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Grove TMS9000-2
Manitowoc Grove TMS9000-2 - User Manual
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Service Manual
Grove TMS9000-2
Fo
r
Reference
Only
2
Table of Contents
Main Page
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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Manitowoc Grove TMS9000-2 Specifications
General
Brand
Manitowoc
Model
Grove TMS9000-2
Category
Construction Equipment
Language
English
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