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Manitowoc Grove TMS9000-2 Series Manuals
Manuals and User Guides for Manitowoc Grove TMS9000-2 Series. We have
2
Manitowoc Grove TMS9000-2 Series manuals available for free PDF download: Operator's Manual, Service Manual
Manitowoc Grove TMS9000-2 Series Operator's Manual (430 pages)
Brand:
Manitowoc
| Category:
Construction Equipment
| Size: 24.17 MB
Table of Contents
Table of Contents
5
Section 1
13
Ambient Operation Temperature
13
Customer Support
13
Section 2
17
Safety Messages
17
General
18
Safety Alert Symbol
18
Signal Words
18
Safety Decals
18
Accidents
18
Operator Information
18
Operator Qualifications
19
Operational Aids
20
Rated Capacity Limiter (RCL) Systems
20
Anti-Two-Blocking Device
21
Working Area Limiter (if Equipped)
21
Crane Stability/Structural Strength
22
Load Charts
22
Work Site
22
Wind Forces
23
Wind Speeds
24
Lifting Operations
36
Counterweight
37
Outrigger Lift off
37
Multiple Crane Lifts
37
Lifting Multiple Loads
37
Tilt-Up Panel Lifting
38
Counterweight
38
Outrigger Lift off
38
Pile Driving and Extracting
39
Crane Equipment
39
Crane Inspection
39
Electrocution Hazard
39
Set-Up and Operation
41
Electrocution Hazard Devices
41
Electrical Contact
42
Special Operating Conditions and Equipment
42
Grounding the Crane
42
Personnel Handling
43
Environmental Protection
44
Maintenance
44
Service and Repairs
44
Lubrication
45
Tires
46
Hoist Rope
46
Synthetic Hoist Rope
46
Wire Rope
46
Sheaves
47
Batteries
48
Super Capacitor (if Equipped)
48
General Maintenance
48
Transporting the Crane
49
Travel Operation
49
Work Practices
50
Personal Considerations
50
Crane Access
50
Job Preparation
50
Working
51
Lifting
52
Hand Signals
53
Boom Extension
55
Parking and Securing
55
Shut-Down
55
Cold Weather Operation
55
Temperature Effects on Hook Blocks
56
Temperature Effects on Hydraulic Cylinders
56
Overload Inspection
57
Boom Inspection
59
Superstructure Inspection
61
Carrier Inspection
63
Section 3
65
Carrier Cab Controls and Indicators
67
Transmission Shift Lever
68
Spare Switch/Indicator
68
USB Ports
68
Volt Outlet
68
Fire Extinguisher
68
Horn Button
68
Turn Signal/Headlight High Beam Low Beam Lever
68
Steering Column Tilt/Telescope Lever
68
Cab Circulating Fan
68
Windshield Wiper and Washer
68
Brake Pedal
69
Clutch Pedal
69
Steering Wheel
69
Headlights Switch
70
Dimmer Switch
70
Beacon Light Switch (Optional)
70
Engine Brake On/Off Switch
70
Engine Brake High/Low Switch
70
Exhaust System Cleaning Initiate Switch
71
Engine Idle Increment/Decrement Switch
71
Remote Control On/Off Switch
71
Remote Control Indicator
71
ABS/ATC Switch
71
Hill Start Aid (HSA) Switch (Optional)
71
HSA Indicator (Optional)
71
Inter-Axle Lock Switch
71
Cross-Axle Lock Switch (Optional)
71
Suspension Inflation Switch
71
Heater/Air Conditioner Control
72
Heater/Air Conditioner Select Switch
72
Ignition Switch
72
Parking Brake Control
72
Dual Air Pressure Gauge
72
Trailing Boom Trailer Emergency Brake Control (Optional)
72
Control Panel Indicator and Gauge Display
73
Cross-Axle Locked Indicator
73
Inter-Axle Locked Indicator
74
Suspension Deflated Indicator
74
Traction Control Indicator
74
Tire Inflation on Indicator
74
Left Turn Signal Indicator
74
Lights on Indicator
74
High Beam Indicator
74
Parking Brake Engaged Indicator
74
Battery Charge Indicator
74
Low Air Pressure
74
Check Transmission (Automated Transmission Only)
75
Malfunction Indicator Lamp
75
Low Oil Pressure
75
Engine Stop Indicator
75
Engine Warning Indicator
75
OK Button
75
Menu Button
75
Fuel Gauge
75
Speedometer
75
Low Fuel Level Indicator
75
Engine Temperature Indicator
76
Cruise Control
76
Engine Coolant Temperature Gauge
76
Down Button
76
Up Button
76
Tachometer
76
Exhaust System Cleaning
76
LCD Display
76
Outrigger Controls and Indicators
78
Outrigger Control Summary
78
Outrigger Control Panel
78
Superstructure Cab
80
Control Panels
84
Control Levers
87
Heating System
88
Operator Display Module (ODM)/CCS Control Unit
90
Operator Display Module (ODM)/CCS Control
90
Unit
90
CCS - Home Screen
92
Alert Icons
94
Short Description of the Operating Elements of the Crane Control System
96
Definition of Direction Information
96
General Rules for Buttons and Symbols on the Display
96
Crane Control System
97
Display CCS
97
Displaying the Operating Hours
106
CCS - Overview Menu Groups
110
Boom Configurator Menu
131
Telescoping Emergency Program
132
ODM Error Code Viewer
142
RDM (RCL Display Module)
143
Resetting the Current Telescoping
145
RCL - Menu Groups
147
Adjusting the Wiper Stroke Interval of the Windshield Wiper
152
Display - Setting the Brightness
153
Crane Functions Speed Control
154
Setting the Characteristic Curves for the Control
154
Operating the Camera
155
Switching the Boom Position Indicator Light (Optional Equipment) on and off
155
Engine
156
Seat Contact Switch and Dead Man's Switches
156
Outriggers
157
Inclination Indicator
160
Anemometer Display
160
Counterweight Menu
160
Main Hoist
161
Auxiliary Hoist
163
Swing
163
Lifting/Lowering Mechanism
164
Telescoping Mechanism
165
Hydraulic System
169
Superstructure House Lock Menu
169
Remote Control
170
Remote Control Icon
170
Remote Control Operation
171
Scope
171
System Overview
171
System Components
172
Remote Control Components
174
Display Components
175
Preparing for Remote Control Operation
177
Operating Remote Control
178
Rated Capacity Limiter (RCL)
192
Telescoping Mode Number Entry
196
Economy Mode
202
Terminology
203
Requirements
203
Operation
204
Benefits
204
Electrical System
204
Voltage Monitoring Warning
204
Lighting, Windshield Wiper/Washing System
205
Lighting
205
Windows
206
Superstructure Cab Door
207
Cranestar® System
208
Overview
208
Position of the Components
208
Breaking-In a New Carrier
212
Pre-Starting Checks
212
Fuel Supply
212
Engine Oil
212
DEF Fluid Level
212
Engine Coolant
213
Batteries
213
Hydraulic Reservoir and Filter
213
Wire Rope
213
Hook Block and Headache Ball
213
Seats
213
Seat Belts
213
Signal and Running Lights
213
Service and Parking Brakes
213
Tires
213
Derated Capacities for each °F below -40°F
214
Derated Capacities for each °C below -40°C
214
Cold Climate Operation
214
Crane Warm-Up Procedures
214
Engine
215
Transmission
215
Hoist
215
Swing Drive and Turntable Bearing
215
Axles
215
Hydraulic Oil System
215
Heating and Ventilating the Superstructure Cab
216
Heating System
216
Heating System Manual Operation
216
Heating System Automatic Operation
219
Air-Conditioning System
220
Anti-Lock Brake System (ABS)
221
ABS Power-Up Sequence
222
ABS Switch Operation
222
Automatic Traction Control (ATC) Functional Overview
222
Automatic Traction Control (ATC) Functional
222
Overview
222
ATC Operation
223
System Operation
223
Component Function
223
Traction Control Power-Up Sequence
223
Traction Control Switch Operation
223
Thermal (Brake Heat) Protection
223
ABS/ATC Partial Shutdown
223
Engine Operation
223
Starting Procedure
223
Cold Weather Starting
224
Jump Starting the Crane
224
Idling the Engine
224
Racing the Engine
225
Shutdown Procedure
225
Exhaust System Cleaning
225
Crane Travel Operation
226
Traveling - General
227
Jobsite Travel Configurations
227
Axle Weight Distribution Table
233
Manual Transmission Clutch Operation
235
Shifting Gears
235
Automatic Transmission (Optional)
238
Differential Control Switches
242
Brakes
242
Engine Brake
243
Recommended Crane Shutdown Procedures
243
Unattended Crane
244
Superstructure Cab Platform
244
Proper Leveling of the Crane
244
Bubble Level Adjustment
244
Using the Outriggers
244
Setting the Outriggers
244
Engaging the Partial/MID Extension Lock Pin
245
Outrigger Monitoring System (OMS) CCS Display
246
Stowing the Outriggers
246
Stowing the Partial/MID Extension Lock Pin
246
Outrigger Monitoring System (OMS) CCS
246
Display
246
Stowing the Center Front Jack
247
Crane Operation
247
Before Operating the Crane
247
Preheating the Hydraulic Oil
251
Switching the 360° Lock On/Off
251
Operation of the Rated Capacity Limiter
252
Enter Rigging Mode
254
Crane Operation with Main Boom
265
Telescoping Mechanism
270
Semi-Auto Mode
281
Boom Configurator
288
High-Speed Mode
290
Swing Gear
290
Possible Movement Combinations
293
Settings and Displays for Crane Operation
293
Inclining the Crane Cab
293
Switching Units of Measure
293
Setting the Characteristic Curves for the Control Levers
294
Setting the Characteristic Curves for the Control
294
Limiting the Power Unit Speeds
295
Carrier Camera Display Setup
296
Using the Slewable Spotlights
296
Warnings in the Start Menu
297
Mechanical Emergency Unlocking and Locking of the Telescopic Sections
297
Mechanical Emergency Unlocking and Locking
297
Prerequisites
298
Maintenance
298
Work Break
299
In Case of Short Work Breaks
299
In Case of Work Breaks of more than 8 Hours
299
Trailing Boom Carrier Option
300
Description
300
Operation
301
Returning to Normal Crane Operation
303
Parking the Trailing Boom Carrier
303
Tilt-Up Panel Procedure Using the Heavy Duty Boom Extension
303
Tilt-Up Panel Procedure Using the Heavy Duty
303
Boom Extension
304
General
305
Environmental Protection
305
Cummins Oil Registration List
305
Arctic Conditions below -18° C (0° F)
306
Lubrication Points
306
Standard Lubricants
307
Cold Weather Lubricants
309
Arctic Lubricants and Conditions
311
Drivetrain Lubrication
312
Clutch Release Bearing Grease Interval
315
Steering Lubrication
318
Axle Lubrication
318
Outrigger Lubrication
321
Miscellaneous Lubrication
322
Turntable & Cab Tilt Lubrication
323
Hoist Lubrication
326
Turntable Central Lubrication
327
Boom Lubrication
328
Monthly Lubrication Work
331
Carwell® Rust Inhibitor
332
Protecting Cranes from Corrosion
332
Cleaning Procedures
332
Inspection and Repair
333
Application
333
Areas of Application
333
General
338
Installing Cable on the Hoist
338
Cable Reeving
338
Dead-End Rigging/Wedge Sockets
339
Installing Wedge and Socket
340
Positioning/Removing the Hoist Cable
341
Possible Reevings on the Main Boom
342
Rigging Work for Crane Operation with the Main Boom
348
Rigging
348
Rigging Work for Crane Operation with the
348
Unrigging
349
Removable Counterweight
349
Counterweight Versions/Combinations
352
Lifting Individual Counterweight Sections
352
Rigging the Counterweight
354
Unrigging the Counterweight
355
Lower 3,000 Lb Tray Plate on the Counterweight Platform
355
Check the Position of the Locking Pins for 3000 and 5,000 Lb Counterweight Sections6-20
356
Check the Position of the Locking Pins for 3000 and 5,000 Lb Counterweight Sections
356
Assembling Counterweight Versions/Combinations
357
Assembling Counterweight Versions/ Combinations
357
Counterweight Hoist Unit
358
Rotating with the Rigged Counterweight
359
Unlocking/Locking the Rear Counterweight Platform
364
Rigging Work on the Main Boom
366
Hook Block on the Bumper
366
Hook Block on a Separate Vehicle
366
Installing/Removing the Anti-Two Block Switch
372
Locking/Unlocking the Anti-Two Block Switch
376
Anemometer and Boom Position Indicator Light
376
Other Rigging Work
377
Cameras for Crane Operation
377
Hoist Maintenance Platform
378
Slinging Points for Personal Protective Equipment
378
Boom Extensions
379
Installing the Folding Boom Extension
380
Extension Erecting Warnings and Requirements
381
Erecting Procedure: 35 Ft (10.5 M) Base Extension
381
Erecting Procedure: 58 Ft (17.7 M) Extension
386
Extension Electrical Connections
392
Connecting the Anti-Two Block Switch
394
Extension Hydraulic Connections (Optional Hydraulic Extension)
394
Extension Hydraulic Connections
394
Hydraulic Extension)
394
Folding Deflection Sheaves
397
Positioning/Removing the Hoist Cable
398
Mechanical Luffing Boom Extension (Adjustable Boom Extension)
399
Stowing the Folding Boom Extension
400
Boom Extension Removal
408
Installing and Removing the 26 Ft (8 M) Extension Insert
412
M (11.4 Ft) Manual Off-Settable Heavy Duty Boom Extension
417
Separating Manual Off-Settable Heavy Duty Boom Extension from Lattice Extension6-81
417
Separating Manual Off-Settable Heavy Duty Boom Extension from Lattice Extension
417
Installing Manually Offsetable Heavy Duty Boom Extension
418
Setting Heavy Duty Boom Extension Manual Offset
418
Removing the Manual Offsetable Heavy Duty Extension
418
Setting Heavy Duty Boom Extension Manual
418
Offset
418
M (11.4 Ft) Hydraulic Off-Settable Heavy Duty Boom Extension
419
Separating Hydraulic Off-Settable Heavy Duty Boom Extension from Lattice Base Extension6-83
419
Separating Hydraulic Off-Settable Heavy Duty Boom Extension from Lattice Base Extension
419
Removing the Hydraulic Offsetable Heavy Duty Extension
422
Auxiliary Single-Sheave Boom Nose (Optional Equipment)
422
Identification
422
Auxiliary Single-Sheave Boom Nose
422
Installing/Removing Auxiliary Single-Sheave Boom Nose
423
Installing/Removing Auxiliary Single-Sheave
423
Boom Nose
423
Removing the Auxiliary Single-Sheave Boom Nose
424
Rigging the Auxiliary Single-Sheave Boom Nose
424
Rigging in Transport Position
424
Rigging in Working Position
424
Attaching and Removing Hoist Cable
424
Possible Reeving Methods on the Auxiliary Single-Sheave Boom Nose
424
Anti-Two Block Switch
424
Raising and Setting down the Main Boom with Rigged Lattice Extension
424
Nose
424
Telescoping with Rigged Lattice Extension
425
Operating with the Lattice Extension
425
Procedure if the Permissible Wind Speed Is Exceeded
425
Anti-Two Block Troubleshooting
425
Procedure if the Permissible Wind Speed Is
425
Exceeded
425
Rear Axle Locking Pins
426
Installing Rear Axle Locking Pins
426
Removing Rear Axle Locking Pins
426
Advertisement
Manitowoc Grove TMS9000-2 Series Service Manual (408 pages)
Brand:
Manitowoc
| Category:
Construction Equipment
| Size: 15.22 MB
Table of Contents
Table of Contents
25
Section 1
33
Using the Service Manual
33
Safety Messages
33
General
33
Safety Alert Symbol
33
Signal Words
33
Manitowoc Cranecare Service Instructions
34
Definitions of Stated Directions
34
General
34
Breaking in a New Crane
35
Safety Rules
35
Handling Substances Which Are Harmful to the Environment
36
What Do Environmentally Harmful Substances Include
36
Overview of the Operating and Display Elements
37
Axle Weight Distribution Table
38
Cleaning
40
Boom Cleaning
40
Overview of the Components that Are Easily Damaged When Cleaning
41
On Truck Crane
41
Fasteners and Torque Values
41
Torque Wrenches
42
Torque Values
42
Weld Studs
56
Section 2
57
Description
58
Maintenance
60
Draining and Flushing
60
Removing Air from the Hydraulic System
61
Parts Replacement
62
Supply Pressure and Return Circuit
62
Description
62
Hydraulic Reservoir and Filter
62
Pump Distribution
63
Maintenance
65
Troubleshooting
65
Return Hydraulic Filter Assembly
66
Element Removal
66
Element Installation
66
Hydraulic Pumps
68
Description
68
Maintenance
68
Carrier Valves
73
General
73
Outrigger Selector-A/C Manifold Valve
75
Description
75
Maintenance
75
Outrigger Control Manifold
77
Description
77
Maintenance
77
Pilot Operated Check Valve
80
Description
80
Internal Leak Testing
80
Maintenance
81
Superstructure Valves
82
Turntable Hydraulic Valves
82
Main Directional Valve Assembly
83
Access Manifold Assembly
84
Hydraulic System of the Superstructure
85
Checking for Leaks
85
Cylinders
85
General
85
Maintenance
85
Steer Cylinder
87
Description
87
Maintenance
87
Outrigger Extension Cylinder
90
Description
90
Maintenance
90
Outrigger Jack Cylinder
93
Description
93
Maintenance
93
Description
96
Center Front Stabilizer Cylinder
97
Description
97
Maintenance
97
Lift Cylinder
100
Description
100
Maintenance
100
Counterweight Cylinder
103
Description
103
Telescope Cylinder
104
Description
104
Pressure Setting Procedures
105
Objective
105
Equipment
105
Valve Pressure Setting Table
105
Service Tool Notes
106
Procedure for Checking/Setting the Piston Pumps Cut-Off & Differential Pressures
106
Procedure for Checking/Setting the Pilot Supply Pressure
108
Procedure for Checking/Setting the Main Directional Control Valve, Load Sense, Lift and Telescope Pressures
109
Procedure for Checking/Setting Cab Tilt Raise and Lower Pressures
114
Procedure for Checking/Setting Counterweight (CWT) Raise and Lower Pressures
114
Procedure for Checking/Setting Counter- Weight (CWT) Raise and Lower Pressures
114
Procedure for Checking/Setting Swing Pressure
115
Procedure for Checking/Setting Outrigger Pressure
115
Procedure for Checking/Setting Air Conditioning Pressure
116
Procedure for Checking/Setting the Center Front Stabilizer Pressure
117
Procedure for Checking/Setting the Front Steer Pressure
118
Procedure for Adjusting Electronic Controllers (Meter-In Dead Band And/Or Max Function Speeds)
119
Description
121
Carrier
121
Maintenance
129
General
129
General Troubleshooting
129
Tools for Troubleshooting
129
Troubleshooting Engine Starting Problems
129
Troubleshooting Engine Charging Problems
130
Troubleshooting Slip Ring-Caused Electrical Problems
130
Connector Troubleshooting
131
DI-Electrical Grease Application
132
Troubleshooting Lights
133
Troubleshooting Gauges and Meters
133
Troubleshooting Alarms, Indicators, and Emergency Components
134
Troubleshooting the Crane Control System (CCS)
134
ODM Error Code Viewer
134
Troubleshooting Crane Components and Accessories
135
Alternator Replacement
135
Starter Replacement
135
Battery Replacement
136
Relay Panel Component Replacement
138
Instrument Replacement
138
Switch Replacement
138
Rocker Switch
138
All Other Switches
139
Windshield Wiper Assembly Replacement
139
Windshield Washer Assembly Replacement
141
Remote Controller (Optional)
142
Receiver
142
Battery Charger
142
Remote Controller Battery
143
Jump Starting the Crane
143
Charging
143
Description of Maintenance Work on the Superstructure
145
Hoist
145
Superstructure
146
Hoist
148
Boom Removal
153
Boom Installation
155
Functional Check
157
Boom Nose Sheaves
157
Boom Nose Sheaves Removal
157
Boom Nose Sheaves Installation
161
Boom Disassembly
161
Boom Assembly
162
Telescope Section 5 Assembly
162
Telescope Section 4 Assembly
164
Telescope Section 3 Assembly
167
Telescope Section 2 Assembly
170
Telescope Section 1 Assembly
173
Telescope Base Section Assembly
177
Pinning Boom Components
182
Mechanical Locking Head Description
182
Proximity Switch Descriptions
183
Hydraulic Actuator Description
185
Precision Length Sensor Description
186
Pinned Boom Control System Description
186
Mechanical Emergency Unlocking and Locking of the Telescopic Sections
187
Prerequisites
187
Maintenance
187
New York House Lock
188
Bleeding the Telescoping Cylinders
188
Prerequisites
188
Bleeding Procedure
188
Telescoping Status
189
Telescope Slide Pad Adjustment
190
Check the Locking System
190
Hoist Ropes
191
Checking the Position of Sheaves and Rope Drums
191
Wire Rope Inspection/Replacement (All Wire Rope)
191
Wire Rope Inspection/Replacement
191
(All Wire Rope)
191
Rated Capacity Limiter
196
Maintenance of the Slip Ring Assembly of the Cable Drum
196
Lubricating the Swing Angle Sensor
198
Superstructure Air Conditioning System (Additional Equipment)
199
Checking Hoses
199
Other Maintenance Work
199
Checking for Correct Operation of the Auxiliary Heater (Additional Equipment)
199
Lubricating the Piston Rod of the Lifting Cylinder
199
Superstructure Air Conditioning System
199
(Additional Equipment)
199
Superstructure Maintenance Overview
201
Maintenance Intervals
201
Maintenance Intervals
202
Maintenance Plans
203
Maintenance Plan W: Weekly
205
Maintenance Plan M 1: Monthly/After 100
206
Operating Hours/Approximately 2,000 Km (1240 MI)
206
Maintenance Plan M 3: Every 3 Months/After
206
Maintenance Plan M 6: Every 6 Months/After
206
Operating Hours/10 000 - 12 500 Km (6,210 - 7,770 MI)
206
Maintenance Plan M 12: Every 12 Months/After 1,000 Operating Hours/20 000 - 25 000 Km (12,430 - 15,530 MI)
207
Maintenance and Inspection Plan y 2: Every 24 Months/After 100 000 - 125 000 Km (62,150 - 77,800 MI)
207
Maintenance and Inspection Plan y 3: Every 36 Months/After 3,000 Operating Hours
207
(12,430 - 15,530 MI)
207
Maintenance and Inspection Plan y 2: Every
207
(62,150 - 77,800 MI)
207
Maintenance and Inspection Plan y 5: Every 60 Months/After 5,000 Operating Hours
208
Maintenance and Inspection Plan y 6: Every 72 Months/After 6,000 Operating Hours
208
Periodic Inspections
209
Load Hook Inspection
209
Measures Required for Hoist Monitoring
210
Theoretical Service Life
210
Proportion of the Theoretical Service Life Used
210
Theoretical Service Life on Hoist no
210
Section 6
213
Theory of Operation
213
Swing Drive
213
Swing Brake
213
Description
214
Swing Drive
214
Maintenance
215
Troubleshooting
215
Swing Box Assemblies
219
Description
219
Swing Motor Maintenance
219
Swing Gear Brake Function Check
220
Swing Brake Assembly Maintenance
220
Swing Gearbox Maintenance
220
Swing Bearing
222
Description
222
Maintenance
222
Description
226
Swivels
227
Description
227
Hydraulic Swivel
229
Electrical Swivel
230
Swing Lock Pin
232
Description
232
Rotating the Turntable Swing Lock Handle
232
Maintenance
232
360° Swing Lock Control (Positive Lock Type)
232
Engine
233
Description
233
Maintenance
234
Removal
234
Installation
236
Engine Drive Belts
236
Engine Control System
237
Description
237
Functional Operation
237
Engine Control System Switches and Indicator Lights
238
Fuel System
238
Description
238
Maintenance
239
Air Intake System
240
Description
240
Maintenance
241
Exhaust System
243
Description
243
Exhaust System Removal
243
System Installation
243
Slip Joint Exhaust Connectors
244
Exhaust System
244
After-Treatment Diesel Exhaust Fluid (DEF)
245
DEF Tank
245
DEF Dosing Unit Filter
246
Water Cooling System
248
Description
248
Maintenance
248
Cleaning
250
Component Inspection
251
Radiator Assembly Removal and Installation
252
Drive Train
254
Description
254
Maintenance
254
Drive Lines
254
Clutch
256
Description
256
Theory of Operation
256
Maintenance
258
Clutch Adjustment Procedure
265
General Maintenance
265
Gearshift
265
Description
265
Maintenance
266
Manual Transmission
266
Description
266
Theory of Operation
266
Maintenance
267
Lubrication
270
Preventive Maintenance
271
Transmission Shift Air System
271
Description
271
Theory of Operation
271
Pump / PTO Assembly
272
Pump / PTO Replacement
272
Section 8
275
Front Axle
276
Suspension
276
Maintenance
276
General
276
Removal
279
Disassembly
279
Assembly
279
Installation
280
Axle Alignment Procedure
281
Steering System
286
Description
286
Maintenance
287
Steering Pump
289
Description
289
Steering Gearbox
289
Maintenance
289
Steer Cylinder
290
Description
290
Maintenance
290
Wheels and Tires
291
Description
291
Maintenance
291
Rear Axle and Suspension
291
Rear Axle
291
Suspension
292
Maintenance
292
Removal
294
Disassembly
294
Assembly
294
Installation
295
Wheels and Tires
295
Description
295
Maintenance
295
Mounting the Wheels on the Axle
295
Air System
296
Description
296
Theory of Operation
296
Braking
298
Maintenance
299
Air System Components
301
Brakes
310
Description
310
Air Supply
310
Normal Braking
310
Vehicle Parking
310
Anti-Lock Braking Systems (ABS)
310
Automatic Traction Control
311
Emergency Braking
311
Non-Asbestos Warning
311
Front Brakes
311
Description
311
Maintenance
312
Automatic Slack Adjuster
318
Description
318
Maintenance
318
Rear Brakes
326
Description
326
Maintenance
326
Rear Brake Assembly
329
Anti-Lock Brake System (Abs)/Automatic Traction Control (ATC)
331
ABS System Description
331
ATC System Description
333
ABS Troubleshooting
335
Troubleshooting Diagnostic Trouble Codes: Traction Control Valves
343
Power Supply Tests
345
Troubleshooting Diagnostic Trouble Codes: J1939 Serial Communications
346
Miscellaneous Troubleshooting
347
Troubleshooting Wiring
348
Special Tools
352
Tests, Repair and Adjustment
352
Component Removal and Installation
354
Outriggers
357
Description
357
Theory of Operation
358
Maintenance
358
Extension Cylinder
366
Outrigger Jack Cylinders
366
Description
366
Maintenance
366
Center Front Jack Cylinder
367
Description
367
Maintenance
367
Functional Check
368
Outrigger Monitoring System (Optional-Standard in North America)
370
Description
370
OMS String Potentiometers
370
General
371
Environmental Protection
371
Cummins Oil Registration List
371
Arctic Conditions below -18° C (0° F)
372
Cylinder Rod Surface Protection
372
Lubrication Points
372
Standard Lubricants
373
Cold Weather Lubricants
375
Arctic Lubricants and Conditions
377
Clutch Release Bearing Grease Interval
381
Steering Lubrication
383
Axle Lubrication
383
Outrigger Lubrication
387
Miscellaneous Lubrication
388
Turntable & Cab Tilt Lubrication
389
Hoist Lubrication
391
Turntable Central Lubrication
392
Boom Lubrication
393
Monthly Lubrication Work
398
Carwell® Rust Inhibitor
399
Protecting Cranes from Corrosion
399
Cleaning Procedures
399
Inspection and Repair
400
Application
400
Areas of Application
400
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