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Grove TMS800E
Manitowoc Grove TMS800E User Manual
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2-5
TMS800E SER
VICE MAN
UAL
HYDRAULIC SYSTEM
2
GROVE
Published 01-29-2014, Control # 496-00
FIGURE
2-
2
Reference
Only
40
42
Table of Contents
Table of Contents
3
Section 1
15
List of Specifications
16
General
16
Dimensions
16
Capacities
16
Transmission
16
Clutch
16
Engine
16
Axles
16
Brakes
17
Wheel and Tires
17
Swing Gearbox
17
Boom
17
Swivel Assembly
17
Hydraulic Pumps
17
Hoists
17
General Maintenance
24
Cleanliness
24
Removal and Installation
24
Disassembly and Assembly
24
Pressing Parts
24
Locks
24
Wires and Cables
25
Shims
25
Bearings
25
Gaskets
25
Batteries
25
Hydraulic Systems
26
Fatigue of Welded Structures
26
Loctite
26
Fasteners and Torque Values
27
Weld Studs
30
Wire Rope
31
Environmental Conditions
31
Dynamic Shock Loads
31
Lubrication
31
Precautions and Recommendations During Inspection or Replacement
31
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 Rope
33
Installing 35X7 Wire Rope
34
Procedures for Cutting and Preparing 35X7
34
Section 2
37
Description
38
Maintenance
38
Hydraulic Oil Recommendations
38
Removing Air from the Hydraulic System
42
Parts Replacement
42
Directional Control Valves
42
Supply Pressure and Return Circuit
43
Description
43
Maintenance
46
Oil Cooler
49
Description
49
Maintenance
49
Hydraulic Pumps
51
Description QSM Cranes
51
Description ISX Cranes
51
Maintenance QSM Cranes
51
Maintenance ISX Cranes
55
Pump/Pto Clutch Replacement
55
Pump/Pto Clutch Assembly
57
PTO Clutch Lubrication
57
Valves
58
General
58
Pressure Setting Procedures
60
Procedure a - for Checking/Setting the Main Directional Control Valve for Hoist(S) and Boom Lift
61
Procedure B - for Checking/Setting the Outrigger/Swing Pressures
62
Procedure C - for Checking/Setting Air Conditioner Relief Valve Pressure
62
Procedure D - for Checking/Setting the Front Steer Pressure
62
Procedure E - for Checking/Setting Swing Brake Release Pressure
62
Procedure F - for Checking/Setting the Pilot Supply Pressure
62
Procedure G - for Checking/Setting the Piston Pump (ISX Engine)
63
Procedure H - for Checking the Center Front Stabilizer Pressure
63
Procedure I - Procedures for Checking/Setting the Piston Pumps (GSM Engine)
63
Procedure J- for Setting Threshold on Electronic Controllers
64
Procedure for Setting Threshold and Max on Swing Brake Pedal
64
Procedure for Setting Threshold and Max on
64
Directional Control Valves
70
Description
70
Maintenance
70
Check Valves
74
Description
74
Maintenance
74
Outrigger Selector Valve
75
Description
75
Maintenance
75
Outrigger Control Manifold
77
Description
77
Maintenance
77
Pilot Operated Check Valve
79
Description
79
Maintenance
79
Cab Tilt Double Pilot Operated Check Valve
80
Description
80
Maintenance
80
Holding Valves
81
Description
81
Maintenance
81
Accessory Manifold with Swing Directional Control Valve
83
Description
83
Maintenance
83
Motor Control Manifold
86
Description
86
Maintenance
86
Swing Power Brake Valve
87
Description
87
Maintenance
87
Swing Brake Release Valve (Optional)
88
Description
88
Maintenance
88
Needle Valve (Optional)
89
Description
89
Maintenance
89
Needle Valve with Reverse Free Flow Check (Optional)
89
Cylinders
90
General
90
Maintenance
90
Lift Cylinder
93
Description
93
Maintenance
93
Lower Telescope Cylinder
96
Description
96
Maintenance
96
Upper Telescope Cylinder
100
Maintenance
100
Description
100
Maintenance
103
Steer Cylinder
103
Description
103
Maintenance
106
Outrigger Extension Cylinder
106
Description
106
Outrigger Stabilizer Cylinder
110
Description
110
Maintenance
110
Center Front Stabilizer Cylinder
114
Description
114
Maintenance
114
Counterweight Removal Cylinder
118
Description
118
Maintenance
118
Cab Tilt Cylinder
121
Description
121
Maintenance
121
Description
125
General
125
Alternator
125
Batteries
125
Carrier Cab Power Panel
126
Carrier Fuse and Relays
132
Superstructure Fuse and Relay Panel
133
Maintenance
133
General
133
General Troubleshooting
134
Troubleshooting Swivel-Caused Electrical Problems
134
Connector Troubleshooting
134
Diagnostic Lights
136
Alternator Replacement
136
Starter Replacement
137
Battery Replacement
138
Relay Panel Component Replacement
138
Instrument Replacement
139
Switch Replacement
139
Windshield Wiper Assembly Replacement
139
Windshield Washer Assembly Replacement
141
Skylight Wiper Assembly Replacement
142
Troubleshooting
142
Section 4
143
Description
144
Lattice Extension
144
Optional Lattice Extension
144
Theory of Operation
144
Extension
144
Boom Retraction
144
Maintenance
144
Removal
144
Boom Disassembly
145
Boom Nose Sheaves
152
Assembly
153
Installation
156
Functional Check
156
Inspection
156
Boom Alignment and Servicing
156
Cam Operated Check Valve Adjustment
157
Stop Block Adjustment
157
Front Upper Pad Adjustment
157
Rear Side Wear Pad Adjustment
157
Jib and Retraction Cable
157
Maintenance
157
Inspection
157
Adjustment
158
Telescope Circuit
159
Description
159
Theory of Operation
159
Maintenance
159
Lift Circuit
162
Description
162
Theory of Operation
162
Maintenance
162
Auxiliary Boom Nose
166
Description
166
Installing the Bi-Fold Manual Jib
167
Checking the Transport Condition
167
Jib Erecting and Stowing Procedure
169
General Warnings
169
Preparing the Crane for Jib Erection Procedure
169
Erecting Procedure
169
Stowing Procedure
174
Raising and Lowering the Hydraulic Jib
178
Transportation on a Separate Vehicle
178
Lifting Limit Switch on the Lattice Extension
179
Folding Out/In the Deflection Sheaves on the 10 M (33 Ft) Section
179
Positioning/Remove the Hoist Cable
180
Setting the Folding Swingaway Extension Offset
180
Removing the Bi-Fold Manual Jib
182
Installing/Removing 5 M (16 Ft) Sections
182
Installing the 5 M (16 Ft) Sections
182
Removing the 5 M (16 Ft) Sections
183
Jib (Additional Equipment)
183
Identification and Slinging Points
183
Assembly of Jibs
183
Electrical Connection at the Jib
184
Unfolding/Folding the Deflection Sheave on the 5 M (16 Ft) Section
185
Positioning/Removing the Hoist Cable
186
Traveling with Manually Offsettable Jib And/Or Inserts Erected
187
Auxiliary Single-Sheave Boom Nose (Additional Equipment)
187
Identification
187
Installing/Removing Auxiliary Single-Sheave Boom Nose
187
Removing the Auxiliary Single-Sheave Boom Nose
188
Rigging the Auxiliary Single-Sheave Boom Nose
188
Rigging in Transport Position
188
Rigging the Auxiliary Single-Sheave Boom
188
Rigging in Working Position
189
Attaching and Removing Hoist Cable
190
Possible Reeving Methods on the Auxiliary Single-Sheave Boom Nose
190
Lifting Limit Switch
190
Raising and Setting down the Main Boom with Rigged Lattice Extension
191
Telescoping with Rigged Lattice Extension
191
Operating with the Lattice Extension
191
Procedure if the Permissible Wind Speed Is Exceeded
191
Monthly Maintenance Work
192
Hookblock
193
Description
193
Maintenance
193
Maintenance
195
Description
195
Theory of Operation
195
Warm-Up Procedure
195
Removal
196
Installation
196
Functional Check
197
Servicing
197
Description
197
Hoist to Boom Alignment
198
Preparation
198
Tools Required
198
Procedure
198
Piston Motor and Control Valve
200
Description
200
Maintenance
200
Idler Drum and Cable Follower
201
Description
201
Maintenance
201
Hoist Drum Indicator System
204
Description
204
Maintenance
204
Hoist Control Valves
205
Description
205
Counterweight
205
Maintenance
205
Mounting the Counterweight
205
Stowing the Counterweight
206
Description
209
Theory of Operation
209
Swing Drive
209
Swing Brake
210
Maintenance
212
Troubleshooting
212
Swing Motor
216
Description
216
Maintenance
216
Swing Gearbox and Brake
217
Description
217
Maintenance
217
Swing Bearing
219
Description
219
Maintenance
219
Swivels
224
Description
224
Hydraulic Swivel
226
Description
226
Theory of Operation
226
Maintenance
226
Integral W/Hydraulic Water Swivel
227
Description
227
Maintenance
227
Installation
228
Electrical Swivel
228
Description
228
Theory of Operation
228
Maintenance
229
Swing Lock Pin
230
Description
230
Maintenance
230
360° Swing Lock Control (Positive Lock Type) (Optional)
230
Description
233
Removal
234
Maintenance
234
Description
236
Installation
239
Removal
239
Engine Drive Belts
240
Engine Control System
241
Description
241
Fuel System
242
Description
242
Maintenance
242
Air Intake System
245
Description
245
Maintenance
245
QSM Engine Muffler
250
Removal
250
Installation
251
ISX Engine Diesel Particulate Filter/Selective Catalyst Reduction Assembly
251
Removal
251
Installation
253
Diesel Exhaust Fluid (DEF) Tank
254
Description
254
Removal
254
Installation
254
Water Cooling System
255
Description
255
Maintenance
255
Winter Front Grill Cover
259
Pump/Pto Clutch Assembly (ISX Engine)
262
PTO Clutch Lubrication
262
Pump/Pto Clutch Replacement
262
Air Valve Replacement
264
Drive Train
265
Description
265
Maintenance
265
Clutch
267
Description
267
Theory of Operation
267
Maintenance
269
Clutch Adjustment Procedure
275
General Maintenance
276
Gearshift
276
Description
276
Maintenance
276
Manual Transmission
277
Description
277
Theory of Operation
277
Maintenance
277
Lubrication
281
Preventive Maintenance
281
Transmission Shift Air System
282
Description
282
Theory of Operation
282
Front Axle and Suspension
283
Maintenance
284
Steering System
294
Description
294
Maintenance
294
Functional Check
296
Steering Pump
296
Description
296
Steering Gearbox
296
Maintenance
296
Steer Cylinder
298
Description
298
Maintenance
298
Rear Axle and Suspension
298
Wheels and Tires
301
Description
301
Maintenance
301
Brakes
303
Description
303
Maintenance
303
Front Brakes
305
Rear Brakes
310
Description
310
Automatic Slack Adjuster (Front)
313
Description
313
Maintenance
314
Removal
314
Installation
314
Adjustment Procedures
314
Installation
318
Adjustment Procedures
318
Automatic Slack Adjuster (Rear)
321
Description
321
Maintenance
323
Air System
328
Description
328
Theory of Operation
328
Maintenance
328
Air System Operational Test
330
Air System Components
332
Description
332
Maintenance
337
Outriggers
342
Description
342
Theory of Operation
342
Maintenance
344
Outrigger Beam
347
Description
347
Theory of Operation
347
Maintenance
347
Extension Cylinder
351
Description
351
Outrigger Monitoring System (Optional-Standard in North America)
352
Description
352
Removal
352
Installation
352
Outrigger Stabilizer Cylinder
352
Maintenance
353
Installation
353
Outrigger System Valves
354
Description
354
Center Front Stabilizer Cylinder
355
Description
355
Maintenance
355
General
359
Arctic Conditions below -15°C (5°F)
359
Standard Lubricants Package
360
Environmental Protection
361
Lubrication Points
362
Surface Protection for Cylinder Rods
362
Carrier Lubrication
363
Hydraulic Lubrication
367
Superstructure Lubrication
368
Boom, Jib, and Boom Accessories Lubrication
369
Wire Rope Lubrication
370
CARWELL® Rust Inhibitor
373
Protecting Cranes from Corrosion
373
Cleaning Procedures
373
Inspection and Repair
374
Application
374
Areas of Application
374
4
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Manitowoc Grove TMS800E Specifications
General
Brand
Manitowoc
Model
Grove TMS800E
Category
Construction Equipment
Language
English
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