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Grove Crane TMS700E Service & Maintenance Manual – PDF DOWNLOAD
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Description
Grove Crane TMS700E Service & Maintenance Manual – PDF DOWNLOAD
FILE DETAILS:
Grove Crane TMS700E Service & Maintenance Manual – PDF DOWNLOAD
Language : English
Pages : 352
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Grove Crane TMS700E Service & Maintenance Manual – PDF DOWNLOAD
Description:
This Manual provides information for the maintenance of the Model TMS700E13 Series Grove Crane (see Figure 1-1). The lift capacities are listed on the Load Chart in the superstructure cab. The carrier incorporates a high strength, low alloy steel, all welded triple box section steel frame.
- The 8x4x4 carrier utilizes two drive axles and two steer axles. Axle steering is power assist controlled and controlled by the steering wheel. The engine is mounted at the front of the crane carrier and provides motive power through an 11-speed forward and three speed reverse manual transmission.
- The outriggers are single stage, double box, telescopic beam type outriggers. The outriggers have three positions; fully extended, intermediate (50%) extended, and fully retracted. The superstructure is capable of 360 degree rotation in either direction.
- All crane functions, with exception of counterweight removal, are controlled from the fully enclosed cab mounted on the superstructure. One boom is available on the crane; a four section, full power, synchronized, 10.84 to 33.5 m (35 to 110 ft) boom.
- Additional reach is obtained by utilizing one of two optional boom extensions; a 9.75 m (32 ft) fixed length offsettable swingaway and a 9.75 to 17.07 m (32 to 56 ft) folding offsettable swingaway. A 6.1 m (20 ft) and a 12.2 m (40 ft) lattice insert is also available for use between the boom nose and the swingaway.
TABLE OF CONTENTS:
Grove Crane TMS700E Service & Maintenance Manual – PDF DOWNLOAD
SECTION 1............................................................................................... 13 Introduction........................................................................................ 13 Description..................................................................................... 13 List Of Specifications.......................................................................... 14 General......................................................................................... 14 Dimensions...................................................................................... 14 Capacities...................................................................................... 14 Transmission.................................................................................... 14 Clutch.......................................................................................... 14 Engine.......................................................................................... 14 Cummins ISX12-2013 or QSMT3 inline 6 cyl. Turbo-Charged..................................... 14 Axles........................................................................................... 14 Front....................................................................................... 14 Rear........................................................................................ 14 Brakes.......................................................................................... 14 Wheel and Tires................................................................................. 14 Swing Gearbox................................................................................... 14 Boom............................................................................................ 14 Swivel Assembly................................................................................. 14 Hydraulic Pumps................................................................................. 14 Pump #1..................................................................................... 15 Pump #2..................................................................................... 15 Pump #3..................................................................................... 15 Hoists.......................................................................................... 15 General Maintenance............................................................................. 20 Cleanliness................................................................................. 20 Removal and Installation.................................................................... 20 Disassembly and Assembly.................................................................... 20 Pressing parts.............................................................................. 20 Locks....................................................................................... 20 Wires and Cables............................................................................ 21 Shims................................................................................... 21 Bearings.................................................................................... 21 Antifriction Bearings................................................................... 21 Double Row, Tapered Roller.............................................................. 21 Heating Bearings........................................................................ 21 Installation............................................................................ 21 Preload................................................................................. 21 Sleeve Bearings......................................................................... 21 Gaskets..................................................................................... 21 Batteries................................................................................... 21 Hydraulic Systems........................................................................... 22 Cleanliness............................................................................. 22 Keep the System Clean................................................................... 22 Sealing Elements........................................................................ 22 Hydraulic Lines......................................................................... 22 Visual Inspection of Hoses and Fittings................................................. 22 Electrical System........................................................................... 23 Connectors, Harnesses, Wires, and Cables................................................ 23 Fatigue of Welded Structures................................................................ 23 Loctite®.................................................................................... 23 Application of Medium Strength Loctite.................................................. 23 Primer Application.................................................................. 24 Adhesive/Sealant Application........................................................ 24 Fasteners and Torque Values................................................................. 24 Torque Wrenches......................................................................... 24 Torque Values........................................................................... 25 Weld Studs.................................................................................. 27 Wire Rope................................................................................... 28 General................................................................................. 28 Environmental Conditions.................................................................... 28 Dynamic Shock Loads......................................................................... 28 Lubrication................................................................................. 28 Precautions and Recommendations During Inspection or Replacement............................ 28 Wire Rope Inspection (Running Ropes and Pendant Cables)..................................... 29 Frequent Inspection..................................................................... 29 Periodic Inspection..................................................................... 29 Wire Rope Inspection (Boom Extension and Retraction Cables)................................. 29 Periodic Inspection..................................................................... 29 Wire Rope Replacement (All Wire Rope)....................................................... 30 Seizing Wire Rope........................................................................... 30 Method 1................................................................................ 30 Method 2................................................................................ 30 Installing 35x7 Class Wire Rope............................................................. 31 Procedures for Cutting and Preparing 35x7 Class Wire Rope................................... 31 Synthetic Hoist Rope........................................................................ 32 SECTION 2............................................................................................... 33 Hydraulic System.................................................................................... 33 Description..................................................................................... 34 Maintenance..................................................................................... 34 Hydraulic Oil Recommendations............................................................... 34 Draining and Flushing................................................................... 34 Removing Air from the Hydraulic System...................................................... 37 Parts Replacement........................................................................... 38 Directional Control Valves.................................................................. 38 Inspection.............................................................................. 38 Valve Leakage........................................................................... 38 Binding Spools.......................................................................... 38 Visual Inspection of Hoses and Fittings................................................. 38 Supply Pressure And Return Circuit.............................................................. 39 Description................................................................................. 39 Hydraulic Reservoir and Filter.......................................................... 39 Pump Distribution....................................................................... 39 No. 1 Pump.......................................................................... 39 No. 2 Pump.......................................................................... 40 No. 3 Pump.......................................................................... 40 Maintenance................................................................................. 41 Troubleshooting......................................................................... 41 Return Hydraulic Filter Assembly........................................................ 42 Element Removal..................................................................... 42 Element Installation................................................................ 42 Reservoir Breather...................................................................... 42 Removal and Replacement............................................................. 42 Oil Cooler...................................................................................... 44 Description................................................................................. 44 Maintenance................................................................................. 44 Removal and Disassembly................................................................. 44 Assembly and Installation............................................................... 44 Hydraulic Pumps................................................................................. 46 Description................................................................................. 46 Maintenance................................................................................. 46 No. 1 Pump Removal...................................................................... 46 No. 1 Pump Inspection and Repair........................................................ 46 No. 1 Pump Installation................................................................. 46 No. 2 Pump Removal...................................................................... 46 No. 2 Pump Inspection and Repair........................................................ 47 No. 2 Pump Installation................................................................. 47 Pump Startup Procedure and Test Procedure After Repair or Replacement................... 47 Pump Drive...................................................................................... 47 Description................................................................................. 47 Maintenance................................................................................. 48 Troubleshooting......................................................................... 48 Removal................................................................................. 48 Installation............................................................................ 48 Valves.......................................................................................... 51 General..................................................................................... 51 Pressure Setting Procedures..................................................................... 54 Description................................................................................. 54 Maintenance................................................................................. 54 General................................................................................. 54 Preparation............................................................................. 54 Procedure for Checking Main Directional Control Valve Reliefs........................... 55 Procedure for Checking Main Directional Control Valve Pilot Supply Pressure............. 56 Procedure for Checking Swing Brake Pilot Supply Pressure................................ 56 Procedure for Checking Swing Valve Main Relief Pressure................................. 57 Procedure for Checking Relief Setting for Counterweight Supply Control Valve............ 57 Procedure for Checking Outrigger Selector Valve Relief Pressure......................... 58 Procedure for Checking the Air Conditioning Circuit Relief Valve Pressure............... 58 Procedure for Checking Center Front Jack Cylinder (Fifth Jack) Relief Valve Pressure.... 59 Procedure for Checking Pump Mounted Relief Valve Pressure............................... 59 Procedure For Checking Front Steering Relief Valve Pressure............................. 60 Directional Control Valves...................................................................... 60 Description................................................................................. 60 Maintenance................................................................................. 61 Swing Valve Bank Removal................................................................ 61 Swing Valve Bank Installation........................................................... 61 Hoist/Lift/Telescope Valve Bank Removal................................................. 61 Hoist/Lift/Telescope Valve Bank Installation............................................ 61 Counterweight Removal Valve Bank Removal................................................ 61 Counterweight Removal Valve Bank Installation........................................... 61 Functional Check (All Valve Banks)...................................................... 61 Functional Check (RCL Lockout Valves)................................................... 61 Check Valves.................................................................................... 66 Description................................................................................. 66 Maintenance................................................................................. 66 Removal................................................................................. 66 Installation............................................................................ 66 Hydraulic Remote Control Valve.................................................................. 66 Description................................................................................. 66 Maintenance................................................................................. 66 Armrest Control Valve Removal........................................................... 66 Armrest Control Valve Installation...................................................... 66 Armrest Control Valve Functional Check.................................................. 66 Telescope Pedal Control Valve Removal (with Auxiliary Hoist Option)..................... 66 Telescope Pedal Control Valve Installation (with Auxiliary Hoist Option)................ 66 Telescope Pedal Control Valve Functional Check (with Auxiliary Hoist Option)............ 67 Outrigger Selector Valve........................................................................ 69 Description................................................................................. 69 Maintenance................................................................................. 69 Removal................................................................................. 69 Installation............................................................................ 69 Functional Check........................................................................ 69 Outrigger Control Manifold...................................................................... 70 Description................................................................................. 70 Maintenance................................................................................. 70 Removal................................................................................. 70 Inspection.............................................................................. 70 Installation............................................................................ 70 Functional Check........................................................................ 70 Pilot Operated Check Valve...................................................................... 72 Description................................................................................. 72 Maintenance................................................................................. 72 Removal................................................................................. 72 Installation............................................................................ 72 Holding Valves.................................................................................. 73 Description................................................................................. 73 Maintenance................................................................................. 73 Removal................................................................................. 73 Installation............................................................................ 73 Swing Brake and Armrest Lockout Valve Manifold.................................................. 75 Description................................................................................. 75 Maintenance................................................................................. 75 Removal................................................................................. 75 Installation............................................................................ 75 Functional Check - Swing Brake Release Valve............................................ 75 Functional Check - Crane Function Valve................................................. 75 Inlet Filter Screen Replacement......................................................... 75 High Speed Boost Selector Valve................................................................. 77 Description................................................................................. 77 Maintenance................................................................................. 77 Removal................................................................................. 77 Installation............................................................................ 77 Front Center Jack Relief Valve.................................................................. 78 Description................................................................................. 78 Maintenance................................................................................. 78 Removal................................................................................. 78 Installation............................................................................ 78 Pump Mounted Relief Valve....................................................................... 78 Description................................................................................. 78 Maintenance................................................................................. 78 Removal................................................................................. 78 Installation............................................................................ 78 Needle Valve.................................................................................... 79 Description................................................................................. 79 Maintenance................................................................................. 79 Removal................................................................................. 79 Installation............................................................................ 79 Needle Valve With Reverse Free Flow Check....................................................... 79 Description................................................................................. 79 Maintenance................................................................................. 79 Removal................................................................................. 79 Installation............................................................................ 79 Swing Power Brake Valve......................................................................... 79 Description................................................................................. 79 Maintenance................................................................................. 79 Removal................................................................................. 79 Installation............................................................................ 80 Functional Check........................................................................ 80 Swing Brake Release Valve (Optional)............................................................ 81 Description................................................................................. 81 Maintenance................................................................................. 81 Removal................................................................................. 81 Installation............................................................................ 81 Priority Flow Divider Valve..................................................................... 82 Description................................................................................. 82 Maintenance................................................................................. 82 Removal................................................................................. 82 Installation............................................................................ 82 Auxiliary Water Jacket Cooler Flow Control Valve................................................ 83 Description................................................................................. 83 Maintenance................................................................................. 83 Removal................................................................................. 83 Installation............................................................................ 83 Cylinders....................................................................................... 84 General..................................................................................... 84 Maintenance................................................................................. 84 General................................................................................. 84 Leakage Check........................................................................... 84 Temperature Effects on Hydraulic Cylinders.............................................. 84 Lift Cylinder................................................................................... 86 Description................................................................................. 86 Maintenance................................................................................. 86 Disassembly............................................................................. 86 Inspection.............................................................................. 86 Assembly................................................................................ 88 Lower Telescope Cylinder........................................................................ 89 Description................................................................................. 89 Maintenance................................................................................. 89 Disassembly............................................................................. 89 Inspection.............................................................................. 89 Assembly................................................................................ 89 Upper Telescope Cylinder........................................................................ 92 Description................................................................................. 92 Maintenance................................................................................. 92 Disassembly............................................................................. 92 Inspection.............................................................................. 92 Assembly................................................................................ 92 Bleeding Procedure...................................................................... 94 Cylinder on Test Bench.............................................................. 94 Cylinder Installed on Crane......................................................... 95 Steer Cylinder.................................................................................. 95 Description................................................................................. 95 Maintenance................................................................................. 96 Disassembly............................................................................. 96 Inspection.............................................................................. 97 Assembly................................................................................ 98 Outrigger Extension Cylinder.................................................................... 99 Description................................................................................. 99 Maintenance................................................................................. 99 Disassembly............................................................................. 99 Inspection..............................................................................100 Assembly................................................................................102 Outrigger Jack Cylinder.........................................................................102 Description.................................................................................102 Maintenance.................................................................................102 Disassembly.............................................................................102 Inspection..............................................................................103 Assembly................................................................................105 Test....................................................................................106 Center Front Jack Cylinder......................................................................106 Description.................................................................................106 Maintenance.................................................................................106 Disassembly.............................................................................106 Inspection..............................................................................107 Assembly................................................................................109 Test....................................................................................110 Counterweight Removal Cylinder..................................................................110 Description.................................................................................110 Maintenance.................................................................................110 Disassembly.............................................................................110 Inspection..............................................................................111 Assembly................................................................................111 SECTION 3...............................................................................................115 Electric System.....................................................................................115 Description.....................................................................................115 General.....................................................................................115 Alternator..................................................................................115 Battery.....................................................................................115 Carrier Relay and Circuit Breaker Panel.....................................................115 Fuses...................................................................................115 Relays..................................................................................118 Superstructure Relay Panel and Fuse Panel...................................................118 Fuses...................................................................................118 Relays..................................................................................121 Maintenance.....................................................................................122 General.....................................................................................122 General Troubleshooting.....................................................................122 Troubleshooting Engine Starting Problems....................................................122 Troubleshooting Engine Charging Problems....................................................123 Troubleshooting Accessories.................................................................123 Troubleshooting Swivel-Caused Electrical Problems...........................................123 Connector Troubleshooting...................................................................123 Troubleshooting Lights......................................................................125 Carrier.................................................................................125 Superstructure..........................................................................125 Troubleshooting Gauges and Meters...........................................................125 Troubleshooting Alarms, Indicators, and Emergency Components................................126 Troubleshooting Crane Components and Accessories............................................127 Carrier.................................................................................127 Superstructure..........................................................................127 Alternator Replacement......................................................................128 Removal.................................................................................128 Installation............................................................................129 Check...................................................................................129 Starter Replacement.........................................................................129 Removal.................................................................................129 Installation............................................................................129 Check...................................................................................129 Battery Replacement.........................................................................130 Removal.................................................................................130 Installation............................................................................130 Relay Panel Component Replacement...........................................................130 Accessory Relay and Flasher Replacement.................................................130 Buzzer Replacement......................................................................130 Plug-in Relays Replacement..............................................................130 Instrument Replacement......................................................................131 Removal.................................................................................131 Inspection..............................................................................131 Installation............................................................................131 Check...................................................................................131 Switch Replacement..........................................................................131 Rocker Switch...........................................................................131 Removal.............................................................................131 Inspection..........................................................................131 Installation........................................................................131 Check...............................................................................131 All Other Switches......................................................................132 Removal.............................................................................132 Inspection..........................................................................132 Installation........................................................................132 Check...............................................................................132 Windshield Wiper Assembly Replacement.......................................................132 Removal.................................................................................132 Inspection..............................................................................132 Installation............................................................................133 Check...................................................................................133 Windshield Washer Assembly Replacement......................................................133 Removal.................................................................................133 Inspection..............................................................................134 Installation............................................................................134 Check...................................................................................134 Skylight Wiper Assembly Replacement.........................................................134 Removal.................................................................................134 Inspection..............................................................................134 Installation............................................................................134 Check...................................................................................134 SECTION 4...............................................................................................135 Boom................................................................................................135 Description.....................................................................................135 Theory of Operation.............................................................................135 Boom Extension..............................................................................135 Boom Retraction.............................................................................136 Maintenance.....................................................................................136 Removal.....................................................................................136 Disassembly.................................................................................138 Boom Nose Sheaves...........................................................................143 Removal.................................................................................143 Installation............................................................................143 Assembly....................................................................................143 Installation................................................................................146 Functional Check............................................................................147 Inspection..................................................................................147 Boom Alignment and Servicing................................................................147 Cam Operated Check Valve Adjustment.........................................................148 Guide Block Adjustment......................................................................148 Boom Extension and Retraction Cable.............................................................148 Maintenance.................................................................................148 Inspection..................................................................................148 Adjustment..................................................................................149 Telescope Circuit...............................................................................149 Description.................................................................................149 Theory of Operation.........................................................................150 Maintenance.................................................................................150 Troubleshooting.........................................................................150 Removal and Installation....................................................................152 Disassembly and Assembly....................................................................152 Lift Circuit....................................................................................152 Description.................................................................................152 Theory of Operation.........................................................................153 Maintenance.................................................................................154 Troubleshooting.........................................................................154 Removal.................................................................................156 Disassembly and Assembly................................................................156 Installation............................................................................156 Swingaway Boom Extension........................................................................158 Description.................................................................................158 Maintenance.................................................................................158 Removal.................................................................................158 Installation............................................................................164 Boom Extension Alignment Device Adjustment......................................................165 Swingaway Mounting Adjustment...............................................................166 Hook Block......................................................................................166 Description.................................................................................166 Maintenance.................................................................................166 Periodic Maintenance....................................................................166 SECTION 5...............................................................................................167 Hoist and Counterweight.............................................................................167 Description.....................................................................................167 Theory Of Operation.............................................................................167 Maintenance.....................................................................................167 Removal.....................................................................................167 Installation................................................................................168 Functional Check............................................................................168 Usage and Inspection........................................................................168 Preventative Maintenance....................................................................170 Oil Change..............................................................................171 Gear Oil Sampling and Analysis..........................................................171 General Guidelines for Iron Contaminant Level...........................................171 Brake Test Procedure........................................................................171 Hoist to Boom Alignment.........................................................................172 Preparation.................................................................................172 Tools Required..............................................................................172 Procedure...................................................................................172 Motor And Brake.................................................................................174 Description.................................................................................174 Maintenance.................................................................................174 Removal.................................................................................174 Installation............................................................................174 Cable Guard Roller And Cable Guide Roller.......................................................174 Description.................................................................................174 Maintenance.................................................................................174 Removal.................................................................................174 Cleaning and Inspection.................................................................174 Assembly................................................................................175 Hoist Drum Indicator System.....................................................................176 Description.................................................................................176 Maintenance.................................................................................176 General.................................................................................176 Rotation Sensor.....................................................................176 Drum Rotation Indicator Control Module (CPU)........................................176 Thumb Thumper Solenoid..............................................................176 Troubleshooting.........................................................................176 Green LED...........................................................................176 Red LED.............................................................................176 Amber LED...........................................................................178 Hoist Rotation Indicator (HRI) Display System...............................................178 Pressure Switches.......................................................................178 HRI Display.............................................................................178 HRI Control Module......................................................................179 Hoist Control Valves............................................................................179 Description.................................................................................179 Hydraulic Hoist Motor Control Valve.....................................................179 Hoist Directional Control Valve.........................................................179 Counterweight...................................................................................179 Description.................................................................................179 Maintenance.................................................................................180 Cylinders...............................................................................180 Removal.............................................................................180 Installation........................................................................180 Jack Screws.............................................................................180 SECTION 6...............................................................................................183 Swing System........................................................................................183 Description.....................................................................................183 Theory Of Operation.............................................................................183 Swing Drive.................................................................................183 Swing Brake.................................................................................184 Maintenance.....................................................................................186 Troubleshooting.............................................................................186 Swing Motor.....................................................................................189 Description.................................................................................189 Maintenance.................................................................................189 Removal.................................................................................189 Installation............................................................................189 Test....................................................................................189 Swing Gearbox and Brake.........................................................................189 Description.................................................................................189 Maintenance.................................................................................189 Swing Brake.............................................................................189 Removal.............................................................................189 Installation........................................................................189 Testing.............................................................................190 Gearbox.................................................................................190 Removal.............................................................................190 Installation........................................................................190 Servicing...........................................................................190 Testing.............................................................................190 Swing Bearing...................................................................................190 Description.................................................................................190 Maintenance.................................................................................190 General.................................................................................190 Torquing Turntable Bolts................................................................191 General.............................................................................191 Torque Values.......................................................................192 Tools Required......................................................................192 Inner Race Torquing.................................................................192 Outer Race Torquing.................................................................192 Removal.................................................................................193 Inspection..............................................................................194 Installation............................................................................194 Testing.................................................................................195 Swivels.........................................................................................195 Description.................................................................................195 Hydraulic Swivel................................................................................197 Description.................................................................................197 Theory of Operation.........................................................................197 Maintenance.................................................................................197 Removal.................................................................................197 Installation............................................................................198 Two Port Water Swivel...........................................................................199 Description.................................................................................199 Maintenance.................................................................................199 Removal.................................................................................199 Disassembly.............................................................................199 Cleaning and Inspection.................................................................199 Assembly................................................................................199 Installation................................................................................199 Electrical Swivel...............................................................................200 Description.................................................................................200 Theory of Operation.........................................................................200 Maintenance.................................................................................200 Removal.................................................................................200 Installation............................................................................200 Preventative Maintenance................................................................201 Slew Potentiometer Preliminary Zero Adjustment Procedure................................201 Slew Potentiometer Adjustment...........................................................201 Swing Lock Pin..................................................................................202 Description.................................................................................202 Maintenance.................................................................................202 360° Swing Lock Control (Positive Lock Type) (Optional).........................................202 Description.................................................................................202 Maintenance.................................................................................202 SECTION 7...............................................................................................205 Power Train.........................................................................................205 Description.....................................................................................205 Maintenance.....................................................................................206 Removal.....................................................................................206 Installation................................................................................208 Engine Drive Belts..........................................................................210 Engine Control System...........................................................................211 Description.................................................................................211 Functional Operation........................................................................211 Engine Control System Switches and Indicator Lights.........................................211 Engine Diagnostics/Idle Switch (+/-)....................................................211 Regen Initiate/Inhibit Switch...........................................................211 Hand Throttle Switch (Engine Increment/ Decrement Switch)...............................211 Engine Stop Light.......................................................................212 Engine Warning Light....................................................................212 Fault Code Flashing Sequence........................................................212 Regen Needed/Inhibit Indicator..........................................................212 High Exhaust Temp Indicator.............................................................212 Fuel System.....................................................................................213 Description.................................................................................213 Fuel Tank...............................................................................213 Injection Fuel Pump.....................................................................213 Fuel Filter-Water Separator.............................................................213 Draining............................................................................213 Filter Replacement..................................................................213 Maintenance.................................................................................213 Fuel Tank...............................................................................213 Removal.............................................................................213 Installation........................................................................213 Air Intake System...............................................................................215 Description.................................................................................215 Maintenance.................................................................................215 Troubleshooting.........................................................................215 Check For Filter Restriction........................................................215 Filter Element Replacement..............................................................215 Element Cleaning........................................................................216 Air Cleaner Body....................................................................217 Vacuator Valve......................................................................218 Duct Work...........................................................................218 Exhaust System..................................................................................219 Description.................................................................................219 ISX System Removal..........................................................................219 ISX System Installation.....................................................................219 QSM System Removal..........................................................................219 QSM System Installation.....................................................................219 Slip Joint Exhaust Connectors...............................................................219 After 1000 Hours, or One Year...........................................................220 2000 Hours or 2 Years...................................................................220 4000 Hours or 4 Years...................................................................220 5000 Hours or 5 Years...................................................................220 ISX Exhaust System..........................................................................220 QSM Exhaust System..........................................................................221 Aftertreatment Diesel Exhaust Fluid (DEF).......................................................222 DEF Tank....................................................................................222 Description.............................................................................222 Removal.................................................................................222 Installation............................................................................222 DEF Dosing Unit Filter......................................................................223 Initial Check...........................................................................223 Preparatory Steps.......................................................................223 Removal.................................................................................224 Clean and Inspect for Reuse.............................................................224 Install.................................................................................224 Finishing Steps.........................................................................224 Water Cooling System............................................................................225 Description.................................................................................225 Maintenance.................................................................................225 General.................................................................................225 Effects Of Cooling System Neglect.......................................................225 Overheating.............................................................................225 Overcooling.............................................................................225 Rust Prevention.........................................................................225 Engine Antifreeze/Coolant Fill Procedure (when level is low)............................225 Engine Antifreeze/Coolant Fill Procedure (after a complete draining of the system)......226 Antifreeze/Supplemental Coolant Additives Maintenance Summary...........................226 Cooling System Level Check Interval.................................................226 SCA Level Check/Coolant Filter Change Interval......................................226 Cleaning....................................................................................227 Pressure Flushing.......................................................................227 Component Inspection........................................................................228 Radiator/Recovery Tank..................................................................228 Engine Water Jacket.....................................................................228 Water Pump..............................................................................228 Fans and Belts..........................................................................228 Thermostat..............................................................................228 Hoses and Clamps........................................................................228 Test Equipment..........................................................................228 Antifreeze/Coolant......................................................................229 Coolant Filter..........................................................................229 Radiator Assembly Removal and Installation..................................................229 Removal.................................................................................229 Installation............................................................................232 Drive Train.....................................................................................233 Description.................................................................................233 Maintenance.................................................................................233 Transmission............................................................................233 Drive Shafts............................................................................233 Removal.............................................................................233 Installation........................................................................233 Lubrication.........................................................................233 Clutch..........................................................................................235 Description.................................................................................235 Maintenance.................................................................................237 Troubleshooting.........................................................................237 Removal.................................................................................239 Inspection..............................................................................239 Installation............................................................................240 Clutch Adjustment Procedure.............................................................242 Clutch Adjustment Inspection Procedure..................................................243 General Maintenance.....................................................................243 Lubrication.............................................................................243 Gearshift And Transmission Shift Air System.....................................................244 Description.................................................................................244 Theory of Operation.........................................................................244 Shifting Gears..............................................................................244 Maintenance.................................................................................245 Troubleshooting.........................................................................245 Removal.................................................................................245 Installation............................................................................245 Lubrication.............................................................................245 Manual Transmission.............................................................................246 Description.................................................................................246 Theory of Operation.........................................................................246 Maintenance.................................................................................246 Troubleshooting.........................................................................246 Diagnostics.............................................................................246 Transmission Removal....................................................................249 Special Procedure for Changing Transmission Input Shaft.................................249 Disassembly.........................................................................249 Assembly............................................................................249 Transmission Installation...............................................................249 Clutch Adjustment Procedure.............................................................250 Lubrication.............................................................................251 General.............................................................................251 Draining Oil........................................................................251 Refilling Oil.......................................................................251 Adding Oil..........................................................................251 Operating Temperature...............................................................251 Proper Lubrication..................................................................251 Preventive Maintenance..................................................................251 SECTION 8...............................................................................................253 UnderCarriage.......................................................................................253 Front Axle And Suspension.......................................................................254 Description.................................................................................254 Front Axle..............................................................................254 Suspension..............................................................................254 Maintenance.................................................................................254 General.................................................................................254 Beam Center Cap Fasteners...........................................................254 Beam End Connections and Bushings...................................................254 Saddle Assembly End Cap Fasteners...................................................254 Beam Center Bushings................................................................254 Beam Center Cross Tube..............................................................254 Air Bags............................................................................256 Height Control Valves...............................................................256 Shock Absorbers.....................................................................256 Removal.................................................................................256 Disassembly.............................................................................256 Assembly................................................................................256 Installation............................................................................257 Axle Alignment Procedure................................................................257 Toe-In Adjustment...................................................................259 Axle Stop Settings..................................................................259 Drag Link Installation and Axle Synchronization.....................................259 Final Adjustments...................................................................260 Setting Axle Stops and Steering Gear Relief Plungers................................261 Front Air Ride Adjustment...............................................................263 Steering System.................................................................................264 Description.................................................................................264 Steering Pump...................................................................................267 Description.................................................................................267 Steering Gearbox................................................................................267 Description.................................................................................267 Maintenance.................................................................................267 Removal.................................................................................267 Installation............................................................................267 Steer Cylinder..................................................................................268 Description.................................................................................268 Maintenance.................................................................................268 Removal.................................................................................268 Installation............................................................................268 Rear Axle And Suspension........................................................................269 Description.................................................................................269 Rear Axle...............................................................................269 Suspension..............................................................................269 Maintenance.................................................................................269 General.................................................................................269 Beam Center Cap Fasteners...........................................................269 Beam End Connections and Bushings...................................................269 Saddle Assembly End Cap Fasteners...................................................269 Beam Center Bushings................................................................269 Beam Center Cross Tube..............................................................269 Air Bags............................................................................269 Height Control Valves...............................................................271 Shock Absorbers.....................................................................271 Removal.................................................................................271 Disassembly.............................................................................271 Assembly................................................................................271 Installation............................................................................272 Rear Air Ride Adjustment................................................................272 Wheels and Tires................................................................................273 Description.................................................................................273 Maintenance.................................................................................273 Mounting the Wheels on the Front Axle...................................................273 Mounting the Wheels on the Rear Axle....................................................274 Brakes..........................................................................................275 Description.................................................................................275 Maintenance.................................................................................275 Non-Asbestos Warning....................................................................275 Front Brakes....................................................................................275 Description.................................................................................275 Maintenance.................................................................................276 Troubleshooting.........................................................................276 Brakes..................................................................................276 Disassembly.........................................................................276 Inspection..........................................................................279 Repair/Replacement..................................................................280 Assembly............................................................................281 Automatic Slack Adjuster........................................................................282 Description.................................................................................282 Maintenance.................................................................................282 Alternative 1...........................................................................282 Removal.....................................................................................282 Installation................................................................................282 Adjustment Procedures.......................................................................283 Brake Applied Stroke Measurement........................................................283 Brake Free Play Measurement and Adjustment..............................................283 Alternative 2...........................................................................286 Installation................................................................................286 Adjustment Procedures.......................................................................286 Brake Applied Stroke Measurement........................................................286 Brake Free Play Measurement and Adjustment..............................................287 Rear Brakes.....................................................................................289 Description.................................................................................289 Brakes..................................................................................289 Spring Brake Actuator...................................................................289 Maintenance.................................................................................290 Troubleshooting.........................................................................290 Spring Brake Actuator...................................................................291 Removal.................................................................................291 Installation............................................................................292 Disassembly.............................................................................292 Assembly................................................................................292 Rear Brake Assembly.....................................................................292 Disassemble Brakes......................................................................292 Brake Shoe Removal......................................................................293 Clean and Inspect Parts.................................................................293 Inspect Parts...........................................................................294 Assemble Brakes.........................................................................294 Camshaft Installation...................................................................294 Brake Shoe Installation.................................................................295 Automatic Slack Adjuster........................................................................296 Description.................................................................................296 Maintenance.................................................................................296 Removal.................................................................................296 Installation............................................................................296 Brake Adjustment........................................................................298 Air System......................................................................................299 Description.................................................................................299 Theory of Operation.........................................................................299 Braking.................................................................................299 Maintenance.................................................................................299 Leak Detection..........................................................................299 Air System Operational Test.............................................................302 Air System Components...........................................................................303 Description.................................................................................303 Air Compressor..........................................................................303 Air Governor............................................................................303 Air Dryer...............................................................................303 Reservoirs..............................................................................304 Low Pressure Indicator Switches.........................................................304 Stop Light Switch.......................................................................304 Air Pressure Gauge......................................................................304 Safety Valve............................................................................304 Automatic Drain Valve...................................................................304 Pressure Protection Valve...............................................................305 Double Check Valve......................................................................305 Relay Valve.............................................................................305 Dual Brake Valve........................................................................306 Spring Brake Control Valve..............................................................306 Park Brake Control Valve................................................................306 Quick Release Valve.....................................................................306 Maintenance.................................................................................306 Air Compressor..........................................................................306 Removal.............................................................................306 Installation........................................................................307 Air Governor............................................................................307 Removal.............................................................................307 Installation........................................................................307 Operational Test....................................................................307 Leakage Test........................................................................307 Preventive Maintenance..............................................................307 Air Dryer...............................................................................307 Removal.............................................................................307 Installation........................................................................307 Preventive Maintenance..............................................................307 Leak Tests..........................................................................308 Reservoirs..............................................................................308 Removal.............................................................................308 Maintenance.........................................................................308 Cleaning............................................................................308 Installation........................................................................308 Low Pressure Indicator Switches.........................................................308 Operating and Leakage Checks........................................................309 Removal.............................................................................309 Installation........................................................................309 Preventive Maintenance..............................................................309 Stop Light Switch.......................................................................309 Operational Test....................................................................309 Leakage Test........................................................................309 Removal.............................................................................309 Installation........................................................................309 Air Pressure Gauge......................................................................309 Removal.............................................................................309 Installation........................................................................309 Functional Check....................................................................309 Safety Valve............................................................................309 Removal.............................................................................309 Installation........................................................................309 Operating and Leakage Checks........................................................309 Automatic Drain Valve...................................................................309 Removal.............................................................................309 Disassembly.........................................................................309 Cleaning............................................................................310 Assembly............................................................................310 Installation........................................................................310 Preventive Maintenance..............................................................310 Operating Leaks and Checks..........................................................310 Pressure Protection Valve...............................................................310 Removal.............................................................................310 Installation........................................................................310 Operational Check...................................................................310 Leakage Test........................................................................310 Preventive Maintenance..............................................................310 Double Check Valve......................................................................311 Removal.............................................................................311 Disassembly.........................................................................311 Cleaning............................................................................311 Assembly............................................................................311 Installation........................................................................311 Operating Check.....................................................................311 Leak Test...........................................................................311 Preventive Maintenance..............................................................311 Relay Valve.............................................................................311 Removal.............................................................................311 Inspection..........................................................................311 Installation........................................................................311 Operating Test......................................................................311 Leakage Test........................................................................311 Preventive Maintenance..............................................................312 Dual Brake Valve........................................................................312 Removal.............................................................................312 Installation........................................................................312 Operating Test......................................................................312 Leakage Test........................................................................312 Preventive Maintenance..............................................................312 Park Brake Control Valve................................................................312 Removal.............................................................................312 Installation........................................................................312 Operating and Leakage Check.........................................................313 Preventive Maintenance..............................................................313 Quick Release Valve.....................................................................313 Removal.............................................................................313 Disassembly.........................................................................313 Cleaning and Inspection.............................................................313 Assembly............................................................................313 Installation........................................................................313 Operating and Leakage Tests.........................................................313 Preventive Maintenance..............................................................313 Outriggers......................................................................................314 Description.................................................................................314 Theory of Operation.........................................................................314 Maintenance.................................................................................315 Troubleshooting.........................................................................315 Outrigger Beam..................................................................................318 Description.................................................................................318 Theory of Operation.........................................................................318 Maintenance.................................................................................318 Removal.................................................................................318 Inspection..............................................................................318 Installation............................................................................319 Wear Pad Adjustment.....................................................................321 Outrigger Extension Cylinder....................................................................321 Description.................................................................................321 Maintenance.................................................................................321 Removal.................................................................................321 Installation............................................................................321 Functional Check........................................................................322 Outrigger Monitoring System (Optional—Standard in North America)................................322 Description.................................................................................322 Removal.................................................................................322 Installation............................................................................323 Outrigger Jack Cylinder.........................................................................323 Description.................................................................................323 Maintenance.................................................................................323 Removal.................................................................................323 Installation............................................................................323 Functional Check........................................................................324 Outrigger Jack Cylinder Internal Leak Test..........................................324 Checking Cylinder for Internal Piston Seal Leak.....................................324 Testing Pilot Operated Check Valve for Leakage......................................325 Outrigger System Valves.........................................................................325 Description.................................................................................325 Pilot Operated Check Valve..............................................................325 Integrated Outrigger Valve..............................................................325 Outrigger Control Manifold..............................................................325 Center Front Jack Circuit Relief Valve..................................................325 Center Front Jack Cylinder......................................................................325 Description.................................................................................325 Maintenance.................................................................................325 Removal.................................................................................325 Installation............................................................................327 Functional Check........................................................................327 SECTION 9...............................................................................................329 Lubrication.........................................................................................329 General.........................................................................................329 Environmental Protection........................................................................329 Arctic Conditions Below -9°C (15°F).............................................................329 All Weather Package & Lubricants................................................................329 Standard Lubricants Package.....................................................................330 Lubrication Points..............................................................................331 Carrier Lubrication.............................................................................333 Superstructure Lubrication......................................................................338 Boom, Boom Extension, and Boom Accessories Lubrication..........................................339 Wire Rope Lubrication...........................................................................341 Carwell® Rust Inhibitor.........................................................................343 Protecting Cranes From Rusting..............................................................343 Cleaning Procedures.........................................................................343 Inspection and Repair.......................................................................344 Application.................................................................................344 Areas of Application........................................................................345
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