Manitowoc Grove TMS500-2 Manuals

Manuals and User Guides for Manitowoc Grove TMS500-2. We have 2 Manitowoc Grove TMS500-2 manuals available for free PDF download: Service Manual, Operator's Manual

Manitowoc Grove TMS500-2 Operator's Manual (298 pages)

Brand: Manitowoc | Category: Construction Equipment | Size: 16.37 MB

Table of Contents
8
Safety Messages
24
General
24
Safety Alert Symbol
24
Signal Words
24
Safety Decals
24
Accidents
24
Operator Information
25
Operator Qualifications
25
Operational Aids
26
Rated Capacity Limiter (RCL) Systems
26
Anti-Two-Blocking Device
27
Working Area Limiter (if Equipped)
27
Crane Stability/Structural Strength
28
Load Charts
29
Work Site
29
Wind Forces
29
Wind Speeds
30
Determination of 3-Second Wind Gust Speed at Boom Tip Height
32
Size and Shape of the Load
32
Determining Wind Drag Coefficient (CD)
33
Example and Sample Calculations (Non-Metric)
40
Lifting Operations
42
Multiple Crane Lifts
43
Lifting Multiple Loads
43
Tilt-Up Panel Lifting
43
Outrigger Lift off
44
Pile Driving and Extracting
44
Counterweight
44
Crane Equipment
45
Crane Inspection
45
Electrocution Hazard
45
Set-Up and Operation
46
Electrocution Hazard Devices
47
Electrical Contact
47
Special Operating Conditions and Equipment
48
Grounding the Crane
48
Personnel Handling
49
Environmental Protection
50
Maintenance
50
Service and Repairs
50
Hydraulic Fluid
50
Moving Parts
51
Before Maintenance or Repairs
51
After Maintenance or Repairs
51
Lubrication
51
Tires
51
Hoist Rope
52
Synthetic Hoist Rope
52
Wire Rope
52
Sheaves
53
Batteries
54
Super Capacitor (if Equipped)
54
General Maintenance
54
Transporting the Crane
54
Travel Operation
55
Work Practices
56
Personal Considerations
56
Crane Access
56
Job Preparation
56
Working
57
Lifting
57
Hand Signals
58
Boom Extension
60
Parking and Securing
60
Shut-Down
60
Cold Weather Operation
60
Temperature Effects on Hook Blocks
61
Temperature Effects on Hydraulic Cylinders
61
Model Specific Information
63
Overload Inspection
63
Boom Inspection
64
Superstructure Inspection
66
Carrier Inspection
68
Carrier Cab Controls and Indicators
74
Transmission Shift Lever
75
Spare Switch/Indicator
75
USB Ports
75
Volt Outlet
75
Fire Extinguisher
75
Horn Button
75
Turn Signal/Headlight High Beam Low Beam Lever
75
Brake Pedal
75
Cab Circulating Fan
75
Windshield Wiper and Washer
75
Steering Wheel Controls
76
Flash Marker Lights Switch
76
Windshield Washer/Wiper/Speeds
76
Horn Switch
76
Cruise Control ON/OFF Switch
76
Cancel Set Speed Switch
76
Set Speed/Coast Switch
76
Resume Set Speed/Accelerate Switch
76
Flash Headlights Switch
76
Headlights Switch
78
Dimmer Switch
78
Beacon Light Switch (Optional)
78
Engine Brake ON/OFF Switch
78
Engine Brake High/Low Switch
78
Exhaust System Cleaning Initiate Switch
79
Engine Speed Increment/Decrement Switch
79
Remote Control ON/OFF Switch (Optional)
79
Remote Control Indicator (Optional)
79
Anti-Lock Braking System/Automatic Traction Control (ABS/ATC) Switch
79
Hill Start Aid (HSA) System
79
Hill Start Aid (HSA) Indicator
79
Inter-Axle Differential Lock Switch
79
Cross-Axle Lock Switch (Optional)
79
Suspension Inflation Switch
79
Tire Inflation Switch
80
Heater/Air Conditioner Fan Speed Switch
80
Heater/Air Conditioner Temperature Control Switch
80
Heater/Air Conditioner Select Switch
80
Ignition Switch
80
Parking Brake Control
80
Dual Air Pressure Gauge
80
Control Panel Indicator and Gauge Display
81
Cross-Axle Lock Indicator (Optional)
82
Inter-Axle Lock Indicator
82
Suspension Deflated Indicator
82
ABS Traction Control Indicator
82
Tire Inflation Indicator
82
Left Turn Signal Indicator
82
Marker Lights on Indicator
82
High Beam Indicator
82
Parking Brake Engaged Indicator
82
Battery Charge Indicator
82
Anti-Lock Braking System (ABS) Indicator
83
Check Transmission Indicator
83
Malfunction Indicator Lamp
83
Low Oil Pressure Indicator
83
Engine Stop Indicator
83
Engine Warning Indicator
83
OK Button
83
Menu Button
83
Fuel Gauge
83
Speedometer
83
High Exhaust System Temperature Indicator
84
Engine Coolant High Temperature Indicator
84
Cruise Control Indicator
84
Engine Coolant Temperature Gauge
84
Down Button
84
Up Button
84
Tachometer
84
Exhaust System Cleaning Indicator
84
Wait to Start Indicator
85
Lcd
85
Seat Belt Unfastened Indicator
86
Outrigger Controls and Indicators
87
Outrigger Control Panel
87
Outrigger Beam Selector Switches
87
Extend Switch
88
Center Front Jack Switch
88
Jack Selector Switches
88
Emergency Stop Switch
88
Retract Switch
88
Power Indicator Light
88
Auto Level Switch
88
Bubble Level Indicator (Not Shown)
88
Outrigger Operation Indicator Lights
88
Superstructure Cab
89
Foot Pedals
89
Turntable Swing Lock Pin Control Handle
89
Seat Joystick and Armrest Controls
89
ODM and RDM Panels
89
Superstructure Overhead Control Panels
89
Superstructure Cab Overhead Controls
90
Skylight Window Latch
90
Skylight Wiper and Wiper Controls
90
Skylight Sunscreen
91
Dome Light
91
Cab Circulating Fan
91
Right Side Window Latch
91
Emergency Stop Switch
91
Overhead Control Panels
91
Radio (Optional)
91
Diesel Fired Cab Heater Controls (Optional)
91
Work Lights Switch
91
Boom Lights Switch (Optional)
91
RCL External Light Tower (Optional)
92
Anemometer (Optional)
92
Removing the Anemometer Assembly
92
Installing the Anemometer Assembly
93
Changing the Anemometer Battery
93
Stowing the Anemometer Assembly for Travel
93
Stowing the Anemometer Assembly for
93
Superstructure Overhead Control Panel
94
Windshield Wiper Switch
94
Windshield Washer Switch
94
Skylight Wiper Switch
94
Heater/Air Conditioner Fan Speed Switch
94
Heater/Air Conditioner Temperature Control Switch
94
Heater/Air Conditioner Switch (Standard)
94
Fresh Air/Recirculation Air Switch
94
Engine Speed Increment/Decrement Switch
94
Heater/Air Conditioner Temperature Control
94
Wait-To-Start Indicator
95
Crane Function Enable/Disable Switch
95
Hoist Bypass Switch
95
Boom up Bypass Switch
95
Limits Bypass Switch
95
Foot Pedal Controls
95
Foot Throttle Pedal
95
Telescope Control Foot Pedal (Optional)
95
Swing Brake Pedal
96
360° Swing Lock Pedal (Optional)
96
360° Swing Lock Release Lever (Optional)
96
Control Seat Assembly
97
Right Hand Arm Rest Controls
97
Left Hand Arm Rest Controls
97
Horn Button
97
Free Swing Button
97
Deadman Switches (Dual Axis - Controllers Only)
97
Deadman Switches
97
Only)
97
Seat Slide Lever
98
Seat Frame Slide Lever
98
Seat Height Adjustment Lever
98
Seat Back Adjustment Lever
98
Seat Switch (Not Shown)
98
Air Conditioner/Heater Climate Unit
98
Left Hand Arm Rest Controls
98
Swing/Telescope or Swing/Auxiliary Hoist Control Lever (Dual Axis)
99
Hoist High Speed Toggle Switch
99
Auxiliary Hoist Rotation Indicator (Optional)
99
Outrigger Extend/Retract Switch
99
Swing Enable/Disable Switch
99
Boom Telescope Enable/Disable Switch
99
Auxiliary Hoist Enable/Disable Switch (Optional)
99
Auxiliary Hoist Enable/Disable Switch
99
(Optional)
99
RCL Bypass Switch
100
Right Hand Arm Rest Controls
100
Boom Lift/Main Hoist Control Lever (Dual Axis)
101
Hoist High Speed Toggle Switch
101
Hoist Rotation Indicator
101
Jog Dial
101
Boom Lift Function Enable/Disable Switch
101
Main Hoist Enable/Disable Switch
101
Main Hoist Controller (Single Axis Option)
102
Boom Lift Controller (Single Axis Option)
102
Boom Telescope or Auxiliary Hoist Controller (Single Axis Option)
102
Swing Controller (Single Axis Option)
103
Operator Display Module and Rated Capacity Limiter Display Module
103
Rated Capacity Limiter Display Module (RDM)
103
Operator Display Module (ODM)
103
Navigation Control Pad
103
USB Connector
104
RCL Shutdown Warning Indicator
104
RCL Early Warning Indicator
104
Anti- Two-Block Indicator
104
Minimum Wrap Limiter System Indicator (Optional)
105
Swing Brake Engaged Indicator
105
Brightness Sensor
105
Internal Temperature Warning Indicator
105
Switching Displays
105
Ignition Switch
106
Turntable Swing Lock Pin Control Handle
106
Operator Display Module (ODM) - Main Screen
106
Alert Icons
109
Status Bar Icons
112
Operating Elements of the Crane Control System (CCS)
114
Crane Directional Information
114
General Rules for Buttons and Symbols on the CCS Display
115
Crane Control System (CCS) - Overview
115
Exiting the Menu/Input Mode
116
Enter the Values with Jog Dial
116
Enter Values on the Crane Control System (CCS) Panel
116
Input Confirmation
117
CCS Display and Menus
117
Menu Groups
117
Warning Message/Error Message Display Area
119
Camera Group (Optional)
119
Crane Function Menu Group
119
Outrigger Function
119
Working Range Limiter (WRL) Group Menu
119
Introduction
119
WRL - Swing Angle Limitation Function
119
WRL - Boom Angle Limitation Function
119
WRL - Boom Height Limitation Function
120
WRL - Working Radius Limitation Function
120
WRL - Virtual Walls Limitation Function
120
Errors (Fault Code) Group Menu
120
Crane Operation Error Function
120
Engine Error Function
120
Information Group Menu
120
Operating Hours Function Icon
120
Software Version Icon
120
Legal Notice Icon
120
Tools User Settings Group Menu
121
Time Zone Function
121
Display Screen Brightness Function
121
Unit of Measure Function
121
Remote Drive (Optional)
121
Carrier Cab Controls and Indicators
121
Superstructure Remote Drive Controls
122
Left Arm Rest
122
Service Brake Pedal
123
Operation
123
Enable the Remote Drive Option
123
Disable the Remote Drive Option
123
Truck Steering Operation
124
Pedal Operation
124
Suspension
124
Troubleshooting
124
Remote Control (Optional)
125
Indicators
125
Remote Control Icon
125
Remote Control Operation
125
Remote Control System Components
125
Remote Control Components
128
Display Components
129
Preparing for Remote Control Operation
130
Operating Remote Control
131
Engine Start/Stop/Throttle
133
Outrigger Beams
135
Outrigger Jacks
137
Hoist Control (Main and Aux)
139
Pre-Starting Checks
144
Fuel Supply
144
Fuel System Description
144
Fuel Tank
144
Fuel Filter-Water Separator
144
Diesel Exhaust Fluid (DEF) Supply
144
Engine Oil
144
Engine Coolant
144
Batteries
144
Hydraulic Reservoir and Filter
144
Seat Belt
145
Seat Belt Maintenance
145
Cleaning Seat Belt Webbing
145
Signal and Running Lights
145
Service and Parking Brakes
145
Anti-Lock Braking System (ABS)
145
ABS Power-Up Sequence
145
ABS Switch Operation
146
Tires
146
Wheels
146
Accessories
146
Daily Lubrication
146
Air Cleaner
146
Preload Check
146
Using Your Load Chart
146
Engine Operation
149
Start-Up Procedure
149
Idling Engine
150
Engine High Idle
150
Racing Engine
150
Exhaust System Cleaning
150
When to Manually Clean the Exhaust System
150
Initiating the Manual Exhaust Cleaning Process
151
Inhibiting the Exhaust System Cleaning
151
Shutdown Procedure
151
Battery Disconnect
151
Cold Weather Operation
151
Auxiliary Cab Heater (Optional)
152
Diesel Fuel
152
Crane Warm-Up Procedures
152
Engine
153
Hydraulic Oil System
153
Hoist
153
Swing Drive and Turntable Bearing
153
Axles
153
Driving the Crane
154
Seat Belts
154
Traveling - General
154
Securing the Superstructure for Travel
155
Securing the Carrier for Travel
155
Tie-Down Procedure for Hook Block
155
Traveling - Towing/Pulling
156
Traveling - Being Towed/Pulled
156
Traveling on Slopes
157
General Conditions
157
Slope Limitations - Fore/Aft Travel
158
Slope Limitations - Side Slope Travel
158
Traveling with Boom Extension Erected
158
Automated Transmission
158
Gear Display
159
Start-Up
159
Power down
160
Reverse Mode
160
Drive Mode
160
MANUAL Mode
160
MANUAL / Hold Mode
161
LOW Mode
161
Hill Start Aid (HSA) System
161
Differential Control Switches
162
Operating the Differential Locks
162
Brakes
162
Anti-Lock Brake System (ABS)
163
ABS Power-Up Sequence
163
ABS Switch Operation
163
Automatic Traction Control (ATC) Functional Overview
164
ATC Operation
164
System Operation
164
Component Function
164
Traction Control Power-Up Sequence
164
Traction Control Switch Operation
164
Thermal (Brake Heat) Protection
165
ABS/ATC Partial Shutdown
165
Engine Brake
165
Recommended Crane Shutdown Procedures
165
Superstructure Cab Platform
165
Craning Functions
166
Controller Operation
166
Proper Crane Leveling
166
Bubble Level Indicator Adjustment
166
Using the Outriggers
166
Setting the Outriggers from the Superstructure Cab
167
Setting the Outriggers from the Outrigger Control Panels
167
Setting the Outriggers from the Superstructure
167
Outrigger Control Panel
168
Outrigger Monitoring System (OMS)
169
Engaging the Outrigger MID-Extend Lock Pin
169
Stowing the Outriggers from the Superstructure Cab
169
Stowing the Outriggers from the Superstructure
169
Stowing the Outriggers Using the Carrier Outrigger Control Panels
170
Stowing the Outrigger MID-Extend Lock Pin
170
Swinging the Superstructure
170
Dual Axis Controllers
171
Single Axis Controller (Optional)
171
Elevating and Lowering the Boom
171
Elevating the Boom
171
Dual Axis Controllers
172
Single Axis Controller (Optional)
172
Lowering the Boom
172
Telescoping the Boom
173
Extending the Boom
173
Dual Axis Controller
173
Single Axis Controller (Optional)
173
Foot Pedal
173
Selecting the Hoist Speed Range
173
Retracting the Boom
174
Dual Axis Controller
174
Single Axis Controller (Optional)
174
Foot Pedal
174
Lowering and Raising the Main Hoist Rope
174
Lowering the Main Hoist Rope
175
Minimum Wrap Limiter System (Optional)
175
Raising the Main Hoist Rope
175
Lowering and Raising the Auxiliary Hoist Rope (Optional)
175
Lowering the Auxiliary Hoist Rope
176
Minimum Wrap Limiter System (Optional)
176
Raising the Auxiliary Hoist Rope
176
Stowing and Parking
176
Leaving Crane Unattended
177
Navigating the Operator Display Module (ODM) and Rated Capacity Limiter (RCL) Display Module
177
Tms500-2 Operator's Manual
177
Module
177
Using the Operator Display Module (ODM)
178
Main (Home) Screen
179
Active Screen Indicator Area
179
Menu Screen Layout
180
Menu Screen
182
Camera Group Menu
182
Crane Function Group Menu
182
Outrigger Group Functions
182
Accessing the Outrigger Group Function Screen
183
Accessing the Outrigger Group Function
183
Extending/Retracting the Outrigger Jacks
184
Screen
184
Extending/Retracting the Outrigger Jacks - Individually
185
Individually
185
Extending/Retracting the Center Front Jack
187
Exiting the Outrigger Extend/Retract Function Screen
187
Working Range Limiter (WRL) Menu Group
188
Introduction
188
WRL Limitations Overview
189
Accessing a WRL Limitation Screen
191
WRL - Swing Angle Limitation Menu
196
Setting the Swing Angle Limitation
196
The Swing Angle Limitation Menu
197
Setting Swing Angle Limitation by Crane Position
197
Setting Swing Angle Limitation by Value
197
Swing Angle Limitation with Lock-Out Function Enabled
198
WRL - Boom Angle Limitation Menu
198
Setting the Boom Angle Limitation Menu
199
Setting the Boom up Angle Limitation by Crane Position
199
Setting the Boom down Limitation by Crane Position
199
Position
199
Setting Boom up Limitation by Value
200
Setting Boom down Limits Menu by Value
200
WRL - Boom Height Limitation Menu
201
Setting the Boom Height Limitation
201
Setting Boom Height Limitation Using Crane Position
201
Position
201
Setting Boom Height Limitation by Value
202
WRL - Working Radius Limitation
203
WRL - Working Radius Limit Menu
204
Setting Inner/Outer Working Radius Limitation by Crane Position
204
Setting Inner/Outer Working Radius Limitation by Value
204
Working Radius Limitation Disable Procedure
205
WRL - Virtual Walls Limitation Menu
206
Defining Subsequent Virtual Walls
208
Errors (Fault Code) Group Menu
210
Crane Operation Function
210
Engine Fault Function
210
Information Group Menu
210
Accessing an Information Group Function Screen
211
Exiting an Information Group Function Screen
211
Viewing the Operating Hours
211
Viewing the Software Version Screen
213
Viewing the Legal Notice Screen
213
Tools Group Menu
214
Accessing a Tools Group Function Screen
214
Exiting a Tools Group Function Screen
214
Setting the Controller Sensitivity Function
214
Setting the Controller Speed Function
216
Setting the Wiper Interval Function
218
Setting the Economy (ECO) Mode Function
219
ECO Terminology
219
ECO Requirements
219
Operating Procedures
219
ECO Operation
220
ECO Benefits
220
Exhaust System Cleaning Function
220
Tools User Settings Group Menu
220
Setting the Time Zone Function
221
Setting the Display Screen Brightness Function
221
Setting the Units of Measure Function
222
Using the Rated Capacity Limiter Display Module (RDM)
222
Rated Capacity Limiter (RCL) Group - Menu
222
Rated Capacity Limiter (RCL) Configuration Screen
222
Using the Rated Capacity Limiter Display Module
222
RCL Configuration Screen
223
Entering a Load Chart Code Number Manually
224
Data Logger
224
Legal Notice Screen
225
Rated Capacity Limiter (RCL) Main Screen
226
Overriding the Outrigger Monitoring System
227
Limits Bypass Indicators
227
Load Chart and Miscellaneous Indicators
227
General
229
Environmental Protection
229
Cummins Oil Registration List
229
Standard Lubricants
231
Arctic Lubricants and Conditions
233
Temperatures below -9°C (15°F)
233
Cold Weather Lubricants
233
Cylinder Rod Surface Protection
235
Wire Rope Lubrication
235
Lubrication Points
235
Drivetrain Lubrication
237
Steering Lubrication
241
Axle Lubrication
242
Outrigger Lubrication
246
Miscellaneous Lubrication
247
Turntable & Cab Platform Lubrication
248
Hoist Lubrication
250
Turntable Central Lubrication
251
Boom Lubrication
253
Monthly Lubrication Work
258
Carwell® Rust Inhibitor
259
Protecting Cranes from Corrosion
259
Cleaning Procedures
259
Inspection and Repair
260
Application
260
Areas of Application
260
Hoist Platform
266
Installing Cable on the Hoist
266
Anti- Two-Block (A2B) Switch
266
Locking A2B Switch
267
Unlocking A2B Switch
267
Before Operation Check
267
Cranes with Main Hoist Only
267
Cranes with Main and Auxiliary Hoists
267
Hoist Rope Reeving
269

Manitowoc Grove TMS500-2 Service Manual (361 pages)

Brand: Manitowoc | Category: Construction Equipment | Size: 20.93 MB

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5
- Table of Contents
  5
Section 1 1

13
- Using the Service Manual
  13
- Safety Messages
  14
- Axles
  15
- Brakes
  15
- Capacities
  15
- Dimensions
  15
- Engine
  15
- General
  15
- List of Specifications
  15
- Suspension
  15
- Transmission
  15
- Wheels and Tires
  15
- Boom 102
  16
- Cable
  16
- Hoists
  16
- Hydraulic Pumps
  16
- Swivel Assembly
  16
- Cleanliness
  23
- Disassembly and Assembly
  23
- General Maintenance
  23
- Locks
  23
- Pressing Parts
  23
- Removal and Installation
  23
- Batteries
  24
- Bearings
  24
- Gaskets
  24
- Wires and Cables
  24
- Fatigue of Welded Structures
  25
- Hydraulic Systems
  25
- Loctite® Thread Locking Compound
  25
- Fasteners and Torque Values
  26
- Hoist Cable Inspection and Maintenance
  33
- Weld Studs
  33
- Wire Rope
  34
- Wire Rope Inspection (Running Ropes and pendant Cables)
  35
- Retraction Cables)
  36
- Seizing Wire Rope
  36
- Wire Rope Inspection
  36
- Wire Rope Inspection (Boom Extension and Retraction Cables)
  36
- Wire Rope Inspection (Running Ropes and pendant Cables)
  36
- Wire Rope Replacement (All Wire Rope)
  36
- Installing 35X7Class Wire Rope
  37
- Procedures for Cutting and Preparing 35X7 Class Wire Rope
  38
Section 2 Hydraulic System 2

39
- Description
  39
- Section 2
  39
- Draining and Flushing
  41
- Maintenance
  41
- Removing Air from the Hydraulic System
  42
- Description
  43
- Hydraulic Reservoir and Filter
  43
- Parts Replacement
  43
- Supply Pressure and Return Circuit
  43
- Pump Distribution
  44
- Maintenance
  46
- Troubleshooting
  46
- Element Installation
  47
- Element Removal
  47
- Environmental Protection
  47
- Return Hydraulic Filter Assembly
  47
- Description
  49
- Hydraulic Pumps
  49
- Maintenance
  49
- Carrier Valves
  55
- General
  55
- Description
  57
- Maintenance
  57
- Outrigger Selector Manifold Valve
  57
- Description
  59
- Maintenance
  59
- Outrigger Control Manifold
  59
- Description
  64
- Internal Leak Testing
  64
- Pilot Operated Check Valve
  64
- Maintenance
  65
- Superstructure Hydraulic Valves
  66
- Main Directional Valve Assembly
  67
- Accessory Manifold Assembly
  68
- Checking for Leaks
  69
- Cylinders
  69
- General
  69
- Maintenance
  69
- Superstructure Hydraulic System
  69
- Equipment
  71
- Objective
  71
- Pressure Setting Procedures
  71
- Valve Pressure Setting Table
  71
- Service Tool Notes
  72
- Procedure for Checking/Setting the Piston Pump Cut-Off and Differential Pressures
  74
- Procedure for Checking/Setting the Pilot Supply Pressure
  75
- Procedure for Checking/Setting the Main Directional Control Valve, Load Sense, Lift and Telescope Pressures
  76
- Procedure for Checking/Setting Swing Pressure
  78
- Procedure for Checking/Setting the Swing
  78
- Procedure for Checking/Setting the Swing Brake Release Pressure
  78
- Procedure for Checking/Setting Outrigger Pressure
  79
- Procedure for Checking Air Conditioning Operation
  81
- Procedure for Checking/Setting the Center Front Stabilizer Pressure
  82
- Procedure for Checking/Setting the Front Steer Pressure
  82
- Procedure for Adjusting Electronic Controllers (Meter-In Dead Band And/Or Max Function Speeds)
  84
Section 3 Electrical System

87
- Batteries
  87
- Carrier Cab
  87
- Description
  87
- Section 3
  87
- Batteries
  88
- Carrier Cab
  88
- Carrier Power Panel and Fuse Panels
  88
- Carrier Cab Fuse and Relay Panels
  90
- Anti-Lock Brake System (ABS)
  91
- Superstructure Cab Fuse and Relay Panels
  93
- Camera System (Optional)
  95
- General
  95
- Maintenance
  95
- Radios (Optional)
  95
- General Troubleshooting
  96
- Tools for Troubleshooting
  96
- Troubleshooting Engine Starting Problems
  96
- Charging the Batteries
  97
- Connector Troubleshooting
  97
- Jump Starting Hazard
  97
- Troubleshooting
  97
- Troubleshooting Battery Charging Problems
  97
- Troubleshooting Slip Ring-Caused Electrical Problems
  97
- DI-Electrical Grease Application
  98
- Troubleshooting Lights
  99
- Alternator Replacement
  100
- Troubleshooting Accessories
  100
- Troubleshooting Alarms, Indicators, and Emergency Components
  100
- Troubleshooting Gauges and Meters
  100
- Starter Replacement
  101
- Battery Replacement
  103
- Instrument Replacement
  104
- Relay Panel Component Replacement
  104
- All Other Switches
  105
- Rocker Switch
  105
- Switch Replacement
  105
- Windshield Wiper Assembly Replacement
  106
- Carrier Cab
  108
- Skylight Wiper Assembly Replacement
  109
- Superstructure Wiper Assembly
  109
- Windshield Washer Assembly Replacement
  109
- Windshield Wiper Assembly Replacement - Superstructure Cab
  110
- Windshield Washer Assembly Replacement
  113
- Computer Modules
  114
- Fault Codes
  114
- Remote Controller (Optional)
  114
- Troubleshooting the Crane Control System (CCS)
  114
- Using the Operator Display Module (ODM)
  114
- Battery Charger
  117
- Receiver
  117
- Remote Controller Battery
  117
Tms500-2 Service Manual Boom Section 4 Boom

119
- Boom Extension Sequence
  120
- Boom System Components
  120
- Extend Synchronizing Cable
  120
- Fly Retraction Cables
  120
- Fly Section Extension Cables
  120
- Outer MID Retract Cables
  120
- Telescope Cylinder
  120
- Telescope Circuit
  122
- Telescope Circuit Troubleshooting
  123
- Description
  124
- Lift Circuit
  124
- Lift Circuit Troubleshooting
  125
- Theory of Operation
  125
- General Maintenance Notes
  126
- Boom Extension Removal (Optional)
  127
- Boom Removal
  128
- Remove the Base Section
  131
- Disconnect the Inner MID Section
  132
- Remove the Inner MID Section
  133
- Remove the Outer MID Section
  135
- Remove the Telescope Cylinder
  137
- Boom Nose Sheaves
  138
- Boom Nose Sheave Removal
  139
- Boom Assembly Procedure
  141
- Install Telescope Cylinder
  141
- Install the Outer MID Section
  144
- Install the Inner MID Section
  148
- Tensioning the Boom Extend and Retract Cables
  153
- Install the Base Section
  156
- Final Boom Installation
  158
- Swingaway Extension Installation (Optional)
  159
- Boom Inspection
  161
- Boom Maintenance
  161
- Functional Test of the Boom
  161
- Boom Alignment and Servicing
  162
- Extension and Retraction Cable Maintenance
  162
- Inspection
  163
- Lift Cylinder Installation
  164
- Lift Cylinder Maintenance
  164
- Lift Cylinder Removal
  164
Section 5 Hoist and Counterweight

167
- Maintenance
  168
- Removal
  168
- Warm-Up Procedure
  168
- Functional Check
  169
- Installation
  169
- Servicing
  169
- Hoist Maintenance and Inspection
  170
- Usage and Inspection
  170
- Brake Test Procedure
  172
- Hoist to Boom Alignment
  173
- Preparation
  173
- Procedure
  173
- Tools Required
  173
- Description
  174
- Maintenance
  174
- Piston Motor and Control Valve
  174
- Description
  175
- Idler Drum and Cable Follower
  175
- Maintenance
  175
- Description
  177
- Hoist Drum Rotation Indicator System
  177
- Maintenance
  177
- Troubleshooting
  177
- Counterweight Removal
  179
- Counterweights
  179
Section 6 Swing Section

183
- Description
  188
- Maintenance
  188
- Swing Motor
  188
- Description
  189
- Maintenance
  189
- Swing Gearbox and Brake
  189
- Description
  190
- Maintenance
  190
- Maintenance of Gearbox
  190
- Swing Bearing
  190
- Description
  196
- Swivels
  196
- Hydraulic Swivel
  198
- Electrical Slip Ring Assembly
  200
Section 7 Power Train

203
- Engine Removal
  204
- Engine Installation
  207
- Description
  208
- Engine Control System
  208
- Engine Drive Belts
  208
- Functional Operation
  208
- Engine Control System Switches and Indicator Lights
  209
- Description
  211
- Fuel System
  211
- Maintenance
  212
- Air Intake System
  213
- Description
  213
- Maintenance
  213
- Description
  217
- Exhaust System
  217
- Exhaust System Removal
  217
- Slip Joint Exhaust Connectors
  217
- System Installation
  217
- Exhaust System
  218
- After-Treatment Diesel Exhaust Fluid (DEF)
  219
- DEF Tank
  219
- DEF Dosing Unit Filter
  220
- Description
  222
- Maintenance
  222
- Water Cooling System
  222
- Cleaning
  224
- Component Inspection
  225
- Radiator Assembly Removal and Installation
  226
- Description
  228
- Drive Lines
  228
- Drive Train
  228
- Maintenance
  228
- ECA Removal and Assembly Instructions
  230
- Electronic Clutch Actuator (ECA)
  230
- Installation Instructions
  230
- Removing Transmission from Engine
  230
- Transmission
  230
- Mounting Transmission to Engine
  231
- Pump/Pto Assembly
  232
- Pump/Pto Replacement
  232
Section 8 Undercarriage

235
- Anti-Lock Brake System (ABS)
  235
- Front Axle
  236
- Maintenance
  236
- Rear Axles
  241
- Description
  246
- Vehicle Maintenance Schedule
  246
- Wheels and Tires
  246
- Description
  247
- Maintenance
  247
- Steering System
  247
- Description
  250
- Maintenance
  250
- Steering Gearbox
  250
- Air System
  251
- Description
  251
- Theory of Operation
  251
- Maintenance
  254
- Air System Components
  256
- Brakes
  266
- Description
  266
- Air Supply
  267
- Anti-Lock Braking Systems (ABS)
  267
- Automatic Traction Control
  267
- Emergency Braking
  267
- Non-Asbestos Warning
  267
- Normal Braking
  267
- Vehicle Parking
  267
- Description
  268
- Front Brakes
  268
- Maintenance
  268
- Automatic Slack Adjuster
  274
- Description
  274
- Maintenance of Slack Adjuster
  274
- Description
  277
- Rear Brakes
  277
- Maintenance
  278
- Rear Brake Assembly
  282
- ABS System Description
  285
- ATC System Description
  287
- ABS Troubleshooting
  289
- Troubleshooting Diagnostic Trouble Codes: Traction Control Valves
  297
- Power Supply Tests
  299
- Troubleshooting Diagnostic Trouble Codes: J1939 Serial Communications
  299
- Miscellaneous Troubleshooting
  301
- Troubleshooting Wiring
  302
- Special Tools
  305
- Tests, Repair and Adjustment
  305
- Component Removal and Installation
  307
- Description
  309
- Outriggers
  309
- Theory of Operation
  309
- Maintenance
  310
- Description
  317
- Extension Cylinder
  317
- Maintenance for Extension Cylinder
  317
- Maintenance for Jack Cylinders
  317
- Outrigger Jack Cylinders
  317
- Center Front Jack Cylinder
  318
- Description
  318
- Maintenance for Center Front Jack Cylinder
  318
- Functional Check of Center Front Jack Cylinder
  319
- Description
  321
- OMS Linear Position Sensors
  321
- Outrigger Monitoring System
  321

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Table of Contents

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Table of Contents

This Page Blank

Section 1 1

Section 2 Hydraulic System 2

Section 3 Electrical System

Tms500-2 Service Manual Boom Section 4 Boom

Section 5 Hoist and Counterweight

Section 6 Swing Section

Section 7 Power Train

Section 8 Undercarriage

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