PDF Service Manual Grove TM500E-2 Crane - 5 MB
This is the factory service manual for the Grove TM500E-2 truck-mounted crane.
It provides in-depth service and repair information, covering hydraulics, electrical systems, boom assembly, and more.
Following the procedures in this manual is critical for maintaining the operational safety and structural integrity of the crane.
It's an indispensable resource for certified crane technicians and maintenance teams.
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--- Page 1 ---
1
SERVICE MANUAL
This Manual has been prepared for and is considered part of -
TM500E-2 2
Crane Model Number
This Manual is divided into the following Sections: 3
SECTION 1 INTRODUCTION
SECTION 2 HYDRAULIC SYSTEM
SECTION 3 ELECTRIC SYSTEM
SECTION 4 BOOM
SECTION 5
SECTION 6
HOIST AND COUNTERWEIGHT
SWING SYSTEM
4
SECTION 7 POWER TRAIN
SECTION 8 UNDERCARRIAGE
SECTION 9 LUBRICATION
NOTICE
5
The crane serial number is the only method your distributor or the factory
has of providing you with correct parts and service information.
The crane serial number is stamped on the top of the outrigger box.
Always furnish crane serial number when ordering parts or
communicating service problems with your distributor or the factory. 6
7
To prevent death or serious injury:
• Avoid unsafe operation and maintenance.
• This crane must be operated and maintained by trained and
experienced personnel. Manitowoc is not responsible for qualifying
8
these personnel.
• Do not operate or work on this crane without first reading and
understanding Operator’s Manual and Rating Plate supplied with
crane.
• Store Operator’s Manual in holder provided on crane.
• Attach laminated Capacity Charts supplied with crane to chain in
9
operator’s cab.
• If Operator’s Manual or Capacity Charts are missing from cab,
contact your distributor for new ones.
© 2006 Manitowoc Crane Group
PRELIMINARY Published 10-19-2007, Control # 151-00
--- Page 3 ---
TM500E-2 SERVICE MANUAL TABLE OF CONTENTS
Modulator Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-59
Anti-Lock Modulator Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-59
ATR-1 Relay Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-59
Electronic Control Unit (ECU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-60
ECU Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-60
Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-62
Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-62
Configuration Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-62
Pass-through Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-62
ABS Warning Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-63
Automatic Traction Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-64
ATC Lamp and Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-64
ABS Self-tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-65
T
ABS Fault Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-65
Test and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-65 O
Traction Control Valve Function Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-65
Traction Control Valve Differential Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . 8-66
Traction Control Valve Solenoid Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-66
C
System Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-67
System Schematic Detail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-68
ABS System Schematic, Relays and Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . 8-69
Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-70
ABS Sensor Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-70
Wheel Speed Sensor Replacement (Front) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-70
Wheel Speed Sensor, Replacement (Rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-72
Front Modulator Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-73
Rear Modulator Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-74
ATR Valve Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-75
ABS Electronic Control Unit Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-76
ABS Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-76
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-76
General Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-76
Data Link Instrument Cluster - Diagnostic Display . . . . . . . . . . . . . . . . . . . . . . . . . 8-77
Diagnostic Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-77
MPSI Pro-Link 9000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-77
AL-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-77
AL-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-77
Readout Window. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-78
Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-78
Push Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-78
Installing and Removing the MPC Cartridge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-78
Non-Volatile Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-79
MPSI Power/Data Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-79
Connecting the Power/Data Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-79
Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-79
Application Cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-79
Installing the Application Card: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-80
Using the Pro-Link 9000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-80
Bendix ABS Application Card and MPC Cartridge (with AL-7 ECU). . . . . . . . . . . . 8-80
MPC Application Menu Structure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-83
Using the Bendix ABS Cartridge (with AL-6 ECU) . . . . . . . . . . . . . . . . . . . . . . . . . 8-84
System Testing Using the Pro-Link 9000 (AL-6). . . . . . . . . . . . . . . . . . . . . . . . . . . 8-85
Preparing for Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-85
ECU LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-87
Diagnosing Faults Using the ECU LEDs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-87
Troubleshooting Quick Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-88
Component Troubleshooting Quick Reference Chart . . . . . . . . . . . . . . . . . . . . . . . 8-89
TOC-9
--- Page 4 ---
TM500E-2 SERVICE MANUAL INTRODUCTION
Hydraulic Systems 1. Visually inspect hoses and fittings once a month or
every 250 hours for the following: 1
a. Leaks at hose fitting or in hose
b. Damaged, cut, or abraded cover
DANGER
Exercise extreme care around pressurized hydraulic c. Exposed reinforcement
systems. Do not work on a hydraulic system while it is in d. Kinked, crushed, flattened, or twisted hose
operation or until all pressure is released.
e. Hard, stiff, heat cracked, or charred hose
Cleanliness f. Blistered, soft, degraded, or loose cover
Contaminants in a hydraulic system affect operation and will g. Cracked, damaged, or badly corroded fittings
result in serious damage to the system components. Dirty
hydraulic systems are a major cause of component failures. h. Fitting slippage on hose
i. Other signs of significant deterioration
Keep the System Clean
If any of the above conditions exist, evaluate hose
When removing components of a hydraulic system, cover all assemblies for correction or replacement. For replacement
openings on both the component and the crane. of hose assemblies, refer to your Manitowoc CraneCARE
Parts Manual.
If evidence of foreign particles is found in the hydraulic
system, flush the system. 2. At the same service interval, visually inspect all other
hydraulic components and valves for the following:
Disassemble and assemble hydraulic components on a
clean surface. a. Leaking Ports
Clean all metal parts in a nonflammable cleaning fluid. Then b. Leaking valve sections or manifolds and valves
lubricate all components to aid in assembly. installed into cylinders or onto motors.
Sealing Elements c. Damaged or missing hose clamps, guard, or
shields.
Inspect all sealing elements (O-ring, gaskets, etc.) when
d. Excessive dirt and debris around the hose
disassembling and assembling the hydraulic system
assemblies.
components. Installation of new elements is always
recommended. If any of these conditions exist, address them appropriately.
3. All hydraulic hose assemblies are recommended to be
Hydraulic Lines
replaced after 8000 hours of service life.
When installing metal tubes, tighten all bolts finger-tight.
4. Hydraulic hose assemblies operating in a temperature
Then, in order, tighten the bolts at the rigid end, the
climate zone “C” (Table 1-1) are recommended to be
adjustable end, and the mounting brackets. After tubes are
replaced after 8000 hours of service life.
mounted, install the hoses. Connect both ends of the hose
with all bolts finger-tight. Position the hose so it does not rub 5. Hydraulic hose assemblies operating in climate zones
the machine or another hose and has a minimum of bending “A” and “B” (Table 1-1) with high ambient temperatures,
and twisting. Tighten bolts in both couplings. could see hose service life reduced by 40 to 50%,
therefore, it is recommended to replace these hoses
Due to manufacturing methods there is a natural curvature to
after 4000 to 5000 hours of service life.
a hydraulic hose. The hose should be installed so any bend
is with this curvature. 6. Hydraulic hose assemblies operating in climate zones
“D” and “E” (Table 1-1) cold climates should expect a
Visual Inspection of Hoses and Fittings degrade of mechanical properties such as elasticity,
therefore, it is recommended these hoses be inspected
and addressed accordingly.
CAUTION
Ensure that the hydraulic hose is depressurized before
loosening the connections.
PRELIMINARY Published 10-05-2007, Control # 151-00 1-7
--- Page 5 ---
TM500E-2 SERVICE MANUAL INTRODUCTION
Procedures for Cutting and Preparing a. If a welder is available, the cut should be made with
FLEX-X 35 an abrasive saw. Immediately after the cut, both 1
ends of the rope are to be cap welded so that all
Flex-X 35 is a special wire rope that must be handled inner and outer strands are welded together,
differently than any other rope we manufacture. One preventing any movement between them.
characteristic that makes this rope special is that the outer
NOTE: The outer strands must not be able to move with
strands are not preformed. It is because of this that the
respect to the inner strands. The weld must not
following procedures for cutting and preparing Flex-X 35
exceed the diameter of the rope.
must be followed:
b. If a welder is not available, the cut is to be made with
1. The welded ends prepared by the manufacturer are not
an acetylene torch. The cut is to be made in such a
to be removed.
way that both ends of the rope are completely fused
2. Before cutting the rope, make three separate bands with so that all inner and outer strands are bonded
seizing strand on each side of where the cut is to be together, preventing any movement between
made (total of six bands for each cut). Each band is to strands.
have a minimum length of one and one half times the
NOTE: The outer strands must not be allowed to move
rope diameter. The two bands closest to the cut should
with respect to the inner strands. The fused end
be located at a distance equal to one rope diameter
must not exceed the diameter of the rope.
away from the cut. The four remaining bands should be
evenly spaced at a distance equal to three rope 4. Once the cuts have been completed, the seizing bands
diameters (Figure 1-10). are to be left in place for shipment of the rope.
3. 5. Attach a “Do not remove welded ends” tag on each reel
flange.
FIGURE 1-10
PRELIMINARY Published 10-05-2007, Control # 151-00 1-17
--- Page 6 ---
TM500E-2 SERVICE MANUAL HYDRAULIC SYSTEM
mechanism and hoist(s), because it can cause these units to Entrapped air may be removed from cylinders having
become noisy during operation. If noisy operation occurs, wet rods by cycling. On certain cylinders, a plugged port
first check the level of the hydraulic reservoir and replenish is provided on the rod end to bleed off entrapped air.
as necessary. Then inspect for leaks in the suction lines
leading to the pumps.
Minute leaks may be hard to locate. If a leak is not readily
DANGER
detectable, use the following way to check for it:
Pressurized fluid can cause serious injury or death. Do 2
Seal all normal openings in the hydraulic system and the not attempt to loosen fittings in pressurized lines or while
reservoir. Using a positive means to control the pressure the hydraulic pumps are in operation.
(like a regulator), pressurize the hydraulic system to
13.8 to 27.6 kPa (0.14 to 0.28 bar) (2 to 4 psi) and In the event that air entrapment should persist, bleeding
inspect all joints and fittings for evidence of leaks. A of air by loosening various clamp and screw type fittings
soap solution applied to the fittings and joints may also may become necessary.
prove helpful in detecting minute leaks while the system
is pressurized. Remove the pressure, repair any leaks If the above procedures fail to eliminate air entrapment,
found, and reopen any openings (such as a vent) closed contact your authorized Grove Distributor.
for inspection. Refill the reservoir after completing any
repairs or service. Operate all hydraulic circuits several Parts Replacement
times in both directions. Parts found damaged or out of tolerance when maintenance
This action should return any entrapped air to the is being performed should be replaced. Refer to the
reservoir where it can be removed from the hydraulic oil Manitowoc CraneCARE Parts Catalog for proper
by the baffles. replacement parts.
Directional Control Valves
The control valves that control the crane functions are
DANGER installed on the right side on the outside of the superstructure
Tipping Hazard side plate, and between the left and right superstructure side
To avoid death or serious injury, locate the machine on a plates under the main hoist.
firm supporting surface and position the boom over the
front on outriggers when extending the boom at low Inspection
angles. Inspect the control valves for visible damage, binding spools,
and evidence of leakage. If excessive internal leakage is
To remove entrapped air from telescope cylinders, lower suspected during operation with a spool in its center position,
the boom to below horizontal and fully telescope the it is possible that the area between the spool and working
boom in and out several times. section bore of the valve body is worn beyond serviceable
If the air is not readily removed, lower the boom to below limits. If this condition exists, the spool and body must be
horizontal, extend the telescope cylinders as far as replaced as an assembly.
practicable, and allow the boom to remain in this position
overnight. This should allow entrapped air to find its way Valve Leakage
to the holding valve so that telescoping the boom IN the Dripping hydraulic oil indicates some type of external
next morning should force the air back to the reservoir. leakage. The machine should be removed from service for
Ensure the boom is first telescoped IN (not OUT) in the immediate repairs. External leaks sometimes develop at
morning. Telescoping OUT may cause air to be forced fittings and seals. Spool seals are susceptible since they are
back into a cylinder. subject to wear. Seals may be damaged by temperatures
that are too high, or by dirt or paint accumulation on the
spool. Damaged or torn seals must be replaced.
DANGER A component functioning at reduced efficiency may indicate
that the control valve for that component is leaking internally.
Pressurized fluid can cause serious injury or death.
If preliminary check-out reveals that adequate volume is
Extreme care must be used when removing any plugs or
being supplied to the affected valve bank, relief valves are
restrictions from a hydraulic system suspected to have
properly adjusted, and the component is not at fault, check
entrapped air that may be pressurized.
the valve for scored or worn parts. Scoring is a sign of the
number one problem in hydraulics - contamination (external
PRELIMINARY Published 10-5-2007, Control # 151-00 2-5
--- Page 7 ---
TM500E-2 SERVICE MANUAL HYDRAULIC SYSTEM
d. Increase the RPM to 1500-1800 for 1 to 2 minutes 4. Start the engine.
with no functions actuated and make checks again
a. Idle engine for two to three minutes with no
as outlined in step a. Incrementally increase throttle
functions actuated. Check for leaks and repair if
to full RPM and then cycle the functions that the
required. Lay hand on pump to check for excessive
pump supples to verify proper speed. Verify pump
heat build-up. If the pump section is too hot to keep
flow.
your hand on, stop immediately. If the pump makes
5. Check pressure settings. Refer to PRESSURE
SETTING PROCEDURES in this section.
excessive noise, air is probably entering the pump
keeping it from priming. If this occurs, stop engine, 2
and inspect all connections of the suction hose/tube
Piston Pump Start-up Procedure for a loose connection, or a missing or damaged O-
ring. Re-start the engine and run until the pump
1. Ensure the reservoir is filled with the proper hydraulic takes prime for a maximum of 30 seconds. If the
fluid to the high level mark on the reservoir sight gauge. pump does not prime in 30 seconds, stop the engine
2. Ensure no air is entering the pump inlet, and that the and repeat until the pump primes.
pump suction or inlet fluid is not bleeding back to the b. Increase the RPM to 1500-1800 for 1 to 2 minutes
reservoir when the engine is stopped, by making sure all with no functions actuated and make checks again
suction or inlet lines are air tight. as outlined in step a. Incrementally increase throttle
3. Remove the case drain hose and adapter from port DR to full RPM and then cycle the functions that the
on the pump (Figure 2-7), and fill housing with the same pump supples to verify proper speed. Verify pump
hydraulic oil that was used to fill the hydraulic reservoir flow.
to the bottom of the O-ring case drain port. Install the 5. Check pressure settings. Refer to PRESSURE
case drain adapter and hose. SETTING PROCEDURES in this section.
3
2
1
4
6950-1
FIGURE 2-7
Item Description Item Description
1 No. 1 - Piston Pump 3 Case Drain To Reservoir
2 No. 2 - Gear Pump 4 Engine
PRELIMINARY Published 10-5-2007, Control # 151-00 2-15
--- Page 8 ---
TM500E-2 SERVICE MANUAL HYDRAULIC SYSTEM
1 2
3
6956-3
Carrier
6956-1
2
FIGURE 2-13 continued
6956-2
Item Description Item Description
1 Front Outrigger Control Manifold 3 Frame
2 Rear Outrigger Control Manifold
PRELIMINARY Published 10-5-2007, Control # 151-00 2-25
--- Page 9 ---
TM500E-2 SERVICE MANUAL HYDRAULIC SYSTEM
PILOT OPERATED CHECK VALVE 3. Lubricate the check valve and O-rings with clean
hydraulic oil.
Description
A pilot operated (PO) check valve is located in each CAUTION
outrigger stabilizer cylinder port block. The check valve Do not damage the O-rings during installation of the check
functions as a holding valve for the stabilizer cylinder. Oil valve. If the check valve turns freely then gets hard to turn,
flow is directed from the “V” port to the “C” ports, while
blocking flow in the opposite direction. Flow is reversed from
then easy to turn, remove the check valve and check the 2
O-rings. They have probably been damaged by a sharp
“C” to “V” when pressure pilot oil is applied to the opposite edge of a port.
side “V” port (Figure 2-17)
NOTE: The check valve should turn by hand until
Maintenance compression of the O-rings begins.
Removal 4. Carefully install the check valve into the port block until
fully seated.
1. Unscrew the check valve from the stabilizer cylinder port
block. 5. Test the check valve and port block by operating the
affected outrigger’s stabilizer cylinder. Verify it extends
Installation and retracts without problems; verify there is no leaking.
Make repairs as needed.
1. Check the inside of the port block for any sharp edges or
burrs and remove as necessary with emery cloth.
2. Install new O-rings onto the check valve.
Item Description
1 Port C - Cylinder