Manitowoc Grove TMS700E

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HYDRAULIC SYSTEM TMS700E SERVICE MANUAL

2-4 Published 01-29-2015, Control # 512-01

FIGURE 2-1 continued

Reference Only

Main Page

Table of Contents5
Section 113
List of Specifications14
General14
Dimensions14
Capacities14
Transmission14
Clutch14
Engine14
Axles14
Brakes14
Wheel and Tires14
Hoists15
General Maintenance20
Cleanliness20
Removal and Installation20
Disassembly and Assembly20
Pressing Parts20
Locks20
Wires and Cables21
Bearings21
Gaskets21
Batteries21
Hydraulic Systems22
Electrical System23
Fatigue of Welded Structures23
Loctite23
Fasteners and Torque Values24
Weld Studs27
Wire Rope28
Environmental Conditions28
Dynamic Shock Loads28
Lubrication28
Precautions and Recommendations During Inspection or Replacement28
Wire Rope Inspection (Running Ropes and pendant Cables)29
Wire Rope Inspection (Boom Extension and Retraction Cables)29
Wire Rope Replacement (All Wire Rope)30
Seizing Wire Rope30
Installing 35X7 Class Wire Rope31
Procedures for Cutting and Preparing 35X7 Class Wire Rope31
Synthetic Hoist Rope32
Section 233
Description34
Maintenance34
Hydraulic Oil Recommendations34
Removing Air from the Hydraulic System37
Parts Replacement38
Directional Control Valves38
Supply Pressure and Return Circuit39
Description39
Maintenance41
Oil Cooler44
Description44
Maintenance44
Hydraulic Pumps46
Description46
Maintenance46
Pump Drive47
Description47
Maintenance48
Valves51
General51
Pressure Setting Procedures54
Description54
Maintenance54
Directional Control Valves60
Description60
Maintenance61
Check Valves66
Description66
Maintenance66
Hydraulic Remote Control Valve66
Outrigger Selector Valve69
Description69
Maintenance69
Outrigger Control Manifold70
Description70
Maintenance70
Pilot Operated Check Valve72
Description72
Maintenance72
Holding Valves73
Description73
Maintenance73
Swing Brake and Armrest Lockout Valve Manifold75
Description75
Maintenance75
High Speed Boost Selector Valve77
Description77
Maintenance77
Front Center Jack Relief Valve78
Description78
Maintenance78
Pump Mounted Relief Valve78
Needle Valve79
Description79
Maintenance79
Needle Valve with Reverse Free Flow Check79
Swing Power Brake Valve79
Swing Brake Release Valve (Optional)81
Description81
Maintenance81
Priority Flow Divider Valve82
Description82
Maintenance82
Auxiliary Water Jacket Cooler Flow Control Valve83
Description83
Maintenance83
Auxiliary Water Jacket Cooler Flow Control83
Valve83
Cylinders84
General84
Maintenance84
Lift Cylinder86
Description86
Maintenance86
Lower Telescope Cylinder89
Description89
Maintenance89
Upper Telescope Cylinder92
Maintenance92
Description92
Steer Cylinder95
Description95
Maintenance96
Maintenance99
Outrigger Extension Cylinder99
Description99
Maintenance102
Outrigger Jack Cylinder102
Description102
Maintenance106
Center Front Jack Cylinder106
Description106
Maintenance110
Counterweight Removal Cylinder110
Description110
Description115
General115
Alternator115
Battery115
Carrier Relay and Circuit Breaker Panel115
Superstructure Relay Panel and Fuse Panel118
Maintenance122
General122
General Troubleshooting122
Troubleshooting Engine Starting Problems122
Troubleshooting Engine Charging Problems123
Troubleshooting Accessories123
Troubleshooting Swivel-Caused Electrical Problems123
Connector Troubleshooting123
Troubleshooting Lights125
Troubleshooting Gauges and Meters125
Troubleshooting Alarms, Indicators, and Emergency Components126
Troubleshooting Crane Components and Accessories127
Alternator Replacement128
Starter Replacement129
Battery Replacement130
Relay Panel Component Replacement130
Instrument Replacement131
Switch Replacement131
Windshield Wiper Assembly Replacement132
Windshield Washer Assembly Replacement133
Skylight Wiper Assembly Replacement134
Section 4135
Description135
Theory of Operation135
Boom Extension135
Boom Retraction136
Maintenance136
Removal136
Disassembly138
Boom Nose Sheaves143
Assembly143
Installation146
Functional Check147
Inspection147
Boom Alignment and Servicing147
Cam Operated Check Valve Adjustment148
Guide Block Adjustment148
Boom Extension and Retraction Cable148
Maintenance148
Inspection148
Adjustment149
Telescope Circuit149
Description149
Theory of Operation150
Maintenance150
Removal and Installation152
Disassembly and Assembly152
Lift Circuit152
Description152
Theory of Operation153
Maintenance154
Swingaway Boom Extension158
Description158
Maintenance158
Boom Extension Alignment Device Adjustment165
Hook Block166
Description166
Maintenance166
Description167
Maintenance167
Removal167
Installation168
Functional Check168
Usage and Inspection168
Preventative Maintenance170
Brake Test Procedure171
Hoist to Boom Alignment172
Preparation172
Tools Required172
Procedure172
Motor and Brake174
Description174
Maintenance174
Cable Guard Roller and Cable Guide Roller174
Description176
Maintenance176
Hoist Drum Indicator System176
Hoist Rotation Indicator (HRI) Display System178
Description178
Hoist Control Valves179
Counterweight179
Description179
Maintenance180
Description183
Theory of Operation183
Swing Drive183
Swing Brake184
Maintenance186
Troubleshooting186
Swing Motor189
Description189
Maintenance189
Swing Gearbox and Brake189
Swing Bearing190
Description190
Maintenance190
Swivels195
Description195
Hydraulic Swivel197
Description197
Theory of Operation197
Maintenance197
Two Port Water Swivel199
Description199
Maintenance199
Installation199
Electrical Swivel200
Description200
Theory of Operation200
Maintenance200
Swing Lock Pin202
Description202
Maintenance202
360° Swing Lock Control (Positive Lock Type) (Optional)202
Section 7205
Description205
Maintenance206
Removal206
Installation208
Engine Drive Belts210
Engine Control System211
Description211
Functional Operation211
Engine Control System Switches and Indicator Lights211
Fuel System213
Description213
Maintenance213
Air Intake System215
Description215
Maintenance215
Exhaust System219
Description219
ISX System Removal219
ISX System Installation219
QSM System Removal219
QSM System Installation219
Slip Joint Exhaust Connectors219
ISX Exhaust System220
QSM Exhaust System221
Aftertreatment Diesel Exhaust Fluid (DEF)222
DEF Tank222
DEF Dosing Unit Filter223
Water Cooling System225
Description225
Maintenance225
Cleaning227
Component Inspection228
Radiator Assembly Removal and Installation229
Drive Train233
Description233
Maintenance233
Clutch235
Description235
Maintenance237
Gearshift and Transmission Shift Air System244
Description244
Theory of Operation244
Shifting Gears244
Maintenance245
Manual Transmission246
Description246
Theory of Operation246
Maintenance246
Front Axle and Suspension254
Description254
Maintenance254
Steering System264
Description264
Maintenance264
Steering Pump267
Description267
Steering Gearbox267
Maintenance267
Steer Cylinder268
Description268
Maintenance268
Rear Axle and Suspension269
Description269
Maintenance269
Wheels and Tires273
Description273
Maintenance273
Brakes275
Description275
Maintenance275
Front Brakes275
Maintenance276
Automatic Slack Adjuster282
Description282
Maintenance282
Removal282
Installation282
Adjustment Procedures283
Installation286
Adjustment Procedures286
Rear Brakes289
Description289
Maintenance290
Automatic Slack Adjuster295
Automatic Slack Adjuster296
Description296
Maintenance296
Air System299
Description299
Theory of Operation299
Maintenance299
Air System Components303
Description303
Maintenance306
Outriggers314
Description314
Theory of Operation314
Maintenance315
Outrigger Beam318
Description318
Theory of Operation318
Maintenance318
Outrigger Extension Cylinder321
Description321
Maintenance321
Outrigger Monitoring System (Optional-Standard in North America)322
Description322
Outrigger Jack Cylinder323
Description323
Maintenance323
Outrigger System Valves325
Description325
Center Front Jack Cylinder325
Maintenance325
Section 9329
General329
Environmental Protection329
Arctic Conditions below -9°C (15°F)329
All Weather Package & Lubricants329
Standard Lubricants Package330
Lubrication Points331
Carrier Lubrication333
Superstructure Lubrication338
Boom, Boom Extension, and Boom Accessories Lubrication339
Wire Rope Lubrication341
Carwell® Rust Inhibitor343
Protecting Cranes from Rusting343
Cleaning Procedures343
Inspection and Repair344
Application344
Areas of Application345

Manitowoc Grove TMS700E - Page 36

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