12. Swing motor Improper port connections. Reverse port connection. turning in wrong b. Improper wiring connection b. Inspect wiring and connections. Make direction. repairs as needed. 13. Swing motor noisy. Air in system. Refer to Hydraulic System, page 2-1, for removal of air from the system.

  • Page 219: Swing Box Assemblies

    TMS9000-2 SERVICE MANUAL SWING SYSTEM SWING BOX ASSEMBLIES Removal Engage the swing brake and the swing lock pin. Description There are two swing box assemblies (Figure 6-1) for turning and stopping the turntable and superstructure. Each swing CAUTION box assembly consists of a hydraulic motor on top, a brake assembly, and a swing gearbox on the bottom.

  • Page 220: Swing Gear Brake Function Check

    If the superstructure turns, the swing gear service brake Check for hydraulic leaks and repair as necessary. plates are worn and must be replaced immediately. • The plates must only be replaced by Manitowoc Crane Swing Gearbox Maintenance Care. Removal Swing Brake Assembly Maintenance Engage the swing lock pin.
  • Page 221 TMS9000-2 SERVICE MANUAL SWING SYSTEM Remove the capscrews and flatwashers securing the Servicing swing gearbox to the superstructure base plate. Normal maintenance should only consist of proper Remove the swing gearbox. lubrication and a periodic check of mounting bolt torque Remove the bolts and bottom plate attaching the pinion values.

  • Page 222: Swing Bearing

    SWING SYSTEM TMS9000-2 SERVICE MANUAL SWING BEARING a high strength bolt is removed, or un-torqued, the bolt must be replaced with a new bolt of the same classification. Description The swing bearing is an anti-friction roller bearing that mates the superstructure to the carrier. The bearing inner race is DANGER bolted to the superstructure and the outer race is bolted to Machine Damage and Personal Injury Hazard!
  • Page 223 TMS9000-2 SERVICE MANUAL SWING SYSTEM Multiplier bar handles must be propped or supported Inner Race Torquing within the outer 1/4 of the handle length, or serious Extend and set the outriggers. Fully elevate the boom. under or over tightening will occur. Torque all bolts to 80% of the full torque value of 466 lb-ft The inner race of the bearing is secured to the turntable by (632 Nm) following star pattern sequence as shown in...
  • Page 224 Description Grove Part Number Quantity Required shall be referred to your 1. 1 13/16 “Socket 3/4” Drive 9-999-101988 Manitowoc distributor or 2. 4 to 1 Torque Multiplier (1/2” Input 3/4” Output) 9-999-100134 Manitowoc Crane Care. 3. Backlash Adapter 9-999-100141 4. 1/2” Drive Torque Wrench 9-999-100136 5.
  • Page 225 TMS9000-2 SERVICE MANUAL SWING SYSTEM NOTE: The swivel assembly will be removed with the can be installed in the exact position it was before turntable. removal. NOTE: The bearing weighs approximately 2030 lb (921 kg). Ensure the bearing lifting device is capable of supporting the weight.

  • Page 226: Description

    SWING SYSTEM TMS9000-2 SERVICE MANUAL NOTE: If a new bearing is being installed, a new pinion Using shims, set backlash by moving the swing gear must also be used. Align the high point drive assemblies toward the bearing in order to (maximum eccentricity) on the bearing with the mesh the pinion with the ring gear teeth.

  • Page 227: Swivels

    TMS9000-2 SERVICE MANUAL SWING SYSTEM SWIVELS jam nuts (10). This allows the spool to remain stationary with the carrier as the case rotates with the superstructure. Description The spool portion of the water swivel is attached to the spool of the hydraulic swivel by four bolts. The hydraulic and water The swivel assembly consists of a 6 port hydraulic, 2 port air swivel spools remain stationary with the carrier as the conditioning swivel and 20 conductor slip ring assembly (2)
  • Page 228 SWING SYSTEM TMS9000-2 SERVICE MANUAL 3, 4 8902 8902-1 FIGURE 6-5 Item Description 8 Port Hydraulic, AC Swivel 20 Conductor Slip Ring Assy Bolt Washer Mounting Bracket Harness 6-16 Published 01-14-2021 Control # 707-01...

  • Page 229: Hydraulic Swivel

    TMS9000-2 SERVICE MANUAL SWING SYSTEM Hydraulic Swivel plates to the spool. Remove the retainer plates from the spool and the lugs on the carrier frame. Description NOTE: It may be necessary to remove some drive line Each of the ports on the spool and case of the swivel is components to remove the swivel.

  • Page 230: Electrical Swivel

    SWING SYSTEM TMS9000-2 SERVICE MANUAL Electrical Swivel NOTE: If connectors are too large to go through the center of the hydraulic swivel, tag each wire on each of the connectors. Using the appropriate pin removal Description tools, remove the pins, with wires still attached, and The swivel assembly consists of a 20 conductor slip ring and mark each wire with the pin socket number in the cover assembly.
  • Page 231 TMS9000-2 SERVICE MANUAL SWING SYSTEM ground wire to the connector mounting bracket on the carrier frame using the bolt and star washers taken off at Bolt and Shims removal and refer to Grove Engineering Specification A- 829-100386 for proper electrical termination of grounds. Install the clamp securing the harness to the retainer plate on the bottom of the hydraulic swivel assembly.

  • Page 232: Swing Lock Pin

    SWING SYSTEM TMS9000-2 SERVICE MANUAL SWING LOCK PIN 360° SWING LOCK CONTROL (POSITIVE LOCK TYPE) Description Description 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 superstructure in position directly over the front or the rear of The purpose of the swing lock is to secure the superstructure the carrier.

  • Page 233: Engine

    TMS9000-2 SERVICE MANUAL POWER TRAIN SECTION 7 POWER TRAIN SECTION CONTENTS Engine ........7-1 Maintenance .

  • Page 234: Maintenance

    POWER TRAIN TMS9000-2 SERVICE MANUAL The air intake filter is located on the right side of the engine 16. Unbolt driveline from piston pump coupler and lay on on the fender. The muffler is located on the left side behind transmission.
  • Page 235 TMS9000-2 SERVICE MANUAL POWER TRAIN X12 Engine Installation 8326-8 Rear Engine Mounts Oil Temperature Sensor Engine Oil Dipstick Oil Pressure Sensor Fan Clutch Engine Oil Filter (Remote Mount) Transmission Transmission Oil Fill Plug Alternator Gear Pump (Power Steering) Front Cross Member and Mounts Lifting Brackets FIGURE 7-1 Grove...

  • Page 236: Installation

    POWER TRAIN TMS9000-2 SERVICE MANUAL Installation 15. Bolt drive line to piston pump coupler. 16. Connect hoses to main piston pump With all components and fittings installed on the engine, lift the engine assembly into the crane. NOTE: Aftertreatment assembly weighs approximately 90 kg (200 pounds).

  • Page 237: Engine Control System

    TMS9000-2 SERVICE MANUAL POWER TRAIN Longitudinal Cracks Intersecting Traverse Cracks Missing Material with Transverse Cracks must be Replaced V-Ribbed Belt Inspection FIGURE 7-2 ENGINE CONTROL SYSTEM reads the logic inputs from the brake, clutch, and cab switches and analog inputs from sensors such as the engine Description coolant temperature sensor and the manifold boost pressure sensor.

  • Page 238: Engine Control System Switches And Indicator Lights

    POWER TRAIN TMS9000-2 SERVICE MANUAL Engine Control System Switches and • A) On Solid: Cleaning should be done within one shift of operation. Indicator Lights • B) Flashing: Cleaning needs to be done soon. Engine Stop Indicator • C) Flashing with Check Engine Light Illuminated: Engine Stop lamp is locate d in the t op rig ht of the Start cleaning immediately.

  • Page 239: Maintenance

    TMS9000-2 SERVICE MANUAL POWER TRAIN Connect the two lines to the fittings on the tank in Injection Fuel Pump accordance with the identification marks made during The fuel is finely atomized as it is injected into the cylinder removal. and ignited by the heat of compression. It is metered also, Service the tank.

  • Page 240: Air Intake System

    POWER TRAIN TMS9000-2 SERVICE MANUAL Fuel Tank Installation 9036 Fuel Supply to Engine Fuel Return From Engine Tank Vent Fuel Quantity Sending Unit Filler Cap Fuel Tank Mounting Straps Fuel Tank Bracket FIGURE 7-3 AIR INTAKE SYSTEM The air cleaner is the dry-type with a replaceable element. It is located on the right front fender.

  • Page 241: Maintenance

    TMS9000-2 SERVICE MANUAL POWER TRAIN the engine temperature is 13°C (55°F) or below to facilitate Maximum restriction in the air cleaner occurs at maximum air engine starting. When activated, the system actuates the flow. On this turbocharged diesel engine, the maximum air valve assembly, passing starting fluid from the bottle through flow occurs only at maximum engine power.
  • Page 242 POWER TRAIN TMS9000-2 SERVICE MANUAL Element Cleaning It is not recommended that filter elements be cleaned. Cummins and most other manufacturers will not warrant a cleaned air filter. Air Cleaner Body Before installing the filter element, remove foreign material (leaves, lint or other foreign matter) that may have collected inside the air cleaner body.

  • Page 243: Exhaust System

    TMS9000-2 SERVICE MANUAL POWER TRAIN and can cause hoses to slip off the connecting pipes, Check hoses for cracks, chafing, or deterioration, and allowing un-filtered air into the engine air intake. replace at the first sign of probable failure. Air Cleaner Mounting Band Air Inlet Hood Service Indicator...

  • Page 244: Slip Joint Exhaust Connectors

    POWER TRAIN TMS9000-2 SERVICE MANUAL Attach the crane’s sensor harness wires, as tagged After 1000 Hours or One Year during removal, to the sensor wire leads of the system. Visually inspect the exhaust connector. If necessary, tighten Attach the tubing as tagged during removal. the v-clamps by one full turn of the nuts.

  • Page 245: After-Treatment Diesel Exhaust Fluid (Def)

    TMS9000-2 SERVICE MANUAL POWER TRAIN AFTER-TREATMENT DIESEL EXHAUST Tag and disconnect the electrical connectors on the DEF tank. FLUID (DEF) Tag and disconnect the fluid lines on the tank. DEF Tank Remove the hardware holding the tank straps in place. Description Remove the tank.

  • Page 246: Def Dosing Unit Filter

    POWER TRAIN TMS9000-2 SERVICE MANUAL DEF Dosing Unit Filter The filter should be replaced every 480,000 km (300,000 miles) or 6750 hours of crane operation. The DEF dosing unit filter (Figure 7-11) is a 10-micron filter The aftertreatment DEF dosing unit filter consists of the designed to prevent foreign objects, that may be suspended following components: in the DEF, from entering the dosing system.
  • Page 247 TMS9000-2 SERVICE MANUAL POWER TRAIN Check the DEF for evidence of contaminated DEF. Use Preparatory Steps visual and aroma characteristics of the filter to determine if contaminated fluid has passed through the dosing system. WARNING Inspect the DEF filter for debris. If debris is evident, also check: Personal Injury Hazard! •...

  • Page 248: Water Cooling System

    POWER TRAIN TMS9000-2 SERVICE MANUAL usually occur gradually. The cooling system needs to be maintained with the same attention as other systems. CAUTION The circulation of water through the cooling system relies entirely upon the water pump. The water pump draws water Machine Damage Hazard! from the radiator and forces it through the water jacket and Do not use the flow test portion of the INSITE™...
  • Page 249 TMS9000-2 SERVICE MANUAL POWER TRAIN and oxygen, and can only be prevented by maintaining full Engine Antifreeze/Coolant Fill Procedure strength corrosion protection at all times. (After a Complete Draining of the System) For maximum rust, freeze, and boiling point protection, a 50/ NOTE: If the engine coolant is changed, the coolant filter 50 blended, fully formulated extended life antifreeze/coolant...

  • Page 250: Cleaning

    SCA levels are above (180°F) so the cleaning solution may take effect. Do not normal (contact Manitowoc Crane Care for filter part drive the vehicle or allow the liquid level in the radiator to number).

  • Page 251: Component Inspection

    TMS9000-2 SERVICE MANUAL POWER TRAIN engine block with water, partly covering the water inlet opening to permit complete filling. Turn on compressed air to blow out water and loose CAUTION sediment. Continue filling with water and blowing out Burn hazard! with air until flushing stream comes out clear.

  • Page 252: Radiator Assembly Removal And Installation

    POWER TRAIN TMS9000-2 SERVICE MANUAL retarding or restricting the circulation of coolant during Disconnect the hoses (12) from the coolant recovery engine warm up. Engine overheating and loss of coolant is tank (2) and remove the tank. sometimes due to an inoperative thermostat. To check for Remove the hardware securing the top center hood t h i s c o n d i t i o n , r e m o v e t h e t h e r m o s ta t a n d t e s t b y panel to the front and rear cowls and remove the panel...
  • Page 253 TMS9000-2 SERVICE MANUAL POWER TRAIN 10. Install the coolant recovery tank. Connect the hoses to 11. Service the engine coolant system as necessary. Start the tank. the engine, operate all systems and check for leaks. Engine Radiator/Charge Air Cooler Assembly Item Description Radiator/Charge Air Cooler...

  • Page 254: Drive Train

    POWER TRAIN TMS9000-2 SERVICE MANUAL DRIVE TRAIN Removal Refer to (Figure 7-14). Description Support the drive line being removed so it does not fall The drive train consists of the manual transmission, clutch, when disconnected. and drive lines. Remove the bolts from the bearing cap on each end of A 39.4 cm (15-1/2 in) - 2 plate pull type disc clutch is used the drive line.
  • Page 255 TMS9000-2 SERVICE MANUAL POWER TRAIN Drive Line Installation TORQUE 149 to 163 Nm 110 to 120 ft-lb) TORQUE 149 to 163 Nm (110 to 120 ft-lb) TORQUE 149 to 163 Nm (110 to 120 ft-lb) TORQUE 149 to 163 Nm (110 to 120 ft-lb) View A TORQUE...

  • Page 256: Clutch

    POWER TRAIN TMS9000-2 SERVICE MANUAL CLUTCH Theory Of Operation Description CAUTION For Clutch Installation, refer to (Figure 7-15). Machine Damage Hazard! The clutch is a 39.4 cm (15-1/2 in), 2-plate, pull-type heavy N e v e r f u l l y d e p r e s s t h e c l u t c h p e d a l b e f o r e t h e duty unit.
  • Page 257 TMS9000-2 SERVICE MANUAL POWER TRAIN Clutch Installation Clutch Assembly Adjusting Lever Governor Spring Pilot Bearing Crank Lockwasher Bolt Clutch Release Shaft and Parts 6, 7 4749 FIGURE 7-15 Grove 7-25 Published 01-14-2021 Control # 707-01...

  • Page 258: Maintenance

    POWER TRAIN TMS9000-2 SERVICE MANUAL Maintenance Troubleshooting SYMPTON PROBABLE CAUSE SOLUTION Loose, broken, or worn engine Chatter. Tighten or replace mounts. mounts. Loose or cracked clutch Tighten or replace. housing. Rear axle attach bushings Replace bushings. worn. Misalignment. Align. Install new facings or disc Oil or grease on facings.
  • Page 259 TMS9000-2 SERVICE MANUAL POWER TRAIN SYMPTON PROBABLE CAUSE SOLUTION Pressure plate return springs Replace springs. bent or stretched. Insufficient amount of release Adjust for proper release travel. travel. Lever nose out of groove in Disassemble and repair as release sleeve retainer. necessary.
  • Page 260 POWER TRAIN TMS9000-2 SERVICE MANUAL SYMPTON PROBABLE CAUSE SOLUTION Replace damaged intermediate Broken intermediate plate. plate driven disc assembly. Intermediate plate lugs should Intermediate plate sticking on have 0.1524 mm (0.006 in) cover. clearance in driving slots of flywheel ring (cover). Warped or bent driven disc Replace.
  • Page 261 TMS9000-2 SERVICE MANUAL POWER TRAIN Removal Remove the transmission following the procedures under Removal of the Transmission, page 7-37. Install two 19 mm (0.75 in) blocks of wood between the clutch flywheel ring and the clutch release bearing housing as the clutch mounting bolts are loosened around the flywheel.
  • Page 262 POWER TRAIN TMS9000-2 SERVICE MANUAL Put the rear driven disc on the aligning tool with the side Installation stamped “pressure plate” facing the pressure plate. Refer to the following Figures for Installation. 4863-4 FIGURE 7-19 4863-6 FIGURE 7-21 Insert two 12.7 cm (5 in) long 7/16 inch - 14 UNC guide Place the intermediate plate in the clutch cover and align studs into the two upper mounting holes of the flywheel.
  • Page 263 TMS9000-2 SERVICE MANUAL POWER TRAIN NOTE: Make sure that the adjustment mechanism will be aligned with the opening in the bell housing of the FLUSH transmission. PROTRUDING FIGURE 7-25 4863-10 FIGURE 7-23 4863-8 Position the clutch over the guide studs and slide it Positive Separator (Roll) pins should be flush on the forward until contact is made with the flywheel surface.
  • Page 264 POWER TRAIN TMS9000-2 SERVICE MANUAL 9.53-15.88 mm 0.375-0.625 in If greater than 15.88 mm (0.625 in), check fly- wheel for potential damper interfer- ence. - 8 Springs need 18.4 cm (7.25 in) bore. - 10 Springs need 21.7 cm (8.56 in) bore. - 7 Springs need 24.8 cm (9.75 in) bore.

  • Page 265: Clutch Adjustment Procedure

    TMS9000-2 SERVICE MANUAL POWER TRAIN Clutch Adjustment Procedure Install the inspection plate on the bottom of the clutch housing and road test the crane for proper clutch Remove the inspection plate from the bottom of the clutch operation. housing and make the following inspections and adjustments if required.

  • Page 266: Maintenance

    POWER TRAIN TMS9000-2 SERVICE MANUAL Maintenance Troubleshooting SYMPTON PROBABLE CAUSE SOLUTION Excessive lever travel or sloppy Setscrews loose in control shaft universal joints or Tighten or replace setscrews. feel when shifting. shift fingers. Bent shift bar in transmission. Damaged cross Disassemble and repair as Hard shifting.

  • Page 267: Maintenance

    TMS9000-2 SERVICE MANUAL POWER TRAIN bushings and sleeves as gears float between mating gears abnormal conditions in other parts of the crane, when noises on the countershafts. are transmitted from the engine, power train, frame, or body to the transmission and will appear to originate there. All Maintenance such sources should be checked out before removing and disassembling the transmission.
  • Page 268 POWER TRAIN TMS9000-2 SERVICE MANUAL SYMPTON PROBABLE CAUSE SOLUTION Jumping out of gear. Misaligned transmission. Check alignment. Shift rail poppet springs broken. Replace poppet springs. Shift rail poppet notch worn. Replace shift rail. Replace sprung fork or tighten setscrew in Shift forks sprung or loose on shift rail.
  • Page 269 TMS9000-2 SERVICE MANUAL POWER TRAIN SYMPTON PROBABLE CAUSE SOLUTION Improper adjustment of shifting linkage. Check and adjust linkage and rods to ensure Worn or bent shifter rails. that transmission is shifting fully into gear. Insufficient lubricant. Fill to proper level. Air lines crossed between control valve on shift lever and air valve on transmission Range shift inoperative or...

  • Page 270: Lubrication

    POWER TRAIN TMS9000-2 SERVICE MANUAL Lubrication Assembly Install the new input shaft into the splines of the drive General gear just far enough to expose the snap ring groove in The transmission is designed so the internal parts operate in the ID of the drive gear.

  • Page 271: Preventive Maintenance

    TMS9000-2 SERVICE MANUAL POWER TRAIN • Main Shaft Rear Bearing Cover. Check oil seal for Proper Lubrication wear. If the transmission operating angle is more than 12 degrees, improper lubrication can occur. The operating angle is the TRANSMISSION SHIFT AIR SYSTEM transmission mounting angle in the chassis plus the percent of upgrade (expressed in degrees).

  • Page 272: Pump / Pto Assembly

    POWER TRAIN TMS9000-2 SERVICE MANUAL PUMP / PTO ASSEMBLY Pump / PTO Replacement The PTO driveline (1), (Figure 7-29) powers the No. 1 Pump (2), (Figure 7-29) in the QSM engine installation. CAUTION Damage Could Occur! Absolute cleanliness is essential when working on the hydraulic pumps.
  • Page 273 TMS9000-2 SERVICE MANUAL POWER TRAIN Remove the four cap screws, nuts and washers Connect the electrical connectors and hoses to the securing the clutch mounting bracket (3), (Figure 7-29) pumps as tagged during removal. to the frame. Tighten the hardware connecting the mounting bracket/ Attach a suitable lifting device to the mounting bracket/ pump to the frame.
  • Page 274 POWER TRAIN TMS9000-2 SERVICE MANUAL This Page Blank 7-42 Published 01-14-2021 Control # 707-01...

  • Page 275: Section 8

    TMS9000-2 SERVICE MANUAL CARRIER SECTION 8 CARRIER SECTION CONTENTS Front Axle ....... . 8-2 Normal Braking .

  • Page 276: Front Axle

    CARRIER TMS9000-2 SERVICE MANUAL Outrigger Monitoring System (Optional— Description ......8-96 Standard in North America) .
  • Page 277 TMS9000-2 SERVICE MANUAL CARRIER Air Bags Shock Absorbers Check for wear or road damage. Check for air leaks. Check Check the shock absorbers for leakage and wear. tightness of nuts and bolts. Torque to 41 Nm (30 lb-ft). Height Control Valves Check valve, fittings, and air lines for leaks.
  • Page 278 CARRIER TMS9000-2 SERVICE MANUAL Axle and Suspension Assembly FIGURE 8-1 Published 01-14-2021 Control # 707-01...

  • Page 279: Removal

    TMS9000-2 SERVICE MANUAL CARRIER Removal NOTE: Check and record the distance for each torque rod from center to center of the rod clevis. Do not Refer to (Figure 8-1). change this dimension when installing torque rods. This will make wheel alignment easier when the NOTE: The axle does not have to be removed from the axle is reinstalled.

  • Page 280: Installation

    CARRIER TMS9000-2 SERVICE MANUAL Installation 10. Install the air fittings in the inlet of the air bags. Connect the air lines to the air bags and brake chambers as Refer to (Figure 8-1). tagged during removal. Position the axle and suspension assembly under the 11.

  • Page 281: Axle Alignment Procedure

    TMS9000-2 SERVICE MANUAL CARRIER AXLE ALIGNMENT PROCEDURE DIM. C KING PIN CENTER KING PIN C/L OF FIRST CENTER 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...
  • Page 282 CARRIER TMS9000-2 SERVICE MANUAL Toe-In Adjustment RIGID AXLE STOP Toe-in is having the wheels of a steerable axle closer KING PIN together in the front than in the rear. Toe-in is necessary for CENTER both tire wear and to keep the wheels from weaving side to C/L OF AXLE side.
  • Page 283 TMS9000-2 SERVICE MANUAL CARRIER axles. Position drag links (Detail 5) into relay arms (Details 8 and 9), (Figure 8-8) thread nut onto drag links and torque 135-170 Nm (99.5-125 ft-lb) and install cotter pin thru nut. Keep clamps on drag links rotated away from frame to assure no interference.
  • Page 284 CARRIER TMS9000-2 SERVICE MANUAL Partially extend the outrigger beams. Attach a string line to front and rear outrigger beams as shown in CAUTION (Figure 8-2), Axle Alignment. Ensure the string line is taut and level. Vehicle Damage Hazard! Do not attempt to adjust the axle drag links or the tie rod Referring to (Figure 8-2), Axle Alignment, ensure that ends while the full weight of the crane is on the axles Dimension C equals Dimension D and that Dimension E...
  • Page 285 TMS9000-2 SERVICE MANUAL CARRIER Setting Axle Stops and Steering Gear Relief Plungers NOTE: Do not attempt to set the relief pressure with the Start the engine and run at idle. tires off the ground. Plungers are fine thread and Determine straight ahead axle position/wheel position. a c c e p t a s m a l l f l a t h e a d s c r e w d r i v e r.

  • Page 286: Steering System

    CARRIER TMS9000-2 SERVICE MANUAL DETAIL B DETAIL A FRONT PLUNGER ADJUST REAR PLUNGER ADJUST ON LEFT HAND TURN. ON RIGHT HAND TURN. SCREW IN TO DECREASE SCREW IN TO DECREASE TRAVEL, SCREW OUT TO TRAVEL, SCREW OUT TO INCREASE TRAVEL INCREASE TRAVEL.

  • Page 287: Maintenance

    TMS9000-2 SERVICE MANUAL CARRIER Maintenance Troubleshooting SYMPTOM PROBABLE CAUSE SOLUTION Oil leaking at output shaft of Damaged sector shaft seal. Replace sector shaft. steering gear. Worn or damaged oil seal. Replace actuating shaft seal. Oil leaking at actuating shaft Replace bearing cap, actuating shafts of steering gear.
  • Page 288 CARRIER TMS9000-2 SERVICE MANUAL SYMPTOM PROBABLE CAUSE SOLUTION Steering out of alignment. Align front end. High operating temperature. Locate and correct cause of overheating. Dirt or foreign matter trapped in piston relief. Check pressure relief. Bent or damaged king pins and tie rods. Repair or replace king pins and tie rods.

  • Page 289: Steering Pump

    TMS9000-2 SERVICE MANUAL CARRIER With the vehicle stationary and engine at idle, place the torque wrench on the steering wheel retaining nut and steer from lock to lock. A reading of more than 1.7 Nm (15 pounds-inch) means improper phasing. To correct, rotate the intermediate steering shaft one spline at a time until the torque reads the same throughout the 360 degree rotation.

  • Page 290: Steer Cylinder

    CARRIER TMS9000-2 SERVICE MANUAL After centering the steering gearbox output shaft, locate bend tab of the tab washer. Bend two opposing tabs of the pitman arm on the output shaft by aligning the timing the washer into the notches of the retainer nut. marks (arrow on shaft and letter ‘B’...

  • Page 291: Wheels And Tires

    TMS9000-2 SERVICE MANUAL CARRIER Removal Assemblies Tag and disconnect the hydraulic lines to the cylinder. NOTE: Do not lubricate the wheel studs or lug nuts. With Cap or plug all lines and openings. aluminum wheels, lubricate the wheel pilot or hub pads only with a synthetic lubricant containing Remove the cotter pin, washer, and the retaining nut Teflon.

  • Page 292: Suspension

    CARRIER TMS9000-2 SERVICE MANUAL ha s t h e s am e g ea rs a n d b ea rin gs as th e s ta nd a rd Beam Center Cap Fasteners differential. An air actuated shift collar moves toward the Periodically check the bolts on the saddle cap to prevent center of the differential and when the splines of the shift wear of the walking beam center bushing into the saddle...
  • Page 293 TMS9000-2 SERVICE MANUAL CARRIER 6982 FIGURE 8-12 Grove 8-19 Published 01-14-2021 Control # 707-01...

  • Page 294: Removal

    CARRIER TMS9000-2 SERVICE MANUAL Removal Remove two shock absorbers from the suspension saddle assembly by removing the bolt and two washers NOTE: The axle does not have to be removed from the securing each. Remove the shock absorber(s). crane for maintenance. Remove each axle from the walking beams by removing Raise the crane on outriggers until the weight is off the the two bolts, washers, and nuts securing each end of...

  • Page 295: Installation

    TMS9000-2 SERVICE MANUAL CARRIER Installation WHEELS AND TIRES Position the axle and suspension assembly under the Description carrier. One size of tire is available on the rear axle: 315/80R22.5. Raise the assembly into position under the carrier aligning the saddle assemblies pivot blocks and air bags NOTE: Always replace tires with the same size that were with the mounting brackets on the carrier.

  • Page 296: Air System

    CARRIER TMS9000-2 SERVICE MANUAL pads with synthetic lubricant containing Teflon. Do The engine-mounted air compressor provides air system not lube the face of the wheel or rim. flow. The air system components are operated by the air that is stored in four reservoirs underneath the frame. Install the wheel assemblies on the mounting studs.
  • Page 297 TMS9000-2 SERVICE MANUAL CARRIER 6972-3 6972-9 6972-4 See View B 6972-1 See View A 6972-2 See View C FIGURE 8-14 Grove 8-23 Published 01-14-2021 Control # 707-01...

  • Page 298: Braking

    CARRIER TMS9000-2 SERVICE MANUAL View A 6972-5 6972-8 6972-6 View C View B Figure 8-14 continued Item Description Item Description Air Dryer Module Tractor Protection Valve Cross-Axle Diff Lock Solenoid Valve Supply Dump Valve (Opt) Front Service Brake Relay Valve Air Suspension Valve ABS Modulator Valve Secondary Air Reservoir B...

  • Page 299: Maintenance

    TMS9000-2 SERVICE MANUAL CARRIER pressure to the valve drops below 280 kPa (40 psi), the valve Leak Detection will release, applying the brakes. If a leak is suspected, shut off the engine and note the air The service brakes are applied by air pressure. Depressing pressure reading of both circuits.
  • Page 300 CARRIER TMS9000-2 SERVICE MANUAL At 731 kPa ±41 kPa (106 ± 6 psi), the pressure Loss of Primary (Rear) Air System protection valve will open and allow air to flow into If necessary, start the engine and charge air system to the reservoirs.

  • Page 301: Air System Components

    TMS9000-2 SERVICE MANUAL CARRIER Apply the service brakes. On units equipped with trailing boom, the trailer emergency supply line should be exhausted between All four rear axle brakes should apply. The brake lights 138 to 310 kPa (20 to 45 psi). on the rear of the crane should illuminate.
  • Page 302 CARRIER TMS9000-2 SERVICE MANUAL 4, 5 Item Description Item Description Governor Auxiliary Delivery Port (Air Out) Unloader Control Valve Inlet Port (Supply From Compressor) Common Reservoir Pressure Pressure Protection Valves Delivery Port Out (To Primary Safety Valve Reservoir) (Not Shown) Delivery Port Out (To Secondary Desiccant Cartridge Reservoir) (Not Shown)
  • Page 303 TMS9000-2 SERVICE MANUAL CARRIER Low Pressure Indicator Switches Safety Valve The low pressure indicator switches (Figure 8-17) are used A safety valve (Figure 8-19) is installed in the air dryer to warn the operator of low pressure in the air systems. One module to protect the air system against excessive air switch is installed in each system and they are electrically pressure buildup.
  • Page 304 CARRIER TMS9000-2 SERVICE MANUAL Relay Valve One valve is mounted on the front of the frame for front service brakes and one is mounted on the rear of the frame The purpose of the two piston operated relay valves for the rear service brakes. Air pressure, which controls the (Figure 8-21) is to speed up application of the service valve, enters through the service port to either deliver or brakes.
  • Page 305 TMS9000-2 SERVICE MANUAL CARRIER control. The solenoids provide the electro-pneumatic Installation interface between the anti-lock controller electronics and the Position the air governor on the air dryer module and air brake system. The modulator is used to control the secure with bolts, lockwashers, and nuts. braking function on actuators during anti-lock activity.
  • Page 306 CARRIER TMS9000-2 SERVICE MANUAL Every 900 hours, or 40,000 km (25,000 mi) check for pressure indicates a possible failed check valve in the moisture in the air system by opening the reservoir’s outlet port. drain cock or automatic drain valve. Test the purge valve by applying a soap solution to the Replacement of the desiccant cartridge may be exhaust.
  • Page 307 TMS9000-2 SERVICE MANUAL CARRIER Removal Functional Check Chock the wheels and completely depressurize both Start the engine and observe the air pressure gauge. The red systems. arrow on the gauge (primary) should rise first until a pressure reading of about 590 kPa (85 psi) at which time the green Disconnect the electrical lead and unscrew the switch arrow (secondary) should begin to climb.
  • Page 308 CARRIER TMS9000-2 SERVICE MANUAL Slowly exhaust the delivery side of the valve. The gauge Operating Test on the supply side should stop while the gauge on the Chock the wheels and pressurize both systems. Adjust delivery side should continue to show a pressure loss. the brakes.
  • Page 309 TMS9000-2 SERVICE MANUAL CARRIER line from delivery port of the valve and install test gauge. Installation Place parking control valve in “release” position. Position the brake valve and pedal assembly onto the Observe that spring brake actuators release fully. studs under the front console and secure with the nuts, With parking control valve in “release”...

  • Page 310: Brakes

    CARRIER TMS9000-2 SERVICE MANUAL BRAKES Disassemble the brake valve and clean and inspect all parts. Park Brake Control Valve Description Removal NOTE: For more in depth information on Bendix system Chock the wheels and completely depressurize both c o m po n e n ts g o t o t h e B e n d i x w e b s i t e a n d systems.

  • Page 311: Automatic Traction Control

    TMS9000-2 SERVICE MANUAL CARRIER In addition to the ABS features above, some advanced • Clean brake parts and assemblies in the open air. During ECUs have a drag torque control feature which reduces disassembly, carefully place all parts on the floor to driv en-a xle wh eel slip (due to driv eline inert ia) by avoid getting dust into the air.

  • Page 312: Maintenance

    CARRIER TMS9000-2 SERVICE MANUAL Maintenance Troubleshooting SYMPTOM PROBABLE CAUSE SOLUTION Check for the correct Brakes are poor or do not Insufficient air pressure. pressure at the compressor apply. and brake air chambers. Restriction or leak in lines, Check all lines, valves, etc., valves, etc.
  • Page 313 TMS9000-2 SERVICE MANUAL CARRIER 11. Do the same for the lower return spring 12. Remove the shoes from the axle (Figure 8-25). Lift up the end of the brake shoe. 13. Remove the slack adjuster; reference Slack Adjuster Removal this Section. 14.
  • Page 314 CARRIER TMS9000-2 SERVICE MANUAL 17. Remove screws and retaining clip securing dust shield Clean all other brake parts thoroughly with a suitable to spider and remove dust shield (Figure 8-27). shop solvent. Wipe dry with a clean, lint-free cloth. Inspection NOTE: Refer to (Figure 8-28) for components referenced in inspection.
  • Page 315 TMS9000-2 SERVICE MANUAL CARRIER Front Brake Assembly Bracket Assembly Cast Spider with Horse Camshaft Retainer Collar Snap Ring Shoe Retainer Springs (Color-Orange) Camshaft Shim Washers Camshaft Shoe Assembly Bushing Lockwasher Slack Adjuster Roller Cam Head Washer Grease Seal Grease Fitting Retainer Shoe Return Springs Camshaft Bushing...
  • Page 316 CARRIER TMS9000-2 SERVICE MANUAL Each time the brake shoes are removed, check 12. Check the grease seals and replace if nicked, cut, or camshaft radial play as outlined in Steps 7a thru 7e distorted. below and (Figure 8-29). 13. Check the air chamber bracket for a bent, broken, or cracked arm and welds.
  • Page 317 TMS9000-2 SERVICE MANUAL CARRIER 17.5 mm (0.688 in) from the ends of the tube Assembly (Figure 8-30). Position the spider on the axle flange and install attaching bolts and nuts. Place hardened washers under the bolt head. At cam head end, recess bushing 7.1 mm (0.281 in) Position the dust shield against the spider.

  • Page 318: Automatic Slack Adjuster

    CARRIER TMS9000-2 SERVICE MANUAL g. Repeat Steps (d) thru (f) on the upper shoe. Removal Install the drum and axle spindle nut(s) and washers. CAUTION AUTOMATIC SLACK ADJUSTER Damage Could Occur! Description You must disengage a pull pawl before rotating the manual adjusting nut, or you will damage the pawl teeth.
  • Page 319 If after adjustment the requirements in Step 7 cannot be pressure in both primary and secondary systems, fully met, contact your Manitowoc Cranes distributor. The apply service brakes and hold brakes on. Do not pump crane cannot be driven on public roads until repaired.
  • Page 320 4 until sure. from the vehicle tool box or Manitowoc Crane Care, Turn the release-bolt 1/4 turn clockwise and pull the bolt as the piggyback spring brake cannot be manually out to lock the formed end into the piston.
  • Page 321 TMS9000-2 SERVICE MANUAL CARRIER Using a 3/4 inch wrench turn the release-nut clockwise until 8.2 cm (3.25 in) length of bolt extends above the nut (Figure 8-38). Do not use an impact wrench. 7092-6 FIGURE 8-39 7092-5 FIGURE 8-38 WARNING For easier manual-releasing, apply 620 - 861.8 kPa (90 - 125 psi) air pressure to inlet port marked “SPRING Death or Injury Could Occur!
  • Page 322 CARRIER TMS9000-2 SERVICE MANUAL MEASURE FREE STROKE FREE STROKE = Y MINUS X Drum brake free stroke must be 12.7 - 15.9 mm (0.5 - 0.625 in) Disc brake free stroke must be 19.1 - 22.2 mm (0.75 - 0.875 in) FIGURE 8-40 7092-7 Continue this process until the stroke is within limits...
  • Page 323 TMS9000-2 SERVICE MANUAL CARRIER Removal Block wheels to prevent crane from moving. Ensure CAUTION system tank pressure is above 689 kPa/6.8 bar (100 Damage Could Occur! psi). Do not use an impact wrench or permanent internal Use a wrench to turn the manual adjusting nut damage will occur.
  • Page 324 CARRIER TMS9000-2 SERVICE MANUAL Free Stroke = B minus A Applied Stroke = C minus A (Fully Retracted) (Brake Application at 621 to 689 kPa (90 - 100 psi) reservoir pressure) 7094-1 FIGURE 8-43 Brake Free Play Measurement and Adjustment The following procedure is required to ensure that the free play of the brakes is within required values.
  • Page 325 TMS9000-2 SERVICE MANUAL CARRIER WARNING Death or Injury Could Occur! There are no serviceable parts inside the spring brake chamber. Never attempt to disassemble the spring brake chamber as serious personal injury could result from accidental sudden release of the high energy spring. Measure the distance from the center of the large clevis to the air chamber mounting face with the brake fully 7093-2...

  • Page 326: Rear Brakes

    CARRIER TMS9000-2 SERVICE MANUAL With brakes released, check installation indicator incorporated into the air brake chamber. The brake chamber (Figure 8-46) and (Figure 8-47) to determine proper has an aluminum body and pressure plate with a steel adjustment. nonpressure plate that houses a service/emergency diaphragm, piston, and two springs.
  • Page 327 TMS9000-2 SERVICE MANUAL CARRIER Troubleshooting Brakes SYMPTOM PROBABLE CAUSE SOLUTION Check for correct pressure at compressor and Brakes are poor or do not apply. Insufficient air pressure. brake chambers. Check all lines, valves, etc., for leaks or Restriction or leak in lines, valves, etc. restrictions.
  • Page 328 CARRIER TMS9000-2 SERVICE MANUAL Check brake adjustment. Removal Uncage the spring brake. Disassembly WARNING Refer to (Figure 8-49). Death or Injury Could Occur! Cage the spring brake before removal of air brake Caging Bolt chamber. Spring Brake Chamber Caging Bolt Torque Rod Stowage Axle #3...

  • Page 329: Rear Brake Assembly

    TMS9000-2 SERVICE MANUAL CARRIER Remove the pawl assembly to keep the pawl teeth from being damaged. b. Turn the manual adjusting nut until the brake shoe is fully retracted. Clamp Install the pawl assembly into the slack adjuster. Remove the brake drum. Diaphragm Brake Shoe Removal Push down on the bottom brake shoe and pull on the...
  • Page 330 CARRIER TMS9000-2 SERVICE MANUAL Check the camshaft for cracks, wear, and corrosion. Check the cam head, bearing journals, and splines. Retainer Spring Check the slack adjuster for the gap between the clevis and collar. If the gap exceeds 1.5 mm (0.060 in), replace the clevis.

  • Page 331: Anti-Lock Brake System (Abs)/Automatic Traction Control (Atc)

    TMS9000-2 SERVICE MANUAL CARRIER If the camshaft bracket was removed, install the gasket and bracket to the spider. Torque to: • 1/2”-13 Grade 8 - 122 to 163 Nm (90 to120 lb-ft) Webs • 1/2”-13 Grade 5 - 88 to 136 Nm (65 to 100 lb-ft) •...
  • Page 332 CARRIER TMS9000-2 SERVICE MANUAL rotation signals are sent to an Electronic Control Unit (ECU) modulator valves control the pressure in the brake assembly which sends signals to the ABS modulator valves if it detects air chambers. that a wheel has locked up or is about to lock up. The Sensor Ring Speed Sensor ATC Valve...

  • Page 333: Atc System Description

    TMS9000-2 SERVICE MANUAL CARRIER 9288 FIGURE 8-61 ATC System Description • At speeds below 40 km/h (25 mph), both engine control and differential brake control are activated as required to Just as ABS improves vehicle stability during braking, ATC control wheel slip. Once triggered, differential braking improves vehicle stability and traction during vehicle mode remains active regardless of vehicle speed.
  • Page 334 CARRIER TMS9000-2 SERVICE MANUAL Port Designation Air Supply Port Air Delivery Port Treadle Port Electrical Connector FIGURE 8-62 ATC Indicator The ATC indicator (2), (Figure 8-61) is the primary indicator • Remains ON if an engine data link failure occurs. of the ATC status.

  • Page 335: Abs Troubleshooting

    TMS9000-2 SERVICE MANUAL CARRIER delivery and exhaust ports on both modulators are identified with a cast, embossed numeral for positive identification. Acceptable Tire Sizes The speed calculation for an exciter ring with 100 teeth is based on a default tire size of 510 revolutions per mile. This figure is based on the actual rolling circumference of the tires, which varies with tire size, tire wear, tire pressure, vehicle loading, etc.
  • Page 336 CARRIER TMS9000-2 SERVICE MANUAL In addition, by operating the blink code switch as described J1 939 tro uble c odes will c le ar a utom atically when below, one of several diagnostic modes can be entered. communications are re-established. Refer to Diagnostic Mode Selection.
  • Page 337 TMS9000-2 SERVICE MANUAL CARRIER commonly referred to as “event history.” When an active System Configuration Check trouble code is cleared, the ECU stores it in the event history memory as an inactive trouble code. 1st Number System Power Using blink codes, the technician may review all inactive 12 Volts trouble codes stored on the ECU.
  • Page 338 CARRIER TMS9000-2 SERVICE MANUAL X1 Connector Pin Assignments Designation Designation Designation Ground J1939 Low J1587 (B) Trailer ABS WL J1939 High J1587 (A) Ignition ABS WL Interlock TCV CMN WSS DA Right (+) Battery WSS DA Right (-) Not Used ATC Lamp/Switch ABS WL Ground ABS WL...
  • Page 339 TMS9000-2 SERVICE MANUAL CARRIER 1st Blink Code Number Troubleshooting Test Location Refer to Miscellaneous page 8-72 Wheel Speed Sensors page 8-65 Wheel Speed Sensors page 8-65 Pressure Modulator Valves page 8-67 Pressure Modulator Valves page 8-67 Traction Control Valves page 8-69 Example: For a message sequence of 3, 2 and 12, 4.
  • Page 340 CARRIER TMS9000-2 SERVICE MANUAL 2nd Blink Diagnostic Trouble Code Repair Information Code Description Adjust sensor to contact exciter ring. Rotate wheel and verify a minimum of 0.25 VAC sensor output at ~0.5 RPS. Verify condition of sensor head. Excessive Air Gap Verify mounting of exciter ring and condition of teeth.
  • Page 341 TMS9000-2 SERVICE MANUAL CARRIER Connector Wheel Speed Sensor Location Right Drive Axle (+) 18 Way Right Drive Axle (-) Left Steer Axle (+) Left Steer Axle (-) Right Steer Axle (+) 18 Way Right Steer Axle (-) Left Drive Axle (+) Left Drive Axle (-) Left Additional Axle (+) Left Additional Axle (-)
  • Page 342 CARRIER TMS9000-2 SERVICE MANUAL Diagnostic Trouble Blink Repair Information Code Description Code Verify no continuity between PMV leads and ground. Verify 4.9 to 5.5 ohms from Release Solenoid Shorted to REL to CMN and HLD to CMN, and 9.8 to 11 ohms from REL to HLD. Check for Ground corroded / damaged wiring or connectors between ECU and PMV.

  • Page 343: Troubleshooting Diagnostic Trouble Codes: Traction Control Valves

    TMS9000-2 SERVICE MANUAL CARRIER Connector PMV Location Left Steer Axle Hold Left Steer Axle Release Left Steer Axle Common Right Steer Axle Hold Right Steer Axle Common Right Steer Axle Release 18 Way Right Drive Axle Common Right Drive Axle Hold Right Drive Axle Release Left Drive Axle Common Left Drive Axle Hold...
  • Page 344 CARRIER TMS9000-2 SERVICE MANUAL ECU Wire Harness Connector: Traction Control Valve Diagnostic Pins Trouble Blink Repair Information Code Code Description The ECU is not configured for TCV, but has detected the presence of a TCV. Verify TCV Configuration wiring. Inspect for the presence FIGURE 8-72 Error of a TCV.

  • Page 345: Power Supply Tests

    TMS9000-2 SERVICE MANUAL CARRIER Diagnostic Trouble Blink Repair Information Code Description Code Measure battery voltage under load. Check vehicle battery and associated Battery Voltage Too Low components. Check for damaged wiring. Check for damaged or corroded connectors and connections. Measure battery voltage under load. Ensure that battery voltage is correct for the model of ECU.

  • Page 346: Troubleshooting Diagnostic Trouble Codes: J1939 Serial Communications

    CARRIER TMS9000-2 SERVICE MANUAL Troubleshooting Diagnostic Trouble Codes: Check for corroded or damaged wiring connector problems such as opens or shorts to voltage or ground. J1939 Serial Communications Check for other J1939 devices which may be loading J1939 Troubleshooting Tests down (inhibiting) J1939 communication.

  • Page 347: Miscellaneous Troubleshooting

    TMS9000-2 SERVICE MANUAL CARRIER Diagnostic Trouble Blink Repair Information Code Description Code Apply and release service brake. Check for brake switch input into ECU (see system wiring schematic). With service brake released, check for presence of the stop lamp bulb. With service brake applied, verify system voltage is now present at the stop lamp switch input to the ECU.

  • Page 348: Troubleshooting Wiring

    CARRIER TMS9000-2 SERVICE MANUAL Verify brake lamp switch is connected to ECU via hard Connector PMV Location wire or J1939. PMV Left Steer Axle Common With service brake released, check for presence of stop PMV Right Steer Axle Common lamp bulb. 18 Way PMV Right Drive Axle Common Dynamometer Test Mode (ATC Indicator Lamp...
  • Page 349 TMS9000-2 SERVICE MANUAL CARRIER CAUTION Possible Equipment Damage! All wires must be carefully routed to avoid contact with rotating elements. Wiring must be properly secured approximately every 6 to 12 inches using UV stabilized, non-metallic hose clamps or bow-tie cable ties to prevent pinching, binding or fraying.
  • Page 350 CARRIER TMS9000-2 SERVICE MANUAL ABS/ATC Cab Wiring Schematic FIGURE 8-76 8-76 Published 01-14-2021 Control # 707-01...
  • Page 351 TMS9000-2 SERVICE MANUAL CARRIER ABS/ATC Frame Wiring Schematic FIGURE 8-77 Grove 8-77 Published 01-14-2021 Control # 707-01...

  • Page 352: Special Tools

    Reconfiguring EC-60 Controllers The EC-60 controller is programmed for features specific to this Grove crane. Contact your Manitowoc Cranes distributor or Manitowoc Crane Care if reconfiguring the controller is necessary. ATC Valve FIGURE 8-79 Follow the steps listed below to locate and correct ATC problems.
  • Page 353 TMS9000-2 SERVICE MANUAL CARRIER Remove any accumulated contaminants and visually Electrical Connector Pin Values inspect the exterior for excessive corrosion and physical damage. Exhaust Inspect all air lines and wire harnesses connected to the Source modulator for signs of wear or physical damage. Hold Replace as necessary.

  • Page 354: Component Removal And Installation

    CARRIER TMS9000-2 SERVICE MANUAL Electrical Tests: Modulator Valves Slide the notched end of an ABS sensor adjustment tool (Figure 8-83) through the opening in the brake spider NOTE: Before testing the solenoid assembly of a suspect until it rests against the sensor (the tool will go in the modulator, its location on the vehicle should be hole at a slight angle).
  • Page 355 TMS9000-2 SERVICE MANUAL CARRIER For vehicles with Automatic Traction Control (ATC), the ATC Modulator Valves M-32, M-32QR function must be disabled (ATC indicator lamp should be ON, Removal see Dynamometer Test Mode, page 8-63) prior to performing any vehicle maintenance where one or more wheels on a Locate the modulator that will be replaced and clean the drive axle are lifted off the ground and moving.
  • Page 356 CARRIER TMS9000-2 SERVICE MANUAL Remove the sensor spring clip (4), (Figure 8-84) from Push the sensor spring clip (4), (Figure 8-84) all the way the mounting block. into the mounting block. Disconnect any fasteners that hold the sensor cable and Insert the sensor cable through the brake spider the hose clamp to other components.

  • Page 357: Outriggers

    TMS9000-2 SERVICE MANUAL CARRIER If equipped with spring brakes, release the brakes. Back Using a J-42942 ABS sensor adjustment tool, adjust the off the slack adjuster. sensor against the tooth wheel, and install the rubber grommet. Remove the brake drum, cam rollers, return spring, and brake shoes.

  • Page 358: Theory Of Operation

    CARRIER TMS9000-2 SERVICE MANUAL on the right hand side console. There is also a control panel the flow first unseats the check valve then extends the on either side of the crane behind the front outriggers. cylinder. The oil from the rod end flows to the selector valve and through the swing bank on the way to the reservoir.
  • Page 359 TMS9000-2 SERVICE MANUAL CARRIER Troubleshooting SYMPTOM PROBABLE CAUSE SOLUTION Slow or erratic operation of outrigger Damaged relief valves. Remove relief valve, clean or replace. extension cylinders. Low hydraulic oil. Replenish oil to proper level. Sticking solenoid valve spool. Repair or replace valve spool. Improper ground to base of Ground properly.
  • Page 360 CARRIER TMS9000-2 SERVICE MANUAL SYMPTOM PROBABLE CAUSE SOLUTION Limit flow through valve to that Flow in excess of valve rating. recommended. Check pump output and cylinder ration. Check relief valve setting or pump Pressure in excess of valve rating. compensation and adjust or replace as necessary.
  • Page 361 TMS9000-2 SERVICE MANUAL CARRIER SYMPTOM PROBABLE CAUSE SOLUTION Cracked or damaged piston. Replace piston and all cylinder seals. Jack cylinder extends while machine Damaged piston seals. Replace all cylinder seals. is traveling. Scored cylinder barrel. Replace jack cylinder. Cracked or damaged piston. Replace piston and seals.
  • Page 362 CARRIER TMS9000-2 SERVICE MANUAL Tag and disconnect the hydraulic lines to the cylinder edges of the outrigger beam, pull the outrigger beam out end of the extension cylinder. Cap all lines and fittings. of the outrigger box, re-adjusting the lifting attachment to prevent the beam from tipping.
  • Page 363 TMS9000-2 SERVICE MANUAL CARRIER FIGURE 8-85 NOTE: outrigger beam assembly weighs Disassembly approximately 776 kg (1710 lb). Remove the two cotter pins and clevis pins securing the 10. Position the outrigger beam on the blocking material. extension cylinder barrel lugs to the brackets on the mid beam.
  • Page 364 CARRIER TMS9000-2 SERVICE MANUAL adequate soft support to cushion any distance the 15. Remove the jack cylinder from the jack beam. Refer to cylinder will drop. OUTRIGGER JACK CYLINDER - REMOVAL in this Section. After attaching a suitable lifting device of straps or belts, instead of chains to prevent damage to the bottom Inspection edges of the outrigger beam, pull the outrigger jack...
  • Page 365 TMS9000-2 SERVICE MANUAL CARRIER Installation Connect the hydraulic lines as tagged prior to removal. Install the side adjustable wear pads in the outrigger Apply grease (EPMPG) to the bottom of the outrigger box. beam assembly. Adjust the wear pads, refer to Wear Pad Adjustment in Install the bottom wear pads with approximately 3.2 mm this section.

  • Page 366: Extension Cylinder

    CARRIER TMS9000-2 SERVICE MANUAL Extension Cylinder Connect the lines to the jack cylinder as marked during disassembly. Description Secure the hoses in place with the bolts, pipe clamps The outrigger extension cylinder is a combination unit with and bolt inserts. two rods, one for extending each direction.

  • Page 367: Center Front Jack Cylinder

    TMS9000-2 SERVICE MANUAL CARRIER CENTER FRONT JACK CYLINDER Remove the cotter pins securing the cylinder retaining pin and remove the cylinder retaining pin. Description Jack the jack cylinder up just enough to insert the retaining pin back into the cylinder. Insert the retaining The center front jack cylinder (Figure 8-87) has a 8.9 cm (3.5 pin into the lugs on the cylinder and secure in place with in) diameter bore and is the double acting type.

  • Page 368: Functional Check

    CARRIER TMS9000-2 SERVICE MANUAL Remove the wear ring from the groove of the cylinder. retaining bracket in place with the retaining pin and Remove the wear ring from the groove in the bottom of cotter pins. the tube. Install the hydraulic lines as tagged prior to removal. Installation Install the cylinder cap and secure with the washers and nuts.
  • Page 369 TMS9000-2 SERVICE MANUAL CARRIER Cylinder Plate 6512 Capscrew Cotter Pin Flatwasher Cylinder Head Wear Plug Ring Capscrew Piston Wear Ring Locknut Outrigger Pad Flatwasher Bushing Hex Nut Washer Lockwasher Acorn Nut FIGURE 8-87 Cap Bracket Grove 8-95 Published 01-14-2021 Control # 707-01...

  • Page 370: Outrigger Monitoring System (Optional-Standard In North America)

    CARRIER TMS9000-2 SERVICE MANUAL OUTRIGGER MONITORING SYSTEM (OPTIONAL—STANDARD IN NORTH AMERICA) Description The Outrigger Monitoring System (OMS) aids the operator in accurately programming the Rated Capacity Limiter (RCL)(EKS.5) by automatically identifying the position of each outrigger beam. The OMS uses eight sensors, two per outrigger beam—one for each outrigger stage—to identify when an outrigger beam is positioned to one of three pre- defined locations, including fully retracted, mid-extend, and...

  • Page 371: General

    When filling and draining crane components, observe the extreme condition lubrication, contact your local Grove following: Cranes distributor or Manitowoc Crane Care. • Do not pour waste fluids onto the ground, down any drain, or into any source of water.

  • Page 372: Arctic Conditions Below -18° C (0° F)

    Boeshield® T-9 Premium Metal Protectant. formation of rust. An Anti-Seize compound may be used if Manitowoc Crane Care has Boeshield® T-9 Premium Metal rust has not formed, otherwise the component must be cleaned first.

  • Page 373: Standard Lubricants

    TMS9000-2 SERVICE MANUAL LUBRICATION Standard Lubricants standard lubricants are effective in ambient temperatures down to -9°C (15°F). Refer to (TABLE 9-1:) for a list of the Standard lubricants are used on all Grove cranes unless the recommended standard lubricants. crane is ordered with a cold weather package. These TABLE 9-1: Standard Lubricants/Fluids [Down to -9°C (15°F)] Recommended Lubricant Lubricant/Fluid...
  • Page 374 LUBRICATION TMS9000-2 SERVICE MANUAL TABLE 9-1: Standard Lubricants/Fluids [Down to -9°C (15°F)] Recommended Lubricant Lubricant/Fluid Grove Spec. Type Grade Classification Hydraulic/Transmission Oil Kendall Hyken 052 Must Meet John Exxon Torque Fluid 56 Deere Std. JDM Esso Torque Fluid 56 J20c 10W-20 BP-Eldoran UTH &...

  • Page 375: Cold Weather Lubricants

    TMS9000-2 SERVICE MANUAL LUBRICATION Cold Weather Lubricants optional lubricants are effective in ambient temperatures down to -29°C (-20°F). Refer to (TABLE 9-2:) for a list of the Cold weather lubricants are used on all Grove cranes when recommended optional lubricants. the crane is ordered with a cold weather package.
  • Page 376 LUBRICATION TMS9000-2 SERVICE MANUAL TABLE 9-2: Optional Lubricants/Fluids [Down to -29°C (-20°F)] Recommended Lubricant Lubricant/Fluid Grove Spec. Type Grade Classification Multipurpose Grease 01373458 Extreme Pressure Gear Lube Aral Getriebeöl EP Synth. SAE 02313611 75W-90 Hydraulic Oil - ATF 66M Avia Avia Fluid ATF 66 M 01930670 Fluid...

  • Page 377: Arctic Lubricants And Conditions

    Therefore, always check with an authorized Grove 16.See operator's manual when ambient temperatures are distributor or Manitowoc Crane Care if in doubt of the expected between +4°C (+40°F) and -62°C (-80°F). suitability of a specific fluid or lubricant.
  • Page 378 LUBRICATION TMS9000-2 SERVICE MANUAL 35.Fill turntable gearbox until oil level is at middle to top of minimum of 100°F. When replacing the filter, also replace the sight gauge. breather. 36.Fill turntable gear brake until oil level is at top of sight 40.
  • Page 379 TMS9000-2 SERVICE MANUAL LUBRICATION ITEM LOCATION APPROXIMATE SERVICE LUBE SPEC NOTES SERVICE SERVICE HOURS NUMBER NAME CAPACITY POINTS 250 HRS CLUTCH See “Clutch Release RELEASE --------------- 6829003477 8, 12 LUBE Bearing Grease BEARING Interval” on page 11. CLUTCH LINKAGE (MANUAL --------------- 6829003477 LUBE...
  • Page 380 LUBRICATION TMS9000-2 SERVICE MANUAL 3a 3b FIGURE 9-1 8885a FIGURE 9-2 8885-1a 9-10 Published 01-14-2021 Control # 707-01...

  • Page 381: Clutch Release Bearing Grease Interval

    TMS9000-2 SERVICE MANUAL LUBRICATION Clutch Release Bearing Grease Interval Clutch Release Grease Interval Reset From the OFF position, turn ignition ON without cranking The transmission has an optional prognostic feature that engine. notifies the operator when the clutch release bearing needs greasing.
  • Page 382 LUBRICATION TMS9000-2 SERVICE MANUAL 8885-2 FIGURE 9-4 8885-3 FIGURE 9-5 9-12 Published 01-14-2021 Control # 707-01...

  • Page 383: Steering Lubrication

    TMS9000-2 SERVICE MANUAL LUBRICATION Steering Lubrication APPROX. SERVICE SERVICE ITEM NUMBER LOCATION NAME LUBE SPEC NOTES SERVICE CAPACITY POINTS HOURS STEERING POWER STEERING --------------- 6829003477 LUBE 1000 HRS GEARBOX STEERING RELAY --------------- 6829003477 LUBE 250 HRS ARMS 8885-4 FIGURE 9-6 Axle Lubrication ITEM APPROX.
  • Page 384 LUBRICATION TMS9000-2 SERVICE MANUAL 11, 12 8885-5 FIGURE 9-7 15, 16 8885-6 FIGURE 9-8 9-14 Published 01-14-2021 Control # 707-01...
  • Page 385 TMS9000-2 SERVICE MANUAL LUBRICATION ITEM APPROX. SERVICE LOCATION NAME LUBE SPEC NOTES SERVICE SERVICE HOURS NUMBER CAPACITY POINTS REAR AXLES REAR WHEEL --------------- 6829003689 BRUSH ON SEE NOTE 18 PILOTS --------------- 6829012964 CHECK & FILL 250 HRS FRONT REAR AXLE BOWL 20.5 QTS 6829012964 2, 3, 13, 14...
  • Page 386 LUBRICATION TMS9000-2 SERVICE MANUAL 8885-8 FIGURE 9-10 9-16 Published 01-14-2021 Control # 707-01...

  • Page 387: Outrigger Lubrication

    TMS9000-2 SERVICE MANUAL LUBRICATION Outrigger Lubrication ITEM APPROX. SERVICE SERVICE LOCATION NAME LUBE SPEC NOTES SERVICE NUMBER CAPACITY POINTS HOURS OUTRIGGERS O/R BEAMS --------------- 6829015304 5, 14 BRUSH ON 50/1 WEEK CENTER FRONT JACK CYLINDER --------------- 6829015304 BRUSH ON SEE NOTE 7 SUPPORT TUBE| (Not Shown) WEAR PADS...

  • Page 388: Miscellaneous Lubrication

    LUBRICATION TMS9000-2 SERVICE MANUAL Miscellaneous Lubrication ITEM LOCATION APPROX. SERVICE LUBE SPEC NOTES SERVICE SERVICE HOURS NUMBER NAME CAPACITY POINTS MISCELLANEOUS 507 L (134 HYDRAULIC CHECK & GAL) (TANK 6829006444 6, 11, 14 10 HRS/DAILY RESERVOIR FILL ONLY) HYDRAULIC CHANGE SEE NOTE 39 FILTER &...

  • Page 389: Turntable & Cab Tilt Lubrication

    TMS9000-2 SERVICE MANUAL LUBRICATION Turntable & Cab Tilt Lubrication ITEM LOCATION APPROX. SERVICE LUBE SPEC NOTES SERVICE SERVICE HOURS NUMBER NAME CAPACITY POINTS TURNTABLE & CAB TILT 0.9 L (.95 QT) 6829014058 CHECK & FILL 50 HRS/1 WEEK TURNTABLE GEAR BOX 0.9 L (.95 QT) 6829014058 14, 35...
  • Page 390 LUBRICATION TMS9000-2 SERVICE MANUAL 8885-12 FIGURE 9-14 9-20 Published 01-14-2021 Control # 707-01...

  • Page 391: Hoist Lubrication

    TMS9000-2 SERVICE MANUAL LUBRICATION Hoist Lubrication ITEM APPROX. SERVICE LOCATION NAME LUBE SPEC NOTES SERVICE SERVICE HOURS NUMBER CAPACITY POINTS HOIST --------------- 6829014058 2, 14 CHECK & FILL 50 HRS / WEEKLY MAIN HOIST - 1000 HRS/12 TRANSMISSION 4.0 L (1 GAL) 6829014058 2, 14 DRAIN &...

  • Page 392: Turntable Central Lubrication

    LUBRICATION TMS9000-2 SERVICE MANUAL Turntable Central Lubrication ITEM APPROX. SERVICE LOCATION NAME LUBE SPEC NOTES SERVICE SERVICE HOURS NUMBER CAPACITY POINTS HOIST TURNTABLE (SLEW) BEARING --------------- 6829003477 LUBE (AUTO) 50 HRS/1 WEEK - INNER RACE LIFT CYLINDER --------------- 6829003477 LUBE (AUTO) 50 HRS/1 WEEK PINS BOOM PIVOT PIN...

  • Page 393: Boom Lubrication

    TMS9000-2 SERVICE MANUAL LUBRICATION Boom Lubrication • Set boom angle at zero degrees (horizontal). • Disable the swing function to engage the swing brakes, Crane Setup and engage the 360-swing lock, if applicable. • Machine to be set up on firm level surface with fully •...
  • Page 394 LUBRICATION TMS9000-2 SERVICE MANUAL ITEM APPROX. SERVICE SERVICE LOCATION NAME LUBE SPEC NOTES SERVICE NUMBER CAPACITY POINTS HOURS BOOM 250 HRS/3 TELE 1 LOCK PIN --------------- 03313195 1, 14, 28, 34 LUBE MONTHS 14, 27, 28, 34, 500 HRS/6 BRUSH ON TELE-CYLINDER SLED --------------- 01373458...
  • Page 395 TMS9000-2 SERVICE MANUAL LUBRICATION Extend and lock Tele 2 to the 50% pinning location. Lower the boom to 0° and perform the following greasing in this position: Grease outer sides of Tele 3 in the areas that touch the front wear pads of Tele 2. b.
  • Page 396 LUBRICATION TMS9000-2 SERVICE MANUAL Lower the boom to 0° and perform the following greasing When Tele 1 greasing is complete, retract and lock in this position: Tele 1 to the 0% pinning location. Grease outer sides of Tele 1 in the areas that touch Boom Tele Section Lubrication procedures are complete.
  • Page 397 TMS9000-2 SERVICE MANUAL LUBRICATION 8885-18b FIGURE 9-19 8885-16a FIGURE 9-20 8885-19a FIGURE 9-21 Grove 9-27 Published 01-14-2021 Control # 707-01...

  • Page 398: Monthly Lubrication Work

    LUBRICATION TMS9000-2 SERVICE MANUAL 8885-24 8885-20 8885-22 8885-21 FIGURE 9-22 8885-23 Monthly Lubrication Work the retaining pins used for fastening the lattice extension sections for transport, Pins the spring latch on the run-up rail. Lubricate the following: NOTE: lubrication interval applies average the pins for the pin connection on the lattice...

  • Page 399: Carwell® Rust Inhibitor

    This To help protect against corrosion of Grove cranes, red tint will turn clear on its own within approximately 24 Manitowoc Crane Care recommends washing the crane at hours after application. least monthly to remove all foreign matter. More frequent c l e a n i n g m a y b e n e e d e d w h e n o p e r a t i n g i n h a r s h Once applied, treatment can appear to leave a slightly “oily”...

  • Page 400: Inspection And Repair

    • Cover all bare metal with a primer that is compatible with the original paint finish and allow to dry thoroughly. Please contact Manitowoc Crane Care should you have any questions. • Prepare the surface prior to applying the finish coat of paint.
  • Page 401 TMS9000-2 SERVICE MANUAL LUBRICATION • Boom applications areas are; pivot pins, hose ends and • All hardware, clips, pins, hose connections not painted fittings, jib pins and shafts, all bare metal surfaces, will have treatment applied. overhaul ball pins/ hook block pins and fasteners. Grove 9-31 Published 01-14-2021 Control # 707-01...
  • Page 402 LUBRICATION TMS9000-2 SERVICE MANUAL 9289 17, 18 9289-1 9289-2 FIGURE 9-23 9-32 Published 01-14-2021 Control # 707-01...
  • Page 403 TMS9000-2 SERVICE MANUAL LUBRICATION Item Description Item Description All Hardware, Clips, Pins, Hose Hoist Hose Connections Connections not painted O/R Pins, Clips Boom Extension Pins, Clips Powertrain Hardware Inside Compartment Valve Bank O/R Pins, Clips Hose Connections Inside Turntable Entire Underside of Unit Boom Extension Hanger Hardware Turntable Bearing Fasteners Boom Nose Pins, Clips...
  • Page 404 LUBRICATION TMS9000-2 SERVICE MANUAL This Page Blank 9-34 Published 01-14-2021 Control # 707-01...
  • Page 405 Maintenance Plans ........... . . 5-3 Manitowoc CraneCare Service instructions........1-2 Manual Transmission.
  • Page 406 SERVICE MANUAL TMS9000-2 Outrigger Jack Cylinder ..........2-37 Outrigger Jack Cylinders .

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