Manitowoc Grove TMS800E

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Published 01-29-2014, Control # 496-00

INTRODUCTION TMS800E SERVICE MANUAL

Reference Only

Main Page

Table of Contents3
Section 115
List of Specifications16
General16
Dimensions16
Capacities16
Transmission16
Clutch16
Engine16
Axles16
Brakes17
Wheel and Tires17
Swing Gearbox17
Boom17
Swivel Assembly17
Hydraulic Pumps17
Hoists17
General Maintenance24
Cleanliness24
Removal and Installation24
Disassembly and Assembly24
Pressing Parts24
Locks24
Wires and Cables25
Shims25
Bearings25
Gaskets25
Batteries25
Hydraulic Systems26
Fatigue of Welded Structures26
Loctite26
Fasteners and Torque Values27
Weld Studs30
Wire Rope31
Environmental Conditions31
Dynamic Shock Loads31
Lubrication31
Precautions and Recommendations During Inspection or Replacement31
Wire Rope Inspection (Running Ropes and pendant Cables)32
Wire Rope Inspection (Jib Extension and Retraction Cables)32
Wire Rope Inspection (Jib and Retraction Cables)32
Wire Rope Replacement (All Wire Rope)33
Seizing Wire Rope33
Installing 35X7 Wire Rope34
Procedures for Cutting and Preparing 35X734
Section 237
Description38
Maintenance38
Hydraulic Oil Recommendations38
Removing Air from the Hydraulic System42
Parts Replacement42
Directional Control Valves42
Supply Pressure and Return Circuit43
Description43
Maintenance46
Oil Cooler49
Description49
Maintenance49
Hydraulic Pumps51
Description QSM Cranes51
Description ISX Cranes51
Maintenance QSM Cranes51
Maintenance ISX Cranes55
Pump/Pto Clutch Replacement55
Pump/Pto Clutch Assembly57
PTO Clutch Lubrication57
Valves58
General58
Pressure Setting Procedures60
Procedure a - for Checking/Setting the Main Directional Control Valve for Hoist(S) and Boom Lift61
Procedure B - for Checking/Setting the Outrigger/Swing Pressures62
Procedure C - for Checking/Setting Air Conditioner Relief Valve Pressure62
Procedure D - for Checking/Setting the Front Steer Pressure62
Procedure E - for Checking/Setting Swing Brake Release Pressure62
Procedure F - for Checking/Setting the Pilot Supply Pressure62
Procedure G - for Checking/Setting the Piston Pump (ISX Engine)63
Procedure H - for Checking the Center Front Stabilizer Pressure63
Procedure I - Procedures for Checking/Setting the Piston Pumps (GSM Engine)63
Procedure J- for Setting Threshold on Electronic Controllers64
Procedure for Setting Threshold and Max on Swing Brake Pedal64
Procedure for Setting Threshold and Max on64
Directional Control Valves70
Description70
Maintenance70
Check Valves74
Description74
Maintenance74
Outrigger Selector Valve75
Description75
Maintenance75
Outrigger Control Manifold77
Description77
Maintenance77
Pilot Operated Check Valve79
Description79
Maintenance79
Cab Tilt Double Pilot Operated Check Valve80
Description80
Maintenance80
Holding Valves81
Description81
Maintenance81
Accessory Manifold with Swing Directional Control Valve83
Description83
Maintenance83
Motor Control Manifold86
Description86
Maintenance86
Swing Power Brake Valve87
Description87
Maintenance87
Swing Brake Release Valve (Optional)88
Description88
Maintenance88
Needle Valve (Optional)89
Description89
Maintenance89
Needle Valve with Reverse Free Flow Check (Optional)89
Cylinders90
General90
Maintenance90
Lift Cylinder93
Description93
Maintenance93
Lower Telescope Cylinder96
Description96
Maintenance96
Upper Telescope Cylinder100
Maintenance100
Description100
Maintenance103
Steer Cylinder103
Description103
Maintenance106
Outrigger Extension Cylinder106
Description106
Outrigger Stabilizer Cylinder110
Description110
Maintenance110
Center Front Stabilizer Cylinder114
Description114
Maintenance114
Counterweight Removal Cylinder118
Description118
Maintenance118
Cab Tilt Cylinder121
Description121
Maintenance121
Description125
General125
Alternator125
Batteries125
Carrier Cab Power Panel126
Carrier Fuse and Relays132
Superstructure Fuse and Relay Panel133
Maintenance133
General133
General Troubleshooting134
Troubleshooting Swivel-Caused Electrical Problems134
Connector Troubleshooting134
Diagnostic Lights136
Alternator Replacement136
Starter Replacement137
Battery Replacement138
Relay Panel Component Replacement138
Instrument Replacement139
Switch Replacement139
Windshield Wiper Assembly Replacement139
Windshield Washer Assembly Replacement141
Skylight Wiper Assembly Replacement142
Troubleshooting142
Section 4143
Description144
Lattice Extension144
Optional Lattice Extension144
Theory of Operation144
Extension144
Boom Retraction144
Maintenance144
Removal144
Boom Disassembly145
Boom Nose Sheaves152
Assembly153
Installation156
Functional Check156
Inspection156
Boom Alignment and Servicing156
Cam Operated Check Valve Adjustment157
Stop Block Adjustment157
Front Upper Pad Adjustment157
Rear Side Wear Pad Adjustment157
Jib and Retraction Cable157
Maintenance157
Inspection157
Adjustment158
Telescope Circuit159
Description159
Theory of Operation159
Maintenance159
Lift Circuit162
Description162
Theory of Operation162
Maintenance162
Auxiliary Boom Nose166
Description166
Installing the Bi-Fold Manual Jib167
Checking the Transport Condition167
Jib Erecting and Stowing Procedure169
General Warnings169
Preparing the Crane for Jib Erection Procedure169
Erecting Procedure169
Stowing Procedure174
Raising and Lowering the Hydraulic Jib178
Transportation on a Separate Vehicle178
Lifting Limit Switch on the Lattice Extension179
Folding Out/In the Deflection Sheaves on the 10 M (33 Ft) Section179
Positioning/Remove the Hoist Cable180
Setting the Folding Swingaway Extension Offset180
Removing the Bi-Fold Manual Jib182
Installing/Removing 5 M (16 Ft) Sections182
Installing the 5 M (16 Ft) Sections182
Removing the 5 M (16 Ft) Sections183
Jib (Additional Equipment)183
Identification and Slinging Points183
Assembly of Jibs183
Electrical Connection at the Jib184
Unfolding/Folding the Deflection Sheave on the 5 M (16 Ft) Section185
Positioning/Removing the Hoist Cable186
Traveling with Manually Offsettable Jib And/Or Inserts Erected187
Auxiliary Single-Sheave Boom Nose (Additional Equipment)187
Identification187
Installing/Removing Auxiliary Single-Sheave Boom Nose187
Removing the Auxiliary Single-Sheave Boom Nose188
Rigging the Auxiliary Single-Sheave Boom Nose188
Rigging in Transport Position188
Rigging the Auxiliary Single-Sheave Boom188
Rigging in Working Position189
Attaching and Removing Hoist Cable190
Possible Reeving Methods on the Auxiliary Single-Sheave Boom Nose190
Lifting Limit Switch190
Raising and Setting down the Main Boom with Rigged Lattice Extension191
Telescoping with Rigged Lattice Extension191
Operating with the Lattice Extension191
Procedure if the Permissible Wind Speed Is Exceeded191
Monthly Maintenance Work192
Hookblock193
Description193
Maintenance193
Maintenance195
Description195
Theory of Operation195
Warm-Up Procedure195
Removal196
Installation196
Functional Check197
Servicing197
Description197
Hoist to Boom Alignment198
Preparation198
Tools Required198
Procedure198
Piston Motor and Control Valve200
Description200
Maintenance200
Idler Drum and Cable Follower201
Description201
Maintenance201
Hoist Drum Indicator System204
Description204
Maintenance204
Hoist Control Valves205
Description205
Counterweight205
Maintenance205
Mounting the Counterweight205
Stowing the Counterweight206
Description209
Theory of Operation209
Swing Drive209
Swing Brake210
Maintenance212
Troubleshooting212
Swing Motor216
Description216
Maintenance216
Swing Gearbox and Brake217
Description217
Maintenance217
Swing Bearing219
Description219
Maintenance219
Swivels224
Description224
Hydraulic Swivel226
Description226
Theory of Operation226
Maintenance226
Integral W/Hydraulic Water Swivel227
Description227
Maintenance227
Installation228
Electrical Swivel228
Description228
Theory of Operation228
Maintenance229
Swing Lock Pin230
Description230
Maintenance230
360° Swing Lock Control (Positive Lock Type) (Optional)230
Description233
Removal234
Maintenance234
Description236
Installation239
Removal239
Engine Drive Belts240
Engine Control System241
Description241
Fuel System242
Description242
Maintenance242
Air Intake System245
Description245
Maintenance245
QSM Engine Muffler250
Removal250
Installation251
ISX Engine Diesel Particulate Filter/Selective Catalyst Reduction Assembly251
Removal251
Installation253
Diesel Exhaust Fluid (DEF) Tank254
Description254
Removal254
Installation254
Water Cooling System255
Description255
Maintenance255
Winter Front Grill Cover259
Pump/Pto Clutch Assembly (ISX Engine)262
PTO Clutch Lubrication262
Pump/Pto Clutch Replacement262
Air Valve Replacement264
Drive Train265
Description265
Maintenance265
Clutch267
Description267
Theory of Operation267
Maintenance269
Clutch Adjustment Procedure275
General Maintenance276
Gearshift276
Description276
Maintenance276
Manual Transmission277
Description277
Theory of Operation277
Maintenance277
Lubrication281
Preventive Maintenance281
Transmission Shift Air System282
Description282
Theory of Operation282
Front Axle and Suspension283
Maintenance284
Steering System294
Description294
Maintenance294
Functional Check296
Steering Pump296
Description296
Steering Gearbox296
Maintenance296
Steer Cylinder298
Description298
Maintenance298
Rear Axle and Suspension298
Wheels and Tires301
Description301
Maintenance301
Brakes303
Description303
Maintenance303
Front Brakes305
Rear Brakes310
Description310
Automatic Slack Adjuster (Front)313
Description313
Maintenance314
Removal314
Installation314
Adjustment Procedures314
Installation318
Adjustment Procedures318
Automatic Slack Adjuster (Rear)321
Description321
Maintenance323
Air System328
Description328
Theory of Operation328
Maintenance328
Air System Operational Test330
Air System Components332
Description332
Maintenance337
Outriggers342
Description342
Theory of Operation342
Maintenance344
Outrigger Beam347
Description347
Theory of Operation347
Maintenance347
Extension Cylinder351
Description351
Outrigger Monitoring System (Optional-Standard in North America)352
Description352
Removal352
Installation352
Outrigger Stabilizer Cylinder352
Maintenance353
Installation353
Outrigger System Valves354
Description354
Center Front Stabilizer Cylinder355
Description355
Maintenance355
General359
Arctic Conditions below -15°C (5°F)359
Standard Lubricants Package360
Environmental Protection361
Lubrication Points362
Surface Protection for Cylinder Rods362
Carrier Lubrication363
Hydraulic Lubrication367
Superstructure Lubrication368
Boom, Jib, and Boom Accessories Lubrication369
Wire Rope Lubrication370
CARWELL® Rust Inhibitor373
Protecting Cranes from Corrosion373
Cleaning Procedures373
Inspection and Repair374
Application374
Areas of Application374

Manitowoc Grove TMS800E - Page 36

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