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Grove Crane TMS 9000E Service Manual 508-00 – PDF DOWNLOAD
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Description
Grove Crane TMS 9000E Service Manual 508-00 – PDF DOWNLOAD
FILE DETAILS:
Grove Crane TMS 9000E Service Manual 508-00 – PDF DOWNLOAD
Language : English
Pages : 344
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Grove Crane TMS 9000E Service Manual 508-00 – PDF DOWNLOAD
USING THE MAINTENANCE MANUAL:
- This manual is not designed to replace proper training and instruction!
Truck crane maintenance personnel are required to have relevant specialised knowledge of proper
safety procedures! - Read sections 1 and 2 carefully before beginning maintenance work.
- Maintenance work on the lattice extensions is described in the operating instructions for lattice
extensions.
SAFETY MESSAGES:
General:
- The importance of safe operation and maintenance cannot be overemphasized. Carelessness or neglect
on the part of operators, job supervisors and planners, rigging personnel, and job site workers can
result in their death or injury and costly damage to the crane and property. - To alert personnel to hazardous operating practices and maintenance procedures, safety messages
are used throughout the manual. Each safety message contains a safety alert symbol and a signal
word to identify the hazard’s degree of seriousness.
TABLE OF CONTENTS:
Table of Contents........................................................................................................... 3 SECTION 1................................................................................................................... 11 General Instructions.................................................................................................... 11 Using the Maintenance Manual........................................................................................ 11 Safety Messages..................................................................................................... 11 General......................................................................................................... 11 Safety Alert Symbol............................................................................................. 11 Signal Words.................................................................................................... 11 Manitowoc customer support maintenance instructions................................................................. 11 Definitions of stated directions.................................................................................... 12 SECTION 2................................................................................................................... 13 Safety and Environmental Protection..................................................................................... 13 Safety Rules........................................................................................................ 13 Handling Substances Which Are Harmful to the Environment............................................................ 14 What do environmentally harmful substances include?............................................................. 14 Use suitable equipment...................................................................................... 14 Filling and draining........................................................................................ 14 Collect and store separately................................................................................ 14 Disposal.................................................................................................... 14 SECTION 3................................................................................................................... 15 Cleaning................................................................................................................ 15 Overview of the Components That Are Easily Damaged When Cleaning.................................................... 16 On Truck Crane.................................................................................................. 16 SECTION 4................................................................................................................... 17 Run-in Regulations...................................................................................................... 17 Breaking in a New Crane............................................................................................. 17 SECTION 5................................................................................................................... 19 Superstructure Maintenance.............................................................................................. 19 Superstructure maintenance overview................................................................................. 19 Maintenance Intervals............................................................................................... 19 Maintenance plans................................................................................................... 21 Maintenance plan D: Daily/Before Commissioning.................................................................. 21 Maintenance plan W: Weekly...................................................................................... 22 Maintenance Plan M 1: Monthly/ After 100 Operating Hours/Approximately 2,000 km (1240 mi)....................... 23 Maintenance Plan M 3: Every 3 Months/After 300 Operating Hours/ 5 000 - 6 000 km (3,100 - 3,730 mi)............. 24 Maintenance Plan M 6: Every 6 Months/After 500 Operating Hours/ 10 000 - 12 500 km (6,210 - 7,770 mi)........... 25 Maintenance Plan M 12: Every 12 Months/ After 1,000 Operating Hours/ 20 000 - 25 000 km (12,430 - 15,530 mi).... 26 Maintenance and Inspection Plan Y 2: Every 24 Months/After 100 000 - 125 000 km (62,150 - 77,800 mi)............ 27 Maintenance and Inspection Plan Y 3: Every 36 Months/After 3,000 Operating Hours................................ 28 Maintenance and Inspection Plan Y 5: Every 60 Months/After 5,000 Operating Hours................................ 29 Maintenance and Inspection Plan Y 6: Every 72 Months/After 6,000 Operating Hours................................ 30 Periodic inspections................................................................................................ 30 Load hook inspection............................................................................................ 31 Measures required for hoist monitoring.............................................................................. 32 Theoretical service life........................................................................................ 32 Proportion of the theoretical service life used................................................................. 32 Determining the operating conditions (collective load)...................................................... 33 Determining the actual operating hours Ti................................................................... 33 Operating hour counter separate for crane operation..................................................... 34 Operating hour counter for driving and crane operation together......................................... 34 Determining the proportion of the theoretical service life used......................................... 35 Alternative provision................................................................................... 35 Example......................................................................................................... 36 Table example to determine the remaining theoretical service life on hoist no. 1 (main hoist)................... 37 SECTION 6................................................................................................................... 39 Lubricants and Fuels.................................................................................................... 39 Lubricant table..................................................................................................... 39 Process materials................................................................................................... 40 Fuel............................................................................................................ 40 Engine coolant and mixtures..................................................................................... 40 Windscreen washing system mixtures.............................................................................. 40 Fuel for crane cab heating system............................................................................... 40 SECTION 7................................................................................................................... 41 Description of Crane.................................................................................................... 41 Overview of the operating and display elements...................................................................... 41 Axle Weight Distribution Table...................................................................................... 41 SECTION 8................................................................................................................... 45 Superstructure.......................................................................................................... 45 Description of maintenance work on the superstructure............................................................... 45 Hoists.......................................................................................................... 45 Hoists – Oil Level Check........................................................................................ 45 If the oil level is too low:................................................................................ 46 Checking for Leaks.............................................................................................. 46 Checking the Hoist Brake........................................................................................ 46 Lubricating Hoist Gearbox....................................................................................... 46 Hoists – Oil Change............................................................................................. 47 Changing the oil in the hoist............................................................................... 47 Checking the oil............................................................................................ 47 Carrying Out Partial Inspection of Hoists....................................................................... 47 Carrying Out General Inspection of Hoists....................................................................... 47 Swinging gear....................................................................................................... 48 Swinging Gear – Oil Level Check................................................................................. 48 If the oil level is too low:................................................................................ 48 If the oil level is too low:................................................................................ 48 Checking for Leaks.............................................................................................. 49 Lubricating the Swing Gear Pinion and Gear Rim.................................................................. 49 First lubrication:.......................................................................................... 49 Subsequent lubrication:..................................................................................... 49 Swing gear – Oil Change......................................................................................... 50 Oil change, swing gear transmission......................................................................... 50 Checking the oil............................................................................................ 50 Oil change, swing gear brake................................................................................ 50 Swing gear brake function check..................................................................................... 51 new york house lock................................................................................................. 51 Torquing Turntable Bolts............................................................................................ 51 Torque Values................................................................................................... 52 Inner Race Torquing......................................................................................... 52 Outer Race Torquing......................................................................................... 52 Hydraulic system of the superstructure.............................................................................. 54 Checking for Leaks.............................................................................................. 54 Bleeding the lift cylinder.......................................................................................... 54 Prerequisites................................................................................................... 54 Bleeding the Piston Rod Chamber................................................................................. 54 Bleeding the Piston Head Chamber................................................................................ 54 Bleeding the Telescoping Cylinders.............................................................................. 55 Prerequisites............................................................................................... 55 Bleeding Procedure.......................................................................................... 55 Telescoping status.......................................................................................... 56 Vent Screw Position No. 1............................................................................... 56 Vent Screw Position No. 2............................................................................... 56 Change the hydraulic oil filter..................................................................................... 56 Hydraulic Oil Filter for Control Circuit........................................................................ 57 Main boom........................................................................................................... 58 Notes on Maintenance of the Main Boom........................................................................... 58 Location of the Lubricating Points.......................................................................... 58 Locking pins............................................................................................ 58 Telescope Slide Faces................................................................................... 59 Prerequisites............................................................................................... 59 Lubricating the locking pins........................................................................................ 59 Pins in Telescopic Section IV to II............................................................................. 60 Pins in Telescopic Section I.................................................................................... 60 Lubricating the Telescope Slide Faces........................................................................... 60 Lubricating Telescopic Section II to IV..................................................................... 60 Lubricating Telescopic Section I............................................................................ 61 Check the locking system............................................................................................ 61 Hoist ropes......................................................................................................... 61 Checking the Position of Sheaves and Rope Drums................................................................. 61 Checking Status................................................................................................. 62 Assessing the Condition of the Hoist Rope................................................................... 63 Replacing the Hoist Rope........................................................................................ 68 Setting the Lowering Limit Switch............................................................................... 70 Lowering Limit Switch Function Control.......................................................................... 70 rated capacity limiter.............................................................................................. 70 Maintenance of the Slip Ring Assembly of the Cable Drum......................................................... 70 Prerequisites............................................................................................... 71 Maintenance of the Slip Ring Assembly....................................................................... 71 Lubricating the Swing Angle Sensor.............................................................................. 72 Central lubrication system.......................................................................................... 73 Hook blocks......................................................................................................... 73 Lubrication..................................................................................................... 73 Superstructure air conditioning system (additional equipment)....................................................... 73 Checking Hoses.................................................................................................. 73 Other maintenance work.............................................................................................. 73 Checking for Correct Operation of the Auxiliary Heater (Additional Equipment)................................... 73 Lubricating the Piston Rod of the Lifting Cylinder.............................................................. 74 SECTION 9................................................................................................................... 75 Longer Periods Out of Operation......................................................................................... 75 Before the truck crane is put out of operation...................................................................... 75 If the crane is out of operation for more than 12 months:....................................................... 75 Before putting the truck crane back into operation.................................................................. 75 SECTION 10.................................................................................................................. 77 Tightening Torques...................................................................................................... 77 Fasteners and Torque Values......................................................................................... 77 Torque Wrenches..................................................................................................... 77 Torque Values....................................................................................................... 78 SECTION 11.................................................................................................................. 83 Engine.................................................................................................................. 83 DESCRIPTION......................................................................................................... 83 MAINTENANCE......................................................................................................... 84 Removal......................................................................................................... 84 Installation.................................................................................................... 87 Engine Drive Belts.............................................................................................. 87 ENGINE CONTROL SYSTEM............................................................................................... 88 Description..................................................................................................... 88 Functional Operation............................................................................................ 88 Engine Control System Switches and Indicator Lights............................................................. 89 Engine Stop Indicator....................................................................................... 89 Engine Warning Indicator.................................................................................... 89 Filter Regeneration/High Exhaust Indicator.................................................................. 89 Engine Idle/Diagnostic Switch............................................................................... 89 Engine Increment/Decrement Switch........................................................................... 89 FUEL SYSTEM......................................................................................................... 89 Description..................................................................................................... 89 Fuel Tank................................................................................................... 89 Injection Fuel Pump......................................................................................... 89 Fuel Filter-Water Separator................................................................................. 90 Maintenance..................................................................................................... 90 Fuel Tank................................................................................................... 90 Removal................................................................................................. 90 Installation............................................................................................ 90 Fuel Filter-Water Separator................................................................................. 90 Draining................................................................................................ 90 Filter Change Procedure................................................................................. 90 AIR INTAKE SYSTEM................................................................................................... 92 Description..................................................................................................... 92 Maintenance......................................................................................................... 92 Troubleshooting................................................................................................. 92 Check For Filter Restriction.................................................................................... 92 Filter Element Replacement...................................................................................... 92 Element Cleaning................................................................................................ 93 Air Cleaner Body................................................................................................ 93 Vacuator Valve.................................................................................................. 93 Duct Work....................................................................................................... 93 Exhaust System...................................................................................................... 95 Description..................................................................................................... 95 ISX System Removal.............................................................................................. 95 ISX System Installation......................................................................................... 95 QSM System Removal.............................................................................................. 95 ISX System Installation......................................................................................... 95 Slip Joint Exhaust Connectors................................................................................... 95 After 1000 Hours, or One Year............................................................................... 95 2000 Hours or 2 Years....................................................................................... 96 4000 Hours or 4 Years....................................................................................... 96 5000 Hours or 5 Years....................................................................................... 96 ISX Exhaust System.............................................................................................. 96 QSM Exhaust System.............................................................................................. 97 Aftertreatment Diesel Exhaust Fluid (DEF)........................................................................... 98 DEF Tank........................................................................................................ 98 Description................................................................................................. 98 Removal..................................................................................................... 98 Installation................................................................................................ 98 DEF Dosing Unit Filter.......................................................................................... 99 Initial Check............................................................................................... 99 Preparatory Steps........................................................................................... 99 Remove......................................................................................................100 Clean and Inspect for Reuse.................................................................................100 Install.....................................................................................................100 Finishing Steps.............................................................................................100 Water Cooling System................................................................................................101 Description.....................................................................................................101 Maintenance.....................................................................................................101 General.....................................................................................................101 Effects Of Cooling System Neglect...........................................................................101 Overheating.................................................................................................101 Overcooling.................................................................................................101 Rust Prevention.............................................................................................101 Engine Antifreeze/Coolant Fill Procedure (when level is low)................................................101 Engine Antifreeze/Coolant Fill Procedure (after a complete draining of the system)..........................102 Antifreeze/Supplemental Coolant Additives Maintenance Summary...............................................102 Cooling System Level Check Interval.....................................................................102 SCA Level Check/Coolant Filter Change Interval..........................................................102 Cleaning........................................................................................................103 Pressure Flushing...........................................................................................103 Component Inspection............................................................................................104 Radiator/Recovery Tank......................................................................................104 Engine Water Jacket.........................................................................................104 Water Pump..................................................................................................104 Fans and Belts..............................................................................................104 Thermostat..................................................................................................104 Hoses and Clamps............................................................................................104 Test Equipment..............................................................................................105 Antifreeze/Coolant..........................................................................................105 Coolant Filter..............................................................................................105 Radiator Assembly Removal and Installation......................................................................105 Removal.....................................................................................................105 Installation................................................................................................108 Pump/PTO Clutch Assembly (ISX Engine)...............................................................................109 PTO Clutch Lubrication..........................................................................................109 Pump/PTO Clutch Replacement.....................................................................................109 Removal.....................................................................................................109 Disassembly.................................................................................................110 Assembly....................................................................................................110 Installation................................................................................................110 Pump/PTO Assembly (QSM Engine)......................................................................................111 Pump/PTO Replacement............................................................................................111 Removal.....................................................................................................111 Installation................................................................................................111 Air Valve Replacement...........................................................................................112 Removal.....................................................................................................112 Installation................................................................................................112 SECTION 12..................................................................................................................113 Drive Train.............................................................................................................113 Description.........................................................................................................113 Maintenance.........................................................................................................113 Drive Lines.....................................................................................................113 Removal.....................................................................................................113 Installation................................................................................................113 Lubrication.................................................................................................113 Clutch..............................................................................................................115 Description.....................................................................................................115 Theory Of Operation.............................................................................................115 Maintenance.....................................................................................................117 Troubleshooting.............................................................................................117 Removal.....................................................................................................120 Inspection..................................................................................................120 Installation................................................................................................121 Clutch Adjustment Procedure.....................................................................................123 Clutch Adjustment Inspection Procedure......................................................................124 General Maintenance.............................................................................................124 Gearshift...........................................................................................................124 Description.....................................................................................................124 Maintenance.....................................................................................................124 Troubleshooting.............................................................................................124 Removal.....................................................................................................125 Installation................................................................................................125 Manual Transmission.................................................................................................125 Description.....................................................................................................125 Theory of Operation.............................................................................................125 Maintenance.....................................................................................................125 Troubleshooting.............................................................................................125 Removal of the Transmission.................................................................................129 Special Procedure for Changing Clutch (Input) Shaft.........................................................129 General.................................................................................................129 Disassembly.............................................................................................129 Assembly................................................................................................129 Installation of the Transmission............................................................................129 Lubrication.....................................................................................................129 General.....................................................................................................129 Draining Oil................................................................................................130 Refilling Oil...............................................................................................130 Adding Oil..................................................................................................130 Operating Temperature.......................................................................................130 Proper Lubrication..........................................................................................130 Preventive Maintenance..........................................................................................130 Transmission Shift Air System.......................................................................................130 Description.....................................................................................................130 Theory of Operation.............................................................................................130 SECTION 13..................................................................................................................133 Front Axle, Suspension, and Steering....................................................................................133 Front Axle..........................................................................................................133 Suspension......................................................................................................133 Maintenance.........................................................................................................133 General.........................................................................................................133 Beam Center Cap Fasteners...................................................................................133 Beam End Connections and Bushings...........................................................................134 Saddle Assembly End Cap Fasteners...........................................................................134 Beam Center Bushings........................................................................................134 Beam Center Cross Tube......................................................................................134 Air Bags....................................................................................................134 Height Control Valves.......................................................................................134 Shock Absorbers.............................................................................................134 Removal.........................................................................................................136 Disassembly.....................................................................................................136 Assembly........................................................................................................136 Installation....................................................................................................136 Axle Alignment Procedure........................................................................................137 Toe-In Adjustment...........................................................................................139 Axle Stop Settings..........................................................................................139 Drag Link Installation and Axle Synchronization.............................................................139 Air Ride Adjustment.........................................................................................140 Final Adjustments...........................................................................................140 Setting Axle Stops and Steering Gear Relief Plungers........................................................142 Steering System.....................................................................................................143 Description.....................................................................................................143 Maintenance.....................................................................................................143 Troubleshooting.............................................................................................143 Functional Check............................................................................................145 Steering Pump.......................................................................................................146 Description.....................................................................................................146 Steering Gearbox................................................................................................146 Description.................................................................................................146 Maintenance.....................................................................................................146 Removal.....................................................................................................146 Installation................................................................................................146 Steer Cylinder......................................................................................................147 Description.....................................................................................................147 Maintenance.....................................................................................................147 Removal.....................................................................................................147 Installation................................................................................................147 Wheels And Tires....................................................................................................148 Description.....................................................................................................148 Maintenance.....................................................................................................148 Assemblies..................................................................................................148 SECTION 14..................................................................................................................149 Rear Axle and Suspension................................................................................................149 Description.........................................................................................................149 Rear Axle.......................................................................................................149 Suspension......................................................................................................149 Maintenance.....................................................................................................149 General.....................................................................................................149 Beam Center Cap Fasteners...................................................................................149 Beam End Connections and Bushings...........................................................................149 Saddle Assembly End Cap Fasteners...........................................................................150 Beam Center Bushings........................................................................................150 Beam Center Cross Tube......................................................................................150 Air Bags....................................................................................................150 Height Control Valves.......................................................................................150 Shock Absorbers.............................................................................................150 Removal.........................................................................................................152 Disassembly.....................................................................................................152 Assembly........................................................................................................152 Installation....................................................................................................153 Wheels and Tires....................................................................................................153 Description.....................................................................................................153 Maintenance.........................................................................................................153 Mounting the Wheels on the Axle.................................................................................153 SECTION 15..................................................................................................................155 Brakes..................................................................................................................155 Description.........................................................................................................155 Air Supply......................................................................................................155 Normal Braking..................................................................................................155 Vehicle Parking.................................................................................................155 Anti-lock Braking Systems (ABS).................................................................................155 Automatic Traction Control......................................................................................156 Emergency Braking...............................................................................................156 Maintenance.........................................................................................................156 Non-Asbestos Warning................................................................................................156 Front Brakes........................................................................................................156 Description.....................................................................................................156 Maintenance.....................................................................................................157 Troubleshooting.............................................................................................157 Disassembly.................................................................................................157 Cleaning....................................................................................................159 Inspection..................................................................................................159 Repair/Replacement..........................................................................................161 Assembly....................................................................................................162 Automatic Slack Adjuster............................................................................................162 Description.....................................................................................................162 Maintenance.....................................................................................................162 Removal.....................................................................................................163 Installation................................................................................................163 Adjustment Procedures.......................................................................................163 Brake Applied Stroke Measurement........................................................................163 Brake Free Play Measurement and Adjustment..................................................................164 Removal.....................................................................................................167 Installation................................................................................................168 Adjustment Procedures.......................................................................................168 Brake Applied Stroke Measurement........................................................................168 Brake Free Play Measurement and Adjustment..............................................................169 Rear Brakes.........................................................................................................171 Description.....................................................................................................171 Brakes......................................................................................................171 Spring Brake Actuator.......................................................................................171 Maintenance.....................................................................................................171 Troubleshooting.............................................................................................171 Spring Brake Actuator.......................................................................................172 Manually Caging the Spring Brake............................................................................172 Removal.....................................................................................................172 Installation................................................................................................173 Disassembly.................................................................................................173 Assembly....................................................................................................173 Rear Brake Assembly.............................................................................................174 Disassemble Brakes..........................................................................................174 Brake Shoe Removal..........................................................................................174 Clean and Inspect Parts.....................................................................................175 Inspect Parts...........................................................................................175 Assemble Brakes.............................................................................................175 Camshaft Installation.......................................................................................175 Brake Shoe Installation.....................................................................................176 Anti-Lock Brake System (ABS)/ Automatic Traction Control (ATC)......................................................176 ABS System Description..........................................................................................176 ABS Indicator...............................................................................................177 ATC System Description..........................................................................................178 ATC Operation...............................................................................................178 System Operation............................................................................................178 ATC Valve...................................................................................................178 ATC Indicator...............................................................................................179 Pressure Modulator Valves...................................................................................179 Acceptable Tire Sizes.......................................................................................180 ABS Troubleshooting.............................................................................................180 Diagnostic Connector and ABS Diagnostic Switch Location.....................................................180 Troubleshooting: Blink Codes and Diagnostic Modes...........................................................181 ECU Diagnostics.............................................................................................181 Active Diagnostic Trouble Codes.........................................................................181 Blink Codes.............................................................................................181 Blink Code Switch Activation............................................................................181 Blink Code Timing.......................................................................................181 Diagnostic Modes............................................................................................182 Diagnostic Mode Selection...............................................................................182 Active Diagnostic Trouble Code Mode.....................................................................182 Inactive Diagnostic Trouble Code Mode...................................................................182 Clearing Active Diagnostic Trouble Codes................................................................182 Dynamometer Test Mode...................................................................................182 Reconfigure ECU Mode....................................................................................182 System Configuration Check Mode.............................................................................183 EC-60 Controller Wire Harness Connector Pin Assignments.................................................183 X1 Connector Pin Assignments............................................................................183 X2 Connector Pin Assignments............................................................................183 X3 Connector Pin Assignments............................................................................184 Active or Inactive Diagnostic Trouble Codes: Index..........................................................184 Troubleshooting Diagnostic Trouble Codes: ECU...............................................................184 Troubleshooting Diagnostic Trouble Codes: Wheel Speed Sensors...............................................185 Speed Sensor Repair Tests...................................................................................186 ECU Wire Harness Connector: Speed Sensor Pins...............................................................186 Troubleshooting Diagnostic Trouble Codes: Pressure Modulator Valves.........................................187 Pressure Modulator Valve Repair Test........................................................................188 ECU Wire Harness Connector: Pressure Modulator Valves Pins..................................................188 Troubleshooting Diagnostic Trouble Codes: Traction Control Valves...............................................189 Traction Control Valve Repair Tests.........................................................................190 ECU Wire Harness Connector: Traction Control Valve Pins.....................................................190 Troubleshooting Diagnostic Trouble Codes: Power Supply......................................................190 Power Supply Tests..............................................................................................191 ECU Wire Harness Connector: Power Supply Pins...............................................................191 Troubleshooting Diagnostic Trouble Codes: J1939 Serial Communications...........................................192 J1939 Troubleshooting Tests.................................................................................192 ECU Wire Harness Connector: J1939 Serial Communications Pins................................................192 Troubleshooting Diagnostic Trouble Codes: Miscellaneous.....................................................193 Miscellaneous Troubleshooting...................................................................................194 Stop Lamp Switch Test.......................................................................................194 Dynamometer Test Mode (ATC Indicator Lamp Continuously Illuminated).........................................194 ABS Indicator Lamp..........................................................................................194 PMV Commons.................................................................................................194 Differential Lock Solenoid..................................................................................194 ECU Wire Harness Connector: Miscellaneous Pins..............................................................194 Troubleshooting Wiring..........................................................................................195 ABS/ATC Wiring..............................................................................................195 CAB ECU Wiring Harness Connectors...........................................................................195 ABS Wiring Requirements.....................................................................................195 ABS/ATC Cab Wiring Schematic................................................................................196 ABS/ATC Frame Wiring Schematic..............................................................................197 Special Tools.......................................................................................................198 Tests, Repair and Adjustment....................................................................................198 ABS EC-60 Controller........................................................................................198 Installing a New ABS EC-60 Controller...................................................................198 Reconfiguring EC-60 Controllers.........................................................................198 ATC Valve...................................................................................................198 ABS Modulator Valves........................................................................................199 Leakage Test: M-32 and M-32QR Modulator Valves..........................................................199 Operation Test: M-32 and M-32QR Modulator Valves........................................................200 Electrical Tests: Modulator Valves......................................................................200 ABS Sensor Adjustment.......................................................................................200 Component Removal and Installation..............................................................................201 ATC Valve...................................................................................................201 Removal.................................................................................................201 Installation............................................................................................201 Leak Test: Traction Control Valve.......................................................................201 Traction Control Valve Component Test with Hand- Held Diagnostic Tool...................................201 \Modulator Valves M-32, M-32QR..............................................................................201 Removal.................................................................................................201 Installation............................................................................................201 Wheel Speed Sensor Replacement (Front)......................................................................201 Removal.................................................................................................201 Installation............................................................................................202 Wheel Speed Sensor, Replacement (Rear)......................................................................203 Removal.................................................................................................203 Installation............................................................................................203 SECTION 16..................................................................................................................205 Air System..............................................................................................................205 Description.........................................................................................................205 Theory Of Operation.................................................................................................205 Braking.........................................................................................................207 Maintenance.........................................................................................................208 Leak Detection..................................................................................................208 Air System Operational Test.....................................................................................208 Pressure Warnings and Pressure Build-up.....................................................................208 Air Leakage Test............................................................................................209 Loss of Primary (Rear) Air System...........................................................................210 Loss of Secondary (Front) Air System........................................................................210 Emergency Brake Application.................................................................................210 Air System Components...............................................................................................210 Description.....................................................................................................210 Air Compressor..............................................................................................210 Air Governor................................................................................................210 Air Dryer...................................................................................................211 Reservoirs..................................................................................................211 Low Pressure Indicator Switches.............................................................................212 Stop Light Switch.......................................................................................212 Air Pressure Gauge......................................................................................212 Safety Valve............................................................................................212 Pressure Protection Valve...............................................................................213 Relay Valve.............................................................................................213 Dual Brake Valve........................................................................................214 Park Brake Control Valve................................................................................214 Antilock Modulator......................................................................................214 Traction Control Valve..................................................................................214 Maintenance.....................................................................................................215 Air Compressor..............................................................................................215 Removal.................................................................................................215 Installation............................................................................................215 Air Governor................................................................................................215 Removal.................................................................................................215 Installation............................................................................................215 Operational Test........................................................................................215 Leakage Test............................................................................................215 Air Dryer...................................................................................................215 Removal.................................................................................................215 Installation............................................................................................215 Preventive Maintenance..................................................................................215 Leak Tests..............................................................................................216 Reservoirs..................................................................................................216 Removal.................................................................................................216 Maintenance.............................................................................................216 Cleaning................................................................................................216 Installation............................................................................................216 Low Pressure Indicator Switches.............................................................................216 Operating and Leakage Checks............................................................................216 Removal.................................................................................................216 Installation............................................................................................217 Preventive Maintenance..................................................................................217 Stop Light Switch...........................................................................................217 Operational Test........................................................................................217 Leakage Test............................................................................................217 Removal.................................................................................................217 Installation............................................................................................217 Air Pressure Gauge..........................................................................................217 Removal.................................................................................................217 Installation............................................................................................217 Functional Check........................................................................................217 Safety Valve................................................................................................217 Removal.................................................................................................217 Installation............................................................................................217 Operating and Leakage Checks............................................................................217 Tire Inflation Pressure Protection Valve....................................................................217 Removal.................................................................................................217 Installation............................................................................................217 Operational Check.......................................................................................217 Leakage Test............................................................................................218 Preventive Maintenance..................................................................................218 Relay Valve.................................................................................................218 Removal.................................................................................................218 Inspection..............................................................................................218 Installation............................................................................................218 Operating Test..........................................................................................218 Leakage Test............................................................................................218 Preventive Maintenance..................................................................................218 Spring Brake Control Valve..................................................................................218 Removal.................................................................................................218 Inspection..............................................................................................218 Installation............................................................................................218 Operating Test..........................................................................................218 Leakage Test............................................................................................219 Dual Brake Valve................................................................................................219 Removal.....................................................................................................219 Installation................................................................................................219 Operating Test..............................................................................................219 Leakage Test............................................................................................219 Preventive Maintenance..................................................................................219 Park Brake Control Valve....................................................................................220 Removal.................................................................................................220 Installation............................................................................................220 Operating and Leakage Check.............................................................................220 Preventive Maintenance..................................................................................220 PTO Clutch Air Valve................................................................................................220 SECTION 17..................................................................................................................221 Hydraulic System........................................................................................................221 Description.........................................................................................................221 Maintenance.....................................................................................................223 Hydraulic Oil Recommendations...............................................................................223 Draining and Flushing...........................................................................................223 Removing Air from the Hydraulic System..........................................................................224 Parts Replacement...............................................................................................225 Supply Pressure And Return Circuit..................................................................................225 Description.....................................................................................................225 Hydraulic Reservoir and Filter..................................................................................225 Pump Distribution...............................................................................................225 No. 1 and 2 Pump............................................................................................225 No. 3 Pump..................................................................................................226 Maintenance.........................................................................................................227 Troubleshooting.................................................................................................227 Return Hydraulic Filter Assembly....................................................................................228 Element Removal.................................................................................................228 Element Installation............................................................................................228 Hydraulic Pumps.....................................................................................................230 Description.....................................................................................................230 Maintenance.....................................................................................................230 No. 1 Pump..................................................................................................230 No. 2 Pump..................................................................................................230 Removal.................................................................................................230 Installation............................................................................................230 No. 3 Pump..................................................................................................230 Removal.................................................................................................230 Installation............................................................................................231 Testing After Rebuild or Replacement........................................................................231 Piston Pump Start-up Procedure (Pump No. 1).................................................................231 Carrier Valves......................................................................................................233 General.........................................................................................................233 Auxiliary Radiator Manifold.........................................................................................235 Description.....................................................................................................235 Maintenance.....................................................................................................235 Removal.....................................................................................................235 Installation................................................................................................235 Functional Check............................................................................................235 Outrigger Selector Valve............................................................................................237 Description.....................................................................................................237 Maintenance.....................................................................................................237 Removal.....................................................................................................237 Installation................................................................................................237 Functional Check............................................................................................237 Outrigger Control Manifold..........................................................................................239 Description.....................................................................................................239 Maintenance.....................................................................................................239 Removal.....................................................................................................239 Inspection..................................................................................................239 Installation................................................................................................239 Functional Check............................................................................................239 Pilot Operated Check Valve..........................................................................................241 Description.....................................................................................................241 Maintenance.....................................................................................................241 Removal.....................................................................................................241 Installation................................................................................................242 Front Center Stabilizer Relief Valve................................................................................243 Description.....................................................................................................243 Maintenance.....................................................................................................243 Removal.....................................................................................................243 Installation................................................................................................243 Superstructure Valves...............................................................................................244 Turntable Hydraulic System......................................................................................244 Crane Control...................................................................................................246 Cylinders...........................................................................................................249 General.........................................................................................................249 Maintenance.....................................................................................................249 General.....................................................................................................249 Cylinder Rod-Surface Protection.............................................................................250 Leakage Check...............................................................................................250 Temperature Effects On Hydraulic Cylinders..................................................................250 Steer Cylinder......................................................................................................252 Description.....................................................................................................252 Maintenance.....................................................................................................252 Disassembly.................................................................................................252 Inspection..................................................................................................254 Assembly....................................................................................................254 Outrigger Extension Cylinder........................................................................................255 Description.....................................................................................................255 Maintenance.....................................................................................................255 Disassembly.................................................................................................255 Upper Barrel............................................................................................255 Lower Barrel............................................................................................255 Inspection..............................................................................................255 Assembly....................................................................................................257 Lower Barrel............................................................................................257 Upper Barrel............................................................................................257 Outrigger Stabilizer Cylinder.......................................................................................258 Description.....................................................................................................258 Maintenance.....................................................................................................258 Disassembly.................................................................................................258 Inspection..................................................................................................260 Assembly....................................................................................................260 Center Front Stabilizer Cylinder....................................................................................262 Description.....................................................................................................262 Maintenance.....................................................................................................262 Disassembly.................................................................................................262 Inspection..................................................................................................264 Assembly....................................................................................................264 Functional Check............................................................................................265 Lift Cylinder.......................................................................................................265 Description.....................................................................................................265 Maintenance.....................................................................................................265 Disassembly.................................................................................................265 Inspection..................................................................................................267 Assembly....................................................................................................267 Differential Cylinder...............................................................................................268 Description.....................................................................................................268 Telescope Cylinder..................................................................................................269 Description.....................................................................................................269 SECTION 18..................................................................................................................271 Pressure Setting Procedures.............................................................................................271 OBJECTIVE...........................................................................................................271 EQUIPMENT.......................................................................................................271 Carrier Notes...................................................................................................272 Carrier Hydraulic Pressure Setting Procedures.......................................................................274 A. Procedure for checking/setting the outrigger/swing pressures.................................................274 B. Procedure for checking/setting the front steer pressure......................................................274 C. Procedure for checking/setting the center front stabilizer pressure..........................................275 Superstructure Hydraulic System.....................................................................................276 D. Procedure for checking/setting pump differential pressure....................................................279 E. Procedure for checking/setting pump cut- off pressure........................................................281 F. Procedure for checking/setting control pressure..............................................................282 G. Procedure for checking/setting main hoist lower pressure.....................................................283 H. Procedure for checking/setting aux hoist lower pressure......................................................284 I. Procedure for checking/setting tele in/out pressure..........................................................285 J. Procedure for checking/setting tele pinning pressure.........................................................286 K. Procedure for checking/setting lift raise pressure...........................................................287 L. Procedure for checking/setting counterweight raise/lower pressure............................................287 M. Procedure for checking/setting cab tilt raise/lower pressure.................................................288 N. Procedure for checking/setting luffing jib out/in pressure...................................................289 O. Procedure for checking/setting swing pressure................................................................290 SECTION 19..................................................................................................................291 Outriggers..............................................................................................................291 Description.........................................................................................................291 Theory Of Operation.................................................................................................291 Maintenance.........................................................................................................292 Troubleshooting.................................................................................................292 Outrigger Beam (with Adjustable Wear Pads)......................................................................295 Removal.....................................................................................................295 Disassembly.................................................................................................296 Inspection..................................................................................................297 Assembly....................................................................................................297 Installation................................................................................................298 Wear Pad Adjustment.........................................................................................298 Extension Cylinder..................................................................................................299 Description.....................................................................................................299 Maintenance.....................................................................................................299 Removal.....................................................................................................299 Installation................................................................................................299 Functional Check............................................................................................299 Outrigger Stabilizer Cylinder.......................................................................................299 Description.....................................................................................................299 Maintenance.....................................................................................................299 Removal.....................................................................................................299 Installation................................................................................................300 Functional Check............................................................................................300 Center Front Stabilizer Cylinder....................................................................................300 Description.....................................................................................................300 Maintenance.....................................................................................................300 Removal.....................................................................................................300 Installation................................................................................................301 Functional Check................................................................................................301 Outrigger Monitoring System (Optional—Standard in North America)....................................................303 Description.....................................................................................................303 OMS String Potentiometers.......................................................................................303 Removal.....................................................................................................303 Installation................................................................................................303 SECTION 20..................................................................................................................305 Electrical System.......................................................................................................305 Description.........................................................................................................305 Carrier.........................................................................................................305 General.....................................................................................................305 Alternator..................................................................................................305 Batteries...................................................................................................305 Carrier Power Panel and Fuse Panels.........................................................................305 Carrier Power Panel.........................................................................................305 Relays..................................................................................................305 Fuse and Fuse & Relay Panels............................................................................307 Superstructure Fuse and Relay Box...........................................................................309 Anti-Lock Brake System (ABS)................................................................................310 Electronic Control Unit (ECU)...........................................................................310 Diagnostic Connector....................................................................................310 Wheel Speed Sensor and Tone Ring........................................................................311 Maintenance.........................................................................................................311 General.........................................................................................................311 General Troubleshooting.........................................................................................311 Troubleshooting Engine Starting Problems........................................................................312 Troubleshooting Engine Charging Problems........................................................................312 Troubleshooting Accessories.....................................................................................313 Troubleshooting Swivel-Caused Electrical Problems...............................................................313 Connector Troubleshooting.......................................................................................314 Troubleshooting Lights..........................................................................................314 Troubleshooting Gauges and Meters...............................................................................314 Troubleshooting Alarms, Indicators, and Emergency Components....................................................315 Troubleshooting Crane Components and Accessories................................................................315 Tools for Troubleshooting.......................................................................................316 Alternator Replacement..........................................................................................316 Removal.....................................................................................................316 Installation................................................................................................316 Check.......................................................................................................317 Starter Replacement.............................................................................................317 Removal.....................................................................................................317 Installation................................................................................................317 Check.......................................................................................................317 Battery Replacement.............................................................................................317 Removal.....................................................................................................317 Installation................................................................................................318 Relay Panel Component Replacement...............................................................................319 Accessory Relay and Flasher Replacement.....................................................................319 Buzzer Replacement..........................................................................................319 Plug-in Relays Replacement..................................................................................319 Instrument Replacement..........................................................................................319 Removal.....................................................................................................319 Inspection..................................................................................................319 Installation................................................................................................319 Check.......................................................................................................319 Switch Replacement..................................................................................................319 Rocker Switch...................................................................................................319 Removal.....................................................................................................319 Inspection..................................................................................................320 Installation................................................................................................320 Check.......................................................................................................320 All Other Switches..............................................................................................320 Removal.....................................................................................................320 Inspection..................................................................................................320 Installation................................................................................................320 Check.......................................................................................................320 Windshield Wiper Assembly Replacement...............................................................................320 Removal.........................................................................................................320 Inspection......................................................................................................322 Installation....................................................................................................322 Check...........................................................................................................322 Windshield Washer Assembly Replacement..............................................................................322 Removal.........................................................................................................322 Inspection......................................................................................................322 Installation....................................................................................................322 Check...........................................................................................................322 SECTION 21..................................................................................................................323 Lubrication.............................................................................................................323 GENERAL.............................................................................................................323 Environmental Protection............................................................................................323 Arctic Conditions Below -18°C (0°F).................................................................................323 LUBRICATION POINTS..................................................................................................324 Carrier Lubrication.............................................................................................325 Hydraulic Lubrication...........................................................................................330 Superstructure Lubrication......................................................................................331 Boom, Boom Extension, and Boom Accessories Lubrication..........................................................335 Boom Locking Pins Lubrication Procedure.............................................................................336 Preparing the Crane.............................................................................................336 Lubricating Tele Locking Pin 4..................................................................................336 Lubricating Tele Locking Pin 3..................................................................................337 Lubricating Tele Locking Pin 1 and 2............................................................................338 Wire Rope Lubrication...............................................................................................339 Carwell® Rust Inhibitor.............................................................................................339 Protecting Cranes From Corrosion................................................................................339 Cleaning Procedures.............................................................................................340 Inspection and Repair...........................................................................................340 Application.....................................................................................................341 Areas of Application............................................................................................341
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