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

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
 To Contact Us:

Manitowoc Cranes, Inc.

2401 South 30th Street
Manitowoc, WI 54220
(920) 684-6621
(920) 683-6277 (fax)

Grove Worldwide
1565 Buchanan Trail East
P.O. Box 21
Shady Grove, PA 17256
(717) 597-8121
(717) 597-4062 (fax)

National Crane Corporation

1565 Buchanan Trail East
P.O. Box 21
Shady Grove, PA 17256
(717) 597-8121
(717) 597-4062 (fax)

Grove Worldwide
1565 Buchanan Trail East
P.O. Box 21
Shady Grove, PA 17256
(717) 597-8121
(717) 597-4062 (fax)

Technical Field Parts Factory Training

Publications Service Service
TM500E-2 SERVICE MANUAL TABLE OF CONTENTS

See end of this manual for Alphabetical Index

SECTION 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Introduction
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
List of Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Superstructure Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Swing Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Boom. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Swivel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 T
Hydraulic Pumps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
General Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
O
Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 C
Pressing Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Locks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Wires and Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Shims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Gaskets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Hydraulic Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Fatigue of Welded Structures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Loctite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Fasteners and Torque Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Dynamic Shock Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Environmental Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Precautions and Recommendations During Inspection or Replacement . . . . . . . . 1-13
Wire Rope Inspection (Running Ropes and Pendant Cables) . . . . . . . . . . . . . . . . 1-14
Wire Rope Inspection (Boom Extension and Retraction Cables) . . . . . . . . . . . . . . 1-14
Wire Rope Replacement (All Wire Rope) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
Seizing Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
Installing FLEX-X 35 Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
Procedures for Cutting and Preparing FLEX-X 35 . . . . . . . . . . . . . . . . . . . . . . . . . 1-17

SECTION 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic System

Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Hydraulic Oil Recommendations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Draining and Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Removing Air from the Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Parts Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Directional Control Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Supply Pressure and Return Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Oil Cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Hydraulic Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

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TABLE OF CONTENTS TM500E-2 SERVICE MANUAL

Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Pressure Setting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Procedure A - For Checking/Setting The Main Control Valve For Hoists(s),
Boom Lift and Piston Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Procedure B - For Setting The Outrigger & Swing Pressures . . . . . . . . . . . . . . . . 2-18
Procedure C- For Checking/Setting the Pilot Supply Pressure . . . . . . . . . . . . . . . 2-18
Procedure D - For Checking/Setting the Swing Brake Release Pressure . . . . . . . 2-18
Procedure E- For Setting Threshold on Electronic Controllers . . . . . . . . . . . . . . . 2-18
Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
Directional Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
Accessory With Swing Directional Control Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
Holding Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
Outrigger Control Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34
Pilot Operated Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35
Outrigger Selector valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36
Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38
Surface Protection for Cylinder Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38
Lift Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40
Dual Rod Telescope Cylinder (102 Foot Boom) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43
Telescope Cylinder (28.9m [95 Foot] Boom) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47
Outrigger Extension Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52
Outrigger Stabilizer Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55

SECTION 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electric System

Superstructure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Batteries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Fuse Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

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TM500E-2 SERVICE MANUAL TABLE OF CONTENTS

Carrier Electrical Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Design and Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Instrumentation Component Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Carrier Electrical Center (CEC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Additional Electrical Information – Typical Circuit Components . . . . . . . . . . . . . . . 3-12
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Special Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Diagnostic Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Relay Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Replace Fusible Link (Battery-Side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
T
Troubleshooting Wiring and Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Data LInk Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 O
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Design and Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Data Link. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
C
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
Electrical Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
Design and Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
Special Tools and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
Instrumentation System Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
Diagnostic Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
Gauge Tester Function Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
Gauge Data Source Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37

SECTION 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boom
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Boom System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Telescope Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Fly Section Extension Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Extend Synchronizing Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Fly Retraction Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Outer Mid Retract Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Boom Extension Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Boom Retract Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Telescope Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Theory Of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Lift Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Theory Of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
General Maintenance Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Swingaway Extension Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Boom Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Boom Disassembly for the Standard 31 m (102 foot) Boom . . . . . . . . . . . . . . . . . . . . . . 4-7
Disconnect the Base Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Remove the Base Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Disconnect the Inner Mid Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Remove the Inner Mid Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

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TABLE OF CONTENTS TM500E-2 SERVICE MANUAL

Remove the Outer Mid Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

Remove the Tele Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Extend Cable Sheave Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Boom Nose Sheaves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Boom Nose Sheaves Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Boom Nose Sheaves Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Boom Assembly Procedure for the 31 m (102 foot) Boom . . . . . . . . . . . . . . . . . . . . . . 4-17
Extend Cable Sheave Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Install Telescope Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Install the Outer Mid Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Install the Inner Mid Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Install the Base Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
Boom Disassembly for the Optional 29 m (95 foot) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31
Remove the Base Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31
Disconnect Inner Mid Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
Remove the Inner Mid Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
Remove Outer Mid Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35
Remove Telescope Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37
Boom Nose Sheaves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38
Boom Assembly for the Optional 29 m (95 Foot) Boom . . . . . . . . . . . . . . . . . . . . . . . . 4-38
Install Telescope Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38
Install Outer Mid Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39
Install Inner Mid Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41
Connect Inner Mid Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42
Install Base Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43
Boom Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44
Swingaway Extension Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44
Boom Cable Adjustment for the 31 m (102 foot) Boom . . . . . . . . . . . . . . . . . . . . . . . . 4-47
Extend Cable Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-47
Retract Cable Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-48
Boom Cable Adjustment for the 29 m (95 foot) Boom . . . . . . . . . . . . . . . . . . . . . . . . . 4-48
Extend Cable Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-48
Retract Cable Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-49
Boom Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-49
Functional Test Of The Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-49
Boom Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-49
Boom Alignment And Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-49
Extension And Retraction Cable Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-50
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-50
Telescope Circuit Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-52
Lift Circuit Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-54
Lift Cylinder Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-56
Lift Cylinder Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-56
Lift Cylinder Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-56
Lift Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-56

SECTION 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . Hoist And Counterweight

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Warm-up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Functional Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Hoist to Boom Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

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TM500E-2 SERVICE MANUAL TABLE OF CONTENTS

Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Piston Motor and Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Idler Drum and Cable Follower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Hoist Drum Rotation Indicator System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Counterweight Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
T
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13 O
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
C
SECTION 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Swing System
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Swing Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Swing Gearbox And Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Swing Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Swivels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Hydraulic Swivel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Electrical Swivel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19

SECTION 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Train

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Electronic Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Engine Wait To Start /Battery Discharge Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Engine Warning/Electrical System Diagnostic Indicator . . . . . . . . . . . . . . . . . . . . . . 7-6
Engine Stop/Module Off Line Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Air Intake System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Water Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
Test Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17

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Antifreeze/Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
Radiator Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18

SECTION 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Undercarriage
Driveshaft and Shaft Phase Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Driveshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Half-Round End Yoke 12-point Bolt Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Maximum Driveshaft Operating Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Driveshaft Phase Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Interaxle Driveshaft Phase Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Design and Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Driveshafts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Driveshaft Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Construction of a Driveshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Example of Spline Galling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Universal Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Input Yoke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Half-Round End Yoke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Driveshaft Center Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Correcting Universal Joint Operating Angles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Typical Chart to Record Driveshaft/Yoke Angles. . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Cutaway View of Center Bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Typical Axle Housing Shims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Balancing a Driveshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Driveshaft Angles and Phasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Driveshaft Arrows Lined Up “in phase” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Driveshaft Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Causes of Universal Joint Operating Angle Changes . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
Vibration-related Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
First Order Vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
Second order vibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
Lubrication Related Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
Typical Lack of Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
Typical Trunnion Brinelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
Typical End Galling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
Bearing Cup Rotation Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
Driveshaft, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
Removal (Half-round End Yoke Style). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
Universal Joint, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
Assembly (Half-round) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
Driveshaft, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
Installation, Half-Round End Yoke Style . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14
Driveshaft, Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14
Lubrications for Universal Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14
Initial Lubrication and Relube Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14
Driveshaft Support Bearing Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
Driveshaft Maintenance Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
Universal Joint, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
Universal Joint, Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18
U-Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18
Slip Splines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18
Driveshaft Angles, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19

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Tools: Electronic Protractor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19

Preparing the crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19
Pinion Angles, Correcting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20
Wheel Bearing Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21
Adjusted Wheel End Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21
Crane Hub Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21
Nut Adjustment Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22
Wheel Bearing Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22
Jam Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22
Determining Acceptable End Play Using a Dial Indicator . . . . . . . . . . . . . . . . . . . . 8-22
T
Steering Linkage and Wheel Alignment Information . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
Wheel Alignment Measurement Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23 O
Design & Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24
Steering Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24
Tie Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24
C
Tie Rod Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-25
Steering Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-25
Draglink. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-25
Steering Gear and Pitman Arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-25
Steering Column / Steering Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-26
Steering Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-26
Wheel Alignment Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-26
Checking Air Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27
Checking Lug Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27
Front Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27
Rear Axle and Rear Suspension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27
Front Wheel Alignment Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27
Caster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27
Camber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-28
Toe-In / Toe-Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-29
Turning Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-29
Rear Wheel Alignment Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-30
Thrust Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-30
Tandem Scrub Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-31
Typical Wear Patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-31
Incorrect Tire Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-31
Incorrect Camber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-31
Incorrect Toe and Axle Alignment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-31
Dual-Wheel Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-32
Incorrect Caster and Wheel Imbalance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-32
Cuts In the Tire Tread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-32
Spot Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-32
Feathered Edges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-33
Cupping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-33
Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-33
Ball Joint Wear Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-33
Toe Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-34
Turn Angle Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-35
Caster Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-35
Drive Axle Thrust Angle Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-36
Important Safety Information Before Making Ride Height Adjustment . . . . . . . . . . . . . 8-38
Shock Absorbers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-38
Air Spring Inflation And Deflation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-38
Air Spring Inflation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-38

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Air Spring Deflation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-38

Support Beam And Cross Brace Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-38
Cross Brace Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-38
Ride Height Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-38
Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-40
Lateral Alignment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-40
Axle Pinion Angle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-41
Drive Axle Alignment Inspection Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-41
Ride Height Alignment Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-42
Ride Height Pinion Angle Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-44
Adjustment Of More Than 1.5 Degrees . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-44
Steering Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-44
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-45
Steering Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-45
Steering Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-45
Steering Fluid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-45
Test and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-46
Special Torque Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-46
Special Tools And Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-46
Special Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-46
Hydraulic Flow Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-46
Design and Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-47
Steering Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-47
Steering Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-47
Power Steering Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-48
Steering Geometry. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-48
Fluid Reservoir and Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-49
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-49
Tests and Adjustments Steering Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-51
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-51
Testing Pump Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-51
Testing Pump Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-51
Testing Steering Gear Internal Leakage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-52
Steering Knuckle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-52
Adjusting Steering Gear Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-52
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-52
Replacing Power Steering Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-52
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-52
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-53
Replacing Steering Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-53
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-53
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-53
Replacing Steering Fluid Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-54
Changing Power Steering Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-54
Bleeding Steering Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-54
Overhauling Steering Assist Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-55
Preparation Before Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-55
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-55
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-55
ABS System General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-56
Anti-Lock Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-56
ABS System Electronic Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-56
Anti-Lock Brake System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-56
Traction Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-57
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-57
Tooth Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-58
Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-58

TOC-8
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
TABLE OF CONTENTS TM500E-2 SERVICE MANUAL

Initial Start-up Procedure for AL-6 / EC-16 or AL-7 / EC-17 ECU . . . . . . . . . . . . . . . . 8-90
Section I - ABS Warning Lamp Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-91
Section II - Inspection for Illuminated LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-92
Section III - Inspection for Illuminated LEDs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-93
Section IV - Inspection for Illuminated LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-94
Section V - Testing for Power to the ABS ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-95
Section VI A - Testing the Modulator Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-96
Section VI B - Testing the Modulator Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-97
Section VII A - Testing the Wheel Speed Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-98
Section VII B - Testing the Wheel Speed Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-99
Section VIII - Testing for False Indication Caused by ABS Warning Lamp Relay . . . 8-100
Section IX - Testing for False Indication Caused by Wheel Speed Components. . . . 8-101
Section X - Testing TCS Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-102
Section XI - Testing Traction Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-103
Section XII - Testing J1922 Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-104
Outriggers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-105
Outrigger Circuit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-105
Outrigger Beam Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-108
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-111
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-111
Wear Pad Adjustment.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-111
Extension Cylinder Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-112
Stabilizer Cylinder Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-113
Outrigger Control Valve Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-114
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-i

SECTION 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubrication
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Arctic Conditions Below -18°C (0°F).. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Surface Protection For Cylinder Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Carrier Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Superstructure Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
Boom, Boom Extension, and Boom Accessories Lubrication. . . . . . . . . . . . . . . . . . . . . 9-9
Wire Rope Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11

TOC-10
 SECTION 1
1
INTRODUCTION
TABLE OF CONTENTS
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
List of Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Superstructure Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Cummins QSB3.3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Swing Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Boom. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Standard: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Optional: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Swivel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Hydraulic Pumps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Pump #1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Pump #2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Hoists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
General Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Pressing Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Locks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Wires and Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Shims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Antifriction Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Double Row, Tapered Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Heating Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Sleeve Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Gaskets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Hydraulic Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Keep the System Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Sealing Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Hydraulic Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Visual Inspection of Hoses and Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Connectors, Harnesses, Wires, and Connectors . . . . . . . . . . . . . . . . . . . . . . . 1-9
Fatigue of Welded Structures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Loctite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Application of Medium Strength Loctite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Fasteners and Torque Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Dynamic Shock Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Environmental Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Precautions and Recommendations During Inspection or Replacement . . . . . . . . 1-14

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INTRODUCTION TM500E-2 SERVICE MANUAL

Wire Rope Inspection (Running Ropes and Pendant Cables). . . . . . . . . . . . . . . . 1-15

Frequent Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
Periodic Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
Wire Rope Inspection (Boom Extension and Retraction Cables) . . . . . . . . . . . . . 1-15
Periodic Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
Wire Rope Replacement (All Wire Rope) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
Seizing Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
Method 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
Method 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
Installing FLEX-X 35 Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
Procedures for Cutting and Preparing FLEX-X 35. . . . . . . . . . . . . . . . . . . . . . . . . 1-18

1-ii
TM500E-2 SERVICE MANUAL INTRODUCTION

SECTION 1
1
INTRODUCTION
DESCRIPTION Mid Extend . . . . . . . . . . . . . .4267 mm (168 in)
Fully Extended . . . . . . . . . . .6096 mm (240 in)
This Manual provides information for the maintenance of the
Model TM500E-2 Series Grove Crane. Capacities
Fuel Tank . . . . . . . . . . . . . . 114 liters (30.1 gallons)
The lift capacities are listed on the Load Chart in the cab. Coolant System . . . . . . . . . . . . . . . . . . See Engine
A sub-frame with outrigger boxes is bolted to the truck Specifications
Engine Lubrication System . . . . . . . . . See Engine
chassis. The standard crane utilizes 3 axles. A fourth Specifications
pusher-type axle is available as an option. Hydraulic Tank (Reservoir Capacity)
Total . . . . . . . . . . . . . . . . 404 liters (106.8 gal)
The superstructure engine is mounted in the powerplant tray at Full Level . . . . . . . . . . . 364 liters (96.1 gal)
installed on the superstructure. at Low Level . . . . . . . . . . . 344 liters (90.9 gal)
Expansion Volume . . . . . . 40.5 liters (10.7 gal)
The superstructure is capable of 360 degree rotation in
either direction. All crane functions are controlled from the Superstructure Engine
fully-enclosed cab mounted on the superstructure.
The crane is equipped with a standard 30 m (102 foot) or Cummins QSB3.3
optional 29 m (95 foot) four-section, full power synchronized HP Rating . . . . . . . . . . . . . . . . . .110 @ 2400 RPM
boom. Additional reach is obtained by utilizing an optional Peak Torque. . . . . . 304 pounds-foot @ 1600 RPM
swingaway boom extension. Lifting is provided by a main Engine Speed:
No Load . . . . . . . . . . . . . . . . . . . . . 2420 RPM
hoist and an optional auxiliary hoist. Full Load . . . . . . . . . . . . . . . . . . . . . 2200 RPM
NOTE: Throughout this manual, reference is made to left, Idle . . . . . . . . . . . . . . . . . . . . . . . . . 1000 RPM
right, front, and rear when describing locations. Swing Gearbox
When operating the crane, these reference
locations are to be considered as those viewed Reduction Ratio . . . . . . . . . . . . . . . . . . . . . . . . 36:1
Output Torque . . . . . . 755 Nm (6680 pounds-inch)
from the operator’s seat with the superstructure
facing forward over the front of the carrier frame. Boom
NOTE: Transportation and Lifting Decal is shown in
(Figure 1-1). Refer to (Figure 1-2) for basic Standard:
component nomenclature. Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Retracted . . . . . . . . . . . . . . .9423 mm (371 in)
Extended. . . . . . . . . . . . . . 29006 mm(1142 in)
LIST OF SPECIFICATIONS Power. . . . . . . . . . . . . . . . . . . 4 Section, Full Power
Elevation . . . . . . . . . . . . . . . . . . .-3 to +76 degrees
NOTE: For information on the truck chassis portion of the Extensions
crane, refer to the Carrier Operator’s Manual. Fixed Offsettable. . . . . . . . . . 7.9 meters (26 ft)
Folding*. . . . . . . . 7.6 - 13.7 meters (25 - 45 ft)
General *Extensions are offsettable at 0, 15, or 30
degrees.
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . TM500E-2
Rated Capacity. . . . . . . . . . . See Load Chart in cab
Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 x 4 Optional:
Gross Weight . . . . . . . . . . . . . . . . See Axle Weight Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Distribution Table Retracted . . . . . . . . . . . . . . .9264 mm (365 in)
Extended. . . . . . . . . . . . . . 28956 mm(1140 in)
Dimensions Power. . . . . . . . . . . . . . . . . . . 4 Section, Full Power
Elevation . . . . . . . . . . . . . . . . . . .-3 to +76 degrees
NOTE: Dimensions listed are for a crane with all Extensions
components fully retracted in the travel mode. Fixed Offsettable. . . . . . . . . . 7.9 meters (26 ft)
Folding*. . . . . . . . 7.6 - 13.7 meters (25 - 45 ft)
Wheelbase (Center of front axle to centerline of *Extensions are offsettable at 0, 15, or 30
crane) . . . . . . . . . . . . . . . . . . . . . 6147 mm (242 in) degrees.
Overall Crane Length . . . . . . . . 12453 mm (490 in)
Overall Crane Width . . . . . . . . . 2586 mm (101.8 in)
Overall Crane Height . . . . . . . . . 3328 mm (131 in) Swivel Assembly
Outrigger Spread Electrical . . . . . . . . . . . . . . . . . . . . . . 10 Slip Rings
Retracted. . . . . . . . . . . . . . . . 2387 mm (94 in) Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ports

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INTRODUCTION TM500E-2 SERVICE MANUAL

Hydraulic Pumps Hoists

Drum Dimensions
Pump #1 Diameter . . . . . . . . . . . . . . . 260 mm (10.25 in)
Length (Standard) . . . . . . . . 421 mm (16.56 in)
Type . . . . . . . . . . . . . . . . .Piston with torque limiter Cable
Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Diameter . . . . . . . . . . . . . . . . . 15 mm (5/8 in)
Displacement . . . 112 cm3 (6.83 in 3) per revolution Length-Main. . . . . . . . . . . . . . . . 137 m (450 ft)
Length-Aux. . . . . . . . . . . . . . . . . 137 m (450 ft)
Pump #2 Max. Permissible Line Pull (6x36)
. . . . . . . . . . . . . . . . . . . . 5280 kg (11,640 pounds)
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear Max. Single Line Speed . . . 156.7 m/min (514 fpm)
Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Hoist Motor Displacement
Displacement . . 33.03 cm3 (2.01 in 3) per revolution Max . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3 cir
Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 cir

7025

FIGURE 1-1

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TM500E-2 SERVICE MANUAL INTRODUCTION

18
1
8 7 6 1 16 15 5
20 14 17

9
6942-1

21
3 3
2 2
7 13
5 19 10 6 11 12 14
8

6942-2
2 4
4 3
3 21

FIGURE 1-2

Item Description Item Description

1 Superstructure Cab 12 Boom Extension
2 Outrigger Float 13 Boom Extension Nose
3 Outrigger Stabilizer Cylinder 14 Boom Pivot
4 Steps 15 Hydraulic Tank
5 Counterweight 16 Hydraulic Filter
6 Lift Cylinder 17 Main Hoist
7 Boom 18 Auxiliary Hoist
8 Boom Nose Sheaves 19 Air Cleaner
9 Auxiliary Boom Nose 20 Boom Rest
10 Superstructure Engine 21 Remote Outrigger Controls
11 Boom Extension Mast Sheave

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13
20 11 12 14 8
7 6
5

6942-3
2 21

View With 95 Foot Boom Option

FIGURE 1-2 continued

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TM500E-2 SERVICE MANUAL INTRODUCTION

GENERAL MAINTENANCE ensure the crane is blocked securely and the weight is

These general suggestions should be helpful in following the

supported by blocks rather than by lifting equipment. 1
i ns t r u c t io n s i n th i s m a nu a l . I n a n al y z i ng a s y s te m When using hoisting equipment, follow the hoist
malfunction, use a systematic procedure to locate and manufacturers recommendations and use lifting devices that
correct the problem. will allow you to achieve the proper balance of the
assemblies being lifted and to ensure safe handling. Unless
1. Determine the problem. otherwise specified, all removals requiring hoisting
2. List possible causes. equipment should be accomplished using an adjustable
lifting attachment. All supporting members (chains and
3. Devise checks.
cables) should be parallel to each other and as near
4. Conduct checks in a logical order to determine the perpendicular as possible to the top of the object being lifted.
cause.
5. Consider the remaining service life of components
against the cost of parts and labor necessary to replace CAUTION
them. The capacity of an eyebolt diminishes as the angle
between the supporting members and the object
6. Make the necessary repair.
becomes less than 90°. Eyebolts and brackets should
7. Recheck to ensure that nothing has been overlooked. never be bent and should only have stress in tension.
8. Functionally test the failed part in its system.
Some removals require the use of lifting fixtures to obtain
NOTE: Your safety and that of others is always the number proper balance. The weights of some components are given
one consideration when working around machines. in their respective sections of the manual.
Safety is a matter of thoroughly understanding the
If a part resists removal, check to be certain all nuts and bolts
job to be done and the application of good common
have been removed and that an adjacent part is not
sense. It is not just a matter of do’s and don’ts. Stay
interfering.
clear of all moving parts.
Disassembly and Assembly
Cleanliness
When assembling or disassembling a component or system,
An important item in preserving the long life of the machine is
complete each step in turn. Do not partially assemble one
keeping dirt out of working parts. Enclosed compartments,
part and start assembling some other part. Make all
seals, and filters have been provided to keep the supply of
adjustments as recommended. Always check the job after it
air, fuel, and lubricants clean. It is important that these
is completed to see that nothing has been overlooked.
enclosures be maintained.
Recheck the various adjustments by operating the machine
Whenever hydraulic, fuel, lubricating oil lines, or air lines are before returning it to the job.
disconnected, clean the adjacent area as well as the point of
disconnect. As soon as the disconnection is made, cap, plug, Pressing Parts
or tape each line or opening to prevent entry of foreign
When pressing one part into another, use an anti-seize
material. The same recommendations for cleaning and
compound or a molybdenum disulfide base compound to
covering apply when access covers or inspection plates are
lubricate the mating surfaces.
removed.
Assemble tapered parts dry. Before assembling parts with
Clean and inspect all parts. Be sure all passages and holes
tapered splines, be sure the splines are clean, dry, and free
are open. Cover all parts to keep them clean. Be sure parts
from burrs. Position the parts together by hand to mesh the
are clean when they are installed. Leave new parts in their
splines before applying pressure.
containers until ready for assembly.
Parts which are fitted together with tapered splines are
Clean the rust preventive compound from all machined
always very tight. If they are not tight, inspect the tapered
surfaces of new parts before installing them.
splines and discard the part if the splines are worn.
Removal and Installation Locks
When performing maintenance, do not attempt to manually
Lockwashers, flat metal locks, or cotter pins are used to lock
lift heavy parts when hoisting equipment should be used.
nuts and bolts.
Never locate or leave heavy parts in an unstable position.
When raising a portion of a crane or a complete crane,

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INTRODUCTION TM500E-2 SERVICE MANUAL

Flat metal locks must be installed properly to be effective. Installation

Bend one end of the lock around the edge of the part. Bend
the other end against one flat surface of the nut or bolt head. Lubricate new or used bearings before installation. Bearings
that are to be preloaded must have a film of oil over the entire
Always use new locking devices on components which have assembly to obtain accurate pre-loading. When installing a
moving parts. bearing, spacer, or washer against a shoulder on a shaft, be
Wh en insta lling loc kwashe rs o n ho usings made of sure the chamfered side is toward the shoulder.
aluminum, use a flat washer between the lockwasher and When pressing bearings into a retainer or bore, uniformly
the housing. apply pressure to the outer race. If the bearing is pressed on
the shaft, uniformly apply pressure on the inner race.
Wires and Cables
Batteries should always be disconnected prior to working on Preload
the electrical system. Preload is an initial load placed on the bearing at the time of
When removing or disconnecting a group of wires or cables, assembly. Whether a tapered roller bearing should have
tag each one to ensure proper identification during preload could depend on any of several conditions: rigidity of
assembly. the housings and shaft, bearing spread, speed of operation,
etc.
Shims To determine whether a bearing requires preload or end
When shims are removed, tie them together and identify c l e ar a nc e , c on s u l t t h e d i s a s s em b l y a n d a s s e m b l y
them as to location. Keep shims clean and flat until they are instructions pertaining to that bearing.
reinstalled. Care should be exercised in applying preload. Misapplication
of preload to bearings requiring end clearance can result in
Bearings bearing failure.

Antifriction Bearings Sleeve Bearings

When an antifriction bearing is removed, cover it to keep out Do not install sleeve bearings with a hammer. Use a press
dirt and abrasives. Wash bearings in non-flammable and be sure to apply the pressure directly in line with the
cleaning solution and allow them to drain dry. The bearing bore. If it is necessary to drive on a bearing, use a bearing
may be dried with compressed air BUT do not spin the driver or a bar with a smooth flat end. If a sleeve bearing has
bearing. Discard the bearings if the races and balls or rollers an oil hole, align it with the oil hole in the mating part.
are pitted, scored, or burned. If the bearing is serviceable,
coat it with oil and wrap it in clean waxed paper. Do not Gaskets
unwrap new bearings until time of installation. The life of an
antifriction bearing will be shortened if not properly Be sure the holes in the gaskets correspond with the
lubricated. Dirt in an antifriction bearing can cause the lubricant passages in the mating parts. If it is necessary to
bearing to lock resulting in the shaft turning in the inner race make gaskets, select material of the proper type and
or the outer race turning within the cage. thickness. Be sure to cut holes in the right places. Blank
gaskets can cause serious damage.
Double Row, Tapered Roller When removed, always install new cylinder head and
Double row, tapered roller bearings are precision fit during manifold gaskets using recommended gasket compound on
manufacture and components are not interchangeable. The head gaskets to allow uniform sealing.
cups, cones, and spacers are usually etched with the same
serial number and letter designator. If no letter designators Batteries
are found, wire the components together to assure correct Clean batteries by scrubbing them with a solution of baking
installation. Reusable bearing components should be soda and water. Rinse with clear water. After cleaning, dry
installed in their original positions. thoroughly and coat terminals and connections with an anti
corrosion compound or grease.
Heating Bearings
If the machine is to be stored or not used for an extended
Bearings which require expansion for installation should be period of time, the batteries should be removed. Store the
heated in oil not to exceed 121 °C (250 °F). When more than batteries in a cool (not subfreezing), dry place, preferably on
one part is heated to aid in assembly, they must be allowed wooden shelves. Never store on concrete. A small charge
to cool and then pressed together again. Parts often should be introduced periodically to keep the specific gravity
separate as they cool and contract. rating at recommended level.

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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.

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INTRODUCTION TM500E-2 SERVICE MANUAL

Table 1-1

Zone Classification
A Tropical Moist: All months average above 18° C. Latitude 15° - 25° North and South
B Dry or Arid: Deficient precipitation most of the year. Latitude: 20° - 35° North and South
C Moist Mid-Latitude: Temperature with mild winters. Latitude: 30° - 50° North & South
D Moist Mid-latitude: Cold winters. Latitude 50° - 70° North & South
E Polar: Extremely cold winters and summers. Latitude: 60° - 75° North & South

Electrical System areas applicable to Manitowoc/Grove machines, and a visual

inspection of these areas should be made part of an owner’s
Connectors, Harnesses, Wires, and planned preventive maintenance program:
Connectors 1. Power Telescope Boom - wear pad retaining structures,
hydraulic cylinder attaching points, boom pivot shaft
Visually inspect all electrical harnesses, cables, and
retaining structures.
connectors every month or 250 hours for the following:
2. Outrigger pads, beams, boxes and attachment
• Damaged, cut, blistered, or cracked insulation.
structures.
• Exposed bare wires.
3. Main frames - generally in the area of doubler plates and
• Kinked or crushed wires and cables. crossmembers; at the junction of front and rear frame
members on truck cranes.
• Cracked or corroded connectors, battery terminals, and
ground connections. 4. Turntable bearing connection (where bearing is welded
to the crane superstructure or chassis).
If any the above conditions exist, evaluate and replace as
necessary. 5. Counterweight support structures.

The climate in which the crane operates affects the service 6. Chassis axle and suspension mounting structures.
life of the electrical components. The climate zones are 7. Hydraulic cylinder end connections.
defined in (Table 1-1). Recommended replacement of
harness and cables is as follows: The above is provided only as a guide, and your inspection
plan should not be limited to the areas listed. A thorough
• Climate zone C after 10,000 hours of service. visual inspection of all weldments is good practice.
• Climate zones A and C with high ambient temperatures Anyone requiring more detailed inspection instructions and/
and duty cycles after 8000 hours of service. or repair procedures may request them by contacting the
• Climate zones D and E after 10,000 hours of service. local Manitowoc/Grove distributor.

• Salt water conditions after 8,000 hours of service. Loctite

Fatigue of Welded Structures
Experience has shown that highly stressed welded
structures when repeatedly subjected to varying stresses DANGER
caused by twisting, shock, bending, and intentional and/or Loctite type adhesives contain chemicals that may be
unintentional overloads, often become subject to weld harmful if misused. Read and follow the instructions on
cracking which may be attributed to fatigue of the welded the container.
joint. This condition is not uncommon in construction
equipment. Always follow the directions on the Loctite container as not
Equipment should be periodically inspected for evidence of all Loctite types are suitable for all applications.Various types
weld fatigue. The frequency of these inspections should be of Loctite are specified throughout the Service Manual.The
commensurate with the age of the equipment, the severity of following types of Loctite brand adhesives are available from
the application, and the experience of the operators and the Parts Department of the local Manitowoc/Grove
maintenance personnel.The following are known high stress distributor.

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Application of Medium Strength Loctite Torque values should correspond to the type bolts, studs,

NOTE: The fastener may be re-used; the adhesive may be

and nuts being used (Figure 1-4) and (Figure 1-5). 1
re-applied over cured adhesive residue. The torque tables (Table 1-2), (Table 1-3), (Table 1-4) and
(Table 1-5) are provided by Manitowoc Crane Care for
The following procedure covers the proper application and reference when performing maintenance.
curing method for medium strength Loctite adhesive/sealant
(Loctite #242) and primer (Locquic Primer T7471). Use of proper torque values is extremely important. Improper
torquing can seriously affect performance and reliability.
Primer Application
Identification of fastener grade is always necessary. When
NOTE: It is not necessary to bathe the threads in primer. marked as a high strength bolt (grade 5, 8, etc.), the
1. Ensure the threaded surface, both male and female, is mechanic must be aware that he is working with a highly
clean and free of dirt and oil. Apply a light spray coating stressed component and the fastener should be torqued
of primer to both male and female parts to be joined to accordingly.
clean and accelerate the curing process. NOTE: Some special applications require variation from
2. Allow the part to dry prior to adhesive/sealant standard torque values. Reference should always
application. be made to component overhaul procedures for
recommendations.
Adhesive/Sealant Application
Special attention should be given to the existence of
lubricant, plating, or other factors that might require variation
Bead Application from standard torque values.
When maximum recommended torque values have been
exceeded, the fastener should be replaced.
When referring to the applicable torque charts, use values as
close as possible to the torque values shown to allow for
4203
wrench calibration tolerance. An erratic or jerking motion of
FIGURE 1-3 the wrench can easily result in excessive torque. ALWAYS
use a slow wrench mo vement and STOP when the
1. Apply a bead perpendicular to the thread, several predetermined value has been reached.
threads wide, in the approximate area of threaded
Torque wrenches are precision instruments and are to be
engagement (Figure 1-3).
handled with care to ensure calibrated accuracy. Calibration
2. In a blind hole application, a bead of several drops of checks should be made on a scheduled basis. Whenever the
adhesive should be applied into the bottom of the hole to wrench might be either over stressed or damaged, it should
be hydraulically forced up during engagement. immediately be removed from service until recalibrated.
3. After application and engagement of mated threads, KNOW YOUR TORQUE WRENCH! Flexible beam type
fixturing will occur within five (5) minutes if primed prior wrenches, even though they might have a preset feature,
to engagement. Fixturing may take up to 30 minutes on must be pulled at right angles and the force must be applied
unprimed parts. at the exact center of the handle. Force value readings must
be made while the tool is in motion.
4. Time required to achieve full strength is 24 hours.
Maximum ultimate strength is achieved using no primer Rigid handle type torque wrenches are available with torque
with this specific threadlocking adhesive. limiting devices that can be preset to required values and
which eliminate dial readings.
Fasteners and Torque Values
NOTE: To convert pounds-foot of torque to newton meters
Use bolts of the correct length. A bolt which is too long may (Nm), multiply the pounds-foot quantity by 1.3558.
bottom out before the head is tight against the part it is to
To convert pounds-inch of torque to newton meters
hold. If a bolt is too short, there may not be enough threads
(Nm), multiply the pounds-inch quantity by
engaged to hold the part securely. Threads can be
0.11298.
d am a ge d . I n s p ec t t he m an d r e p la c e fa s t e ne r s , a s
necessary. When multipliers and/or special tools are used to
reach hard to get at spots, ensure torque readings
are precisely calculated.

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INTRODUCTION TM500E-2 SERVICE MANUAL

Dynamic Shock Loads 1. High velocity movement e.g.; hoisting or swinging of a

load followed by abrupt stops.
Subjecting wire rope to abnormal loads beyond the
endurance limit will shorten the wire ropes, life expectancy. 2. Suspending loads while traveling over irregular surfaces
Examples of this type of loading are listed below. such as railroad tracks, potholes, and rough terrain.
3. Moving a load that is beyond the rated capacity of the
lifting mechanism, i.e.; overloading.

Grade 5

120° 120°

No 3 Lines 1 Line 3 Dots 3 Radial 1 Radial 1 Row

Markings Spaced 1 Dot Spaced Lines Line Notched
120° 120° 1 Dot Corners
Heat
Grade 8

60° 60°

6 Lines 1 Line 6 Radial 6 Dots 1 Radial 2 Rows

Spaced 1 Dot Lines Spaced Line Notched
60° 60° 1 Dot Corners

FIGURE 1-4

SAE Grade 1 SAE Grade 5 SAE Grade 7 SAE Grade 8

and Grade 2

Socket Socket Serrated

Capscrew Shoulder Flange Head
Screw

FIGURE 1-5

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Table 1-2
Torque Values For Unfinished Fasteners With No Special Lubrication - Coarse Threads 1
Bolt Diameter - Inches
Torque Values (Pounds-Foot)
Coarse Thread
1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1 1-1/8 1-1/4 1-3/8 1-1/2
Capscrew
SAE Grade 1 5.5 11 20 31 47 69 97 156 210 312 493 685 919 1100
and Grade 2 5.0 9 18 29 43 63 89 144 194 288 455 633 849 1015
9.0 19 32 52 78 114 156 270 416 606 813 1141 1519 2028
SAE Grade 5
7.7 17 30 48 72 106 144 249 384 560 751 1053 1403 1865
12.5 26 48 73 120 161 234 385 615 929 1342 2043 2496 3276
SAE Grade 8
11.5 24 44 67 110 143 216 355 567 857 1234 1885 2296 3024
Socket 12.5 26 48 73 120 161 234 385 615 929 1342 2043 2496 3276
Capscrew 11.5 24 44 67 110 143 216 355 567 857 1234 1885 2296 3024
Socket 5 12 23 42 42 100 174 346
— — — — — —
Shoulder Screw 3 9 21 38 38 92 160 320
SAE 5.2
Serrated 12 25 45 72 110 — 220 — — — — — — —
Flange Head 9 19 34 54 83 166

NOTE 1: Studs shall be torqued using capscrew figures when grade is known.
NOTE 2: Torque values for zinc plated fasteners are the same as for unfinished fasteners.

Table 1-3
Torque Values For Unfinished Fasteners With No Special Lubrication - Fine Threads

Bolt Diameter - Inches

Torque Values (Pounds - Foot)
Fine Thread
1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1 1-1/8 1-1/4 1-3/8 1-1/2
Capscrew
SAE Grade 1 6.3 12 22 34 52 76 108 172 230 340 535 751 1032 1221
and Grade 2 5.8 10 20 32 48 70 100 158 212 314 493 693 952 1127
10 21 36 57 88 126 182 312 458 658 882 1251 1704 2288
SAE Grade 5
9 19 34 53 81 116 167 287 421 606 814 1155 1572 2105
14.5 26 53 85 125 177 250 425 672 1009 1500 2092 2833 3640
SAE Grade 8
13.5 24 49 79 115 163 230 393 620 931 1380 1925 2605 3360
Socket 14.5 26 53 85 125 177 250 425 672 1009 1500 2092 2833 3640
Capscrew 13.5 24 49 79 115 163 230 393 620 931 1380 1925 2605 3360

SAE 5.2
Serrated 15 28 52 81 125 — 251 — — — — — — —
Flange Head 11 21 39 61 94 189

NOTE 1: Studs shall be torqued using capscrew figures when grade is known.
NOTE 2: Torque values for zinc plated fasteners are the same as for unfinished fasteners.

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INTRODUCTION TM500E-2 SERVICE MANUAL

Table 1-4
Torque Values For Metric Fasteners With No Special Lubrication - Coarse Threads

Bolt Diameter - Metric

TORQUE VALUES (Nm)
M4 M5 M6 M7 M8 M10 M12 M14 M16 M18 M20 M22 M24 M27 M30
Grade
0.157 0.197 0.236 0.276 0.315 0.394 0.472 0.551 0.630 0.709 0.787 0.866 0.945 1.06 1.18
3.1 6.5 11 19 27 53 93 148 230 391 447 608 774 1134 1538
8.8
2.8 5.9 10 17 25 49 85 136 212 294 413 562 714 1046 1420
4.5 9.2 16 26 38 75 130 212 322 455 629 856 1089 1591 2163
10.9
4.1 8.5 14 24 35 69 120 195 298 418 581 790 1005 1469 1997
5.4 11 19 31 45 89 156 248 387 532 756 1029 1306 1910 2595
12.9
4.9 10 17 28 42 83 144 228 357 490 698 949 1206 1763 2395

NOTE 1: Torque values for fine threads are 8% higher.

Table 1-5
Torque Values For Metric Fasteners With No Special Lubrication - Coarse Threads

Bolt Diameter - Metric

TORQUE VALUES (Pounds - Foot)
M4 M5 M6 M7 M8 M10 M12 M14 M16 M18 M20 M22 M24 M27 M30
Grade
0.157 0.197 0.236 0.276 0.315 0.394 0.472 0.551 0.630 0.709 0.787 0.866 0.945 1.06 1.18
2.3 4.8 8.1 14.0 20 39 69 109 170 235 329 448 548 836 1134
8.8
2.1 4.3 7.4 12.5 18 36 63 100 156 217 304 414 526 771 1047
3.3 6.8 11.8 19.0 29 55 96 156 237 335 464 631 803 1173 1594
10.9
3.0 6.3 10.3 17.6 26 51 88 144 220 308 428 582 741 1083 1472
4.0 8.1 14.0 23.0 33 66 115 183 285 392 557 758 963 1408 1913
12.9
3.6 7.4 12.5 20.6 31 61 106 168 263 361 514 699 889 1299 1765

NOTE 1: Torque values for fine threads are 8% higher.

WIRE ROPE The following provides inspection and maintenance

procedures for wire ropes used on Grove products (e.g. wire
General rope used as load lines [hoisting cables], boom extension
and retraction cables, pendant cables, tow winch cables, and
The following information is a compendium of information hook block tie down cables).
from various wire rope manufacturers and includes
inspection, replacement, and maintenance guidelines for Environmental Conditions
wire rope as established by ANSI/ASME B30.5, federal
regulations, and Grove Worldwide. The inspection interval The life expectancy of wire rope may vary due to the degree
shall be determined by a qualified person and shall be based of environmental hostility and other conditions to which these
on such factors as expected rope life as determined by mechanical devices are subjected. Variation in temperature,
expe rience on t he particula r ins ta llat ion or similar continuous excessive moisture levels, exposure to corrosive
installations, severity of environment, percentage of capacity chemicals or vapors or subjecting the wire rope to abrasive
lifts, frequency rates of operation, and exposure to shock material may shorten normal wire rope life. Frequent/
loads. Periodic Inspections need not be at equal calendar periodic inspections and maintenance of your wire rope is
intervals and should be performed at shorter time intervals recommended for preventing premature wear and to insure
as the wire rope approaches the end of its useful life. A long-term satisfactory performance.
periodic inspection shall be performed at least once a year.

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Lubrication 1. It should be free from acids and alkalis.

A wire rope cannot be lubricated sufficiently during 2. It should have sufficient adhesive strength to remain on
1
manufacture to last it’s entire life. Therefore, new lubricant the ropes.
must be added throughout the life of a rope to replace factory 3. It should be of a viscosity capable of penetrating the
lubricant which is used or lost. It is important that lubricant interstices between wires and strands.
applied as part of a maintenance program shall be
compatible with the original lubricant, and to this end, the 4. It should not be soluble in the medium surrounding it
rope manufacturer should be consulted. Lubricant applied under the actual operating conditions (i.e. water).
shall be of the type which does not hinder visual inspection. 5. It should have a high film strength.
Those sections of rope which are located over sheaves or
otherwise hidden during inspection and maintenance 6. It should resist oxidation.
procedures require special attention when lubricating rope. Before applying lubrication, accumulations of dirt or other
The object of rope lubrication is to reduce internal friction and abrasive material should be removed from the rope.
to prevent corrosion. Cleaning can be accomplished by using a stiff wire brush
During fabrication, ropes receive lubrication; the kind and and solvent, compressed air, or live steam. Immediately after
amount depends on the rope’s size, type, and anticipated the wire rope is cleaned, it should be lubricated. Many
use. This in-process treatment will provide the finished rope techniques may be used; these include bath, dripping,
with ample protection for a reasonable time if it is stored pouring, swabbing, painting or pressure spray methods
under proper conditions. But, when the rope is put into (Figure 1-6). Whenever possible, the lubricant should be
service, the initial lubrication may be less than needed for the applied at the top of a bend in the rope, because at that point
full useful life of the rope. Because of this possibility, periodic the strands are spread by bending and are more easily
applications of a suitable rope lubricant are necessary. penetrated. There should be no load on the rope while it is
being lubricated. It should be noted, the service life of wire
The following are important characteristics of a good wire rope will be directly proportional to the effectiveness of the
rope lubricant: method used and amount of lubricant reaching the working
parts of the rope.

FIGURE 1-6

Precautions and Recommendations During 5. When replacing fixed length cable assemblies (e.g.
Inspection or Replacement pendants) having permanently attached end fittings use
only pre-assembled lengths of wire rope as supplied
1. Always lock out equipment power when removing or from Grove Customer Support. Do not build lengths from
installing wire rope assemblies. individual components.
2. Always use safety glasses for eye protection. 6. Replace an entire wire rope assembly. Do not attempt to
rework damaged wire rope or wire rope ends.
3. Wear protective clothing, gloves, and safety shoes as
appropriate. 7. Never electroplate wire rope assemblies.
4. Use supports and clamps to prevent uncontrolled 8. Do not weld any wire rope assembly or component
movement of wire rope, parts, and equipment. unless welding is recommended by the wire rope

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INTRODUCTION TM500E-2 SERVICE MANUAL

manufacturer. Welding spatter shall never be allowed to Periodic Inspection

come in contact with the wire rope or wire rope ends. In
addition, be sure that the wire rope is not an electrical Wire rope should be inspected periodically/annually or at a
path during other welding operations. shorter time interval if necessitated by environmental or
other adverse conditions, and shall cover the entire length of
9. Wire ropes are manufactured from special steels. If the wire rope. Only the outer surface of the wire rope need
heating a wire rope assembly is absolutely necessary for be inspected, and no attempt should be made to open the
removal, the entire wire rope assembly shall be rope. Periodic inspection should include all items listed
discarded. under frequent inspection plus the following:
10. On systems equipped with two or more wire rope 1. Inspect for reduction of rope diameter below nominal
assemblies operating as a matched set, they shall be diameter.
replaced as an entire set.
2. Inspect for severely corroded or broken wires at end
11. Do not paint or coat wire ropes with any substance connections.
except approved lubricants.
3. Inspect for severely corroded, cracked, bent, worn, or
Wire Rope Inspection (Running Ropes and improperly applied end connections.
Pendant Cables) 4. Inspect wire rope in areas subjected to rapid
deterioration such as:
Wire rope should be inspected frequently/dally and
periodically/yearly in accordance with the following • Sections in contact with saddles, equalizer
information excerpted from a National Consensus Standard sheaves, or other sheaves where wire rope travel is
as referenced by Federal Government Agencies. limited.
Recommended inspection intervals may vary from machine • Sections of wire rope at or near terminal ends where
to m a ch i ne a nd m a y v ar y ba s ed o n e nv i r o nm en ta l corroded or broken wires may protrude.
conditions, frequency of lifts, and exposure to shock loads.
The inspection time intervals may also be predetermined by 5. Inspect boom nose sheaves, hook block sheaves, boom
state and local regulatory agencies. extension/jib sheaves, auxiliary boom nose sheaves,
and hoist drums for wear. Damaged sheaves or hoist
NOTE: Wire rope may be purchased through Manitowoc drums can accelerate wear and cause rapid
CraneCARE. deterioration of the wire rope.
Any deterioration observed in the wire rope should be noted
in the equipment inspection log and an assessment Wire Rope Inspection (Boom Extension and
concerning wire rope replacement should be made by a Retraction Cables)
qualified person.
Periodic Inspection.
Frequent Inspection
It is recommended that a periodic inspection of all boom
A frequent daily visual inspection is recommended for all extension and retraction cables be performed using the
running ropes in service. This inspection should be made on following guidelines. This inspection shall cover the entire
all wire rope which can be expected to be in use during the length of the extension and retraction cables. This inspection
day’s operation. This inspection should be used to monitor should be used to monitor progressive degradation and to
progressive degradation and to discover severe damages d i s c o v e r s e v e r e d a m a g e s n e c e s s i ta t i n g w i r e r o p e
necessitating wire rope replacement such as: replacement or equipment repair. Inspection criteria are as
follows:
1. Distortion, Kinking, Crushing, Un-stranding, Bird caging,
Reduction of diameter, etc. 1. Inspect for reduction of rope diameter below nominal
diameter.
2. General corrosion.
2. Inspect for severely corroded or broken wires at end
3. Broken or cut strands.
connections.
4. Number, distribution and type of broken wires.
3. Inspect for severely corroded, cracked, bent, worn, or
5. Evidence of core failure. improperly applied end connections.
6. End fitting wear/abrasion. 4. Inspect wire rope in areas subjected to rapid
deterioration such as:
• Sections in contact with saddles, equalizer sheaves,
or other sheaves where wire rope travel is limited.

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TM500E-2 SERVICE MANUAL INTRODUCTION

• Sections of wire rope at or near terminal ends where 6. Grove Worldwide recommends that for cable extended
corroded or broken wires may protrude. booms, a single damaged wire rope assembly shall 1
require replacement of the entire set of extension
• Sections of wire rope in contact with stationary
cables.
surfaces where abrasion or chafing may take place
as a result of equipment vibration. 7. Grove Worldwide recommends for cable extended
booms, that boom extension cables be replaced every
5. Inspect for damaged or wobbly boom extension and
seven (7) years.
retraction sheaves that may cause rapid deterioration of
the wire rope.
Seizing Wire Rope
6. Inspect for unusual cable sag/stretch and be sure cables
It is important to seize the ends of rotation resistant wire
used in sets all have an equal tension applied. Repeated
ropes to prevent the displacement and unraveling of the
need for adjustment of an individual cable is evidence of
individual wires and strands at the ends. All preformed and
cable stretch and indicates the need for additional and
non-preformed styles of wire rope should be seized prior to
more thorough inspection in order to determine and
cutting. Seizings must be placed on both sides of the point
correct the cause.
where the wire rope is to be cut.
Wire Rope Replacement (All Wire Rope) The two preferred methods for seizing wire ropes are:
No precise rules can be given for determination of the exact
time for replacement of wire rope since many variable factors
Method 1
are involved. Determination regarding continued use or Using a length of soft annealed wire, place one end in the
replacement of wire rope depends largely upon the good groove between two strands of the wire rope. Turn the long
judgement of an appointed and qualified person who end of the annealed wire at right angles to the wire and wrap
evaluates the remaining strength in a used rope after it tightly over the portion in the groove (Figure 1-7).
allowance for any deterioration disclosed by inspection.
The two ends of the annealed wire should be twisted
Wire rope replacement should be determined by the together tightly. Cut off the excess wire and pound the twist
following information excerpted from a National Consensus flat against the wire rope.
Standard as referenced by Federal Government Agencies
and as recommended by Grove Worldwide. All wire rope will
eventually deteriorate to a point where it is no longer usable.
Wire rope shall be taken out of service when any of the
following conditions exist:
1. In running ropes, six randomly distributed broken wires
in one lay or three broken wires in one strand in one lay.
2. Wear of one-third the original diameter of outside
individual wires. Kinking, crushing, bird caging, or any
other damage resulting in distortion of the rope
structure.
3. Evidence of any heat damage from any cause.
4. Reductions from nominal diameter of more than: FIGURE 1-7

• 1/64 inch for diameters up to and including 5/16

inch. Method 2
• 1/32 inch for diameters 3/8 and 1/2 inch inclusive. Wind a length of soft annealed wire around the wire rope at
least seven times. The two ends should be twisted together
• 3/64 inch for diameters 9/16 to 3/4 inch inclusive.
in the center of the seizing. Tighten the seizing by alternately
• 1/16 inch for diameters 7/8 to 1 1/8 inches inclusive. prying and twisting. Cut off both ends of the wire and pound
• 3/32 inch for diameters 1/14 to 1 1/2 inches the twist flat against the rope (Figure 1-8).
inclusive. NOTE: Non-preformed wire rope should have two seizings
5. In standing ropes, more than two broken wires in one lay located on each side of the cut (Figure 1-9).
in sections beyond end connections or more than one
broken wire at an end connection.

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INTRODUCTION TM500E-2 SERVICE MANUAL

1. Unload properly and relieve any twists. Pull the rope off
the shipping reel or unroll it from a shipping coil. (If done
improperly, you may kink the rope, which will result in
permanent damage to the rope.) Then lay the rope on
the ground in direct line with the boom. This helps
release any twist in the rope.
2. Attach rope’s end to drum. Pull the rope over the point
sheave and attach the end to the drum. Be sure not to
remove the welded end.
3. Wind rope onto drum slowly and carefully. At this point, it
isn’t necessary to provide additional load other than the
weight of the rope being pulled across the ground.
4. Spool first layer tightly. It is essential on smooth-faced
drums that the first layer is spooled with wraps tight and
close together since the first layer forms the foundation
for succeeding layers. If need be, use a rubber, lead or
brass mallet (but never a steel hammer) to tap the rope
in place.
5. Spool multiple layers with sufficient tension. It’s very
important to apply a tensioning load to the ropes during
FIGURE 1-8 the rope breaking-in process. (If not, the lower layers
may be loose enough that the upper layers become
wedged into the lower layers under load, which can
seriously damage the rope.) The tensioning load should
NONPREFORMED
range from 1 to 2% of the rope’s minimum breaking
force.
6 ROPE 6. For ropes in multi-part systems: Reeve the traveling
BEFORE CUTTING DIAM. block and boom tip sheaves so the rope spacing is
maximized and the traveling (hook) block hangs straight
and level to help assure block stability.
7. Breaking in your new Flex-X 35: After installation, you
PREFORMED should properly break in your rope, which allows the
rope’s component parts to adjust themselves to your
operating conditions.
BEFORE CUTTING
With the boom fully raised and fully extended, attach a
light load at the hook and raise it a few inches off the
ground. Allow to stand for several minutes. Then cycle
AFTER CUTTING the load between the full “up” and “down” positions
several times. Stand back and watch the drum winding
and rope travel for any potential problems.
FIGURE 1-9
After making the lifts with a light load, increase the load
and cycle it up and down a few times. This procedure will
Installing FLEX-X 35 Wire Rope train the rope and help assure smooth operation during
its useful life.
Ideally, you should run these loads with reeving that lets
CAUTION you place the loads on the block with all rope off the
Any cutting of this specific wire rope is not recommended. drum except the last three wraps. If this is not possible,
If FLEX-X 35 wire rope must be cut for any reason, it is alternate methods must be used to assure proper
necessary to follow the attached instructions. Also, unlike tensioning of the rope on the drum.
other types of wire rope, the ends on this wire rope must
be welded.

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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

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 SECTION 2
HYDRAULIC SYSTEM
TABLE OF CONTENTS
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Hydraulic Oil Recommendations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2
Draining and Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Removing Air from the Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Parts Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Directional Control Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Valve Leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Binding Spools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Supply Pressure and Return Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Hydraulic Reservoir and Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Pump Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Return Hydraulic Filter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Hydraulic Reservoir Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Hydraulic Reservoir Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Oil Cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Hydraulic Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
No. 1 Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
No. 1 Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
No. 2 Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
No. 2 Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Testing After Rebuild or Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Hydraulic Gear Pump Start-up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Piston Pump Start-up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Pressure Setting Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Procedure A - For Checking/Setting The Main Control Valve For Hoists(s),
Boom Lift and Piston Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Procedure B - For Setting The Outrigger & Swing Pressures. . . . . . . . . . . . . . . . . 2-18
Procedure C- For Checking/Setting the Pilot Supply Pressure. . . . . . . . . . . . . . . . 2-18
Procedure D - For Checking/Setting the Swing Brake Release Pressure . . . . . . . 2-18
Procedure E- For Setting Threshold on Electronic Controllers . . . . . . . . . . . . . . . . 2-18
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
Directional Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
Boom Lift/Telescope/Hoist Valve Bank Removal . . . . . . . . . . . . . . . . . . . . . . 2-26
Boom Lift/Telescope/Hoist Valve Bank Installation . . . . . . . . . . . . . . . . . . . . . 2-26
Functional Check (All Valve Banks) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
Function Check - LMI Lockout Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
Accessory With Swing Directional Control Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29

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HYDRAULIC SYSTEM TM500E-2 SERVICE MANUAL

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
Holding Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
Outrigger Control Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34
Functional Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34
Pilot Operated Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35
Outrigger Selector valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36
Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38
Surface Protection for Cylinder Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38
Leakage Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38
Temperature Effects on Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . 2-39
Lift Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40
Dual Rod Telescope Cylinder (102 Foot Boom). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45
Telescope Cylinder (28.9m [95 Foot] Boom) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49
Outrigger Extension Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52
Outrigger Stabilizer Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55

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TM500E-2 SERVICE MANUAL HYDRAULIC SYSTEM

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57

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HYDRAULIC SYSTEM TM500E-2 SERVICE MANUAL

2-iv
TM500E-2 SERVICE MANUAL HYDRAULIC SYSTEM

SECTION 2
HYDRAULIC SYSTEM
DESCRIPTION operation of individual hydraulic circuits are discussed within
their individual sections as applicable. A complete hydraulic
This section describes the hydraulic system, the system schematic showing all options is at the back of this
components which make up the hydraulic system, and the manual and a figure titled A.N.S.I. Graphical Symbols 2
components dependent upon the hydraulic system for their provides hydraulic symbol information for this section
operation. This includes descriptions of the supply pressure (Figure 2-1) and (Figure 2-2).
and return hydraulic circuit, hydraulic pumps, all hydraulic
valves, and all hydraulic cylinders. Detailed descriptions and

PRELIMINARY Published 10-5-2007, Control # 151-00 2-1

HYDRAULIC SYSTEM TM500E-2 SERVICE MANUAL

FIGURE 2-1

2-2 PRELIMINARY Published 10-5-2007, Control # 151-00

TM500E-2 SERVICE MANUAL HYDRAULIC SYSTEM

FIGURE 2-2

PRELIMINARY Published 10-5-2007, Control # 151-00 2-3

HYDRAULIC SYSTEM TM500E-2 SERVICE MANUAL

MAINTENANCE 10. Disconnect the return lines from a pair of outrigger

stabilizer cylinders and activate the cylinders to their
Hydraulic Oil Recommendations. maximum down positions.

For the hydraulic oil specifications, refer to Section 9 - 11. Connect the return lines and raise the outrigger
LUBRICATION. stabilizer cylinders to the stowed position. Replenish the
reservoir hydraulic oil level as necessary.
Draining and Flushing 12. Repeat Steps 10 and 11 for the remaining two outrigger
If a component has been changed because of a failure that cylinders.
might allow metal or abrasive particles to enter the system, 13. Disconnect the return line from the telescope cylinder
all systems must be thoroughly checked, drained, and and fully extend the boom.
flushed.
14. Connect the return line and retract the boom. Replenish
1. Remove the reservoir drain plug. Allow about three the reservoir hydraulic oil level as necessary.
minutes after hydraulic oil stops flowing from the drain
port for the side walls to drain. 15. Disconnect the return line from the main hoist motor and
fully hoist up the hoist.
2. Clean and install the reservoir plug and fill the reservoir
with a 50/50 mixture of fuel oil and clean hydraulic oil. 16. Connect the return line to the main hoist motor and fully
hoist down the hoist, then hoist up again. Replenish the
3. Cycle the crane through all functions several times. reservoir hydraulic oil level as necessary.
Then return the crane to its stowed position and turn the
front and rear wheels to the extreme left. Shut down the 17. Repeat Steps 15 and 16 for the auxiliary hoist as
engine. necessary.

4. Remove the reservoir drain plug and drain the reservoir. 18. Disconnect one of the lines from the swing motor and
Clean and install the drain plug and fill the reservoir with drive the motor in the direction it will go.
clean hydraulic oil. 19. Connect the line to the swing motor, then drive the swing
motor in the opposite direction until the boom is centered
and forward. Replenish the reservoir hydraulic oil level
CAUTION as necessary.
Hydraulic oil supply lines must be connected to the
cylinders when flushing the system.
CAUTION
NOTE: Draining the various components will be aided by When hydraulic oils are changed or added, ensure that
connecting a drain line in place of the disconnected hydraulic oils of different manufacturers are of the same
return line. specifications. Discoloration may occur.
5. Disconnect the return line from the lift cylinder and raise
the boom to maximum elevation. When hydraulic oils are changed, recheck the reservoir
hydraulic oil level after brief system operation and add
6. Connect the cylinder return line and lower the boom to hydraulic oil as required. Working reservoir capacity
its stowed position. Replenish the reservoir hydraulic oil (capacity to full mark) is 364.04 liters (96.1 U.S. gallons).
level as required. Ensure the crane is level and in the travel mode of operation
7. Disconnect the return line from an outrigger extension when the hydraulic system is being filled. The system must
cylinder and fully extend the outrigger. be filled with all cylinders retracted. Fill the reservoir to the
full mark on the reservoir sight gauge. After the reservoir is
8. Connect the outrigger return line and retract the filled, operate all circuits and recheck the reservoir sight
outrigger. Replenish the reservoir hydraulic oil level as gauge. Add hydraulic oil as required.
necessary.
9. Repeat Steps 7 and 8 for the remaining outriggers. Removing Air from the Hydraulic System
Air entering the hydraulic oil will normally be removed
automatically by passage of the hydraulic oil over the baffles
CAUTION in the hydraulic reservoir. If a component has been replaced,
When draining the outrigger cylinders, always operate the reservoir level is too low, or a leak develops in the suction
either both front or both rear cylinders together to prevent lines to the pumps, air can enter the system. If air becomes
twisting the crane. entrapped in the hydraulic oil, it may be detectable in pumps
and motor operated components such as the swing

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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

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HYDRAULIC SYSTEM TM500E-2 SERVICE MANUAL

contamination by dust or internal contamination by debris warped mountings. When scorched, deteriorated hydraulic
from deteriorating components or oxidized hydraulic oil). oil or contamination is the cause, flushing the system and
Scored or severely worn valve components must be replenishing with clean hydraulic oil may solve the problem.
replaced. If the spool bores are badly scored or galled, the valve must
be removed for servicing.
Check valves in the control valves are designed to permit a
flow of hydraulic oil in one direction only. If a piece of dirt or Warping occurs when mounting plates are not level or they
rust has worked its way into the check valve and lodges become distorted from machine damage. As mentioned
between the poppet and seat, it will keep the valve open and previously, the valve can be shimmed level.
allow a return flow of hydraulic oil. The remedy is to clean the
Also, check the valve for rust. Rust or dirt collecting on the
valve, but it is also a good idea to follow through and ensure
valves can prevent free movement of the spool, and keep it
the hydraulic system filter is still serviceable.
from the true center position. Excessive system pressure
can create both internal and external leaks in valves that are
Binding Spools otherwise sound. Only qualified technicians using the correct
Some of the most common causes for stiff spool movement equipment should make pressure adjustments when
or jammed spool action are system overheating, excessive pressure adjustments are needed.
pressure, contaminated or deteriorated hydraulic oil, or

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SUPPLY PRESSURE AND RETURN CIRCUIT that the breather be kept clean to prevent damage to the
reservoir. The breather/fill cap also provides for filling the
Description reservoir.

The supply pressure and return circuit is made up of several A large access cover on top of the reservoir provides for
circuits which route hydraulic oil from the hydraulic pumps to cleaning. The access cover can also be used to fill the
the directional control valves for the individual operating reservoir after it has been completely drained.
circuits. The supply pressure and return circuit consists of
the reservoir and integral filter, two hydraulic pumps, a
An oil temperature gauge is located on the lower front of the 2
reservoir to indicate oil temperature.
hydraulic oil cooler, and a 2-port hydraulic swivel. Refer to
HYDRAULIC PUMPS in this section for descriptions and The hydraulic oil filter (Figure 2-3) is located in the top of the
maintenance instructions for each hydraulic pump. Refer to reservoir. The filter housing contains a replaceable filter
Section 6 - SWING for description and maintenance element. Returning hydraulic oil flows through the filter head,
instructions for the 2-port hydraulic swivel. through the filter element and into the reservoir.
An element condition indicator on the filter head indicates
Hydraulic Reservoir and Filter when to change the filter element. When back pressure
The reservoir (Figure 2-3), is installed in the left side of the caused by a dirty filter element exceeds 172.3 kPa/1.72 bar
superstructure powerplant tray. Refer to (Table 2-1) for (25 psid), the filter head’s bypass feature functions to allow
reservoir capacities. the hydraulic oil to bypass the filter element and flow into the
reservoir through the bypass outlet instead. A bypass filter
Table 2-1 screen prevents gross contamination from passing through
the filter even during bypass. Refer to Return Hydraulic Filter
Hydraulic Reservoir Capacities
for filter changing instructions.
Level Capacity
Total Reservoir 404.62 L (106.8 gallon) Pump Distribution
Full Level 364.04 L (96.1 gallons) Pump No. 1 is mounted to the superstructure engine located
in the superstructure powerplant tray. Pump No. 2 is installed
Low Level 344.32 L (90.9 gallons) to the No. 1 pump.
Expansion Volume 40.58 L (10.7 gallons)
Pump No. 1
The all-steel reservoir has an internally mounted full-flow Pump No. 1 is a piston pump with torque limiter. It has a
filter and integral baffles that help cool the hydraulic oil and
displacement of 112 cm3/rev. (6.83 in3/rev).
prevent hydraulic oil foaming.
The pump differential or standby pressure is 2413 kPa/24
Hydraulic oil flows through two tubes at the rear of the
bar (350 psi) and the pump cut-off pressure is 31,716 kPa/
reservoir to the two hydraulic pumps. Almost all of the return
317.1 (4600 psi). Both of these pressures are adjustable
flow goes through the filter at the top of the reservoir.
using adjustment screws on the pump
A magnetized drain plug in the bottom of the reservoir
Pump No. 1 supplies oil to the boom lift/telescope/hoist
collects metal particles from the hydraulic oil if it becomes
directional valve.
contaminated.
Pump No. 2
A sight gauge is located on the front of the reservoir to
indicate hydraulic oil level. Pump No. 2 is a gear pump with a displacement of 33.03
1. A breather/fill cap located on the top of the reservoir cm3/rev. (2.01 in3/rev) delivering a theoretic flow of 79.1lpm
allows air to enter or exhaust the reservoir. It consists of (20.9 gpm). Pump No. 2 supplies oil to the outrigger selector
a breather, fill neck, gaskets and strainer. It is important valve and swing directional valve.

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HYDRAULIC SYSTEM TM500E-2 SERVICE MANUAL

Maintenance

Troubleshooting

Symptom Probable Cause Solution

1. No hydraulic oil a. Low hydraulic oil level. a. Fill reservoir.
flows in systems.
b. Reservoir-to-pump suction lines b. Clean, repair, or replace lines as
broken or restricted. Air entering at necessary. Check lines for security,
suction lines. Pump not priming. absence of cracks, and proper
a t ta c h m e n t . Ti g h t e n , r e pa i r, o r
replace parts as necessary.
c. Pump shaft sheared or disengaged. c. If drive shaft is damaged or sheared,
remove and repair or replace as
necessary
d. Internal contamination. d. Drain, flush with recommended oil
mixture, then drain and refill system
with recommended hydraulic oil.
2. Slow response. a. Low hydraulic oil level. a. Fill reservoir.
b. Hydraulic oil temperature too high b. If too low, warm up system. As
(watery thin oil) or too low (thick needed, troubleshoot cooler circuit. If
sluggish oil). too high, troubleshoot cooler circuit.
Likely suspects are in-line check
valve and related hydraulic circuits.
c. Faulty pump section(s). c. Repair or replace pump section(s) or
entire pump.
3. Pump noise a. Low hydraulic oil level. a. Fill reservoir.
accompanied by
b. Excessive engine speed. b. Regulate engine speed.
hydraulic oil
foaming in c. Air entering at suction lines. c. Check all lines for security and proper
reservoir. repair. Tighten, repair, or replace as
needed.
4. Excessive a. System relief valve set too high. a. Using adequate pressure gauge,
pressure buildup. adjust system relief valve as
necessary.
b. Restricted pump-to-control b. Clean, repair, or replace line as
valve supply line. necessary.
5. Specific hydraulic a. Leak in system. a. Repair leak.
system (lift, hoist,
b. Faulty electric controls/signals. b. Adjust or replace controls signals.
telescope, swing)
not working. c. Faulty directional control valve. c. Replace valve.
d. Poorly adjusted control in circuit. d. Troubleshoot circuit with schematic.
Adjust hydraulic component per
schematic.
e. Faulty hydraulic cylinder, motor, or e. Replace faulty component.
valve.

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5
7, 8
2

9
10

2, 3, 4

6955-1

2, 3, 4

FIGURE 2-3

Item Description Item Description

1 Reservoir 6 Breather With FIll Cap
2 Capscrew 7 Bolt
3 Flatwasher 8 Lockwasher
4 Lockwasher 9 Thermometer (Not Shown)
5 Return Filter 10 Magnetic Plug (Not Shown)

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HYDRAULIC SYSTEM TM500E-2 SERVICE MANUAL

2
3
11

5, 6

12

10

13

6728

FIGURE 2-4

Item Description Item Description

1 Capscrew 8 Filter Head
2 Washer 9 Gauge
3 Cap 10 O-ring
4 O-ring 11 Element
5 Bypass Valve 12 Bowl
6 Spacer 13 Gasket
7 Capscrew

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Return Hydraulic Filter Assembly 3. If by-pass valve was removed from cap, install by-pass
capscrews to cap.
Element Removal
4. Install cap assembly on filter head and secure with the
four bolts. Torque bolts 14.9 ±2.7 Nm (11.00 ±2.00
pounds-foot) until the gasket starts to bulge slightly. Do
not over torque. Torque bolt in a criss-cross pattern.
DANGER
Ensure that all hydraulic systems are shut down and the 5. Activate the hydraulic system and check for leaks. make 2
pressure is relieved. repairs as necessary.

1. Shut down all hydraulic systems. Hydraulic Reservoir Removal

2. Wipe any dirt from the filter head and cap assembly. 1. Remove the capscrews, lockwashers, flatwashers and
nuts securing the tank cover. Remove the cover.
NOTE: The bypass valve assembly is installed to the cap
and is removed with the cap. 2. Remove the capscrews, flatwashers and lockwashers
securing the reservoir to the floor of the powerplant tray.
3. Remove the four bolts securing the cap assembly to the Using a suitable lifting device, remove the reservoir.
filter head. Remove the cap and bypass valve assembly.
4. Remove the filter element from the filter bowl (housing). Hydraulic Reservoir Installation
5. Ensure the new filter element is correct by comparing 1. Using a suitable lifting device, install the reservoir to the
their part numbers with the part numbers of the used floor of the powerplant tray and secure with the
element. capscrews, flatwashers and lockwashers. Torque the
capscrews 85 to 93 Nm (63 to 69 pounds-foot).
6. Discard the element.
2. Install the tank cover and secure with the capscrews,
Element Installation lockwashers and flatwashers. Torque capscrews 49 to
1. Place a new element into the filter bowl (housing). 53 Nm (36 to 39 pounds-foot).

2. Install new O-ring in the cap assembly.

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OIL COOLER telescoping), more oil has to flow through this return line,
causing a pressure buildup. When this pressure reaches
Description 206.8 kPa/2.0 bar (30 psi), the normally closed check valve
will open, letting some hydraulic oil bypass the hydraulic oil
The oil cooler (Figure 2-5) is installed on the left side of the cooler and flow directly into the reservoir filter.
powerplant tray beside the hydraulic reservoir.
When fewer functions are being used, the pressure in the
The oil cooler return circuit is in parallel with the reservoir system will decrease below 206.8 kPa/2.0 bar (30 psi) and
return circuit and a 206 kPa/2.0 bar (30 psi) check valve in the check valve will close again.
the directional control valve manifold regulates flow through
the oil cooler. NOTE: A temperature switch in the return line monitors the
temperature of the hydraulic oil and illuminates a
Normally, most hydraulic oil from components is routed red indicator the top center of the front console in
through the oil cooler by way of a return line and on to the the superstructure cab when the oil temperature
filter in the reservoir. When several hydraulic functions are reaches 32 ° C (190 °F).
b e i n g u s e d a t o n e t i m e ( i . e . , h o i s t i n g , l i ft i n g , a n d

2
1
6955-2

FIGURE 2-5

Item Description Item Description

1 Powerplant Tray 4 Oil Cooler
2 Hose Assembly 5 Mounting Hardware
3 Elbow 6 Elbow

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HYDRAULIC PUMPS No. 2 Pump Removal

Description
Pump No. 1 is a piston pump with torque limiter and is CAUTION
mounted to the superstructure engine located in the Absolute cleanliness is essential when working on the
superstructure powerplant tray. hydraulic pumps. Always work in a clean area. The

Pump No. 2 is a gear pump installed to the No. 1 pump and

presence of dirt and foreign materials in the system can
result in serious damage or inadequate operation. 2
supplies oil to the outrigger selector valve.
1. Tag and disconnect the supply lines from the pump. Cap
Maintenance or plug the lines and ports.

No. 1 Pump Removal

CAUTION
When removing the pump, keep the pump as level as
CAUTION possible to avoid damaging the input spline.
Absolute cleanliness is essential when working on the
hydraulic pumps. Always work in a clean area. The 2. Remove the capscrews and flatwashers attaching the
presence of dirt and foreign materials in the system can No. 2 pump to the No. 1 pump. Remove the pump.
result in serious damage or inadequate operation.
3. Remove the gasket material and coupling from the
pump mounting surface.
1. Tag and disconnect the oil lines from both pumps. Cap
or plug the lines and ports. 4. Cover the opening to prevent dirt from entering.

No. 2 Pump Installation

CAUTION
1. Install new gasket material and coupling to pump
When removing the pump, keep the pump as level as
mounting surface
possible to avoid damaging the input spline.
2. Install No. 2 pump to pump No. 1 pump with capscrews
2. Remove the capscrews and flatwashers attaching the and flatwashers. Make sure gear teeth mesh properly.
pump to the engine flywheel housing. Remove the Torque capscrews to 49 to 53 Nm (36 to 39 pounds-
pump. foot).
3. Clean the gasket material from the flywheel pump 3. Connect the distribution and supply lines as tagged
mounting surface. during removal.
4. Cover the flywheel opening to prevent dirt from entering.
5. To remove the No. 2 pump from No. 1 pump, refer to CAUTION
No.2 Pump Removal. Do not feed hot hydraulic oil into a cold pump. This may
cause the pump to seize.
No. 1 Pump Installation
1. Install new gasket material to the pump mounting Testing After Rebuild or Replacement
surface. 1. Operate the pump for at least two minutes at zero
2. Install pump on flywheel with capscrews and washers. pressure and moderate speed (not over 1500 rpm).
Make sure the splines mesh properly. Torque capscrews
292 to 317.2 Nm (216 to 234 foot-pounds).
CAUTION
3. Connect the distribution and supply lines as tagged If the pump becomes hot to the touch, it is binding and
during removal. may seize. Stop engine, disassemble pump, and repair it
4. If installing No.2 pump, refer to No. 2 Pump Installation. so it will not bind.

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HYDRAULIC SYSTEM TM500E-2 SERVICE MANUAL

3, 4
6, 7

6950

1 FIGURE 2-6

Hydraulic Gear Pump Start-up Procedure

Item Description
1. Ensure the reservoir is filled with the proper hydraulic
1 No. 1 Pump fluid to the high level mark on the reservoir sight gauge.
2 No. 2 Pump 2. Ensure no air is entering the pump inlet, and that the
3 Capscrews pump suction or inlet fluid is not bleeding back to the
reservoir when the engine is stopped, by making sure all
4 Flatwashers suction or inlet lines are air tight.
5 Flywheel Housing
3. Remove all pump outlet hoses. Fill pump outlet port on
6 Capscrews each pump section with hydraulic oil. Reconnect hoses.
7 Flatwashers 4. Start the engine.
2. Touch pump to verify it has not become hot from binding. a. Idle engine for two to three minutes with no
Listen for abnormal noises indicating low hydraulic oil functions actuated. Check for leaks and repair if
level or internal pump problems. If the pump appears to required. Lay hand on pump to check for excessive
be operating satisfactorily, increase the rpm by steps, heat build-up. If the pump section is too hot to keep
until reaching governed rpm. Operate pump about five your hand on, stop immediately.
minutes while checking for proper operation and
leakage. Fix leaks; make repairs as needed. b. If the pump makes excessive noise, air is probably
entering the pump keeping it from priming. If this
3. Cycle the components the pump powers to verify the occurs, stop engine, and inspect all connections of
pump drives them all properly. the suction hose/tube for a loose connection, or a
missing or damaged O-ring.
c. Re-start the engine and run until the pump takes
prime for a maximum of 30 seconds. If the pump
does not prime in 30 seconds, stop the engine and
repeat until the pump primes.

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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.

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

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HYDRAULIC SYSTEM TM500E-2 SERVICE MANUAL

PRESSURE SETTING PROCEDURES engine at idle RPM and move the controller to its
fully stroked position. Then slowly accelerate the
The following procedures should be used to properly check, engine to the specified RPM. Read gauge and
adjust and set the hydraulic system pressures. make adjustments to specified setting.
NOTE: A Digital Pressure Gauge and accessories may be NOTE: When checking the outrigger relief valve setting,
purchased through Manitowoc CraneCARE. start with the engine at idle RPM and activate and
The following equipment is required for checking the hold the extend switch. Then slowly accelerate the
hydraulic pressure settings. engine to the specified RPM. Read gauge and
make adjustment as required.
• Pressure Gauge
NOTE: GP (gauge Port) and number corresponds to
• Three dial gauge 0-34.5 MPa (0-5000 psi) gauge ports on the valve and on the hydraulic
• Pressure check diagnostic quick disconnect - Grove P/N schematic.
9999101806 and straight adapter fitting 7447040401 NOTE: Telescope extend and retract pressure settings are
• ORFS reducers as required to attach work port hoses to determined by the boom option installed on the
the gauge. machine; 30 m (95 foot) or 31 m (102 foot). Refer to
(Table 2-2).
NOTE: When checking the directional control valve relief
settings, unless otherwise specified, start with the

Table 2-2
Valve Pressure Setting Table

Pressure
Tolerance
Valve To Be Set Setting Adjustment Location
PSI (MPa)
PSI (MPa)
4000 (27.6) ± 50 (0.4) GP2 - Superstructure mounted main
Hoist (s), and Lift Pressure Setting directional control valve load sense
relief valve (Figure 2-9)
Telescope Extend Pressure Setting (102 3500 (24.2) ± 50 (0.4) GP7 - Superstructure mounted main
Foot Boom) directional control valve port relief
valve (Figure 2-10)
Telescope Retract Pressure Setting (102 3250 (22.5) ± 50 (0.4) GP7 - Superstructure mounted main
Foot Boom) directional control valve port relief
valve (Figure 2-10)
Telescope Extend Pressure Setting (95 2700 (18.6 ± 50 (0.4) GP7 - Superstructure mounted main
Foot Boom( directional control valve port relief
valve (Figure 2-10)
Telescope Retract Pressure Setting (95 3000 (20.7) ± 50 (0.4) GP7 - Superstructure mounted main
Foot Boom) directional control valve port relief
valve (Figure 2-10)
Outrigger Extend/Retract & Swing Left/ 1800 (12.4) ± 50 (0.4) GP - Superstructure mounted outrigger
Right Pressure control manifold (Figure 2-11)
Swing Brake Supply Pressure Setting 250 - 300 See Range GP4 - Superstructure mounted
(1.7 - 2.1) accessory manifold with swing
directional control valve (Figure 2-9)

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Pressure
Tolerance
Valve To Be Set Setting Adjustment Location
PSI (MPa)
PSI (MPa)
Pilot Supply Pressure Setting 400 - 450 See Range GP3 - Superstructure mounted
(2.8 - 3.1) accessory manifold with swing
directional control valve (Figure 2-9)
Non-CE Machines 325 - 400 See Range GP2 - Superstructure mounted piston 2
Piston Pump ΔP Pressure Setting (2.2 - 2.8) pump (Figure 2-12)

CE Machines 525 - 550 See Range GP2 - Superstructure mounted piston

Piston Pump ΔP Pressure Setting (3.6 - 3.8) pump (Figure 2-12)

NOTE: Procedures A through H in the following text to decrease so that a gauge pressure reading of 27.6±
correlate with (Figure 2-8) through (Figure 2-12). 0.4 MPa (4000 ± 50 psi) is achieved (Figure 2-10).

Procedure A - For Checking/Setting The 6. Stop engine and remove the diagnostic couplers from
the test nipples
Main Control Valve For Hoists(s), Boom Lift
and Piston Pump Set telescope extend and retract as follows:

NOTE: Procedure A for max. and Δ P settings. Extend

Set hoist(s) and boom lift as follows: 7. If boom is not installed, install a pressure check
diagnostic quick disconnect with gauge onto test nipple
1. Install pressure check diagnostic quick disconnect with @ the GP7 port of the main directional control valve
gauge onto test nipple @ the GP2 Port of the accessory (Figure 2-10).
manifold with swing directional control valve
(Figure 2-9). 8. Cap hose (the larger of the two) running from port A,
telescope section of the main directional control valve to
2. Assure piston pump cut-off max.(Figure 2-12) factory the cylinder port block at the back of the base section.
setting is correct. Loosen the jam nut on the cut-off max
adjusting screw and turn it in until it softly seats or 9. Start engine and throttle up to full RPM. Attempt to
bottoms out. Then back the adjusting screw out 1/4 to 1/ telescope OUT by feathering into the controller to full
2 turn and lock in place with jam nut. This will ensure that controller stroke. Adjust the work port relief “in” to
full system pressure of 27.6 MPa (4000 psi) can be increase or “out” to decrease so that a gauge pressure
obtained in step #4. of 24.2 ±0.4 MPa (3500 ±50 psi) is achieved for the 30 m
(95 foot) boom or 18.6 ±0.4 MPa (2700 ±50 psi) for the
3. Assure piston pump ΔP (stand-by) factory setting is 31 m (102 foot) boom (Figure 2-10).
correct. With diagnostic quick disconnect still installed @ 10. If the boom is installed, start engine and throttle up to full
the GP2 port of the accessory manifold with swing RPM. Telescope out to fully extend the boom and hold.
directional control valve (Figure 2-9), start engine and @ Adjust the work port relief valve “in” to increase or “out”
idle RPM adjust the piston pump differential setting to decrease so that a gauge pressure reading of 24.2
screw “in” to increase or “out” to decrease so that a ±0.4 MPa (3500 ±50 psi) is achieved for the 30 m (95
gauge reading of 2.2 - 2.8 MPa (325 - 400 psi) foot) boom or 18.6 ±0.4 MPa (2700 ±50 psi) for the 31 m
(Figure 2-12). (102 foot) boom (Figure 2-10).
4. If the lift cylinder is not installed, plug the extend hose 11. Stop engine and remove pressure gauge and re-connect
(the larger of the two). If lift cylinder is installed, omit this plumbing.
step and continue to step #5.
Retract
5. With diagnostic quick disconnect still installed @ the
GP2 port of the accessory manifold with swing 12. If the boom is not installed, install a pressure check
directional control valve (Figure 2-9), start engine and diagnostic quick disconnect with gauge onto test nipple
throttle up to full RPM. Feather into the boom lift @ the GP7 port of the main directional control valve
controller to full controller stroke (up or down) and hold. (Figure 2-10).
If the boom is installed, boom up to max elevation and
13. Cap hose (the smaller of the two) running from port B,
hold or boom down to minimum elevation and hold.
telescope section of the main directional control valve to
Adjust the load sense relief valve “in” to increase or “out”
the cylinder port block at the back of the base section.

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14. Start engine and throttle up to full RPM. Attempt to Procedure D - For Checking/Setting the
telescope IN by feathering into the controller to full Swing Brake Release Pressure
controller stroke. Adjust the work port relief valve “in” to
increase or “out” to decrease so that a gauge pressure 1. Install pressure check diagnostic quick disconnect with
reading of 22.5 ±0.4 MPa (3250 ±50 psi) is achieved for gauge onto test nipple @ GP4 port of the accessory
the 30 m (95 foot) boom or 20.7 ±0.4 MPa (3000 ±50 psi) manifold with swing directional control valve
for the 31 m (102 foot) boom (Figure 2-10). (Figure 2-9).
15. If the boom is installed, start engine and throttle up to full 2. Start engine and idle, select and depress the swing
RPM. Telescope in to fully retract the boom and hold. brake release switch and adjust the swing brake
Adjust the work port relief valve “in” to increase or “out” pressure reducing valve “in” to increase or “out” to
to decrease so that a gauge pressure reading of 22.5 decrease so that a gauge pressure of 1.7 - 2.1 MPa (250
±0.4 MPa (3250 ±50 psi) is achieved or the 30 m (95 - 300 psi) (Figure 2-9).
foot) boom or 20.7 ±0.4 MPa (3000 ±50 psi) for the 31 m
3. Stop engine. Remove diagnostic couplers.
(102 foot) boom (Figure 2-10).
16. Stop the engine and remove pressure gauge and re- Procedure E- For Setting Threshold on
connect plumbing. Electronic Controllers
Procedure B - For Setting The Outrigger & 1. Attach test fitting and pressure gauge in the pilot end
caps one at a time at GPS for main hoist up, GPB for
Swing Pressures
auxiliary hoist up, GPC telescope retract, GPD lift
1. Install a pressure check diagnostic quick disconnect with down(Figure 2-11), GP8 and GP9 swing left and right
gauge onto test nipple at GP port of the outrigger control (Figure 2-9).
manifold (Figure 2-11).
2. Attach laptop to diagnostic connector in superstructure
2. Start engine and throttle up to full RPM. Select and hold cab and bring up the eprom settings (Figure 2-8).
either the outrigger "extend or retract" switch on the Arrange windows so you can view the eprom window
superstructure cab armrest. Adjust the pressure and output window values.
reducing valve integrated in the outrigger selector valve
3. Start engine and run at idle rpm’s. make sure to lower left
"in" to increase or "out" to decrease so that a gauge
armrest.
pressure of 12.4 MPa ± 0.4 (1800 ±50 PSI) is achieved
(Figure 2-11). 4. Start with GPS main hoist up (Figure 2-10). View the
pressure gauge and stroke the joystick just off center for
3. Stop engine. Remove the diagnostic coupler.
main hoist in the up position. Watch the pressure gauge
stroke until it reaches approximately 100 psi. Hold and
Procedure C- For Checking/Setting the Pilot
look at the value for main hoist in the output window. If
Supply Pressure the pressure goes over 100 psi, back the value down. To
1. Install pressure check diagnostic quick disconnect with change the value, double click the value you want to
gauge onto test nipple @ GP3 port of the accessory change in the eprom window and the value window will
manifold with swing directional control valve turn blue. Enter the value for the main hoist up and
(Figure 2-9). select “Set” and change the main hoist down with the
same settings.
2. Start engine and @ idle RPM, lower left armrest, fully
stroke and hold the boom lift raise or lower joystick. Repeat again and make sure that it does not exceed 100
Adjust the pilot pressure reducing valve of the accessory psi. Do not change the default settings for the MAX.
manifold with swing directional control valve “in” to R e p e a t t h e p r o c e s s f o r p o r ts G PB , G P C , G P D
increase or “out” to decrease so that the gauge pressure (Figure 2-10) and GP8, GP9 (Figure 2-9) and enter
of 2.8 - 3.1 MPa (400 - 450 psi) is achieved (Figure 2-9). values to respected function. Make sure to select SAVE
ALL after completing the entered value settings.
3. Stop engine. remove diagnostic couplers.
5. After setting all of the functions and selecting save all,
select the File Down-Load button. Save the file.

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TM500E-2 SERVICE MANUAL HYDRAULIC SYSTEM

Eprom Window
2
Set

Output Window
Value Window

File Down-Load
Save All

FIGURE 2-8

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HYDRAULIC SYSTEM TM500E-2 SERVICE MANUAL

Item Description
1 Procedure D - Swing Brake PSI Reducing Valve
2 Procedure C - Pilot Supply PSI Reducing Valve
3 Pilot End Cap GP8 - Swing Left
4 Pilot End Cap GP9 - Swing Right
5 Gauge Port 2
6 Gauge Port 3
7 Gauge Port 4B
88 Gauge Port 4A

6
6951-2

FIGURE 2-9

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TM500E-2 SERVICE MANUAL HYDRAULIC SYSTEM

Item Description
1 Procedure A - Telescope Extend Port Relief
2 Procedure A - Load Sense Relief Valve
3 Procedure A - Telescope Retract Port Relief
2
4 Gauge Port 7
5 Pilot End Cap GPB Optional Auxiliary Hoist Up
6 Pilot End Cap GPA Main Hoist Up
7 Pilot End Cap GPC Telescope Retract
8 Pilot End Cap GPD Lift Down

5 7
6 8 6951-3
FIGURE 2-10

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HYDRAULIC SYSTEM TM500E-2 SERVICE MANUAL

GP

6951-4

Procedure B - Outrigger PSI Reducing Valve

FIGURE 2-11

Item Description
1 Procedure A -Pump Cut-Off Max Setting Adjustment
1
2 Procedure A - Pump ΔP (Stand-by) Adjustment

6951-5

FIGURE 2-12

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TM500E-2 SERVICE MANUAL HYDRAULIC SYSTEM

VALVES functions in the individual circuits, refer to the description and

operation procedures of that circuit.
General NOTE: On each valve illustration in this section, each item
This subsection provides descriptive information for all the number in table correlates to location on the valve,
hydraulic valves used on the crane superstructure. For a and to the valve hydraulic schematic.
listing of all valves, the circuit they are used in, and their NOTE: For information on the truck chassis hydraulic
physical location, refer to (Table 2-3). Refer to (Figure 2-13)
for valve locations. The description of each valve given here
valves, refer to the Carrier Operator’s Manual. 2
is for the valve itself. For information on how each valve

Table 2-3
Valve Usage Table

Valve Name Circuit Used In Physical Location

Directional Control Valves Boom Lift/Telescope(s)/Hoist(s) Superstructure Right Side Plate
Accessory Manifold with Swing Valve Swing Directional Control Superstructure Right Side Plate
Swing Brake Release
Pilot Supply
Holding Valves Boom Lift Lift Cylinder (Bolt on Manifold)
Telescope Cylinder Port Blocks (Cartridge style)
Hoist Motor Control Valve Hoist(s) Both Hoists (Refer to Section 5)
Outrigger Control Manifold Outrigger On Front and Rear Face of Carrier
Frame Front and Rear Cross Member
Pilot Operated Check Valve Outrigger Port Block of each Stabilizer Cylinder
(4)

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HYDRAULIC SYSTEM TM500E-2 SERVICE MANUAL

2
3

6949

Superstructure

FIGURE 2-13

Item Description Item Description

1 Hoist/Telescope/Lift Directional Valve 3 Outrigger Selector Valve
2 Accessory Manifold with Swing Valve 4 Superstructure Turntable

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1 2

6956-3

Carrier

6956-1

FIGURE 2-13 continued

6956-2

Item Description Item Description

1 Front Outrigger Control Manifold 3 Frame
2 Rear Outrigger Control Manifold

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HYDRAULIC SYSTEM TM500E-2 SERVICE MANUAL

DIRECTIONAL CONTROL VALVES NOTE: The lift/telescope/hoist valve bank weighs

approximately 81.30 kg (179.2 pounds).
Description 3. Remove the capscrews, washers and nuts securing the
The directional control valve directs and controls hydraulic oil valve bank and remove the valve bank.
flow from the pump to the boom lift and telescope cylinders,
each hoist motor and the swing motor. The control valve Boom Lift/Telescope/Hoist Valve Bank
(Figure 2-14) is located on the outside of the right Installation
superstructure side plate. The valve bank is removed and
installed as an assembly. 1. Place the valve bank on the superstructure side plate
and secure it with the capscrews, washers and nuts.
The valve is a three position four way pressure Torque the capscrews 85 to 93 Nm (63 to 69 pounds-
compensated, closed center directional valve. It receives foot).
pump flow from pump No. 1. Lift, telescope and hoist (s)
functions are controlled by proportional two position two way 2. Connect the hydraulic lines to the valves as tagged
solenoid cartridges installed into the valve’s casting under during removal.
each spool. These valves receive an electrical signal from 3. Connect the electrical connectors as tagged during
the controllers on the cab armrest. removal.
LMI lockout is achieved by de-energizing the proportional
solenoids. Functional Check (All Valve Banks)
The inlet section of the boom lift/telescope/hoist directional 1. Start the engine and run it at normal speed.
control valve contains a load sense relief valve set at 27,579 2. Operate the control levers of the valve bank(s). Check
kPa/275.7 bar (4000 psi) protecting the main and auxiliary for smooth operation of cylinders and motors.
hoist and boom lift sections.
3. Check the valve bank(s) and lines for leakage. Make
The boom lift retract has a thermal port relief set of repairs as needed.
29,647.4kPa/296.4 bar (4300 psi). The telescope section
has port reliefs set at 22,407.9 kPa/224.0 bar (3250 psi) and Function Check - LMI Lockout Valves
24,131.6 kPa/241.3 bar (3500 psi) with the 31 m (102 foot)
boom option. With the 30 m (95 foot) boom option, the 1. Remove circuit breaker F14 from the power panel in the
telescope section has port reliefs set at 20,684.2 kPa/206.8 cab. This cuts off power to the LMI.
bar (3000 psi) and 18615.8 kPa/186.1 bar (2700 psi). 2. Start the engine.
The swing directional control valve is installed on the outside 3. Try to telescope the boom out, lower the boom, hoist up
of the right superstructure side plate. Refer to Accessory the main hoist, and hoist the auxiliary hoist up (if
Manifold with Swing Directional Control Valve. installed). Verify none of these functions work.
Maintenance 4. Shut down the engine. Reinstall F14.
5. Telescope the boom out, lower the boom, hoist up the
Boom Lift/Telescope/Hoist Valve Bank main hoist, and hoist the auxiliary hoist up (if installed).
Removal Verify all of these functions work.
1. Tag and disconnect all of the electrical connectors from 6. Check for leaks. Make repairs as needed.
the valve.
2. Tag and disconnect the hydraulic lines from the valves.
Cap or plug the lines and ports.

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13
14
15

10
3 2
1

5
9 7

18

12

11
8
16
6946-1
17
FIGURE 2-14

Item Description Item Description

1 Port 1A -Main Hoist Up 10 Inlet Port P1 - From Pump #1
2 Port 1B - Main Hoist Down 11 Port P2 - Inlet Plugged
3 Port 2A - Aux Hoist Up 12 Load Sense - Input Port
4 Port 2B - Aux Hoist Down 13 Port PS - Pilot Supply
5 Port 3A - Telescope Extend 14 Gauge Port
6 Port 3B - Telescope Retract 15 Relief Valve - Telescope Extend
7 Port 4A - Lift Up 16 Relief Valve - Telescope Retract
8 Port 4B - Lift Down 17 Relief Valve - Lift
9 Load Sense - Outlet Port 18 Relief Valve - Load Sense

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HYDRAULIC SYSTEM TM500E-2 SERVICE MANUAL

2 3 4 5 6 8
1 7
14 15 16 17
13

12

18

9 11

10 Hoist Lift 6946-2

Hoist Telescope

31 m (102 foot) Boom Option

14
2
3 5 6 7 8 17
13 1 4
15 16

12

18

9 11

10
Hoist Hoist Telescope Lift 6954-2

30 m (95 foot) Boom Option

FIGURE 2-14 continued

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ACCESSORY WITH SWING DIRECTIONAL resistance check valve providing make-up oil to the swing
CONTROL MANIFOLD motor for motor over-run when the valve is centered. It
receives oil from pump #1. This section is controlled by two
Description proportional two position, three way solenoid valves. These
valves receive an electrical signal from the superstructure
The accessory manifold with swing directional valve cab armrest controllers.
( F i g u r e 2 -1 5 ) i s l o c a t e d o n t h e r i g h t s i d e o f t h e
superstructure turntable. The manifold contains an Maintenance 2
adjustable pressure reducing valve, five 3-way two position
solenoid valves, 3-way four position swing directional valve, Removal
and a check valve.
1. Tag and disconnect all of the electrical connectors or
The pressure reducing valve provides 1.72 mPa (250 psi) for manual control levers.
operation of the swing brake.
2. Tag and disconnect the hydraulic lines from the valves.
Each solenoid valve is held in its normally closed position by Cap or plug the lines and ports.
a spring. When the solenoid is energized, the plunger
assembly forces the spool to shift, causing the valve to shift. NOTE: The swing/steer/brake valve manifold weighs
De-energizing the solenoid causes spring pressure to shift approximately 8.0 kg (17.0 pounds).
the spool to its normally closed position. 3. Remove the capscrews, lockwashers and flatwashers
One two position, three way solenoid valve serves as the securing the manifold. Remove the manifold.
swing brake release valve. This normally closed valve, when
de-energized, prevents hydraulic oil pressure from releasing Installation
the swing brake. When the swing brake switch is off, this 1. Place the manifold on the superstructure side plate and
valve opens to allow hydraulic oil pressure to release the secure with the capscrews, lockwashers and
swing brake. flatwashers. Torque the capscrews 23 to 26 Nm (17 to
One proportional two position, three way solenoid valve 19 pounds-foot)
actuated by the superstructure cab swing foot brake 2. Connect the hydraulic lines to the valves as tagged
proportionally supplies pressurized oil to the swing drive during removal.
brake.
3. Connect the electrical connectors to the valve as tagged
The three position four-way swing directional valve is during removal.
installed onto the manifold. Both swing working ports have
check valves that are flooded by a.41 mPa (60 psi)

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HYDRAULIC SYSTEM TM500E-2 SERVICE MANUAL

15
6
14
9
13

1 7

11
4

5
8
10

12

20

19

22

6945-2

21
23

FIGURE 2-15

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14
13

2
16

15

18
24

17
6945-4
2
FIGURE2-15continued

Item Description Item Description

1 Adjustable Relief Valve 13 Drain Port - D4 (Swing Motor Pilot Supply)
2 Gauge Port- GP4 14 Drain Port - D6 (Hoist/Tele/Lift Valve Pilot Supply)
3 Swing Brake Relief Valve 15 Drain Port - D7 (Swing Brake/Lift Cylinder Pilot)
4 Solenoid Valve - Swing Brake 16 Drain Port - D3 (Plugged)
5 Solenoid Valve - Swing Brake Release 17 Gauge Port - GP2
6 Solenoid Valve - Pilot Supply 18 Drain Port - D1
7 Gauge Port - GP1 19 Gauge Port - GP3
8 Pilot Supply Port - PS 20 Swing Brake Release Port - SBR
9 Drain - D2 21 Drain Port - D5
10 Port 1B - Swing Left 22 Swing Brake Supply Port -SBS
11 Port 1A - Swing Right 23 Tank Port
12 Swing Directional Valve 24 Proportional Two Position Two Way Solenoid

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HYDRAULIC SYSTEM TM500E-2 SERVICE MANUAL

9 16 22 5 19 24
2 6 24
18 8

12

10

11

6945-3

13 23
21
14 15
7
3 1

17

FIGURE2-15continued

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TM500E-2 SERVICE MANUAL HYDRAULIC SYSTEM

HOLDING VALVES Removal

Description 1. Unscrew holding valve from its port block or manifold.

A bolt-on manifold style holding valve is installed on the Installation

boom lift cylinder. A cartridge style holding valve is used on
the telescope cylinder installed in the piston side of the 1. Check the inside of the port block or manifold for any
sharp edges or burrs and remove as necessary with
cylinder.
emery cloth. 2
The holding valve provides meter out control, will lock the
cylinder in place, prevent a load from running ahead of the oil 2. Install new O-rings onto the holding valve.
supply, and will relieve excess pressure caused by thermal 3. Lubricate the holding valve and O-rings with clean
expansion. hydraulic oil.

Maintenance
CAUTION
Do not damage the O-rings during installation of the
holding valve. If the holding valve turns freely then gets
DANGER hard to turn, then easy to turn, remove the holding valve
Boom must be fully lowered and fully retracted before and check the O-rings. They have probably been
removing lift cylinder and telescope cylinder holding damaged by a sharp edge of a port.
valves. The counterweight must be removed or pinned
before removing counterweight removal cylinder holding NOTE: The holding valve should turn by hand until
valves. compression of the O-rings begins.
4. Carefully install the holding valve into the port block or
manifold until fully seated.
5. Test the holding valve and port block or manifold by
operating the lift cylinder and/or the telescope cylinder,
as applicable. Verify lift cylinder and/or telescope
cylinder works without problems; verify there is no
leaking. Make repairs as needed.

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HYDRAULIC SYSTEM TM500E-2 SERVICE MANUAL

OUTRIGGER CONTROL MANIFOLD Inspection

Description Visually inspect the valves and hydraulic connections for any
evidence of leaks or other damage. Check security of the
There are two outrigger control manifolds utilized on the electrical connections. Inspect the wiring for any evidence of
crane, one for the front outriggers and one for the rear cracks or breaks.
outriggers. The manifold consists of four normally closed two
position two way solenoid valves (Figure 2-16). They are Installation
mounted inside the frame of their respective outrigger box.
1. Position the manifold on the mounting and secure with
When energized, the solenoid shifts the spool to open the lockwashers, flatwashers, nuts and capscrews.
allowing extension or retraction of the outrigger cylinders. Torque capscrews 49 to 53 Nm (36 to 39 pounds-foot).

Maintenance 2. Connect the electrical connectors to the solenoids as

marked during removal.
Removal 3. Connect the hydraulic lines to the valves as marked
during removal.
1. Tag and disconnect the hydraulic lines to the solenoid
valves; cap all lines and openings.
Functional Check
2. Tag and disconnect the electrical connectors.
Activate the hydraulic system and cycle the affected
3. Remove the capscrews, nuts, lockwashers and cylinder(s) several times. Observe for proper functioning of
flatwashers securing the manifold to the outrigger box; the affected cylinder(s). Ensure the solenoid valve hydraulic
remove the manifold. connections are secure.

4
3

1 2

5
6 7 8

6544-2 8
7
1 2 3 4
6
9
5
6544-1

FIGURE 2-16

Item Description Item Description

1 Solenoid Valve - Left Front or Rear Extension Cyl 6 Outlet Port Left Front or Rear Stabilizer Cyl
2 Solenoid Valve - Left Front or Rear Stabilizer Cyl 7 Outlet Port Right Front or Rear Stabilizer Cyl
3 Solenoid Valve Right Front or Rear Stabilizer Cyl 8 Outlet Port Right Front or Rear Extension Cyl
4 Solenoid Valve Right Front or Rear Extension Cyl 9 In Port (Far Side) - From Swivel
5 Outlet Port - Left Front or Rear Extension Cyl

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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
2 Port P - Pilot 1
3 Port V - Valve

6155

6155-2 3

3 FIGURE 2-17

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HYDRAULIC SYSTEM TM500E-2 SERVICE MANUAL

OUTRIGGER SELECTOR VALVE 3. Remove the capscrews, nuts and washers securing the
valve to the superstructure side plate. Remove the
Description valve.

The outrigger selector valve (Figure 2-18) controls the Installation

outrigger circuit. The valve is mounted on the right side of the
superstructure side plate. It receives flow from pump #2. 1. Secure the valve to the superstructure side plate with
the washers, nuts and capscrews. Torque the capscrews
The valve contains a 12,410.5kPa/ bar (1800 psi) relief valve 25 to 27 Nm (18 to 20 pounds-foot).
and a two position two way solenoid valve that is normally
open by passing oil from the inlet port to the tank port by way 2. Connect the hydraulic hoses to the ports on the valve as
of the swing directional valve. tagged during removal.

The valve also contains a three position four way solenoid 3. Connect the electrical connectors to the valve as tagged
directional control valve and two, two position three way during removal.
solenoid valves that control the outrigger extend and retract 4. Verify proper operation by extending and retracting the
function. outriggers.
Maintenance 5. Check valve and hoses for leaks. Make repairs as
needed.
Removal
1. Tag and disconnect the electrical connectors to the
valve.
2. Tag and disconnect the hydraulic hoses from the valve.
Cap or plug the lines and ports.

7
2

10

5
6
6947-1

FIGURE 2-18
9

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4 5
6

2
7

6947-2

3 9 10
2 FIGURE 2-18 continued

Item Description Item Description

1 Port P 6 SV1 (Port B - Extend)
2 Port T 7 SV2 (Port A - Retract)
3 Outrigger Relief Valve 8 Port GP
4 Port A - Retract (SV2) 9 SV3
5 Port B - Extend (SV1) 10 Directional Valve

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HYDRAULIC SYSTEM TM500E-2 SERVICE MANUAL

CYLINDERS Maintenance
General General
This subsection provides descriptive information for all the There must be a gap between the ends of each wear ring
hydraulic cylinders used on this crane. The description of the when it is installed onto the piston (as applicable) or head. In
cylinder given here is for the cylinder itself. For information addition, each wear ring gap is to be located as follows:
on how the cylinder functions in the individual circuits, refer Divide 360 degrees by the number of wear rings on the
to the Description and Operation of that circuit. component. The resulting value is the number of degrees
each wear ring gap is to be located with respect to each
other.
The approximate wear ring gaps are as follows:

Table 2-4
Wear Ring Gap

Head (or Piston) Size Wear Ring Gap

Inch mm Inch mm
1 to 4.75 25.4 to 120.7 0.125 3.18
5 to 10.0 127.0 to 254.0 0.187 4.75
greater than 10.0 greater than 254.0 0.250 6.35

Surface Protection for Cylinder Rods Leakage Check

Steel cylinder rods include a thin layer of chrome plating on A hydraulic cylinder should not be disassembled unless it is
their surfaces to protect them from corroding. However, essential. The following checks will provide a means of
chrome plating inherently has cracks in its structure which determining if a cylinder has a faulty or leaking piston seal.
can allow moisture to corrode the underlying steel. At typical
1. Extend the rod to its maximum stroke. Remove the
ambient temperatures, hydraulic oil is too thick to penetrate
retract hose from the cylinder. Cap the retract hose.
these cracks. Normal machine operating temperatures will
allow hydraulic oil to warm sufficiently to penetrate these
cracks and if machines are operated daily, protect the rods.
Machines that are stored, transported, or used in a corrosive
environment (high moisture, rain, snow, or coastline DANGER
conditions) need to have the exposed rods protected more Ensure pressure is applied to the piston side of the
frequently by applying a protectant. Unless the machine is cylinder only and the retract hose is capped.
operated daily, exposed rod surfaces will corrode. Some
cylinders will have rods exposed even when completely 2. Apply hydraulic pressure to the piston side of the
retracted. Assume all cylinders have exposed rods, as cylinder and observe the open cylinder port for leakage.
corrosion on the end of the rod can ruin the cylinder. If leakage is observed, the seals in the cylinder must be
replaced.
It is recommended that all exposed cylinder rods be
protected using Boeshield® T-9 Premium Metal Protectant. 3. Fully retract the cylinder rod (except the telescope
Manitowoc CraneCARE has Boeshield® T-9 Premium Metal cylinder). Remove the extend hose from the cylinder.
Protectant available in 12 oz. cans that can be ordered Cap the extend hose.
through the Parts Department.
NOTE: Cylinder operation and inclement weather will
remove the Boeshield® protectant; therefore,
inspect machines once a week and reapply
DANGER
Boeshield® to unprotected rods. Ensure pressure is applied to the retract (rod) side of the
cylinder only and that the extend hose is capped.

4. Apply hydraulic pressure to the retract (rod) side of the

cylinder and observe the open cylinder port for leakage.

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TM500E-2 SERVICE MANUAL HYDRAULIC SYSTEM

If leakage is observed, the seals in the cylinder must be movement, of the boom may be undetected by the operator
replaced. unless a load is suspended for a long period of time.
5. Reconnect all cylinder ports. If a load and the boom is allowed to remain stationary for a
period of time and the ambient temperature is cooler than the
Temperature Effects on Hydraulic Cylinders trapped oil temperature, the trapped oil in the cylinders will
cool. The load will lower as the telescope cylinder(s) retracts
Hydraulic oil expands when heated and contracts when
cooled. This is a natural phenomena that happens to all
allowing the boom to come in. Also, the boom angle will
decrease as the lift cylinder(s) retracts causing an increase 2
liquids. The coefficient of expansion for API Group 1 in radius and a decrease in load height.
hydraulic oil is approximately 0.00043 cubic inches per cubic
inch of volume for 1°F of temperature change. Thermal This situation will also occur in reverse. If a crane is set up in
contraction will allow a cylinder to retract as the the morning with cool oil and the daytime ambient
hydraulic fluid which is trapped in the cylinder cools. temperature heats the oil, the cylinders will extend in similar
The change in the length of a cylinder is proportional to the proportions.
extended length of the cylinder and to the change in
The chart below has been prepared to assist you in
temperature of the oil in the cylinder. For example, a cylinder
determining the approximate amount of retraction/extension
extended 25 feet in which the oil cools 60°F would retract
that may be expected from a hydraulic cylinder as a result of
approximately 7 3/4 inches (see chart below). A cylinder
change in the temperature of the hydraulic oil inside the
extended 5 feet in which the oil cools 60°F would only retract
cylinder. The chart is for dry rod cylinders. If the cylinder rod
approximately 1 1/2 inches. The rate at which the oil cools
is filled with hydraulic oil, the contraction rate is somewhat
depends on many factors and will be more noticeable with a
greater.
larger difference in oil temperature verses the ambient
temperature. NOTE: Operators and service personnel must be aware
that load movement, as a result of this phenomena,
Thermal contraction coupled with improper lubrication or
can be easily mistaken as leaking cylinder seals or
improper wear pad adjustments may, under certain
faulty holding valves. If leaking seals or faulty
conditions, cause a “stick-slip” condition in the boom. This
holding valves are suspected to be the problem,
“stick-slip” condition could result in the load not moving
refer to Service Bulletin 98-036 dealing with testing
smoothly. Proper boom lubrication and wear pad adjustment
telescope cylinders.
is important to permit the boom sections to slide freely. Slow

BOOM DRIFT CHART (Cylinder length change in inches)

3 3
Coeff. = 0.00043 (in /in / °F)
STROKE Temperature Change (°F)
(FT.) 10 20 30 40 50 60 70 80 90 100
5 0.26 0.52 0.77 1.03 1.29 1.55 1.81 2.06 2.32 2.58
10 0.52 1.03 1.55 2.06 2.58 3.10 3.61 4.13 4.64 5.16
15 0.77 1.55 2.32 3.10 3.87 4.64 5.42 6.19 6.97 7.74
20 1.03 2.06 3.10 4.13 5.16 6.19 7.22 8.26 9.29 10.32
25 1.29 2.58 3.87 5.16 6.45 7.74 9.03 10.32 11.61 12.90
30 1.55 3.10 4.64 6.19 7.74 9.29 10.84 12.38 13.93 15.48
35 1.81 3.61 5.42 7.22 9.03 10.84 12.64 14.45 16.25 18.06
40 2.06 4.13 6.19 8.26 10.32 12.38 14.45 16.51 18.58 20.64
45 2.32 4.64 6.97 9.29 11.61 13.93 16.25 18.58 20.90 23.22
50 2.58 5.16 7.74 10.32 12.90 15.48 18.06 20.64 23.22 25.80
55 2.84 5.68 8.51 11.35 14.19 17.03 19.87 22.70 25.54 28.38
60 3.10 6.19 9.29 12.38 15.48 18.58 21.67 24.77 27.86 30.96

Length change in inches = Stroke (Ft.) X Temperature Change ( °F) X Coeff. (in3/in3/ °F) X 12 in/ft

Temperature Effects on Hydraulic Cylinders

FIGURE 2-19

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HYDRAULIC SYSTEM TM500E-2 SERVICE MANUAL

LIFT CYLINDER NOTE: Arranging discarded seals and rings in the order of
disassembly will aid in installation of new seals and
Description rings. Pay attention to how each seal and ring is
installed to avoid installing replacement seals and
The lift cylinder (Figure 2-20) has a bore of 25.4 cm (10.0 rings improperly.
inches). The retracted length of the cylinder from the center
of the barrel bushing to the center of the rod bushing is 6. Remove the set screw securing the piston to the rod.
265.1cm (104.4 inches). The extended length of the cylinder 7. Unscrew the piston from the rod.
from the center of the barrel bushing to the center of the rod
bushing is 464.5 cm (182.9 inches). Its stroke is 199.3 cm 8. Remove the O-ring and two backup rings from the inside
(78.5 inches). A wiper ring prevents foreign material from of the piston.
entering the cylinder. O-rings and other seals prevent 9. Remove the head from the rod.
internal and external leakage.
10. Remove the O-ring and the backup ring from the outside
The cylinder weighs approximately 578 kg (1274 pounds). of the head and the wear rings, buffer seal, rod seal, and
wiper ring from the inside of the head.
Maintenance
Inspection
Disassembly
1. Clean all parts with solvent and dry with compressed air.
NOTE: Any maintenance requiring disassembly of the Inspect all parts for serviceability.
cylinders should include replacement of all seals
and rings. A seal kit will supply the required items. 2. Inspect the barrel carefully for scoring. If barrel is
scored, it must be repaired or replaced.
1. Disconnect the tube assembly from the holding valve.
3. Check piston for damage. If piston is damaged,
2. Remove the capscrews and washers securing the determine if it can be repaired or must be replaced.
holding valve and remove the holding valve from the
cylinder barrel. 4. Inspect rod for straightness. Determine if it can be
straightened or must be replaced.
3. Using a spanner wrench or chain wrench, unscrew the
head from the barrel.
CAUTION
Before installing new seals and rings, clean all surfaces
and carefully remove burrs and nicks. Parts displaying
DANGER excessive wear or damage should be replaced.
Do not use air pressure to remove the rod. Use only a
source of controlled hydraulic oil pressure if the rod is 5. Stone out minor blemishes and polish with a fine crocus
hard to move. cloth.
CAUTION 6. Clean with solvent and dry with compressed air any
Exercise extreme care when handling or setting down the parts that have been stoned and polished.
rod. Damage to the rod surface may cause unnecessary
maintenance and expense. Assembly
4. Remove the rod and attached parts from the barrel.
NOTE: Cover the barrel opening to avoid contamination. CAUTION
When installing new seals and rings, avoid stretching
seals or scratching the grooved or gland surfaces. Make
CAUTION sure parts are clean before and during assembly. Make
When removing seals and rings, avoid scratching the sure seals and rings are installed in the proper order.
grooved and gland surfaces.
NOTE: Lubricate seals and rings with clean hydraulic oil.
5. Remove the two hydrolock seals and guidelock ring from
the outside of the piston.

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TM500E-2 SERVICE MANUAL HYDRAULIC SYSTEM

2
2
6
5
1
5 3

11 9 8
12 8
4

13 7
14
15 18

10 19
20

16
21

22, 23, 24

17

6865-1

FIGURE 2-20

Item Description Item Description

1 Grease Fitting 10 Head
2 Rod 11 Backup Ring
3 Setscrew 12 O-ring
4 Piston 13 Wear Ring
5 Seal Assembly 14 Buffer Seal
6 Guidelock Ring 15 Rod Seal
7 Capscrew 16 Wiper Ring
8 Backup Ring 17 Capscrew
9 O-ring 18 Washer

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HYDRAULIC SYSTEM TM500E-2 SERVICE MANUAL

Item Description
19 Plug Hydrolock Piston Seals

20 Holding Valve
21 Tube Assembly
22 Nut
23 Capscrew
24 Pipe Clamp
1. Install the replacement wear rings, buffer seal, rod seal FIGURE 2-22
and wiper ring in the inside of the head. Make sure the
buffer seal’s step is closer to the rod seal. Make sure the 7. Install the replacement hydrolock seals on the outside of
rod seal’s rim groove is closer to the buffer seal the piston. Make sure the “vees” on the two hydrolock
(Figure 2-21). seals point at each other (Figure 2-22).

Wear Ring
8. Lubricate all parts freely with clean hydraulic oil.
Rod Seal Wiper Ring
Buffer Seal

CAUTION
Exercise extreme care when handling the rod. Damage to
the rod surface may cause unnecessary maintenance
and expense. Also, take care to avoid damaging grooved
or gland surfaces or rings or seals during rod insertion.
6865-2
9. Remove the cover from the barrel. Insert the rod and
FIGURE 2-21
attached parts into the barrel with a slight twisting
2. Install the replacement O-ring and the backup ring on motion.
the outside of the head. 10. Using a spanner wrench or chain wrench, screw the
3. Install the replacement O-ring and backup rings in the head into place in the barrel.
inside of the piston.
4. Lubricate the rod with clean hydraulic oil. CAUTION
5. Slide the head, wiper ring end first, onto the rod. Do not use air pressure to cycle or pressurize the cylinder.
6. Screw the piston onto the rod until tight. Secure the 11. Position the holding valve on the cylinder barrel and
piston with the set screw. secure with four capscrews and washers. Torque
capscrews 97.6 to 105.7 Nm (72 to 78 pounds-foot).
Connect tubing to holding valve.
12. Pressurize and cycle the cylinder with hydraulic oil
pressure. Test the cylinder at 41,368 kPa/413.6 bar
(6000 psi). Check for proper operation and any leakage.
Make repairs as needed.

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TM500E-2 SERVICE MANUAL HYDRAULIC SYSTEM

DUAL ROD TELESCOPE CYLINDER (102

FOOT BOOM)
CAUTION
Description When removing seals and rings, avoid scratching
grooved and gland surfaces.
The boom dual rod telescope cylinder for the 31 m (102 foot)
boom (Figure 2-23) has a 17.7 cm (7.0 inch) bore. The NOTE: Aligning discarded seals and rings in the order of
cylinder is internally ported (rod ported). Oil from the disassembly will facilitate installation of new seals 2
telescope control valve is routed to the cylinder by external and rings.
lines. Foreign material is prevented from entering the
cylinder rod during retraction by a wiper seal in the head. O- 3. Remove the hydrolock piston seal to gain access to the
ring seals prevent internal and external leakage setscrew securing the piston to the outer cylinder rod.
(Figure 2-23). 4. Remove the setscrew and unscrew the piston from the
The cylinder incorporates two cylinder rods with separate cylinder rod.
strokes. One rod has a stroke of 709.1 cm (279.2 inches), 5. Remove the remaining hydrolock seal and wear rings
and one rod has a stroke of 707.8 cm (278.7 inches), which from the outside of the piston and the O-ring and two
provides a combined overall stroke of 1417.0 cm (557.9 backup rings from the inside of the piston.
inches).
6. Remove the spacer from the rod.
7. Remove the cylinder head from the outer rod.
CAUTION
8. Remove the O-ring and backup ring from the outside of
Do not retract the cylinder completely if it is not attached
the head and the wear rings, buffer seal, rod seal,
to the boom. Maintain a spacer that is split or hinged 6.88”
backup ring and the wiper ring from the inside of the
long to prevent cylinder from retracting completely.
head.
The cylinder weighs approximately 1249 kg (2753.5 pounds) 9. Using a spanner wrench, unscrew the inner cylinder
wet. head from the outer cylinder rod.

Maintenance
CAUTION
Disassembly Do not use air pressure to remove the cylinder rod
assembly. Use only a source of controlled hydraulic oil
NOTE: Any maintenance requiring disassembly of the
pressure if the rod is hard to remove.
cylinder should include replacement of all cylinder
seals and O-rings. CAUTION
Exercise extreme care when handling or setting down the
1. Using a spanner wrench, unscrew the outer cylinder
cylinder rod. Do not damage the chrome surface.
head from the cylinder barrel.
10. Remove the inner cylinder rod assembly from the outer
cylinder rod and cover the opening to avoid
contamination.
DANGER
Do not use air pressure to remove the cylinder rod 11. Remove the hydrolock piston seal to gain access to the
assembly. Use only a source of controlled hydraulic oil setscrew securing the piston to the inner cylinder rod.
pressure if the rod is hard to remove. 12. Remove the setscrew and unscrew the piston from the
CAUTION cylinder rod.
Exercise extreme care when handling or setting down the 13. Remove the remaining hydrolock seal and wear ring
cylinder rod. Do not damage the chrome surface. from the outside of the piston and the O-ring and two
backup rings from the cylinder rod
2. Remove the cylinder rod assembly from the cylinder
barrel and cover the barrel to avoid contamination. 14. Remove the spacer from the rod and remove the wear
ring from the spacer.
15. Remove the cylinder head from the inner rod.

PRELIMINARY Published 10-5-2007, Control # 151-00 2-43

HYDRAULIC SYSTEM TM500E-2 SERVICE MANUAL

3
4

3
1
19
20
12
5
2
7

17 6
7

5
8
9
18
8
21
22 9
24 15
23
25
13
11
10
11
14
28

29

16
26

34
27 6714
32 31 30
35 33 FIGURE 2-23

Item Description Item Description

1 Barrel 10 O-ring
2 Piston 11 Backup Ring
3 Seal 12 Spacer
4 Wear Ring 13 Piston
5 Setscrew 14 Spacer
6 O-ring 15 Rod
7 Backup Ring 16 Rod
8 Hydrolock Seal 17 Head
9 Wear Ring 18 Wear Ring

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TM500E-2 SERVICE MANUAL HYDRAULIC SYSTEM

Item Description Assembly

19 O-ring 1. If removed, install the holding valves. Refer to HOLDING
VALVES in this section.
20 Backup Ring
21 Buffer Seal
22 Backup Ring CAUTION
23 Rod Seal
When installing new seals and rings, clean all surfaces
and carefully remove burrs and nicks. Parts displaying
2
24 Backup Ring excessive wear or damage should be replaced.
25 Wiper Ring
NOTE: Lubricate new seals and rings with clean hydraulic
26 Head oil.
27 Wear Ring NOTE: Locate the gap of wear ring 180 degrees with
28 O-ring respect to each other.

29 Backup Ring 2. Install the wiper ring into the cylinder head.
30 Seal 3. Install the wear rings into the head (Figure 2-24).
31 Seal
32 Backup Ring
33 Wiper Ring Backup Ring

34 Holding Valve
35 Plug
16. Remove the O-ring and backup ring from the outside of
the head and the wear rings, buffer seal, deep Z rod
seal, backup ring and the wiper ring from the inside of
the head. Wear Ring Wiper Ring
Buffer Seal Rod Seal
17. If necessary, remove the holding valve from the inner 6488-2
cylinder rod and from the cylinder barrel.
FIGURE 2-24
Inspection
1. Clean all parts with solvent and dry with compressed air. CAUTION
Inspect for damaged or worn parts and replace as
Improper seal installation can cause faulty cylinder
required.
operation.

CAUTION 4. Install the buffer seal, rod seal and backup ring inside
the head ensuring the seals are assembled properly and
Clean all surfaces and remove all burrs and nicks before
installed in the correct direction (Figure 2-24).
installing new seals and rings. Replace all damaged or
worn parts. 5. Install the O-ring and backup ring onto the outside of the
head.
2. Stone out minor blemishes and polish with fine crocus
6. Install the inner cylinder head onto the inner cylinder rod.
cloth.
7. Install the wear ring onto the spacer and install the
3. Clean all with solvent and dry with compressed air any
spacer onto the rod.
parts that have been stoned and polished.
8. Install the O-ring and backup rings onto the rod and
4. Inspect the barrel for scoring.
install the piston onto the inner cylinder rod. Secure the
piston in place with the setscrew.

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HYDRAULIC SYSTEM TM500E-2 SERVICE MANUAL

15. Install the O-ring and backup ring onto the outside of the
outer cylinder head.
Hydrolock Piston Seals
16. Install the outer cylinder head onto the outer cylinder
rod.
17. Install the spacer onto the rod.
18. Install the O-ring and backup rings into the inside of the
piston and install the piston onto the outer cylinder rod.
Secure the piston in place with the setscrew.

Hydrolock Piston Seals

FIGURE 2-25

9. Install the hydrolock seals onto the piston (Figure 2-25).

CAUTION
Avoid scratching or damaging the grooved and gland
surfaces or the seals and rings.

10. Lubricate the inner cylinder rod assembly with clean

hydraulic oil and install the rod assembly into the outer
FIGURE 2-27
cylinder rod with a slight twisting motion.
11. Using a spanner wrench, secure the inner cylinder head 19. Install the hydrolock seals and wear rings onto the piston
to the outer cylinder rod. (Figure 2-27).

12. Install the wiper ring into the outer cylinder head.
13. Install the wear rings into the head. CAUTION
Avoid scratching or damaging the grooved or gland
surfaces or the ring and seals.
CAUTION
Improper installation of seals could cause faulty cylinder 20. Lubricate the outer cylinder rod assembly with clean
operation. hydraulic oil and install the rod assembly into the
cylinder barrel with a slight twisting motion.
14. Install the buffer seal, backup rings and rod seal into the 21. Using a spanner wrench, secure the outer cylinder head
head ensuring the seals are assembled properly and to the cylinder barrel.
installed in the correct direction (Figure 2-26).

Backup Ring
Backup Ring
DANGER
Do not use air pressure to cycle or pressurize the cylinder.

22. Pressurize and cycle the cylinder with hydraulic oil

pressure. Test the cylinder at 32,750 kPa/327.5 bar
(4750 psi). Check for proper operation and any leakage.
Wear Ring Wiper Ring
Buffer Seal Rod Seal
6488-1

FIGURE 2-26

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TM500E-2 SERVICE MANUAL HYDRAULIC SYSTEM

TELESCOPE CYLINDER (28.9M [95 FOOT] 5. Remove a hydrolock seal from the outside of the inner
BOOM) rod piston to gain access to the set screw.
NOTE: Arranging discarded seals and rings in the order of
Description disassembly will aid in installation of new seals and
rings. Pay attention to how each seal and ring is
The telescope cylinder for the 28.9 m (95 foot) boom
installed to avoid installing replacement seals and
(Figure 2-28) has two hollow rods for internal porting. It has a
16.02 cm (6.31 inch) bore and a 10.8 cm (4.25 inch) bore.
rings improperly.
2
The retracted length of the cylinder is 733 cm (288.5 inch). 6. Remove the set screw. Unscrew the piston from the
The extended length of the cylinder is 2096 cm (825 inch). inner rod.
The outer rod has a stroke of 687.7 cm (270.75 inch) and the
inner rod has a stroke of 675.0 cm (265.75 inch). 7. Remove the other hydrolock seal from the outside of the
inner rod piston.
Wiper rings prevent foreign material from entering the
cylinder. O-rings and other seals prevent internal and 8. Remove the O-ring and the two backup rings from the
external leakage. inside of the inner rod piston.

The cylinder weighs approximately 907 kg (2000 pounds). 9. Remove the spacer from the inner rod.
10. Remove the head from the inner rod. Remove the two
Maintenance O-rings and the backup ring from the outside of the
head. Remove the wear rings, the buffer seal, the deep
Disassembly Z rod seal, and the wiper ring from the inside of the
NOTE: Any maintenance requiring disassembly of the head.
cylinders should include replacement of all seals 11. Using a chain wrench, unscrew the outer head from the
and rings. A seal kit will supply the required items. inner rod.
1. Using hydraulic power, extend the cylinder
approximately 61 cm (24 inch).
2. Remove the three bolts securing the holding valve block
to the outer rod and remove the holding valve block.
DANGER
Do not use air pressure to remove the rod. Use only a
3. Using a chain wrench, unscrew the inner head from the source of controlled hydraulic oil pressure if the rods are
barrel. hard to move.

DANGER CAUTION
Do not use air pressure to remove the rods. Use only a Exercise extreme care when handling or setting down the
source of controlled hydraulic oil pressure if the rod is rod. Damage to the rod surface may cause unnecessary
hard to move. maintenance and expense.

12. Remove the inner rod and attached parts from the inner
rod.
CAUTION
NOTE: Cover the opening to avoid contamination.
Exercise extreme care when handling or setting down the
rod. Damage to the rod surface may cause unnecessary
maintenance and expense.
CAUTION
4. Remove the inner and outer rods and attached parts as When removing seals and rings, avoid scratching the
an assembly from the barrel. grooved and gland surfaces.

NOTE: Cover the barrel opening to avoid contamination. 13. Remove a hydrolock seal from the outside of the outer
rod piston to gain access to the set screw.

CAUTION
When removing seals and rings, avoid scratching the
grooved and gland surfaces.

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HYDRAULIC SYSTEM TM500E-2 SERVICE MANUAL

23
29

24
28

23
22
27

17
26

16
25

15
21
16

20
19
18

14

9
8
13
12

7
11

2
10
6
5

3
1

FIGURE 2-28

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TM500E-2 SERVICE MANUAL HYDRAULIC SYSTEM

16. Remove the O-ring and the two backup rings from the
Item Description inside of the outer rod piston.

1 Barrel 17. Remove the spacer from the outer rod.

2 Inner Rod Piston 18. Remove the head from the outer rod. Remove the two
O-rings and the backup ring from the outside of the
3 Hydrolock Piston Seals
head. Remove the wear ring, the buffer seal, the deep Z
4 Set ccrew rod seal, and the wiper ring from the inside of the head. 2
5 O-ring Inspection
6 Backup Rings 1. Clean all parts with solvent and dry with compressed air.
7 Hydrolock Piston Seals Inspect all parts for serviceability.
8 O-ring 2. Inspect the barrel carefully for scoring. If barrel is
9 Backup Rings scored, it must be repaired or replaced.

10 Outer Rod Piston 3. Check pistons for damage. If pistons are damaged,
determine if they can be repaired or must be replaced.
11 Spacer
4. Inspect rods for straightness. Determine if they can be
12 Spacer straightened or must be replaced. Verify internal
13 Inner Rod passages and ports are clean and undamaged.
14 Outer Rod
15 Inner Head CAUTION
16 O-ring Before installing new seals and rings, clean all surfaces
and carefully remove burrs and nicks. Parts displaying
17 Backup Ring excessive wear or damage should be replaced.
18 Wear Ring
5. Stone out minor blemishes and polish with a fine crocus
19 Buffer Seal
cloth.
20 Deep Z Rod Seal
6. Clean with solvent and dry with compressed air any
21 Wiper Ring parts that have been stoned and polished.
22 Outer Head
Assembly
23 O-ring
24 Backup Ring
CAUTION
25 Wear Rings When installing new seals and rings, avoid stretching
26 Buffer Seal seals or scratching the grooved or gland surfaces. Make
sure parts are clean before and during assembly. Make
27 Deep Z Rod Seal
sure seals and rings are installed in the proper order.
28 Wiper Ring
29 Holding Valve NOTE: Lubricate seals and rings with clean hydraulic oil.
NOTE: Make sure the gaps of the two wear rings are 180
NOTE: Arranging discarded seals and rings in the order of
degrees apart.
disassembly will aid in installation of new seals and
rings. Pay attention to how each seal and ring is 1. Install the replacement wear ring, buffer seal, deep Z rod
installed to avoid installing replacement seals and seal, and wiper ring in the inside of the outer rod head.
rings improperly. Make sure the deep Z rod seal’s rim groove is closer to
the wear ring. Make sure the buffer seal’s step is away
14. Remove the set screw. Unscrew the piston from the
from the wear ring (Figure 2-29).
outer rod.
2. Install the replacement O-rings and backup ring on the
15. Remove the other hydrolock seal from the outside of the
outside of the outer rod head.
outer rod piston.
3. Install the replacement O-ring and two backup rings in
the inside of the outer rod piston.

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HYDRAULIC SYSTEM TM500E-2 SERVICE MANUAL

13. Install the replacement wear rings, buffer seal, deep Z

rod seal, and wiper ring in the inside of the inner rod
head. Make sure the deep Z rod seal’s rim groove is
closer to the wear ring. Make sure the buffer seal’s step
is away from the wear ring (Figure 2-31).

Wiper Ring
Buffer Seal
Deep Z Rod Seal
FIGURE 2-29

4. Install one replacement hydrolock seal (Figure 2-30) on

the outside of the outer rod piston. Leave the other Buffer Seal Wiper Ring
hydrolock seal off for now so there is still access to the
piston’s set screw hole. Deep Z Rod Seal
FIGURE 2-31
Hydrolock Piston Seals
14. Install the replacement O-rings and backup ring on the
outside of the inner rod head.
15. Install the replacement O-ring and two backup rings in
the inside of the inner rod piston.
16. Install one replacement hydrolock seal (Figure 2-32) on
the outside of the inner rod piston. Leave the other
FIGURE 2-30 hydrolock seal off for now so there is still access to the
piston’s set screw hole.
5. Lubricate the outer rod with clean hydraulic oil.
6. Slide the head, larger OD end first, onto the outer rod. Hydrolock Piston Seals

7. Slide the spacer onto the outer rod.

8. Screw the piston onto the outer rod. Secure the piston in
place with a new nylon point set screw.
9. Install the other replacement hydrolock seal on the
outside of the piston over the set screw. Make sure the
“vees” on the two hydrolock seals point at each other. FIGURE 2-32
10. Lubricate all parts freely with clean hydraulic oil. 17. Lubricate the inner rod with clean hydraulic oil.
18. Slide the head, larger OD end first, onto the inner rod.
CAUTION 19. Slide the spacer onto the inner rod.
Exercise extreme care when handling the rod. Damage to
the rod surface may cause unnecessary maintenance 20. Screw the piston onto the inner rod. Secure the piston in
and expense. Also, take care to avoid damaging grooved place with a new nylon point set screw.
or gland surfaces, rings or seals during rod insertion. 21. Install the other replacement hydrolock seal on the
outside of the piston over the set screw. Make sure the
11. Remove the cover from the inner rod. Insert the outer “vees” on the two hydrolock seals point at each other.
rod and attached parts into the inner rod with a slight
twisting motion. 22. Lubricate all parts freely with clean hydraulic oil.

12. Clean all oil from the threads of the head. Coat the
threads with an anti-seize compound (ex: Never-Seez CAUTION
paste lubricant or similar lubricant). Using a chain Exercise extreme care when handling the rods. Damage
wrench, screw the head into place on the inner rod to the rod surface may cause unnecessary maintenance
tightly so its larger OD end is flush with the end of the and expense. Also, take care to avoid damaging grooved
rod. or gland surfaces, rings or seals during rod insertion.

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TM500E-2 SERVICE MANUAL HYDRAULIC SYSTEM

23. Remove the cover from the barrel. Insert the inner and
outer rods and attached parts as an assembly into the
barrel with a slight twisting motion. CAUTION
24. Clean all oil from the threads of the head. Coat the Do not damage the o-rings during installation of the
threads with an anti-seize compound (ex: Never-Seez holding valve. If the holding valve turns freely then gets
paste lubricant or similar lubricant). Using a chain hard to turn, then easy to turn, remove the holding valve
and check the o-rings. They have probably been
wrench, screw the head into place on the barrel tightly
so its larger OD end is flush with the end of the barrel. damaged by a sharp edge of a port. 2
25. Position the holding valve block on the outer rod and NOTE: The holding valve should turn by hand until
secure with the three bolts. Torque the bolts to 102 Nm compression of the O-rings begins.
(75 pounds-foot)
29. Carefully install the holding valve into the port block until
NOTE: If the holding valve was removed from the block fully seated.
perform steps 26 thru 29.
26. Check the inside of the port block for any sharp edges or
burrs and remove as necessary with emery cloth.
CAUTION
Do not use air pressure to cycle or pressurize the cylinder.
27. Install new O-rings onto the holding valve.
28. Lubricate the holding valve and O-rings with clean 30. Pressurize and cycle the cylinder with hydraulic oil
hydraulic oil. pressure. Test the cylinder at 24,100 kPa (241 bar)
(3500 psi). Check for proper operation and any leakage.
Make repairs as needed.

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HYDRAULIC SYSTEM TM500E-2 SERVICE MANUAL

OUTRIGGER EXTENSION CYLINDER 6. Remove the piston, spacer and head from the rod.
7. Remove the O-ring and the backup ring from the outside
Description of the head.
The four extension cylinders (Figure 2-33) have 6.4 cm (2.5- 8. Remove the rod seal, wear ring and wiper ring from the
inch) diameter bores. Each cylinder has a retracted length of inside of the head.
218.1 ± 0.30 cm (85.88 ± 0.12 inches) from the center of the
rod bushing to the center of the barrel bushing. Each 9. Remove the O-ring from the rod.
cylinder’s extended length is 403.8 cm (159 inches). The
stroke of each cylinder is 185.4 cm (73.0 inches). A wiper Inspection
ring prevents foreign material from entering each cylinder. O-
1. Clean all parts with solvent and dry with compressed air.
rings and other seals prevent internal and external leakage.
Inspect all parts for serviceability.
The cylinder weighs approximately 42 kg (112.5 pounds).
2. Inspect the barrel carefully for scoring. If barrel is
scored, it must be repaired or replaced.
Maintenance
3. Check rod’s piston area for damage. If it is damaged,
Disassembly determine if it can be repaired or must be replaced.

NOTE: Any maintenance requiring disassembly of the 4. Inspect rod for straightness. Determine if it can be
cylinders should include replacement of all seals straightened or must be replaced.
and rings. A seal kit will supply the required items.
1. Remove all dirt, grease and other contaminants from CAUTION
around the ports and the head
Before installing new seals and rings, clean all surfaces
and carefully remove burrs and nicks. Parts displaying
excessive wear or damage should be replaced.

DANGER 5. Stone out minor blemishes and polish with a fine crocus
Do not use air pressure to remove the rod. Use only a cloth.
source of controlled hydraulic oil pressure if the rod is
hard to move. 6. Clean with solvent and dry with compressed air any
parts that have been stoned and polished.
CAUTION
Exercise extreme care when handling or setting down the Assembly
rod. Damage to the rod surface may cause unnecessary
maintenance and expense.
CAUTION
2. Using a spanner wrench, unscrew the cylinder head.
When installing new seals and rings, avoid stretching
3. Remove rod and attached parts from the barrel. seals or scratching the grooved or gland surfaces. Make
sure parts are clean before and during assembly. Make
NOTE: Cover the barrel opening to avoid contamination.
sure seals and rings are installed in the proper order.

NOTE: Lubricate seals and rings with clean hydraulic oil.

CAUTION
When removing the seals and rings, avoid scratching the 1. Install the replacement wear ring, rod seal and wiper ring
grooved and gland surfaces. in the inside of the head.
2. Install the replacement O-ring and the backup ring on
4. Remove the wear rings and piston seal from the outside the outside of the head.
of the piston.
3. Install the O-ring onto the rod.
NOTE: Arranging discarded seals and rings in the order of
disassembly will aid in installation of new seals and 4. Lubricate the rod with clean hydraulic oil.
rings. Pay attention to how each seal and ring is 5. Slide the head onto the rod.
installed to avoid installing replacement seals and
rings improperly. 6. Install the spacer and piston on the rod.

5. Remove the nut from the rod. 7. Install the locknut onto the rod.

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TM500E-2 SERVICE MANUAL HYDRAULIC SYSTEM

1
3
2
6

8
7 9
2
8
5

14
12
13

10 4

6815

11

FIGURE 2-33

Item Description Item Description

1 Barrel 8 Wear Ring
2 Rod 9 O-ring
3 Piston 10 O-ring
4 Head 11 Backup Ring
5 Spacer 12 Seal
6 Nut 13 Wiper Ring
7 Piston Seal 14 Wear Ring

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HYDRAULIC SYSTEM TM500E-2 SERVICE MANUAL

8. Install the replacement piston seal and wear rings on the 10. Remove the cover from the barrel. Insert the rod and
outside of the piston. attached parts into the barrel with a slight twisting
motion.
9. Lubricate all parts freely with clean hydraulic oil.
11. Push the head into the barrel.

CAUTION
Exercise extreme care when handling the rod. Damage to CAUTION
the rod surface may cause unnecessary maintenance Do not use air pressure to cycle or pressurize the cylinder.
and expense. Also, take care to avoid damaging grooved
or gland surfaces, rings or seals during rod insertion. 12. Pressurize and cycle the cylinder with hydraulic oil
pressure. Test the cylinder at 20,700 kPa (270 bar)
(3000 psi). Check for proper operation and any leakage.
Make repairs as needed.

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TM500E-2 SERVICE MANUAL HYDRAULIC SYSTEM

OUTRIGGER STABILIZER CYLINDER 5. With the ports open, extend the rod assembly with a
hoist enough to access the top of the head with spanner
Description wrench. Do not extend completely.

The four outrigger stabilizer cylinders (Figure 2-34) each 6. Turn the head counterclockwise with a fitted spanner
have a hollow rod for internal porting. Each cylinder has a wrench until the threads disengage.
10.1 cm (4.0 inch) diameter bore. A port block is welded to 7. Extend the rod assembly slowly until the piston is free of
the rod of each cylinder and a pilot operated check valve is
threaded into each port block.
the barrel assembly. Place the rod assembly horizontally 2
on a workbench taking care not to damage the surface
The retracted length of the cylinder from the end of the barrel of the rod.
to the center of the rod’s port block rod bushing is 122.2 ±
NOTE: Cover the barrel opening to avoid contamination.
30.8 cm (48.12 ±.12 inches). The extended length of the
cylinder from the end of the barrel to the center of the rod’s NOTE: Do not clamp on the rod working surface.
port block rod bushing is 185.7 cm (73.12 inches). Its stroke
8. Secure the rod assembly using the 1 3/4 inch pinholes.
is 63.5cm (25 inches). A wiper ring prevents foreign material
from entering the cylinder. O-rings and other seals prevent 9. Remove the piston seal to gain access to the piston
internal and external leakage setscrew Using a 3/16 inch Allen wrench, remove the
setscrew from the piston.
The cylinder weighs approximately 64.6 kg (142.52 pounds).
10. Remove the piston by turning counterclockwise with a
Maintenance fitted spanner wrench.

Disassembly 11. Remove the spacer and head from the rod.

NOTE: Any maintenance requiring disassembly of the

cylinder should include replacement of all cylinder CAUTION
seals. When removing seals and rings, avoid scratching the
1. Clean away all dirt from the head. Place protective grooved and gland surfaces.
padding around the rod near the head to prevent
damaging the chrome. Using a spanner wrench, 12. Remove the seal assembly from the outside of the
unscrew the head from the barrel. piston and the O-ring and backup rings from he inside of
the piston.
NOTE: Arranging discarded seals and rings in the order of
disassembly will aid in installation of new seals and
DANGER rings. Pay attention to how each seal and ring is
Do not use air pressure to remove the rod. Use only a installed to avoid installing replacement seals and
source of controlled hydraulic oil pressure if the rod is rings improperly.
hard to remove. 13. Remove the O-ring and backup ring from the outside of
CAUTION the head. Remove the wear rings, buffer seal, rod seal
Exercise extreme care when handling or setting down the and wiper ring from the inside of the head.
rod. Do not damage the chrome surface.
Inspection
2. Open ports on the side of the cylinder barrel and drain
1. Inspect the rod. There should be no scratches or pits
the oil from the cylinder.
deep enough to catch the fingernail. Pits that go to the
3. Secure cylinder barrel in a chain vise without putting base metal are unacceptable. Chrome should be
pressure on the side feeder tube in the vertical position present over the entire surface of the rod. If lack of
with the rod assembly up. chrome on rod, the rod should be replaced.
4. Using a 5/32 inch Allen wrench, remove the setscrew on 2. Inspect rod for straightness. Determine if it can be
the barrel OD at the head. straightened or must be replaced.
NOTE: Oil or oil/air mixture may rapidly exit out of the ports 3. Inspect the head. Visually inspect the inside bore for
during rod extension. Shield the work area from the scratching or polishing. Deep scratches are
exiting oil. unacceptable. Polishing indicates uneven loading, and
the bore should be checked for out-of-roundness.

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HYDRAULIC SYSTEM TM500E-2 SERVICE MANUAL

18 16
18
17

5
7, 8
15

4
13
12 14

10
11

6
6940

FIGURE 2-34

Item Description Item Description

1 Barrel 10 Wiper Ring
2 Rod 11 Rod Seal
3 Head 12 Buffer Seal
4 Piston 13 Wear Ring
5 Spacer 14 O-ring
6 Check Valve 15 Backup Ring
7 Setscrew 16 Hydrolock Seal
8 Insert 17 O-ring
9 Plug 18 Backup Ring

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TM500E-2 SERVICE MANUAL HYDRAULIC SYSTEM

4. Inspect the piston. Visually inspect the outside surface 5. Install the spacer onto the rod with the ID lip at the piston
for scratches or polishing, Deep scratches are end.
unacceptable. Polishing indicates uneven loading, and
6. Install the setscrew in the piston with a 3/16 inch Allen
the diameter should be checked for out-of roundness.
wrench until hand tight. Install the seal assemblies onto
5. Inspect the barrel carefully for scoring. If barrel is the piston.
scored, it must be repaired or replaced.
7. Remove the cover from the barrel.
6. Thoroughly rinse parts, allow to drain, and wipe with a 2
lint-free rag. Inspect all parts for serviceability.
CAUTION
Exercise extreme care when handling the rod. Damage to
CAUTION the rod surface may cause unnecessary maintenance
Before installing new seals and rings, clean all surfaces and expense. Also, take care to avoid damaging grooved
and carefully remove burrs and nicks. Parts displaying or gland surfaces or rings or seals during rod insertion.
excessive wear or damage should be replaced.
8. With a hoist, raise the rod assembly back into a vertical
7. Stone out minor blemishes and polish with a fine crocus position taking care not to damage the OD seals on the
cloth. head and piston.
8. Clean with solvent and dry with compressed air any 9. Lubricate the OD seals on the piston and head with
parts that have been stoned and polished. clean light oil and lower the assembly into the barrel.
Stop just before the head enters the barrel.
Assembly 10. Place a spanner wrench on the head and turn
counterclockwise until the thread clicks, then reverse
direction to clockwise and thread in until there is no gap
CAUTION between the head shoulder and top of barrel.
When installing new seals and rings, avoid stretching
seals or scratching the grooved or gland surfaces. Make 11. Using a 5/32 inch Allen wrench install the setscrew into
sure parts are clean before and during assembly. Make the head until hand tight.
sure seals and rings are installed in the proper order. 12. Slowly lower the rod down to the fully retracted position.

NOTE: Lubricate seals and rings with clean hydraulic oil.

1. Install the replacement wiper ring, rod seal, buffer seal
CAUTION
and wear rings in the inside of the head. Do not use air pressure to cycle or pressurize the cylinder.

2. Install the replacement O-ring and backup ring on the 13. Pressurize and cycle the cylinder with hydraulic oil
outside of the head. pressure. Test the cylinder at 31,026 kPa/310.2 bar
3. Lubricate the rod with clean hydraulic oil. (4500 psi). Check for proper operation and any leakage.
Make repairs as needed.
4. Slide the head, onto the rod. Tap the head with a rubber
mallet to engage the seals. Push the head about half
way down the length of the rod assembly.

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HYDRAULIC SYSTEM TM500E-2 SERVICE MANUAL

THIS PAGE BLANK

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 SECTION 3
ELECTRIC SYSTEM
TABLE OF CONTENTS
Superstructure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Fuse Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3
General Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Troubleshooting Swivel-Caused Electrical Problems . . . . . . . . . . . . . . . . . . . . 3-3
Connector Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Superstructure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Alternator Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Starter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Battery Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Relay Panel Component Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Instrument Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Ignition And Fan Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Windshield Wiper Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Windshield Washer Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Skylight Wiper Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Carrier Electrical Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Electrical Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Design and Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Instrumentation Component Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Additional Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Anti-Lock Brake System (ABS) ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Transmission ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Gateway Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Carrier Electrical Center (CEC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Circuit Breaker Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Additional Electrical Information – Typical Circuit Components . . . . . . . . . . . . . . . 3-12
Wiring Harnesses, Wires and Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Wiring Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Circuit Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Fusible Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Diodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Switches and Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Sensors and Senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Special Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Diagnostic Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
General Work Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Charging the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Jump-Starting the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

3-i
ELECTRIC SYSTEM TM500E-2 SERVICE MANUAL

Relay Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Replace Fusible Link (Battery-Side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Troubleshooting Using a Digital Multimeter . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Troubleshooting Wiring and Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
General Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Visual Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Checks - Short Circuit to Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Checks - Short Circuit to Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Grounded Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
High Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Possible causes of High Resistance: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Contact Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Dielectric Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Routing and Clipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Switch Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Electronic Control Unit (ECU) Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 3-21
Data LInk Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Data Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Design and Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Data Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Data Link System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Data Links Design and Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Messages and Information Content . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
Instrumentation Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
SAE J1939 Control Data Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
SAE J1587/1708 Data Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Diagnostic Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
J1939 Control Data Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
J1939 Control Data Link Troubleshooting Example . . . . . . . . . . . . . . . . . . . . 3-26
Using A Driver Information Center (DIC) as a Troubleshooting Tool . . . . . . . 3-28
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
J1939 Control Data Link Wiring (Shielded) . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
Electrical Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
Instrumentation System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
Design and Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
Gauge Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
Special Tools and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
Gauges and Telltale Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
Using the Driver Information Center as a Troubleshooting Tool . . . . . . . . . . 3-32
Control Data Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
Testing Using Gauge Tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
Instrumentation System Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
Diagnostic Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
Gauge Tester Function Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36

3-ii
TM500E-2 SERVICE MANUAL ELECTRIC SYSTEM

Gauge Data Source Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37

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ELECTRIC SYSTEM TM500E-2 SERVICE MANUAL

3-iv
TM500E-2 SERVICE MANUAL ELECTRIC SYSTEM

SECTION 3
ELECTRIC SYSTEM
SUPERSTRUCTURE amount of gases that are produced in the battery to escape.
On some batteries, a test indicator located on the top of the
Description battery is used to determine if the battery can be tested in
case of a starting problem.
General There is a battery disconnect on the right side of the
The electrical system is 24-volt operation with 24-volt powerplant tray close to the batteries. The disconnect switch
starting, consisting of an alternator and two lead-acid is accessible through an opening in the powerplant tray
batteries. The system is the single wire ground return type, sheet metal cover (Figure 3-3).
using the machine’s structure as ground 3
Alternator
The alternator mounted on the superstructure engine
(Figure 3-1) is belt driven. It is a 140 ampere alternator with
an integral transformer - rectifier unit. When the engine is
running, and the alternator is turning, the alternator’s 24-volt
output terminal supplies the crane’s electrical circuits. The
output terminal also supplies the voltage to recharge the
batteries and maintains them at a full state of charge.

7008-2 Batteries
Powerplant Tray FIGURE 3-2

Battery Box
7008-1 Engine Alternator
Powerplant Tray FIGURE 3-1

Batteries
Two 12-volt batteries are located on the right side of the
crane in the powerplant tray (Figure 3-2). The batteries are 7008-3
the maintenance free type and completely sealed except for Battery Disconnect Switch
FIGURE 3-3
a small vent hole in the side. The vent hole allows what small

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ELECTRIC SYSTEM TM500E-2 SERVICE MANUAL

Fuse Panel Fuse Protects Amps Location

Fuses are located behind the seat in the superstructure cab F11 24 Vdc Spare (3A max) 5 (Figure 3-4)
(Figure 3-4).
F12 Not Used N/A (Figure 3-4)
Turntable L/R SIde
F13 10 (Figure 3-4)
Module
F14 LMI 5 (Figure 3-4)
Armrest L/R Side
F15 10 (Figure 3-4)
Module
F16 Not Used N/A (Figure 3-4)

Relays
The relays are located on the fuse and relay panel in the
powerplant tray next to the batteries (Figure 3-5).

1 2 3 4 5 6 7

7008-4 Fuse Panel

FIGURE 3-4

The following fuse assignments apply:

Table 3-1

Fuse Protects Amps Location

Ignition and Diagnostic
F1 10 (Figure 3-4)
Tool
F2 Work Lights 10 (Figure 3-4)
+12 Accessory Outlet/
F3 15 (Figure 3-4) 7008-5
Heater Valve FIGURE 3-5
F4 Dome Light 5 (Figure 3-4)
Item Description
F5 Cab Circulation Fan 5 (Figure 3-4)
1 Starter Relay
F6 24 VDC Spare (3A max) 5 (Figure 3-4)
2 Heater Grid Relay
F7 Skylight Wiper 10 (Figure 3-4)
3 Power Relay
F8 Windshield Wiper 15 (Figure 3-4)
4 200 Amp Fuse
Superstructure Cab
F9 10 (Figure 3-4) 5 150 Amp Fuse
Module
F10 Voltmeter/Gauge Lights 5 (Figure 3-4) 6 125 Amp Fuse
7 50 Amp Fuses

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TM500E-2 SERVICE MANUAL ELECTRIC SYSTEM

Maintenance components and guide you from the easiest and most
likely problems to the hardest and least likely problems.
General 3. Using a multimeter, test the circuit for continuity if you
Electrical system maintenance includes troubleshooting and suspect a broken circuit or for voltage if you suspect a
replacement of damaged components. Observe standard power problem. Check the electrical schematic and
wiring practices when replacing components. wiring diagram for most accurate wiring information.
4. If the component proves faulty, replace it with a known
working component. If wiring proves faulty, replace it
with wiring of equal diameter.
DANGER 5. After troubleshooting, test the repaired circuit. Verify the
If it is necessary to perform electrical maintenance on live circuit works properly.
or hot circuits, remove all rings, watches, and other
jewelry before performing maintenance as serious burns Troubleshooting Swivel-Caused Electrical 3
result from accidental grounding or shorting circuits.
Problems
Many crane component electrical troubles can be traced to
the electrical swivel. Troubles common to the swivel are
improper mounting, foreign material between the brushes
DANGER and slip rings, incorrect wiring from the swivel to the
Ensure the batteries are disconnected before performing components, incorrect wire size, worn brushes, improper
any maintenance on an electrical circuit which is not fused spring tension on the brush assembly, and loose setscrews
or when performing continuity checks. on the slip ring assembly. Refer to the electrical schematic
and wiring diagram for slip ring connections and amperages.

Connector Troubleshooting
CAUTION The cause of an electrical problem may be a loose or
Never replace original wiring with wiring of a smaller size corroded connection in the pin or socket connectors. Check
(gauge). the connectors to ensure that the pins and sockets are
properly seated and engaged. If the pins and sockets show
General Troubleshooting any signs of corrosion, use a good quality electrical contact
cleaner or fine sandpaper to clean them. When the pins or
sockets show signs of arcing or burning, it will probably be
necessary to replace them.
DANGER Refer to (Table 3-2), (Table 3-3), (Table 3-4), and (Table 3-5)
Many steps in the troubleshooting procedures require listing tools necessary for connector maintenance.
testing live (energized) components. Perform these steps Because the pins and sockets are crimped to the wires, it is
observing good safety practices to avoid electrical shock not possible to remove them. Using the proper extraction
injury. tool, remove the pin(s) or socket(s) from the plug or
receptacle. Cut the wire as close to the pin or socket as
NOTE: Make voltage checks at terminations when possible. After cutting the pin or socket off, the wire will most
components are installed and operating. Make likely be too short. Using a wire that is too short will allow
continuity checks (with batteries disconnected) pressure to be applied to the pin or socket and wire where
when components are isolated or removed. they are crimped when the pin or socket is inserted in the
Troubleshoot per the following guidelines: plug or receptacle. Add a short length of the same size wire
1. First, use reported symptoms to identify a problem or a to the short wire by crimp splice or solder. Use heat
suspect component. shrinkable tubing or other suitable material to insulate the
splice.
2. Test the suspect component per instructions in this
section. The instructions identify the fuses and

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ELECTRIC SYSTEM TM500E-2 SERVICE MANUAL

Table 3-2
AMP Extraction Tool Table

Description AMP Part Number Grove Part Number

Tool Die Tool Die
14 to 12 gauge wire 69710-1 90145-1 9-999-100177 N/A
10 to 8 gauge wire 69710-1 90140-1 9-999-100177 9-999-100178
4 to 9 circuit
69710-1 90306-1 9-999-100177 N/A
(in-line connectors)
15 circuit
90299-1 -- N/A --
(in-line connectors)

Table 3-3
AMP Crimping Tool Table

Description AMP Part Number Grove Part Number

Tool Die Tool Die
14 to 12 gauge wire 69710-1 90145-1 9-999-100177 N/A
10 to 8 gauge wire 69710-1 90140-1 9-999-100177 9-999-100178
4 to 9 circuit
69710-1 90306-1 9-999-100177 N/A
(in-line connectors)
15 circuit
90299-1 -- N/A --
(in-line connectors)

Table 3-4
Deutsch Extraction Tool Table

Description Deutsch Part Number Grove Part Number

12 gauge wire 114010 9-999-100194
16 gauge wire 0411-204-1605 9-999-100195
8-10 gauge wire 114008 7-902-000012
4-6 gauge wire 114009 7-902-000009
20-24 gauge wire 0411-240-2005 9-999-102084

Table 3-5
Deutsch Crimping Tool Table

Description Deutsch Part Number Grove Part Number

12, 14, 16, 18, 20, 22, 24 gauge wire HDT-48-00 9-999-100808
4, 6, 8, 10 gauge wire HDT04-08 9-999-100842

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TM500E-2 SERVICE MANUAL ELECTRIC SYSTEM

Superstructure 5. Verify alternator pulley nut is torqued to 95 to 108 Nm

(70 to 80 pounds-foot).
The following superstructure circuit designs apply. Table
3-6 (connecting wiring and passage through swivel slip 6. Connect the electrical leads to the terminals as tagged
ring -- as applicable -- is understood): during removal.
7. Connect the batteries.
Table 3-6: Superstructure Light Circuits
8. Install the engine covers.
Lights Circuit
Check
F2, WORK light switch, lamp,
Work Lights grounds. Parallel circuit to LED 1. Run engine. Verify reading of voltmeter on front console
indicator in switch to ground is 12 volts or greater. Make repairs as needed.
F4, switch on dome light, lamp, 2. Continue troubleshooting charging system as needed if
Cab Dome Light
grounds replacement of alternator did not correct problem in 3
charging system.
F10, PANEL DIM control, lamps,
Gauge Lights
grounds
Starter Replacement
Alternator Replacement Removal
Removal 1. Remove the covers to gain access to the battery tray in
the powerplant tray in the superstructure.
1. Disconnect the batteries located in the powerplant tray
on the superstructure. 2. Disconnect the batteries.

2. Remove the engine covers. 3. Tag and disconnect the electrical leads from the
terminals on the starter located on the fuse and relay
3. Tag and disconnect the electrical leads from the panel located in the powerplant tray on the
terminals on the alternator. superstructure.
4. Turn the tensioner above the alternator clockwise to 4. Remove the screws, washers and nuts holding the
remove tension from the belt. Slip the belt off of the starter to the mounting pad. Remove the starter.
alternator pulley, then let the tensioner return to its
normal position. Installation
5. Remove and tag all wires. Remove the capscrews, 1. Place the starter on its mounting pad. Secure the starter
flatwashers and locknut securing the alternator. Remove with the screws, washers and nuts.
the alternator. 2. Connect the electrical leads to the terminals as tagged
Installation during removal.

1. Inspect the belt. Verify it has no cracks or other damage. 3. Connect the batteries.
Replace damaged belt as needed. 4. Install the engine covers.
2. Install the alternator on the mounting bracket and secure Check
with the capscrews, washers and locknuts. Torque the
capscrews 78 to 106 Nm (72 to 78 pounds-foot). 1. Try to start the engine. Verify the starter starts the
engine.
3. Install the belt on all engine pulleys except the alternator
pulley for now. 2. Start engine again, and listen for starter noises. Verify
there is no abnormal noise indicating the starter’s gear is
4. Turn the tensioner clockwise. Slip the belt onto the meshing improperly with the flywheel, that the starter’s
alternator pulley, then carefully return the tensioner to its gear hasn’t disengaged from the flywheel after the
normal position so it puts tension on the belt. Make sure ignition switch is in the ignition (run) position, or some
the belt is centered on the tensioner. other problem. Install starter properly as needed.

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ELECTRIC SYSTEM TM500E-2 SERVICE MANUAL

Battery Replacement 1. Place the batteries in the battery box on the powerplant
tray.
Removal
2. Install the hold down bracket so it can hold down the
batteries. Secure the bracket (and batteries) to the
bracket hold down rods with nuts and washers.
3. Connect leads to the battery terminals starting with the
negative terminals (Figure 3-7)
4. Install the battery box covers.
5. Verify replacement batteries work by starting crane’s
engine and operating various crane components.

Relay Panel Component Replacement

Accessory Relay
1. Remove the battery box covers.
2. Disconnect the batteries.
3. Tag and disconnect the electrical leads from the suspect
relay.
4. Remove the hardware securing the suspect relay to the
relay panel assembly. Remove suspect relay.
5. Install replacement relay on relay panel and secure it
7008-6
FIGURE 3-6 with attaching hardware.

1. Remove the battery box covers on the powerplant tray. 6. Connect the electrical leads to the relay as tagged
during removal.
2. Tag and disconnect leads from the battery terminals
starting with the positive terminals. 7. Connect the batteries and install battery box covers.

3. Remove the nuts and washers from the bracket hold 8. Verify proper installation by operating all components
down rods. Remove the hold down bracket. involved with the replacement relay verifying they all
work.
4. Remove the batteries.
Installation Instrument Replacement
Removal
1. Disconnect the batteries.
2. Remove the hardware securing the console front cover
and remove the cover.
3. Tag and disconnect the electrical wiring from the
instrument.
4. Remove the hardware securing the instrument to the
console panel. (Typically, remove nuts and lockwashers,
and then a bracket or clamp.) Pull the instrument
through the front of the console panel and remove it.
Inspection
1. Examine the instrument for cracked and broken lenses.
7008-7 FIGURE 3-7 Check instrument terminals, bracket or clamp, and
mounting studs for damage. Replace damaged

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TM500E-2 SERVICE MANUAL ELECTRIC SYSTEM

instrument; repair or replace damaged connecting Installation

hardware.
1. Place the switch on the front console panel and secure it
2. Check wiring for damaged insulation or damaged by pushing the switch into the panel, until it snaps into
connectors. Make repairs as needed. place.)
Installation 2. Connect the electrical connector or wires to the switch.
1. Put the instrument in place on the console panel and 3. Position the console front cover on the console and
secure it with the attaching hardware. secure with the attaching hardware.
2. Connect the electrical wiring to the instrument as 4. Connect the batteries.
marked during removal.
Check
3. Position the console front cover on the console and
1. Operate the switch per the Operator’s and Safety
secure with the attaching hardware.
Handbook. Verify each of its functions works. 3
4. Connect the batteries.
2. As needed, troubleshoot further any system or circuit
Check malfunction not corrected by repair or replacement of
the switch or associated wiring.
1. Start the engine and verify that the instrument works.
Refer to Operator’s Manual.
Ignition And Fan Switch
2. As needed, troubleshoot further any system malfunction
not corrected by repair or replacement of the instrument Removal
or associated wiring. 1. Disconnect the batteries.

Switch Replacement 2. Remove the hardware securing the console front cover
and remove the cover.
Rocker Switch
3. Tag and disconnect the electrical leads from the switch.
Removal
4. On the front of the console panel, remove the nut
1. Disconnect the batteries. securing the switch to the panel. If removing the fan
switch, remove the knob from the switch first.
2. Remove the hardware securing the console front cover
and remove the cover. 5. Remove the switch from the hole in the panel.
3. Disconnect the electrical connector or tag and INSPECTION
disconnect the electrical wiring from the switch.
1. Visually check the switch for evidence of cracks,
4. Depress the plastic tabs on top and bottom of switch and damaged connections, or other damage. Replace
pull the switch through the front of the console panel to damaged switch as needed.
remove it.
2. Check wiring for damaged insulation or damaged
Inspection connectors. Repair as needed.
1. Visually check the switch for evidence of cracks, 3. Perform the following check to determine switch
damaged connections, or other damage. Replace serviceability.
damaged switch as needed.
a. Using an ohmmeter, check for continuity between
2. Check wiring for damaged insulation or damaged the switch terminals with switch at ON or activated
connectors. Repair as needed. position(s). Ohmmeter should register zero ohms
(continuity).
3. Perform the following check to determine switch
serviceability. b. Place switch at OFF or deactivated position.
Ohmmeter should register infinity (no continuity).
a. Using an ohmmeter, check for continuity between
the switch terminals with switch at ON or activated c. Replace switch if it fails either part of the
position(s). Ohmmeter should register zero ohms check.Installation.
(continuity).
4. Place the switch through the hole in the front console
b. Place switch at OFF or deactivated position. panel and secure to the front of the panel with the nut.
Ohmmeter should register infinity (no continuity). Install the knob on the fan switch.
c. Replace switch if it fails either part of the check.

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ELECTRIC SYSTEM TM500E-2 SERVICE MANUAL

5. Connect the electrical leads to the switch as tagged Remove the wiper motor from its bracket. Leave the
during removal. other parts attached to the bracket for now.
6. Position the console front cover on the console and Inspection
secure with the attaching hardware.
1. Visually check the motor housing for evidence of cracks
7. Connect the batteries. or other damage. Check for excessive shaft end play
indicating worn or damaged bearings. Replace motor if
Check
damaged.
1. Operate the switch per the Operator’s and Safety
2. Inspect the wiper blade for serviceability. Replace wiper
Handbook. Verify each of its functions works.
blade when worn.
2. As needed, troubleshoot further any system or circuit
3. Inspect the wiper arm and parts of the linking component
malfunction not corrected by repair or replacement of
kits (pantograph adapter kit, pivot shaft kit, wiper motor
the switch or associated wiring.
kit link and crank, wiper motor bracket) for damage.
Replace as needed.
Windshield Wiper Assembly Replacement
Installation
Removal
1. Verify the pivot shaft and the wiper motor kit link and
1. Disconnect the batteries. crank are in place on the motor bracket. (Washers and
2. Tag and disconnect the electrical leads from the motor. clip springs fasten the link to the pivot pins on the crank
and the pivot shaft. The pivot shaft’s pivot pin mounts in
3. Disconnect the washer hose on the wiper arm (also the hole nearest the end of the pivot shaft’s lever.)
called the pantograph arm assembly) from the washer
nozzle fitting assembly. 2. Connect the wiper motor to the motor bracket with
screws and washers. Connect the wiper motor’s shaft to
4. Remove the cap nut and washer securing the wiper arm the wiper motor kit crank with the nut and washer.
to the pantograph adapter kit. (The nut and washer are
part of the pantograph adapter kit.) Remove the cap nut, 3. Secure the adapter and the gasket of the pantograph
washer, and tapered sleeve securing the wiper arm to adapter kit to the cab exterior with capscrews and
the pivot shaft kit. (The nut, washer, and sleeve are part lockwashers.
of the pivot shaft kit.) 4. Install the motor bracket and attached parts in the cab
5. Remove the wiper arm from the pantograph adapter kit interior with attaching hardware. Ensure the pivot shaft
and the pivot shaft kit. sticks through the hole in the pantograph adapter kit.

6. Remove the flanged sleeve, nut, and two flat washers NOTE: Take care not to damage any parts while moving
from the pivot shaft kit. (The sleeve, nut, and washers the bracket and attached parts around the steering
are part of the pivot shaft kit.) column.

7. Remove the two capscrews and lockwashers securing 5. Secure the pivot shaft to the pantograph adapter with the
the pantograph adapter kit’s adapter to the cab exterior. pivot shaft kit’s nut and washers. Install the flanged
Remove the pantograph adapter kit’s adapter and sleeve on the pivot shaft.
gasket. 6. Install the wiper arm on the shafts of the pantograph
8. Remove attaching hardware to free the windshield wiper adapter kit and the pivot shaft kit. Secure the wiper arm
motor bracket from the cab interior. Remove the bracket, to the pantograph adapter kit shaft with the kit’s own
with motor and pivot shaft connected, from the cab. washer and cap nut. Secure the wiper arm to the pivot
shaft with the pivot shaft kit’s own tapered sleeve,
NOTE: You may have to remove or move other parts to get washer, and cap nut.
the bracket and attached parts around the steering
column. Take care not to damage any parts. 7. Connect the wiper arm’s washer hose to the washer
nozzle fitting assembly.
9. Remove the nut to free the wiper motor’s shaft from the
wiper motor kit crank. Remove the three screws and 8. Connect the electrical leads to the wiper motor as
washers to free the wiper motor from its bracket. marked before removal.
9. Connect the batteries.

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TM500E-2 SERVICE MANUAL ELECTRIC SYSTEM

Check Skylight Wiper Assembly Replacement

1. Squirt some cleaning fluid onto the windshield with the Removal
windshield washer.
1. Disconnect the batteries.
2. Operate the windshield wiper. Verify it works. (Replace
wiper blade as needed if it streaks or otherwise wipes 2. Tag and disconnect the electrical leads from the motor.
poorly.) 3. Remove the wiper arm from the motor shaft.

Windshield Washer Assembly Replacement 4. Remove the nut, spacer, leather washer, and nylon flat
washer from the motor shaft outside the cab roof.
Removal
5. Remove the nut and lockwasher securing the motor
1. Disconnect the batteries. bracket to the cab roof and remove the motor from the
cab roof. Remove large nylon flat washer from motor
2. Locate the windshield washer container and pump on
the left rear side of the cab. shaft and flat washer and smaller nylon flat washer from 3
mounting screw.
3. Tag and disconnect the pump’s electrical lead and
ground wire. 6. Remove mounting screw and nylon flat washer from
outside cab roof.
4. Disconnect the hose from the windshield washer pump.
Point it so it won’t spill cleaning fluid. Catch cleaning fluid 7. Clean any sealing material from around holes in cab
from the windshield washer container with a suitable roof.
container. Inspection
5. Remove four self tapping screws securing the 1. Visually check the motor housing for evidence of cracks
windshield washer container to the cab. Remove the or other damage. Check for excessive shaft end play
windshield washer container and pump. indicating worn or damaged bearings. Replace motor if
6. Remove pump and pump seal from container. damaged.

Inspection 2. Inspect the wiper blade for serviceability. Replace wiper

blade when worn.
1. Visually check the pump for evidence of cracks, leaks, or
other damage. Replace pump if damaged. 3. Inspect the wiper arm and parts for damage. Replace as
needed.
2. Inspect the container for leaking. Replace pump seal if it
is leaking. Replace container if it is damaged and Installation
leaking. 1. Install sealant material around both holes in cab roof,
3. Inspect spray nozzle on the wiper arm. As needed, clean both inside and outside.
the nozzle with a fine piece of wire and compressed air. 2. Install screw with nylon flat washer (from outside)
Installation through mounting hole in cab roof.

1. Install pump and pump seal on container. 3. Install flat nylon washer on motor shaft and insert motor
shaft through hole in cab roof. Position small nylon
2. Install windshield washer container on the cab. Secure washer and flat washer on screw between mounting
the container with four self tapping screws. bracket and cab roof. Secure with lockwasher and nut.
3. Attach the hose to the windshield washer pump. 4. Install nylon flat washer, leather washer, spacer, and nut
on motor shaft. Tighten nut.
4. Connect the pump’s electrical lead and ground wire as
tagged during removal. 5. Install wiper arm and blade on motor shaft.
5. Connect the batteries. 6. Connect the electrical leads to the wiper motor as
marked before removal.
6. Fill the container with cleaning fluid.
7. Connect the batteries.
Check
1. Squirt some cleaning fluid onto the windshield with the
windshield washer.
2. Make repairs if windshield washer doesn’t work.

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ELECTRIC SYSTEM TM500E-2 SERVICE MANUAL

Check cable may be ordered from Manitowoc

CraneCARE.
1. Operate the skylight wiper. Verify it works. (Replace
wiper blade as needed if it streaks or otherwise wipes
poorly.) CARRIER ELECTRICAL FEATURES
Troubleshooting Introduction
NOTE: This machine incorporates a CAN-BUS Multiplex
system. In order to effectively troubleshoot the Electrical Features
electrical system, you need a Windows-based PC, This publication includes information on the electrical
CAN-link service software, and a connection cable. features available for your Manitowoc crane. The information
The CAN-link service software and connection includes component locations, as well as troubleshooting
procedures for some of the crane’s electrical components.

Table 3-7
Electrical Abbreviations and Acronyms
Term Acronym / Symbol Definition
A measurement of flow of electrical
current. “I” is used to indicate current
Ampere I, A in a mathematical calculation. “A” is
used to indicate the quantity of current
in amperes. Example: I = 10A
A measurement of electrical
resistance. “R” is used to indicate
resistance in mathematical
Ohm R, Ω
calculations. “Ω” is used to indicate the
quantity of resistance in ohms.
Example: R = 10Ω
A measurement of electrical pressure.
“E” is used to indicate voltage in a
Volt E, V mathematical calculation. “V” is used
to indicate the unit of pressure in volts.
Example: E = 10V
Digital Volt/Ohm Meter DVOM —
A circuit that is connected to ground
Short to Ground —
that should not be.
A circuit that is connected to positive
Short to Power —
battery voltage and should not be.

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TM500E-2 SERVICE MANUAL ELECTRIC SYSTEM

Design and Function Gateway Module

Instrumentation Component Location
Figure -1

1
FIGURE 3-9
E D
C
F B
A
Item Description

G H
J
1 Gateway Module
2 ABS ECU
AC-380-0704-01220-A The Gateway module, (Figure 3-9) (1), is located on the
FIGURE 3-8 chassis, just after the transmission. A protective housing
covers the Gateway module.
The 9-pin diagnostic connector is located under the
dashboard at the left side of the cab (Figure 3-8). Carrier Electrical Center (CEC)

Additional Fuses Circuit Breaker Panel

Figure -2

Your crane includes a dedicated power and ground supply

that supplies power directly from the batteries to the engine
ECU and transmission ECU. Power is provided by a red
power cable which includes an in-line fuse(s) for ECU/TCU
circuit protection. The fuses are located in the battery box.

Anti-Lock Brake System (ABS) ECU

The ABS ECU is located beneath the chassis crossmember
just after the transmission (Figure 3-9) (2). The ABS
diagnostic switch (1) is mounted beside the diagnostic
connector under the dash. ABS wiring is combined with the
main cab and engine harnesses, and there are separate
ABS wiring harnesses on the chassis.

Transmission ECU
AC-371-0705-01237-A
The transmission ECU is located under the dashboard on
the right side of the cab. FIGURE 3-10

The Carrier Electrical Center (CEC) (Figure 3-10) is located

on the left side of the cab to the left of the steering wheel on
the driver kick panel. Most of the circuit breakers and relays

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ELECTRIC SYSTEM TM500E-2 SERVICE MANUAL

are found at this location. Since the function of some special attention must be paid to finding and repairing the
breakers or relays may change based on crane application, cause.
refer to the list of functions attached to the underside of the
CEC cover. Diodes
Additional Electrical Information – Typical Diodes are used on a few of the crane’s circuits to protect
and isolate them from voltage surges, which can occur when
Circuit Components a circuit is turned off. Diodes allow current to flow in one
direction only, like a one-way check valve.
Wiring Harnesses, Wires and Connectors
Each circuit uses a wire of a specific size, based on the Circuit Breakers
current demands for that circuit. The circuit number is When any circuit breaker trips, it should be viewed as an
stamped into the insulation every 3" (75 mm). This aids in indication of a fault in the circuit, and every effort should be
proper connections and simplifies circuit tracing. made to find and correct the fault. Never replace a Type 3
Multi-colored wire harnesses may be used as interfaces to circuit breaker with a Type 1 or Type 2 to prevent severe
some components; the function of the multi-colored wires damage to an electronic device or wiring harness.
varies by component. Circuit breakers also protect a circuit from overload. Both
Some wires are grouped together and encased in a split Type 2 and Type 3 circuit breakers may be used to protect
plastic casing or convoluted tubing called a conduit. This accessory and ignition circuits.
grouping of wires is called a harness. Major wiring harnesses Type 2 circuit breakers are opened by current overload and
are joined by using multiple plug and receptacle connectors. remain open as long as the power is on. A Type 2 circuit
Terminals used throughout the system vary. breaker keeps the bimetallic strip hot after tripping by
diverting a small amount of current through a small coil of
Wiring Schematics resistance wire. If power to the circuit breaker is switched off
long enough for the bimetallic strip and resistance wire to
Simplified schematics are sometimes used in manuals and cool down, the breaker will automatically reset. Type 2 circuit
bulletins to help explain component design and function breakers should never be used on battery feed circuits but
features or to clarify troubleshooting instructions. See can be used on accessory and ignition systems. Type 3
Manitowoc electrical schematics for the most current circuit breakers trip in response to an over-current condition
information. and create an open circuit until reset. Once the problem has
been diagnosed, the circuit breaker can be reset by pressing
Circuit Protection in the colored button on top of the breaker.
To protect wiring and equipment from overloads, circuit
protectors, such as circuit breakers, fuses and fusible links, Switches and Relays
are used. Circuit controls are switches or relays. Switches are usually
NOTE: Failure to use proper circuit protection devices in on the power side of a circuit but can be used to control a
the crane can result in damage to the crane and its ground path. Relays are remote-controlled switches. They
components. Replace faulty circuit breakers only use a low current signal through a coil to control larger
with the same type and rating as the original. Never currents conducted through their contacts.
use Type 1 circuit breakers. Replace blown fuses This Manitowoc Crane circuit also include micro-relays. The
only with fuses of the same rating. Replace fusible micro-relay is smaller in size than a conventional relay, and
links only with proper replacement parts of the the pin arrangement is different.
exact gauge and length. Failure to use proper
circuit protection could overload the circuit, causing Sensors and Senders
severe damage to the crane.
Many electronic signals used by ECU’s and the instruments
Fusible Links are supplied by sensors and senders. A sensor or sender
sends a signal to a control unit, or to the Gateway. Sensors
Fusible links are used to protect high-current circuits against used in the crane system include the axle oil temperature
current overload when there is a short to ground. The fusible sensor, the throttle position sensor and ABS wheel speed
link is a short length of wire that is smaller in gauge than the sensors.
wire in the protected circuit. In the event of an overload, the
fusible link will melt, breaking the circuit and preventing The fuel sender, mounted in the fuel tank, transmits the fuel
damage to the electrical system. If a fusible link does open, level to the Gateway. The resistance changes with the fuel
level.

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TM500E-2 SERVICE MANUAL ELECTRIC SYSTEM

The axle oil temperature sensor information is directly input

Figure -3

An ABS wheel speed sensor is mounted in each monitored into the Gateway. The resistance changes as the oil
wheel. As the wheel spins, the sensor sends a fluctuating temperature changes.
signal to the ABS ECU, which the ECU interprets as wheel
speed. Engine oil pressure and water temperature values are sent
via the J1939 data bus to the Gateway. The Gateway sends
The crane is also equipped with combination sensors that a signal through the instrumentation bus to the speedometer.
can measure both pressure and temperature of certain The speedometer then calculates which values the engine
engine functions. oil pressure and water temperature gauges should indicate.
The pyrometer measures exhaust temperature and this is a Boost pressure, tachometer and axle oil temperature gauges
d i r e c t i n p u t i n t o t h e G a t e w a y. T h e p y r o m e t e r i s a use the same path to display values.
thermocouple; the voltage potential (mV) changes with
temperature.

Specifications 3
Special Torque Chart
Figure -4

Item Specification
Bulkhead Pass-Through Stud Nut 88 ± 10 in.-lb (10 ± 2 N·m)
Starter Solenoid Stud Nut 22 ± 2.6 ft-lb (31 ± 3.5 N·m)
Battery Cable Clamping Bracket 150 ± 27 in.-lb (17 ± 3 N·m)
Battery Cable Terminal Clamp 212 ± 35 in.-lb (24 ± 4 N·m)
Negative Battery Cable at the Starter Ground Stud 22 ± 2.6 ft-lb (31 ± 3.5 N·m)
Fusible Link Cable Assembly Nut-to-the-Engine Block 168 ± 35 in.-lb (19 ± 4 N·m)

Diagnostic Equipment
Example of diagnostic tools:

2
1
4

FIGURE 3-11

Item Description Item Description

1 ABS Cartridge 4 9-Pin Deutsch Connector
2 Multi-Protocol Cartridge (MPC) 5 Power/Data Cable
3 Digital Input/Output Data Display

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ELECTRIC SYSTEM TM500E-2 SERVICE MANUAL

Digital Multimeter
FIGURE 3-12

Repair • Shorts in cables and harnesses – Check for proper

routing and the security of cables and harnesses. Refer
General Work Practices to Troubleshooting in this section.
• Periodically check to see that all wiring connections are
clean and tight.
• Corrosion is due mainly to poor wire splicing. Wires
WARNING should not be spliced by twisting them together and
You must read and understand the precautions and wrapping with tape.
guidelines as provided in service bulletin General Safety
Precautions for crane Electronics, System Group 300, • Dielectric grease is recommended to protect terminals
prior to performing repair procedures on electrical against moisture and the elements. To apply dielectric
components. Failure to adhere to these precautions can grease, remove the connector from the connection. If
cause damage to crane components, or can lead to bodily corroded, clean with a wire brush. After cleaning, spray
injury, or even death. If you are not properly trained and a light film of dielectric grease on the terminal to seal out
certified in these procedures, ask your supervisor for salt, dirt and moisture.
proper training prior to performing repair procedures. • Correct wire size must be used when replacing wires.
Each harness or wire must be held securely in place to
The following section provides electrical reference prevent chafing or damage to the insulation. Never
information, as well as suggested methods for service and replace a wire with one of a smaller size; never replace a
maintenance. Refer to the Operator’s Manual for a specific fusible link with a wire that is larger, or of a different
crane’s recommended maintenance schedules. length.
Make every effort to determine the root cause of a failure. • Poor grounds can cause multiple problems, including
Recurring electrical problems may be the result of open circuits or intermittent component failures.
incomplete or inadequate diagnosis and improper repairs.
• Use extreme caution when steam cleaning or pressure
Check the following items to eliminate common problems washing electrical components or wiring. This can
found in heavy-duty trucks: permanently damage the components.

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TM500E-2 SERVICE MANUAL ELECTRIC SYSTEM

Connectors (after disconnecting additional grounds). When

reconnecting, always connect the main positive terminals
A variety of connectors is used throughout the electrical first.
system. Special tools are required for these procedures. If
contact removal is attempted with an ordinary pick, there is a Jump-Starting the Engine
good chance that the terminal will be bent or deformed.
These terminals must not be reused once they are bent.
Refer to (Table 3-2), (Table 3-3), (Table 3-4), and (Table 3-5)
in this section that list tools necessary for connector
maintenance. CAUTION
Always wear eye protection when working around
Molded-on connectors require complete replacement of the batteries to prevent the risk of injury due to contact with
connection. This means splicing a new connector assembly sulfuric acid or an explosion.
into the harness. It is important that the best possible bond
be made at all wire splices. NOTE: Never use a “Hot Shot” type starting cart, as most 3
Sealed connectors are used to isolate terminations from the use extremely high voltages. Use of a “Hot Shot”
environment. Sealed connectors must not be replaced with device to jump-start the crane will seriously
standard connectors – only with sealed connectors. If a damage the ECU’s and other electrical equipment.
connector is replaced with one having more cavities, the If the crane needs to be restarted immediately, use starting
unused cavities must be plugged to provide an batteries. NEVER use battery chargers with “boosting”
environmental seal. capability. These utilize a high voltage that will cause
Use care when probing the connections or replacing damage to the crane's electrical and electronic components.
terminals in them; it is possible to create a short between
opposite terminals. If this happens to the wrong terminal
part, it is possible that damage may be done to certain
components. Always use jumper wires between connectors
for circuit checking. Never probe through seals or wire
insulation.
When diagnosing for possible open circuits, it is often difficult
to locate them by sight because oxidation or terminal
misalignment are hidden by the connectors. Merely wiggling
a connector or a sensor in the wiring harness may correct an
open circuit condition. Intermittent problems may also be
caused by oxidized or loose connections.

Charging the Battery

AC-333-0307-00589-A

CAUTION FIGURE 3-13

It is extremely important to exercise caution when
charging batteries or jump-starting a crane with a modern
electrical system. Electronic control units can be
damaged by voltage spikes and current surges created by CAUTION
jump-starting. To minimize any risk for damage to the Connect jumper cables to positive, or “hot,” terminals first
electronic components, see the following guidelines for and the ground terminal last (Figure 3-13).
working with the electrical system.
When jumping batteries to start an engine, it is important that
If the batteries are discharged to the point where they do not the jumper cables are connected directly from one set of
have enough stored energy to start the engine, they should batteries in the crane to the other set of batteries. This is so
be recharged with a charger's output voltage, not to exceed the cranking current is carried through the proper starter
16 volts. wiring.
For full access to the batteries, they must be disconnected Do not permit the vehicles to touch each other when jump-
and removed from the battery box. When disconnecting starting.
terminals, always disconnect the main ground terminal first

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ELECTRIC SYSTEM TM500E-2 SERVICE MANUAL

Relay Replacement provides diagnostic capabilities such as current, resistance

and voltage tests, as well as specialized features for
NOTE: Care must be used when removing a relay from the automotive troubleshooting.
panel to avoid damaging it. Figure -6

Replace Fusible Link (Battery-Side)

Removal
NOTE: Check the electrical system for a short circuit
before beginning this procedure to prevent another
fusible link from melting.
NOTE: If a battery side fusible link becomes an open
circuit, power will not be supplied to the cab power
stud on that circuit (no continuity between the cab
stud and starter solenoid).

1 2

AC-311-0306-00280-A

FIGURE 3-14
Figure -5

1. Turn the ignition key OFF and disconnect the battery FIGURE 3-15
cables, negative cable first. Always consult the DMM manufacturer instructions for the
2. Since there are several fusible links, check the continuity proper use of the DMM before beginning troubleshooting.
in the fusible link wire to make sure you are replacing the NOTE: Use the ohmmeter mode only when power is
one that has melted. After locating the melted fusible removed from the circuit.
link, cut the wire as close as possible to the wiring
harness conduit and tape to prevent future use. Before using the DMM to measure resistance, check its
calibration by touching the leads together. It should indicate
3. Remove cable clips to allow for enough slack to work on less than 2 Ω.
wires more easily.
4. Cut the melted fusible link wire as close as possible to Troubleshooting Wiring and Connectors
the wiring harness conduit and tape to prevent future
use. General Troubleshooting Procedures
• Use a multimeter to perform tests. The use of test lights
Installation is discouraged as they present too low of a resistance to
1. Install the new fusible link and reattach cable clips. many sensitive circuits.

2. Connect the positive and negative battery cables, • When troubleshooting wiring and connectors, use
connecting the positive cable first. Tighten nuts to 24 ± 4 breakout boxes/harnesses when available.
N·m (212 ± 35 in.-lb). • Never pierce the wiring insulation with test probes.
Troubleshooting • Do not pierce through seals on water-resistant
connectors.
Troubleshooting Using a Digital Multimeter • Never insert test probes into connectors. The probes
A Digital Multimeter (D MM ) (Figure 3-15) is highly may spread the terminals and cause intermittent faults.
recommended for electrical troubleshooting. The DMM

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TM500E-2 SERVICE MANUAL ELECTRIC SYSTEM

• If breakout boxes/harnesses are not available, contact Open Circuit

the metal outer edges of connector terminals as Figure -8

necessary to take readings.

• See Autocar electrical schematics for crane-specific
wiring and connector information. These schematics
include pin-out and crane location drawings for
connectors.

Visual Inspection

3
AC-370-0307-00519-A

FIGURE 3-17

Whenever there is a complete break or interruption in the

normal current path, such as a break in wiring from the
source of power to the electrical unit or within the unit itself,
current will not flow. In a circuit, current normally travels
through the wires or cables, to switches and electrical unit(s),
such as the starter solenoid and cranking motor, through
another wire to ground and back to the source.
A break anywhere along this route results in an open circuit
(Figure 3-17) and the complete loss of power. An ammeter
AC-371-0307-00518-A will not register at all because there cannot be current flow
FIGURE 3-16 through an open circuit. A voltmeter, depending on where it
Figure -7
is placed in relation to the open circuit, may or may not give a
reading.
Before beginning electrical checks, visually inspect the
wiring and connectors (Figure 3-16).
Checks
• Inspect for corrosion in wiring or connectors. Figure -9

• Check that terminal pins are not bent or damaged,

locked into their connectors, and properly crimped.
• Check that the terminal pins make good mechanical
contact with their mating pin. Refer to Contact Problems
in this section.
• To help locate intermittent faults, wiggle wire and
connector while testing.

AC-370-0307-00520-A

FIGURE 3-18

1. Visually inspect the circuit.

2. Disconnect the connectors at both ends of the wiring
harness.

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ELECTRIC SYSTEM TM500E-2 SERVICE MANUAL

3. Measure resistance using a multimeter (or equivalent

Figure -11

tool) between the ends of the wire. The expected value

is <1 ohm. Readings of “OL” (infinite resistance) indicate
an open circuit. If an open circuit is detected, disconnect
and test progressively smaller lengths of the circuit until
the faulty wiring is located (Figure 3-18).
4. Test for intermittent faults by wiggling the connectors
and/or wiring while monitoring the meter.

Short Circuit
Figure -10

AC-370-0307-00522-A

FIGURE 3-20

If the short circuit is to a power wire (Figure 3-20) it can result

in components operating at inappropriate times. This occurs
because power that normally should be supplied by one
component switch or circuit is bypassed by the short circuit
and power is supplied by a different switch or circuit.

Checks - Short Circuit to Ground

AC-370-0307-00521-A
NOTE: Never check a short circuit by using a jump wire
FIGURE 3-19 across the fuse or terminals, or by installing an
oversized fuse in the fuse panel. This could cause
The term “short circuit” is used to describe another type of damage to the electrical system.
condition which can develop in electrical circuits or units. It Figure -12

refers to a circuit that is completed in the wrong way, such as

two bare wires touching each other, so that the current ?
bypasses part of the normal circuit (Figure 3-19).
If the short circuit is to a ground wire this will result in open
circuits, blown fuses, open circuit breakers, wiring or
component overheat, burned parts and insulation and, of
course, inoperative components.
Hot, smelly insulation is always a sign of trouble. If the wire
melts through, there is no electrical path, so the circuit then
becomes open.

AC-370-0307-00523-A

FIGURE 3-21

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TM500E-2 SERVICE MANUAL ELECTRIC SYSTEM

1. Visually inspect the circuit. together. If a short circuit is detected, disconnect and
test progressively smaller lengths of the circuit until the
2. Turn ignition key to the ON or ACCESSORY position as
faulty wiring is located (Figure 3-22).
necessary.
6. Test for intermittent faults by wiggling the connectors
3. Activate the suspect circuit and check if the fuse blows
and/or wiring while monitoring the meter.
or if there is excessive current draw.
4. Turn the ignition to the OFF position. Disconnect the Grounded Circuit
connectors at both ends of the wiring harness. Figure -14

5. Measure resistance using a multimeter (or equivalent

tool) between the end of the wire and ground. The
expected value is “OL” (infinite resistance). Low
resistance readings may indicate a circuit shorted to
ground. If a short circuit is detected, disconnect and test
progressively smaller lengths of the circuit until the faulty
3
wiring is located (Figure 3-21).
6. Test for intermittent faults by wiggling the connectors
and/or wiring while monitoring the meter.

Checks - Short Circuit to Power

Figure -13

?
AC-370-0307-00525-A

FIGURE 3-23

A grounded circuit (Figure 3-23) is similar to a short circuit in

that the current bypasses part of the normal circuit. In this
instance, the current flows directly to ground. This may be
caused by a wire touching ground or part of the circuit within
a unit coming in contact with the frame or housing of the unit.
A grounded circuit may also be caused by deposits of oil, dirt
and moisture around connections or terminals. Refer to
Checks - Short Circuit in this section.

High Resistance
A high resistance condition in a circuit is often difficult to find.
AC-370-0307-00524-A Symptoms of high resistance include dim or flickering lamps
or inoperative components. (Since current decreases when
FIGURE 3-22
resistance increases, the components may not be receiving
1. Visually inspect the circuit. enough current to operate properly.)

2. Turn ignition key to the ON or ACCESSORY position as The first step in finding a high resistance problem should be
necessary. a visual check of all connectors and wires in the circuit.

3. Activate the suspect circuit and check to see if another Possible causes of High Resistance:
inappropriate circuit operates at the same time.
• An inadequate power or ground path due to corrosion,
4. Turn the ignition to the OFF position. Disconnect the loose terminals or fasteners.
connectors at both ends of the wiring harness of each
affected circuit. • A chafed cable where one or more wires have been cut,
effectively reducing the diameter of the wire.
5. Measure resistance using a multimeter (or equivalent
tool) between the ends of the wires of each affected • A terminal that is worn due to excessive cycling
circuit. The expected value is “OL” (infinite resistance). (connecting, disconnecting).
Low resistance readings may indicate the circuit shorted • An internal component fault.

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ELECTRIC SYSTEM TM500E-2 SERVICE MANUAL

Corrosion kits. If the terminal does not have any clamping force, is
weak or loose, the terminal must be replaced.
Corrosion in sockets and connectors is caused by acids and
road salt reacting with the copper. Connections exposed to NOTE: Note: Excessive use of the test gauge will degrade
concentrated splash, spray and wheel wash should be the clamping force of the mating terminal and may
sealed tightly. Periodically check to see that all wiring cause additional terminal faults.
connections are clean and tight.
Dielectric Grease
Corrosion in wiring is due mainly to poor wire splicing or Figure -16

breaks in the wire insulation. Several hand crimped

connectors are available which will result in a good joint or
union, but most do not provide a watertight seal.
Corrosion is also caused by terminals that are improperly
fastened to the crane. Excessive vibrations at the contact
points will cause fretting corrosion.
Corroded wires should be replaced as needed. Corroded
terminals can be cleaned with wire brushes, or scraped to
remove corrosion. Always check for corrosion in the wire if a
terminal is corroded. The wire can act like a wick and absorb
moisture. Cleaning chemicals can also be used, if they are
designed for electronic terminal cleaning. If cleaning with
chemicals, use compressed air to blow the terminal dry. AC-371-0307-00529-A

After cleaning, closely inspect the terminals to determine FIGURE 3-25

their serviceability. Check for proper contact as outlined in
Contact Problems. Replace any connectors that are The use of dielectric grease is recommended for certain non-
determined to be in less than serviceable condition. sealed plugs, sockets, and connectors that are exposed to
the weather. It reduces corrosion by providing protection
Contact Problems against moisture and the elements. Sealed connectors do
Figure -15
not require dielectric grease.

Routing and Clipping

Figure -17

FIGURE 3-26

Wiring should be secured as necessary to prevent rubbing

AC-371-0307-00527-A
against objects that may wear through the wiring insulation
FIGURE 3-24 and cause circuit failures.

Loose or corroded connections (Figure 3-24) are often the When securing wiring near connectors, switches, or sensors
cause of intermittent faults. Intermittent faults are usually with cable ties, leave some slack at the connector to prevent
difficult to find since the fault must be active at the time of vibration from pulling the wiring out of the connector.
troubleshooting to ensure that the fault is corrected. Wiggling
the suspected wiring or connector while monitoring the Switch Troubleshooting
circuit function or multimeter may be effective in helping to Checking the continuity between pin or cavity positions in
locate intermittent faults. various operating positions may help with troubleshooting
For other types of terminal pins or connectors, use a new switches. The switch detail information in the electrical
mating terminal of the correct type to check for proper schematics may be used as a guide when checking for
contact. Several types of terminals can be found in available proper switch operation.

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TM500E-2 SERVICE MANUAL ELECTRIC SYSTEM

Electronic Control Unit (ECU) • To help locate intermittent faults, wiggle the wire and
Troubleshooting connector while testing.

If tests exist for an ECU, the details of those tests will be Wiring and Connectors
covered in the service procedures for that ECU. Troubleshooting data link wiring is no different than
troubleshooting any other wiring. A DMM is used to take
DATA LINK COMMUNICATION measurements for resistance or voltage at various points in
the circuit. Based on those readings and working with wiring
Introduction schematics, the technician can narrow the search area until
the exact cause of a wiring failure is determined.
Data Link
DESIGN AND FUNCTION
General Troubleshooting Procedures
The following service information describes the proper Data Link 3
procedure for repair of data link wiring. Use only Manitowoc
replacement parts for this repair. Do not use regular wiring. Data Link System
• Use Digital Multimeter (DMM) to perform tests. Manitowoc’s crane electronics are constructed on the
principle that all communications between the electronic
• When troubleshooting wiring and connectors, use
control units (ECU’s) in the system are accomplished via two
breakout boxes/harnesses when available.
data links:
• Never pierce the wiring insulation with test probes.
• The J1939 control data link (Figure 3-27)
• Do not pierce through seals on water-resistant
• The J1587/1708 Information data link.
connectors.
The crane’s main components have their own electronic
• Never insert test probes into connectors. The probes
control units (ECU’s) that are connected to one or both links
may spread the terminals and cause intermittent faults.
in order to be able to communicate with each other.
• If breakout boxes/harnesses are not available, contact
The EECU (Engine Electronic Control Unit) communicates
the metal outer edges of connector terminals as
with the other electronic control units (ECU’s) via the data
necessary to take readings.
links, either by requesting or by receiving direct information
that all prerequisites are met in order to be able to carry out
Visual Inspection the request.
• Before beginning electrical checks, visually inspect the
If an error should occur in any of the systems, a signal is sent
wiring and connectors.
out on the J1587/1708 information data link, which makes it
• Inspect for corrosion in wiring or connectors. possible to read the information, either on the driver’s
instrument cluster, or via a PC or diagnostic tool (e.g. Pro-
• Check that terminal pins are not bent or damaged, and Link) connected to the diagnostic connector.
that they are locked into their connectors and properly
crimped. The data link system provides an extremely flexible solution
with great potential for expansion.
• Check that the terminal pins make good mechanical
contact with their mating pin.

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 ELECTRIC SYSTEM TM500E-2 SERVICE MANUAL

FIGURE 3-27

Item Description Item Description

1 Data Link Backbone 3 Stub Connections for ECU’s
2 Terminating Resistors 4 Diagnostic Connector
Figure 1

The J1939 control data link (Figure 3-27) consists of a

Figure 2

backbone (1), terminating resistors (2) at each end, and

stubs spliced out (3) for each ECU on the data link. Data links
incorporate a shield and drain wire.
The J1939 control data link complies with SAE standards
and consists of three twisted wires.
• Wire 406 is yellow in color and carries the Controller
Area Network high (CAN_H) digital signal of
approximately 2 – 5 volts.
• Wire 407 is green in color and carries the Controller
Area Network low (CAN_L) digital signal of
approximately 0 – 3 volts.
• Wire 408 is not insulated and serves as the shield drain
wire. The drain wire should be connected directly to
ground at only one point.
NOTE: No modifications or connections should be made to
wire 406 (yellow), wire 407 (green) or wire 408 FIGURE 3-28
(shielded). These wires carry the high-speed
communications between the electronic systems in Analog signals (Figure 3-29) mean that different voltage
the crane. Any modification, connection to, or levels represent different values. A simplified example of
damage to these wires can result in the failure of analog signals could be:
the crane’s electronic systems.
• 1 V = 50°F (10°C)
Data Links Design and Function • 2 V = 68°F (20°C)
Data links (Figure 3-28) are one way of transferring • 3 V = 86°F (30°C)
information between various components. In conventional
systems, analog signals have mostly been used.

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 TM500E-2 SERVICE MANUAL ELECTRIC SYSTEM

eight bits makes up a “byte” (a decimal number from 0 – 255

Figure 3

representing information), as well as a start bit and a stop bit.

The purpose of the start and stop bits is to function as
markers for where that group of data begins and ends. In the
diagram above, only the start and stop bits are labeled. The
other information is shaded.
Example:
Figure 5

3
FIGURE 3-29

Data links use digital communication. This means that the

voltage only varies between two different values, either
“high” or “low,” and that by combining these high and low
signals various values can be described.
(Figure 3-29) shows an oscilloscope image where the
voltage of the data link is measured. As can be seen from the
diagram, a large part of the time the link is “silent,” but, at
times, a number of fast pulses are sent. A group of pulses is
called a message. FIGURE 3-31
The enlarged portion of the diagram shows that each (Figure 3-31) shows the information content in the four
message consists of a combination of high and low voltage different parts of the message. The start and stop bits are
levels. shaded since they do not contain any information.
The following sections describe what type of information this The box in the diagram shows the different binary and
message may contain. decimal values which comprise the message.

Messages and Information Content NOTE: Note: The information is sent over the data link with
the “least” bit first in the binary numbers. The
Different voltage levels are represented by the different normal way to notate binary numbers is shown in
numbers in the binary number system. The binary number the box in the diagram.
system has only two values: one and zero (Figure 3-30).
Figure 4
Instrumentation Communication
Instrumentation communication takes place via the gateway
module (mounted on either the right or left frame rail) which
monitors the J1939 data bus and provides the necessary
data via a multiplexed signal to the gauge system. The
gauge system gets these and other instrumentation signals
from the multiplexed data bus that joins the gateway module
to the dash. The speedometer receives the initial data
(signal), then forwards the data to the gauge responsible for
the specific operation.
FIGURE 3-30
The gateway module monitors items such as the
The value one is normally represented by a high voltage and transmission sump temperature and directs the engine to
zero by a low voltage. turn on the radiator fan to cool the transmission oil cooler
when the transmission sump temperature gets too high.
Each binary number is called a “bit.” The illustrated message
Previously, this was accomplished with a temperature switch
consists of four groups of binary numbers. Each group of
in the cooler line. The switch and its harnesses, mounting
hardware, etc. have been eliminated.

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 ELECTRIC SYSTEM TM500E-2 SERVICE MANUAL

Figure 6

J1939 Data Link J1587/1708 Data Link

Engine Gateway
Module Engine

Antilock
60 Brake
Terminating System
Resistor

Cab Chassis
Antilock
Brake
System

Cab Chassis

Diagnostic Body
Connector Builder
Serial Port

Shift Transmission 60
Diagnostic Terminating
Controller Connector Control Instrument Data Bus
Panel Unit Resistor

x2 for Speedometer
dual drive
vehicles
Gateway Chassis Cab
Module

Diagnostic
Connector

AC-300-0704-01218-C

FIGURE 3-32

(Figure 3-32) s hows how the gateway module, the SAE J1587/1708 Data Link
diagnostic connector, and the electronic control units are
connected in principle. Information and diagnostic signals are sent via J1587 and
J1708 data links. SAE J1708 is a standard that specifies
Observe the difference of operation between the J1939 and hardware and a data bus speed of 9600 bits per second.
J1587/1708 data links. The instrumentation data bus is also SAE J1587 is a protocol that provides a standard method for
shown. exchanging information between microprocessors. The
J1587/1708 information data link consists of two wires (400
SAE J1939 Control Data Link and 401) that are twisted around each other (approximately
The system’s control signals are sent via this link. 30 turns per yard). The twisted-pair wires are designed to
protect the link against electrical interference.
The J1939 control data link is very fast, operating at 250,000
bits per second. This operating speed allows the system to Terminating Resistor
function more effectively and adapt quickly to changing Terminating resistors are wired into each end of the J1939
conditions and crane requirements. control data link. One is located near the TCM ECU and the
This data link follows SAE standards, and consists of three other near the engine ECU.
twisted wires: a green wire (407), a yellow wire (406) and a Only two terminating resistors are used in a crane. Never
shield wire (408). The twisted wire set (30 turns per yard) is install three in one truck. If more than two terminating
used to protect the link from electrical interference. resistors exist in the J1939 circuit, damage to the ECU
electronics can occur over time. You can easily check to see
if you have two resistors by measuring the resistance
between circuits 406 and 407 with the ignition OFF. The
correct resistance is 60 ohms.

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TM500E-2 SERVICE MANUAL ELECTRIC SYSTEM

The purpose of these resistors is to prevent data link signal part of fault tracing to carry out basic checks of all the vital
reflections. They must remain connected for the system to parts of the crane's electronics.
function properly.
Some programming can also be done via the diagnostic
NOTE: If a circuit must be added to the electrical system, connector.
and will carry high currents or frequencies, route it
in a location AWAY from wires 400, 401, 404 and Table 3-8: Diagnostic Pin Description
405 to prevent mutual inductance from interfering Pin Letter Wire Number
with data link functions. A OV
NOTE: Wires 400, 401, 404, 405, 406, 407 and 408 MUST B Battery (fused CBI)
NOT be cut or spliced for any connections. These
C 406 (CAN_H, yellow)
wires are used for the transmission of data for
diagnostic messages and gauges. Modifying this D 407 (CAN_L, green)
circuit can cause these functions to fail. E 408 (drain, no insulation) 3
Diagnostic Connector F 400 H
G 401 L
H 404 H
J 405 L

Troubleshooting

J1939 Control Data Link

Checking Terminator Resistor
Terminating resistors are wired to each end of the J1939
control data link to prevent signal reflections. They must
remain connected for the data link to function properly. The
resistance value of each terminating resistor is 120 ohms.
When properly installed in the data link, wire 406 (CAN_H,
yellow) and wire 407(CAN_L, green) have a resistance of 60
E D
C ohms at any point on the data link.
F B
A Figure 7

J The terminating resistor at one end of the J1939 control data

G H
link is located near the EECU. The location of the second
terminating resistor is on the opposite end of the 1939
AC-380-0704-01220-A control data link by the Transmission Control Module (TCM).
FIGURE 3-33 To check the terminating resistors, the J1939 control data
The J1939 control data link can be accessed at the 9-pin link can be accessed at the 9-pin diagnostic connector.
diagnostic connector. The 9-pin diagnostic connector is Use a DMM to check the resistance at suspected fault
loc ated under t he da shboa rd at the left en d of the locations observing the following points.
dashboard.
• For detailed, crane specific schematics, refer to
The diagnostic connector is a round Deutsch connector “Electrical Schematics” found in group 37.
located to the left of the steering column on the lower portion
of the dashboard. The diagnostic connector is connected to • Back probe connectors when possible to avoid pin or
the J1939 control data link and allows the system a way to socket damage.
communicate with an external PC or diagnostic tool. • Terminating resistors must remain in the circuit for test.
With a PC or diagnostic tool connected, error codes can be Use a DMM to check the following.
read from all the electronic control units. This is an important

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ELECTRIC SYSTEM TM500E-2 SERVICE MANUAL

Table 3-9: 9-pin Diagnostic Connector

Measuring Expected
Function Key Position Note If Expected Value not met, check
Point Value
60 ohms If 120 ohms, one terminating resistor
missing or wiring fault.
Terminating If > 1 kW, both terminating resistors
Off Pin D - Pin C missing or wiring fault.
Resistor Check
If OL ohms (infinite), open circuit.
If < 1 ohms, short circuit in data link wires.
Pins for wire OL (Infinite
Grounded
Off 406 (yellow) - Resistance) Grounded Circuit
Circuit Check
Ground
Pins for wire OL (Infinite
Grounded
Off 407 (green) - Resistance) Grounded Circuit
Circuit Check
Ground
J1939 Control Pins for wire 60 ohms Check terminating resistors.
Data Link 406 (yellow) - Wiring/connector fault in backbone or
Off
Resistance wire 407 stubs. Refer to J1939 Control Data Link
Check (green) Troubleshooting in this section

Table 3-10: J1939 Control Data Link Voltage Check

Data Link Wires Key Position Measuring Point Expected Value
Pins for wire 406 (yellow) – Fluctuating between
Wire 406 (CAN_H, yellow) On
Ground 2–5V
Pins for wire 407 (green) – Fluctuating between
Wire 407 (CAN_L, green) On
Ground 0–3V
Pins for wire 406 (yellow) – Pins Fluctuating between
Between wire 406 and wire 407 On
for wire 407 (green) 0–5V

It is expected that the voltages quoted in the table above ignition key is on, the voltage reading will have limited
exist on wire 406 (CAN_H, yellow) and wire 407 (CAN_L, troubleshooting value.
green) at any point on the data link. Due to the fact that
multiple ECU’s are both “talking” and “listening” any time the J1939 Control Data Link Troubleshooting
Example

ECU ECU GATEWAY TCU

(ENGINE) (ABS)
2 2
3 3 3 3

1 4
AC-370-0609-00311-C

FIGURE 3-34

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NOTE: Note: This example is intended as a guide for the 4. With the wiring harness disconnected at the pass-
logic used to troubleshoot a data link wiring through connector and 120 ohms present at the
problem. The illustration should be used to help diagnostic connector, the data link from the diagnostic
clarify the troubleshooting example. Always refer to connector to the terminating resistor in the cab is most
crane-specific wiring schematics when performing likely intact. The problem should be in the data link from
crane troubleshooting. the diagnostic connector to the terminating resistor at
the ABS ECU. Go to 4a.
1. Begin at the diagnostic connector. It is expected that a
resistance of approximately 60 ohms exists between a. Reconnect the engine pass-through connector.
wire 406 (CAN_H, yellow) and wire 407 (CAN_L, green) Disconnect the chassis pass-through connector.
at any point on the data link. If 60 ohms is observed at Check for damaged (bent) terminals at the chassis
the diagnostic connector, it is likely that the backbone pass-through connector.
circuit is intact. Go to Step 5. If approximately 120 ohms
If OK, check the resistance on the cab side terminal
is observed, it is likely that an open circuit exists in one
of the data link wires, or a terminating resistor is missing.
pin between wire 406 (CAN_H, yellow) and wire 407
(CAN_L, green). If approximately 120 ohms
3
NOTE: Note: Any reading other than approximately 60 or resistance is still present, the data link from the
120 ohms indicates a wiring failure or both chassis pass-through connector to the terminating
terminator resistors missing. resistor at the EECU is most likely intact. Go to 4b.
2. Check the terminating resistors. Refer to Checking If not OK, the problem should be between the
Terminator Resistor in this section. If OK, proceed to chassis pass-through and the diagnostic connector.
next step. Use standard wire troubleshooting procedures to
locate the specific wiring fault.
3. Assuming 120 ohms resistance is still present, indicating
an open circuit in the data link, disconnect the wiring b. At this point, it has been established that the data
harness at the pass-through connector. If 120 ohms is link should be intact from the chassis pass-through
still present at the diagnostic connector, go to 3a; if not, connector to the terminating resistor at the EECU.
go to Step 4. Check the resistance on the harness side terminal
pins between wire 406 (CAN_H, yellow) and wire
a. If 120 ohms is still present at the diagnostic 407 (CAN_L, green). There should not be
connector, the data link from the diagnostic approximately 60 ohms resistance. If approximately
connector to the terminating resistor in the cab is 60 ohms resistance is indicated, it is likely that a
most likely intact. The problem should be in the data poor connection exists in the chassis pass-through
link from the diagnostic connector to the terminating connector. Readings other than approximately 60
resistor at the EECU. Go to 3b. ohms resistance indicate a problem in the data link
b. Check for damaged (bent) terminals at the pass- between the chassis pass-through connector to the
through connector. terminating resistor at the ABS ECU. Use standard
wire troubleshooting procedures to locate the
If OK, check the resistance on the cab side terminal specific wiring fault.
pin between wire 406 (CAN_H, yellow) and wire 407
(CAN_L, green). If approximately 120 ohms 5. If approximately 60 ohms is observed at the diagnostic
resistance is still present, the data link from the connector, it is likely that the backbone circuit is intact. If
pass-through connector to the terminating resistor a data link problem is still suspected, disconnect
in cab is most likely intact. individual ECU harness connectors and check the
condition of the terminal pins.
If not OK, the problem should be between the pass-
through and the diagnostic connector. Use standard If OK, check the resistance on the harness side terminal
wire troubleshooting procedures to locate the pins between wire 406 (CAN_H, yellow) and wire 407
specific wiring fault. (CAN_L, green). The value should be approximately 60
ohms.
c. At this point it has been established that the data
link should be intact from the pass-through If not OK, there is likely a circuit fault between the ECU
connector to the terminating resistor in the cab. connector and backbone splice. Use standard wire
Check the resistance on the harness side terminal troubleshooting procedures to locate the specific wiring
pins between wire 406 (CAN_H, yellow) and wire fault.
407 (CAN_L, green). There should be
approximately 120 ohms resistance.

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ELECTRIC SYSTEM TM500E-2 SERVICE MANUAL

Using A Driver Information Center (DIC) as a

Troubleshooting Tool Item Description
1 Existing Cable Bundle
2 New Cable Bundle

HOLD TO
3 Crimp Connector on Drain Wire
HOLD TO SET
EXPAND
Heat-Shrink Connector on Yellow and Green
4
Wires
HOLD TO
EXPAND HOLD TO SET
5 Clear Filler Wire
NOTE: Note: Stagger wire cuts and splices to minimize
bulges in data link cable (Figure 3-36).
AC-300-0604-G1044
NOTE: Note: Never splice regular automotive wire (GXL,
FIGURE 3-35 SXL, TXL) into J1939 backbone cables. Regular
automotive wire will not meet the more stringent
If you have a Driver Information Center (DIC) (Figure 3-35)
s p e c i f i c a t i o n s f o r i m p e d a n c e , r e s i s ta n c e ,
handy it can be used as a troubleshooting tool. By plugging
capacitance and physical dimensional
the DIC into the speedometer connector the DIC will power
requirements.
up and allow the technician to scroll through the monitored
systems. For example, if the oil pressure reads zero, the 1. Make certain the crane ignition is OFF before beginning
technician can scroll through the menus to the oil pressure this procedure.
reading. If the driver information center shows a connection
NOTE: Note: The replacement section of cable must be
to the oil pressure sending unit (pressure reading present),
somewhat longer than the original to allow for
the error lies with the gauge or with the 3-wire bus to the
staggering of the splices. Also cut out the clear filler
gauge. If the driver information center does not show a
wire – this will take some of the bulk out of the wire
connection to the sending unit, the error lies in the sending
bundle in the repaired area.
unit. The technician should also be reminded that the
preferred method of troubleshooting the dash instruments NOTE: Note: For crimp and seal repairs, use only splice or
with the J1939 control data link is as follows: terminal connectors with heat-shrink covering. If
connectors without heat-shrink sealing are used, a
1. Determine that the J1939 control data link is working.
separate piece of heat-shrink tubing must be used
2. If nothing is showing on the instrumentation data bus, to seal the connection.
the problem lies in the gateway module, or after the
2. Remove the data link from the wiring harness as
module. Refer to Instrumentation section of this manual
necessary and cut out the damaged section of cable.
for more detailed information.
3. Strip approximately 2" (50 mm) of cable jacket and
Repair shield at each end of the splices to expose the wiring.
Use caution not to cut the wire insulation.
J1939 Control Data Link Wiring (Shielded)
NOTE: Note: This procedure complies with TMC RP142 1 3 2
“High-Speed Data Link Repair Guidelines.”

1 3 4 5 2

FIGURE 3-37

Item Description
FIGURE 3-36 1 Existing Cable Bundle
2 New Cable Bundle
3 Heat Shrink Tubing

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 TM500E-2 SERVICE MANUAL ELECTRIC SYSTEM

Figure 8

4. Slide a piece of heat-shrink tubing over each end of the

cut cable bundle to seal the data link after the wires have
been spliced. The tubing should be approximately 2" (50
mm) longer than the repair area.

1 2


  

FIGURE 3-38
FIGURE 3-41 3
Figure 12

Item Description
8. Insert the connector into the proper anvil on the crimping
1 Existing Cable Bundle tool and crimp. Gently tug on the spliced connection to
2 New Cable Bundle be sure the wire is secure.
Figure 9

5. Stagger-cut the wiring to minimize bulges in the data link

cable. Strip approximately 0.25" (6 mm) of wiring
insulation at each wire end. Use caution not to cut the
wire strands.
1
1
Figure 10

$&$
FIGURE 3-42
FIGURE 3-39
Item Description
6. Remove wiring insulation approximately 0.5" (12.7 mm)
from the end of the wire. 1 Visible Sealant
NOTE: Note: Never use an open flame to apply heat
Figure 11

shrink.
9. Use a heat gun to activate the heat shrink. Look for
sealant at each end of the connector as evidence of a
good application.
10. After both ends of the cable are spliced, install the data
link back into the wiring harness and secure as
necessary.
Figure -18

AC-SM-371-0705-P144

FIGURE 3-40

7. Place the strands of wire overlapping each other inside

of the splice connector.

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 ELECTRIC SYSTEM TM500E-2 SERVICE MANUAL

ELECTRICAL FEATURES Stepper Motors

• Precision Swiss made stepper motors control needle
Introduction positioning. This ensures positive placement of the
gauge needle within 0°, 20' of angular rotation.
Instrumentation System
• Stepper motors have much greater torque than
The gauges on your crane are designed to provide accurate conventional air core movements utilizing full torque to
display of information for the driver/operator. The information the last 1/3 of a degree of rotation.
is sent from the gateway instrumentation data bus to the
speedometer. The speedometer then sends the information Gauge Lighting
to the gauge responsible for displaying that information. This • Gauge dial faces are backlit and needles are illuminated
publication includes information on the system design, with long life LEDs for optimum night time viewing.
function, troubleshooting and mechanical installation of Telltale indicators are lit by long life LEDs and are
system gauges. designed with dead front icons to compensate for
viewing in bright, ambient lighting.
Design and Function
Special Tools and Equipment
System Overview
Figure 13
In some cases, use of a special tool is necessary in order to
carry out the troubleshooting or repair procedure. The
following tool is recommended for use in the procedures
described in this section of your manual.
Figure 14

NOTE: A wrist grounding strap must be worn when

working on electronic equipment such as the
instrument cluster. This is to prevent electrostatic
discharge, which can damage electronic
components. To use the wrist strap in a vehicle,
attach the alligator clip to the nearest electrical
ground such as a ground terminal or preferably a
ground stud.

7007

FIGURE 3-43

Gauge Function
Datalink
• The gauges receive information via the instrumentation
data bus. FIGURE 3-44
• These messages originate from the gateway/analog to
the digital module which collects both analog and SAE
Repair
J1939 data to be transmitted to the instrumentation • (Figure 3-45) Speedometer electrical connections and
system. connector definition
• Information is transferred from gauge to gauge via a
proprietary three-wire, “daisy chain” link.

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 TM500E-2 SERVICE MANUAL ELECTRIC SYSTEM

Figure 15

FIGURE 3-45

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 ELECTRIC SYSTEM TM500E-2 SERVICE MANUAL

• (Figure 3-46) Large gauge (non-speedometer) electrical the operation of the gauge system. This troubleshooting
connections and connector definition section is meant to help read the clues that have been
Figure 16
placed into the system to diagnose problems.
Troubleshooting is best done with a good understanding of
the total system operation. Refer to Instrumentation System
Schematic (Figure 3-49) to view the system layout.
The gauge tester is used to test gauge and telltale indicator
operations that respond to the data bus protocol and validate
truck wiring between the gateway module and the instrument
cluster. The gauge tester is connected to the electrical
system in place of the gateway module.

Using the Driver Information Center as a

Troubleshooting Tool
If you have a Driver Information Center (DIC) handy it can be
used as a troubleshooting tool. By plugging the DIC into the
speedometer connector, the DIC will power up and allow the
FIGURE 3-46 technician to scroll through the monitored systems. For
example, if the oil pressure reads zero, the technician can
• (Figure 3-47) Small gauge electrical connections and scroll through the menus to the oil pressure reading. If the
connector definition DIC shows a connection to the oil pressure sending unit
Figure 17
(pressure reading present), the error lies with the gauge. If
the DIC does not show a connection to the sending unit, the
error lies in the sending unit. The preferred method of
troubleshooting instruments with the Data Link is as follows:
1. Determine that the data link is working.
2. If nothing is showing on the instrumentation data bus,
the problem lies in the gateway module, or after the
gateway module.

FIGURE 3-47 FIGURE 3-48

Figure 18

Troubleshooting Table 3-11

(Table 3-12) Diagnostic Troubleshooting Table is intended as Gauge Tester Connector Pin Function Chart
a guide to assist the technician in discovering the possible Pin GA Type Color Description
cause of the problem. The table is not intended to cover all A 18 GXL White J1587 Data Bus (–)
the possible problems or their exact remedy. The table
should not be used in place of good troubleshooting B 18 GXL White J1587 Data Bus (+)
technique and experience, but as a time saving tool to help J 18 GXL White Ground
locate possible causes and possible cures of problems. K 18 GXL White Ignition (12 V)

Gauges and Telltale Indicators (Pins C, D, E, F, G, H not used)

The crane’s instrumentation system can be complex to

troubleshoot if you do not have a thorough understanding of

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TM500E-2 SERVICE MANUAL ELECTRIC SYSTEM

The gauge tester simulates gauge parameter values to 3. Plug the removed connector directly into the gauge
perform a range sweep by repeatedly sequencing the tester's 10-way connector.
parameter values.
4. Once connected, the gauge tester is automatically in the
“on” mode. A full function gauge sweep will be initiated,
Control Data Link confirming that the gauge tester is fully operational.
See the Data Link Communications manual for
5. If any gauge shows abnormalities during the test, the
troubleshooting the J1939 data bus.
gauge should be replaced.
Testing Using Gauge Tester 6. Refer to Diagnostic Troubleshooting Table (Table 3-12)
and the Gauge Tester Function Table (Table 3-13) To
1. Locate the gateway module on the left-hand side of learn how each telltale and gauge should respond to the
frame rail. gauge tester.
2. Remove the 10-way connector from the front of the
gateway module.
3

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 ELECTRIC SYSTEM TM500E-2 SERVICE MANUAL

Instrumentation System Schematic

System Gauges - Air Pressure, Oil Pressure, etc.

Telltale Warning Indicator Panel

Speedometer 9 1
3 20
2 10
1
1 5 Tachometer
2 6

Engine Fuel Park Brake Switch

Oil Temp Level Aux Trans Buzzer Input
Sensor Sensor Fan Relay Left Signal Light
Low Air Switch (es)
Air Filter Restriction Switch
HEST Lamp
Seat Belt Switch
High Beam Relay
Low Fuel Switch
Right Signal Switch
Alternator
C1 C2
C3
K
A
C4 Transmission Neutral Switch (High Side)
Gateway Transmission Neutral Switch (Low Side)
E Ignition
F
D
C5
A
C7 C6 ABS Blink
A Code Relay

Instrument Backlight Circuit

Vehicle Battery Circuit
Vehicle Ignition Circuit

Engine Rear RR Fwd RR

Exhaust Axle Temp Axle Temp
Thermocouple Sensor Sensor

J1939 Backbone
ECM Switch Common-

J1939 H(+)
J1939 L(-)
J1939 L (-)
J1939 H (+)

Wait To Start Signal

J1939 H(+)
Fan On Signal

J1939 L(-)

ATC Light
J1587 +
J1587 -

ABS Fault Light

Trans
Engine ECM ECU ABS ECU
AC-300-0605-01063-C

FIGURE 3-49
Figure 19

NOTE: Note: See schematic drawings for wire code

designations of various circuits (Figure 3-49).

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Diagnostic Troubleshooting Table

Table 3-12:
Symptoms Possible Cause Diagnostic/Corrective Action
Check fuses/breakers and wiring to
All gauges and telltale indicator lights
Power interruption to panel ensure power to gauges and telltale
are off.
display.
Check speedometer connection for
No power to speedometer
battery, ground & ignition.
All gauges not responding, “COMM
ERROR” light ON, Engine, Trans & Connect gauge tester in place of
Instrumentation data bus connection
ABS lights ON gateway. If problem remains, check
between gateway module and
data bus wiring. If problem goes
speedometer
away, check gateway. 3
Failed information source can be
Partial or no J1939 data bus determined by lights in telltale display.
“COMM ERROR” light blinking, information If engine lights are ON, check engine
pressure and analog input gauges Note: Data bus connection between ECM. If transmission lights, then
working gateway and speedometer confirmed transmission ECM, if ABS lights, then
by working gauges. ABS ECM. Check wiring between
backbone and problem ECU.
3-wire daisy chain malfunction or Check daisy chain harness
disconnection connection on malfunctioning gauge.
Individual pressure or Analog gauge Connect gauge tester at gateway. If
not working, “COMM ERROR” light Gauge not working gauge still not working, replace
OFF gauge.
Bad connection between sensor and Remove sensor plug at gateway and
gateway module check for continuity.
3-wire daisy chain malfunction or Check daisy chain harness
disconnection connection on malfunctioning gauge.
Connect gauge tester at gateway. If
Gauge not working gauge is still not working, replace
Individual engine gauge not working, gauge.
“COMM ERROR” light OFF If gauge does work with tester
connected, check data bus output
Fault with data bus message from
from engine for that particular gauge.
engine
This will need to be checked with
engine ECM diagnostic tool.
3-wire daisy chain malfunction or Check daisy chain harness
disconnection connection on malfunctioning gauge.
Transmission temperature gauge not
working, “COMM ERROR” light OFF Connect gauge tester at gateway. If
Gauge not working gauge is still not working, replace
gauge.
Check for proper message
Transmission temperature gauge
Interruption of data bus message transmission from transmission ECM
only not working, “COMM ERROR”
from transmission ECM using transmission ECM diagnostic
light flashing
tool.

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ELECTRIC SYSTEM TM500E-2 SERVICE MANUAL

Gauge Tester Function Table

Table 3-13
Phase I 10 Phase II 10 Phase III 10 Phase IV 10
Message PID
Second Second Second Second
Attention/Warning Indicator Lamp Status: 44 - - - -
Bit 2-1: Stop Engine Status 44 Off Off On Off
Bit 4-3: Check Engine Status 44 Off Off On Off
Bit 6-5: Engine Fluids Status 44 Off Off Off Off
Bit 8-7: Check Transmission Status 44 On Off Off Off
Engine Wait to Start (intake air heater
45 Off On Off Off
active)
Tractor ABS Failure 49 Off On Off Off
Forward Rear Axle Temperature 77 100°F (38°C) 200°F (93°C) 300°F (149°C) 200°F (93°C)
Rearward Rear Axle Temperature 78 100°F (38°C) 200°F (93°C) 300°F (149°C) 200°F (93°C)
Vehicle Speed 84 0 MPH 40 MPH 80 MPH 40 MPH
Fuel Level 96 0% 50% 100% 50%
60 psi (410 120 psi (830 60 psi (410
Engine Oil Pressure 100 0 psi (0 kPa)
kPa) kPa) kPa)
20 psi (140 40 psi (275 20 psi (140
Turbo Boost Pressure 102 0 psi (0 kPa)
kPa) kPa) kPa)
Engine Coolant Temperature 110 100°F (38°C) 175°F (79°C) 250°F (121°C) 175°F (79°C)
75 psi (517 150 psi (1030 75 psi (517
Truck Application Air Pressure (optional) 116 0 psi (0 kPa)
kPa) kPa) kPa)
75 psi (517 150 psi (1030 75 psi (517
Primary Air Pressure 117 0 psi (0 kPa)
kPa) kPa) kPa)
75 psi (517 150 psi (1030 75 psi (517
Secondary Air Pressure 118 0 psi (0 kPa)
kPa) kPa) kPa)
ATC Warning 151 Off Off Off On
Volts 168 10 V 13 V 16 V 13 V
Engine Oil Temperature 175 100°F (38°C) 200°F (93°C) 300°F (149°C) 200°F (93°C)
Transmission Oil Temperature 177 100°F (38°C) 200°F (93°C) 300°F (149°C) 200°F (93°C)
Outside Air Temperature 171 -40°F (-40°C) 72°F (22°C) 120°F (49°C) 33°F (0°C)
1000°F 1500°F 1000°F
Pyrometer 173 500°F (260°C)
(538°C) (815°C) (538°C)
Engine Speed 190 0 RPM 1500 RPM 3000 RPM 1500 RPM

NOTE: Note: A complete list of MID’s (sources of data) is

published in the SAE J1708/1587 document.

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Gauge Data Source Table

Table 3-14
Gauge Function Description Data Source Alternate Data Source
Speedometer Engine ECM through gateway -
Tachometer Engine ECM through gateway -
Engine Oil Pressure Engine ECM through gateway -
Engine Coolant Temperature Engine ECM through gateway -
Voltmeter Engine ECM through gateway -
Engine Turbo Pressure Engine ECM through gateway -
Engine Oil Temperature Engine ECM through gateway Analog input to gateway
Transmission Oil Temperature Trans. ECM through gateway - 3
Reserve “A” Pressure Pressure input to gateway -
Reserve “B” Pressure Pressure input to gateway -
Brake Application Pressure Pressure input to gateway -
Fuel Level Analog input to gateway Engine ECM through gateway
Engine Exhaust Temperature Analog input to gateway -
FWD Rear Axle Temperature Analog input to gateway -
RWD Rear Axle Temperature Analog input to gateway -
Air Filter Restriction Direct input to gauge -

Description of basic operation: • The instrumentation data bus data is collected by

system speedometer.
• Gateway/analog to digital converter module (referred to
as “gateway”) collects data from SAE J1939 data bus • Data is relayed from speedometer to tachometer, and all
and from various analog input sources. Refer to other small gauges as well as the telltale display via a
Instrumentation System Schematic (Figure 3-49) in this three-wire, daisy chain harness.
section. Information is then broadcast on
instrumentation data bus to the vehicle speedometer.

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THIS PAGE BLANK

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 SECTION 4
BOOM
TABLE OF CONTENTS
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Boom System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Telescope Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Fly Section Extension Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Extend Synchronizing Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Fly Retraction Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Outer Mid Retract Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Boom Extension Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Boom Retract Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Telescope Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Theory Of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Lift Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 4
Theory Of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
General Maintenance Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Swingaway Extension Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Boom Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Boom Disassembly for the Standard 31 m (102 foot) Boom . . . . . . . . . . . . . . . . . . . . . . 4-7
Disconnect the Base Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Remove the Base Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Disconnect the Inner Mid Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Remove the Inner Mid Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Remove the Outer Mid Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Remove the Tele Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Extend Cable Sheave Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Boom Nose Sheaves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Boom Nose Sheaves Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Boom Nose Sheaves Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Boom Assembly Procedure for the 31 m (102 foot) Boom . . . . . . . . . . . . . . . . . . . . . . 4-17
Extend Cable Sheave Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Install Telescope Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Install the Outer Mid Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Install the Inner Mid Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Install the Base Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
Boom Disassembly for the Optional 29 m (95 foot) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31
Remove the Base Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31
Disconnect Inner Mid Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
Remove the Inner Mid Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
Remove Outer Mid Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35
Remove Telescope Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37
Boom Nose Sheaves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38
Boom Assembly for the Optional 29 m (95 Foot) Boom . . . . . . . . . . . . . . . . . . . . . . . . 4-38
Install Telescope Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38
Install Outer Mid Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39
Install Inner Mid Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41
Connect Inner Mid Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42
Install Base Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43
Boom Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44
Swingaway Extension Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44

Published 2-20-2007, Control # 101-00 4-i

BOOM TM500E-2 SERVICE MANUAL

Boom Cable Adjustment for the 31 m (102 foot) Boom . . . . . . . . . . . . . . . . . . . . . . . . 4-47

Extend Cable Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-47
Retract Cable Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-48
Boom Cable Adjustment for the 29 m (95 foot) Boom . . . . . . . . . . . . . . . . . . . . . . . . . 4-48
Extend Cable Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-48
Retract Cable Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-49
Boom Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-49
Functional Test Of The Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-49
Boom Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-49
Boom Alignment And Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-49
Extension And Retraction Cable Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-50
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-50
Telescope Circuit Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-52
Lift Circuit Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-54
Lift Cylinder Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-56
Lift Cylinder Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-56
Lift Cylinder Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-56
Lift Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-56

4-ii
TM500E-2 SERVICE MANUAL BOOM

SECTION 4
BOOM
DESCRIPTION Fly Section Extension Cables
The crane is equipped with a standard 9.8 to 31.0 m (32.3 to The fly section has five extension cables (7) attached to it.
102 foot) or optional 8.81 to 29.0 m (28.7 to 95.0 foot), four Refer to (Figure 4-1) 31 m (102 foot) boom or (Figure 4-91)
section, synchronized full power, cable extended boom. 29 m (95 foot) boom for item location.
The boom is rectangular in design and utilizes one two- The extension cables (7) are secured to the inner mid
stage double-acting, rod ported telescope cylinder. The section (8) and are routed around a five groove sheave
telescoping sections are supported on graphite impregnated assembly (9) at the barrel end (boom nose) of the telescope
nylatron wear pads. Adjustable side wear pads prevent metal cylinder (10). These cables are secured at the base end of
to metal contact between the sections. the fly section (11).
Boom assembly lift is provided by a single lift cylinder. Boom Extend Synchronizing Cable
elevation range is from -3 to 76 degrees.
Refer to (Figure 4-1) 31 m (102 foot) boom or (Figure 4-91)
An optional auxiliary boom nose (rooster sheave) is available
29 m (95 foot) for item location. The long extend
for the boom to simplify single part cable usage. The rooster
sheave is installed on the main boom nose and is secured by
synchronizing cables (12) are connected to the rear of the
outer mid section (6) and is routed around two sheaves (11)
4
pins that pass through the rooster sheave.
on the top front of the inner mid (4), and secured to the rear
The boom has a 7.92 m (26 ft) offsetable or a 7.92 to 13.7 m of the base section (13).
(26 to 45 ft) telescoping offsetable swingaway boom
extension provided to obtain additional boom reach. The Fly Retraction Cables
boom extension mounts directly to the boom nose utilizing a
Refer to (Figure 4-1) 31 m (102 foot) boom or (Figure 4-91)
four point attachment. The boom extensions may be offset at
29 m (95 foot) for item location. The two retraction cables
0 to 30 degrees. In addition, the swingaway can be stowed
(14) are secured at the outside front of the inner mid section
on the right side of the boom base section.
(4), are routed around sheaves (15) mounted on the end of
the outer mid section (6) and are secured at the opposite end
Safety
(16) to the fly section (17).
Do not attempt to work on the boom without experienced
supervision. Outer Mid Retract Cables
Refer to (Figure 4-1) 31 m (102 foot) boom or (Figure 4-91)
29 m (95 foot) for item location. The four retraction cables
(18) are secured at the outside front of the base section (2),
DANGER are routed around sheaves (19) mounted on the end of the
To prevent serious injury or death, always wear personal inner mid section (4) and are secured (20) at the opposite
protective equipment; i.e., a hard hat, eye protection, end to the outer mid section (6).
gloves and metatarsal boots.
BOOM EXTENSION SEQUENCE
BOOM SYSTEM COMPONENTS Refer to (Figure 4-1) 31 m (102 foot) boom or (Figure 4-91)
29 m (95 foot) for item location. As the telescope cylinder
Telescope Cylinder extends, the cylinder barrel (5), which is attached to the outer
mid section (6), and the inner cylinder rod (3) which is
The telescope cylinder is attached to the boom in three
attached to the inner mid section (4), pulls the mid sections
places: Refer to (Figure 4-1) for item location.
out along with it.
• The outer rod end (1) of the telescope cylinder is
At the same time, the five groove sheave assembly (9) at the
secured to the boom base section (2)
nose end of the telescope cylinder pulls on the five fly
• The inner rod end (3) is secured to the inner mid section extension cables around it. This causes the fly section (17)
(4) and mid sections (6, 4) to deploy at the same time and rate.
• The cylinder barrel (5) is secured to the outer mid The long extend synchronizing cable (12) ensures the mid
section (6) sections and the telescope cylinder remain in
synchronization.

PRELIMINARY Published 10-05-2007, Control # 151-00 4-1

BOOM TM500E-2 SERVICE MANUAL

4
12

11

18 21

14

10

13
12
9

6
6838-1 5 1

12

19

8
20

15

11

7
17
16 (31 m (102 foot)
6838-2 FIGURE 4-1

4-2 PRELIMINARY Published 10-05-2007, Control # 151-00

TM500E-2 SERVICE MANUAL BOOM

The telescope control valve is the closed spool type and is

Item Description described under Valves in Section 2 - HYDRAULIC AND
PRESSURE SETTINGS in this manual.
1 Telescope Cylinder - Rod End
Refer to Valve in Section 2 - HYDRAULIC AND PRESSURE
2 Base Section
SETTINGS for a complete description of the hydraulic
3 Telescope Cylinder - Inner Rod remote controller.
4 Inner Mid Section - Front The boom telescope cylinder is a two stage double acting,
5 Telescope Cylinder Barrel rod ported cylinder. Foreign material is prevented from
entering the cylinder by a wiper seal during rod retraction. O-
6 Outer Mid Section ring seals prevent internal and external leakage. Refer to
7 Extension Cables Cylinders in Section 2 - HYDRAULIC AND PRESSURE
8 Inner Mid Section SETTINGS for a complete description of the telescope
cylinder.
9 Sheave Assembly
The holding valve is threaded into a port block on the inner
10 Telescope Cylinder rod end of the telescope cylinder. The holding valve
11 Fly Section Base End functions during the retraction, extension, or holding
operation. When holding the boom section at a given length,
12 Synchronizing Cables
oil is trapped in the cylinder by the holding valve. Refer to
13 Base Section - Rear Holding Valves in Section 2 - HYDRAULIC and PRESSURE 4
14 Retraction Cables SETTINGS for a complete description of the holding valve.
15 Sheave Theory Of Operation
16 Retraction Cable to Fly Section
Flow from the pump travels to the telescope directional
17 Fly Section control valve. Movement of the control lever for telescope
Retraction Cables to Outside Front of Base functions from neutral sends a pilot pressure signal to the
18 directional control valve to shift the spool in the directional
Section
control valve. This aligns the appropriate passages in the
19 Sheave control valve to route oil to the telescope cylinder holding
20 Retract Cables to Outer Mid Section valve. The holding valve, with its’ internal make-up of valves
and springs, passes oil to and from the telescope cylinder.
21 Base Section Top and Bottom Wear Pads
During extension, oil unseats the poppet (check) valve in the
holding valve. This oil is routed to the piston sides of the
BOOM RETRACT SEQUENCE cylinder which forces the rods out of the cylinder, causing the
Refer to (Figure 4-1) 31 m (102 foot) boom or (Figure 4-91) boom section to extend.
29 m (95 foot) for item location. As the telescope cylinder is During retraction, oil enters the retract port and flows to the
retracted, the outer mid section (6) (attached to the cylinder rod sides of the cylinder. When pilot pressure reaches a pre-
barrel) and the inner mid section (4) (attached to the inner determined value, the main poppet unseats, and oil flows
cylinder rod) are pulled in. from the piston sides of the cylinder to the reservoir causing
During retraction the two fly and four outer mid retraction the boom section to retract. All return flow from the
cables are forced around sheaves (15, 19) at the rear of the directional control valve goes to the reservoir.
mid section. This cable arrangement keeps the fly section,
outer mid section, and the telescope cylinder in the proper LIFT CIRCUIT
sequence and timing.
Description
TELESCOPE CIRCUIT The boom lift circuit consists of the lift hydraulic remote
controller, lift directional control valve, holding valve, and the
Description lift cylinder. These components enable the boom to be raised
The boom telescope circuit consists of the telescope or lowered to various degrees of elevation ranging from -3 to
hydraulic remote controller, telescope directional control +76 degrees from horizontal.
valve, holding valve, and the telescope cylinder. The lift directional control valve is described under Valves in
NOTE: If the crane is equipped with an auxiliary hoist, the Section 2 - HYDRAULIC AND PRESSURE SETTINGS.
telescope function is controlled by a foot pedal
instead of a controller.

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BOOM TM500E-2 SERVICE MANUAL

R e f e r t o Va l v e s i n S e c t i o n 2 - H Y D R A U L I C A N D • Adjust top rear adjustable wear pads such that the wear
PRESSURE SETTINGS for a complete description of the pad is just in contact with side plate of next outer section.
hydraulic remote controller.
• To adjust lower side wear pads use shims so that wear
The lift cylinder is the double acting type. Dirt and other pads are just in contact with the side plate of the next
foreign material is prevented from entering the cylinder and outer section.
causing internal damage by a wiper seal during rod
• To adjust rear bottom wear pads use shims so that wear
retraction. Oil seals on both the piston and cylinder head
pads are with in 2mm of the bottom plate of the next
prevent internal and external hydraulic oil leakage. Refer to
outer section.
Cylinders in Section 2 - HYDRAULIC AND PRESSURE
SETTINGS for a complete description of the lift cylinder.
SWINGAWAY EXTENSION REMOVAL
The holding valve is a balanced poppet type hydraulic valve.
It is threaded into the port block which is an integral portion of
the lift cylinder barrel. The holding valve functions when
booming up (cylinder rod extended), booming down (cylinder
rod retracted), or holding (cylinder rod stationary). DANGER
To prevent serious injury or death, always wear personal
A velocity fuse is installed in the LMI piston transducer port of protective equipment; i.e., a hard hat, eye protection,
the lift cylinder port block. The velocity fuse is used to gloves and metatarsal boots.
prevent inadvertent retraction (lowering) of the lift cylinder
should the line to the transducer develop a leak. The fuse will
close when flow reaches 11.4 L/min (3 gpm).

Theory Of Operation
DANGER
The directional control valve bank housing the lift control Boom angles are used to control speed at which
valve is supplied by flow from hydraulic pump No.1. extensions swing during erecting and stowage. Improper
When booming up, oil unseats the poppet (check) valve in boom angles will cause uncontrollable swing speeds of
the holding valve, letting oil flow to the piston side of the extension.
cylinder. Pressure is applied to the piston, forcing the rod to
extend, raising the boom. NOTE: Tag line used in these procedures is to control the
movement of the boom extension.
When booming down, oil enters the retract port of the port
block and flows to the cylinder rod side. When pilot pressure
reaches a pre-determined value, the main poppet unseats
and oil flows from the piston side of the cylinder to the
reservoir.
DANGER
Before attempting to remove the boom extension; read
All return flow from the control valve goes to the reservoir. and strictly adhere to all danger decals installed on the
boom/boom nose, boom extension, and stowage
GENERAL MAINTENANCE NOTES brackets.
• Apply medium strength thread locking adhesive/sealant
1. Visually check to ensure all pins are installed.
and primer to all hardware except items mid syncro
cable threads, fly retract cable threads, and outer mid 2. Crane should be set up on outriggers using normal
retract cable threads. setup procedures as found in Section 3 - OPERATING
CONTROLS and PROCEDURES in this Operator’s
• Unless otherwise specified, torque values for all metric
Manual.
class 8.6 and/or 0.9 and grade 5 and/or grade 6
fasteners shall be as specified under Fasteners and a. Fully retract boom.
Torque Values in Section 1 - INTRODUCTION in this
b. Lower boom to horizontal for extending over the
manual.
front of the crane for removal.
• Apply multipurpose grease to all wear surfaces.
3. Remove the retainer clips from the right side attachment
• Adjust bottom front adjustable wear pads such that wear pins stowed in the base of the boom extension and
pad is within mm 1 from side plate or bottom plate of remove the attachment pins from the boom extension.
next inner section. Use shims only if section needs to be Insert the right side attachment pins (1) (Figure 4-2),
adjusted for twist. through the boom attachment and boom extension

4-4 PRELIMINARY Published 10-05-2007, Control # 151-00

TM500E-2 SERVICE MANUAL BOOM

anchor fittings (2) (Figure 4-2). Install the retainer clips in guide pins (1) (Figure 4-4), and ramp (4) (Figure 4-3), on
the attachment pins. the front and rear stowage brackets.
NOTE: Some illustrations and photos show the standard
31 m (102 foot). The same boom extension
removal procedure applies to the 29 m (95 foot)
unless otherwise noted.

1
1

6821-3 FIGURE 4-4

2 4
DANGER
When removing the boom extension, ensure that all
personnel and equipment are kept clear of the swing path.

7. Slightly raise and/or lower the boom to help control the

6814-4
boom extension. Using the rope attached to the top of
the boom extension, manually swing the extension into
FIGURE 4-2 place ahead of the boom nose.
4. Remove the retaining pin from the hitch pin (3) 8. Attach a lifting devise to the lifting lugs on the swingaway
(Figure 4-3), that secures the boom extension to the rear extension taking pressure off the attaching pins (1)
stowage bracket. Remove the hitch pin, unlocking the (Figure 4-2). Remove the pins.
boom extension from the boom.
9. Place the now free swingaway extension in a safe
3 secure location.

BOOM REMOVAL
NOTE: Boom removal procedures are identical for the
4 standard 31 m (102 foot) boom and the optional 29
m (95 foot) boom.
The disassembly and assembly will be in separate
procedures in this section.
Do not attempt to work on the boom without experienced
supervision.

6821-1

FIGURE 4-3
DANGER
5. Attach a length of rope to the boom extension tip to aid in To prevent serious injury or death, always wear personal
swinging the boom extension into place ahead of the protective equipment; i.e., a hard hat, eye protection,
boom nose. gloves and metatarsal boots.
6. Raise the boom to horizontal and extend the boom
approximately 51 to 64 cm (20 to 25 inches). Make NOTE: The boom may be disassembled with the base
certain that the boom extension stowage lugs clear the section left on the crane if repair of the base section
is not necessary.

PRELIMINARY Published 10-05-2007, Control # 151-00 4-5

BOOM TM500E-2 SERVICE MANUAL

NOTE: The complete boom assembly without the 10. Remove the capscrew (1), and flatwasher (2) securing
swingaway boom extension attached weighs the upper lift cylinder shaft (3) to the side of the pivot box
approximately 4900 kg (10,803 pounds) (4) on the boom (Figure 4-5).
NOTE: Removal of the swingaway boom extension will
simplify boom removal.
1. Extend and set the outriggers to level the crane and
ensure the boom is fully retracted and in a horizontal
position over the front of the crane.
2. Fully retract the boom.

DANGER
Wear gloves when handling wire rope.

3. Remove the hook block or headache ball and wind all

the wire rope onto the hoist drum.
4. Elevate the boom slightly so that the lift cylinder is
extended approximately 30.48 cm (12 in) to allow for
withdrawal of the lift cylinder rod end from the lift cylinder
lift box on the bottom of the boom. 6818-32 4 3 1, 2
FIGURE 4-5

11. Remove the upper lift cylinder shaft (3) (Figure 4-5).
DANGER 12. Activate the hydraulic system and withdraw the lift
Ensure the boom lift cylinder is properly supported before cylinder rod enough to clear the pivot box (4)
disconnecting it from the boom. (Figure 4-5).
Ensure all blocking and lifting devices are capable of 13. Take up the slack on the boom lifting device.
supporting the boom assembly.

5. Shut down hydraulic power to crane.

6. With hydraulic power removed, move the boom extend DANGER
control from “EXTEND” to “RETRACT” several times. Shut down the crane before proceeding.
This will relieve most residual pressure in telescope
circuit and make telescope cylinder removal easier. 14. Remove the clip pin and retaining pin (1) (Figure 4-6),
securing the boom pivot shaft (2) (Figure 4-6), on the
7. Attach a lifting device to the boom to provide for equal
boom to the superstructure assembly.
weight distribution.
15. Remove the grease fittings (3) (Figure 4-6), from the
8. Disconnect any electrical wiring from the boom.
pivot shaft to prevent damage. Remove the boom pivot
9. Tag and disconnect the hydraulic lines to the telescope shaft.
cylinder. Hard cap or plug the lines and openings.

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TM500E-2 SERVICE MANUAL BOOM

c. Disconnect cable connector from side of junction

box.

2
1
2

3
6835
FIGURE 4-6

16. Raise the boom clear of the crane and lower to blocking
or cribbing for service.
4
BOOM DISASSEMBLY FOR THE STANDARD 6837
31 M (102 FOOT) BOOM FIGURE 4-7

3. Disconnect cable from the Fly section (3) (Figure 4-8),

Disconnect the Base Section
and feed cable through cable guides (1) and attach to
Do not attempt to work on the boom without experienced the base section cable guide (2) (Figure 4-8).
supervision
.

DANGER
To prevent serious injury or death, always wear personal
protective equipment; i.e., a hard hat, eye protection,
gloves and metatarsal boots.
6818-14
1. Remove the boom from the crane superstructure in
accordance with “Boom Removal” procedure. 3
2 1
2. Remove the LMI, A2B/Cable from boom nose.
a. Remove cover from junction box.
b. Disconnect “SHD” wire (1) (Figure 4-7), from
terminal 1 and “CORE” wire (2) (Figure 4-7), from
terminal 2.
FIGURE 4-8

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BOOM TM500E-2 SERVICE MANUAL

4. Chain the fly, outer mid and inner mid sections together. Remove the Base Section
This will prevent the inadvertent or unexpected
extension of these sections during the boom Do not attempt to work on the boom without experienced
disassembly (Figure 4-9). supervision.
.

DANGER
The combined weight of the boom inner mid, outer mid,
and fly sections, including the telescope cylinder, is
approximately 3680 kg (8110 pounds). Ensure that
adequate and properly tested lifting devices are used to
remove these sections

FIGURE 4-9
5. Remove the capscrews and washers securing the DANGER
telescope cylinder outer rod (1) (Figure 4-10), to the rear To prevent serious injury or death, always wear personal
of the base section. protective equipment; i.e., a hard hat, eye protection,
gloves and metatarsal boots.

1. Remove the access cover (1) (Figure 4-11), on the top

CAUTION rear of the base section. Slide the assembly out of the
base section (1) (Figure 4-12), enough to gain access to
Use extreme caution during piston and rod tube assembly
the top rear adjustable wear pads on the inner mid (2)
removal. The telescopic cylinder will still be under
(Figure 4-12).
hydraulic pressure due to the holding valve.

6748-30
1 6748-39
FIGURE 4-10 FIGURE 4-11
6. Remove the nuts and washers securing the
synchronizing cable(s) (2) (Figure 4-10), ends to the
base section.

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5. Remove the capscrews and washers securing each top

1 2 (1) and bottom (2) side wear pads at the front of the base
(Figure 4-14). Remove wear pads, shims, and mounting
angle (top left side only).

FIGURE 4-12
2. Remove the capscrews, washers, and offset washers
(1) (Figure 4-13) securing each top rear adjustable wear. 4
Remove the wear pads, keeper plates and bolts
2
(Figure 4-13) from the top of the inner mid. Note location
of wear pads and shims for installation. 6748-25
FIGURE 4-14
1 6. Attach a suitable lifting device to the fly/outer/Inner mid
assembly. Raise the front of the assembly slightly and
remove the wear pad mounting bolts and the wear pads
from the bottom of the base section.
7. Continue to pull the assembly until it is clear of the base
section.
NOTE: Pull the outer mid retract cables out with the
assembly to prevent them from becoming
damaged.

2
8. Place base section in a secure location
FIGURE 4-13
3. On the top front of the base section, remove the Disconnect the Inner Mid Section
capscrews and washers securing the kick back plate Do not attempt to work on the boom without experienced
and remove the plates. supervision.
4. Remove the capscrews and washers securing the outer .
mid retract cable anchor plates to the lower front of the
base section. Remove the cable nuts and anchor plates
from the cables. DANGER
To prevent serious injury or death, always wear personal
protective equipment; i.e., a hard hat, eye protection,
gloves and metatarsal boots.

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BOOM TM500E-2 SERVICE MANUAL

1. On both sides, remove the screws, washers and nuts (1) Remove the Inner Mid Section
(Figure 4-15), securing each retract sheave assembly.
Remove the shaft, spacer bushing, sheave assembly, Do not attempt to work on the boom without experienced
and thrust washers. If necessary, remove the grease supervision.
fitting from the shaft weldments.

DANGER
To prevent serious injury or death, always wear personal
protective equipment; i.e., a hard hat, eye protection,
gloves and metatarsal boots.

DANGER
The combined weight of the boom outer mid, and fly
s e c t i o n s , i n c l u d i n g t h e t e l e s c o p e c y l i n d e r, i s
approximately 3029 kg (6678 pounds). Ensure that
adequate and properly tested lifting devices are used to
6818-15 remove these sections
1
FIGURE 4-15
1. Slide the assembly out of the inner mid (1) (Figure 4-17)
2. Remove the two screws and bushings securing the enough to gain access to the top rear adjustable wear
cylinder inner rod (1) (Figure 4-16), to the rear of the pads on the outer mid through the hole in the top of the
inner mid (2) (Figure 4-16). inner mid.
2. Remove the capscrews, washers, and offset washers
(2), (Figure 4-17) securing each top rear adjustable
wear pad. Remove the wear pads, keeper plates and
bolts (3) from the top of the outer mid (4). Note location
of wear pads and shims for installation.

1 2

1
FIGURE 4-16

3. Remove the nuts from the extend cable anchor plate

adjusting bolts.

4. Pull the four retract cables up through the holes in the

bottom of the inner mid and lay them out to the rear.

4 3 FIGURE 4-17

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TM500E-2 SERVICE MANUAL BOOM

3. At the top front of the inner mid, remove the capscrews 6. Remove the screws and washers securing each top (1)
and washers (1) securing the synchronizing cable (2) and bottom (2) side wear pads (Figure 4-20) at the front
sheave assembly (3) (Figure 4-18). Lay the assembly of the inner mid. Remove wear pads and shims. Keep
with cables on top of the outer mid (4). the shims with each individual wear pad for re-
installation.

3 4
1

3
2

4
FIGURE 4-18
4
4. At the lower front of the inner mid, remove the 2
capscrews and washers securing the fly retract cable
6748-25
anchor plates (1) (Figure 4-19). Remove the cable 3
locknuts and the anchor plates from the cables. FIGURE 4-20
5. Install thread protectors on cable ends. 7. Remove the LMI cable guide mounting angle (3) (top left
side only).
8. Lift up on the front of the assembly and remove the wear
pad bolts and wear pads (4) (Figure 4-20) from the
bottom of the inner mid.

6748-23

1 FIGURE 4-19

FIGURE 4-21

9. Remove the lock nut and adjustment nut from the extend
cable adjustment bolt (Figure 4-21). This will free the
extend cable from the inner mid weldment.

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BOOM TM500E-2 SERVICE MANUAL

10. Secure the extend cable keeper plate and adjustment 14. If necessary, remove the two bolts securing each lower
bolt to the tele cylinder with cable ties (1) (Figure 4-22), rear side wear pad to the inner mid. Remove wear pads
or tape. Failure to do so may allow the cables and and shims. Note location of shims for installation.
keeper to become jammed during disassembly.
15. Remove the inner mid Section from outer/fly/tele
NOTE: It is not necessary to remove the extend cable cylinder assembly.
keeper plates at this time. If it is necessary to
remove the cable keeper plates, be sure to mark Remove the Outer Mid Section
the extend cable in the proper sequence for re-
Do not attempt to work on the boom without experienced
assembly.
supervision.
.

DANGER
To prevent serious injury or death, always wear personal
protective equipment; i.e., a hard hat, eye protection,
1 gloves and metatarsal boots.

DANGER
The combined weight of the boom fly section including the
telescope cylinder, is approximately 1960 kg (3720
6748-29
FIGURE 4-22 pounds). Ensure that adequate and properly tested lifting
devices are used to remove these sections
11. Continue to pull the assembly from the inner mid section
until access to the rear of the outer mid is gained to 1. At the rear of the outer mid, on both sides, remove the
disconnect the four retract cables (1) (Figure 4-23). capscrew, shim and pin from each retract cable sheave
12. Remove the cotter pins and pins (2) (Figure 4-23), assembly (1) (Figure 4-24).
securing the four retract cables to the rear of the outer 2. Remove the pin, shim and retract sheave assembly. If
mid. necessary, remove the grease fitting (2) from the shaft
weldments.
.

6748-27

2 1
2
FIGURE 4-23
6838-34
13. If necessary, remove the two bolts securing the bottom FIGURE 4-24
wear pad to the inner mid. Remove wear pad.

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3. Place wood block (1) (Figure 4-25) under cylinder and 7. Remove the bolt, washer, and offset washer (1)
remove the four bolts and bushings securing the cylinder (Figure 4-27) securing each top rear adjustable wear
barrel (2) (Figure 4-25), to the rear of the outer mid. pad (2) and remove the wear pads, keeper plates (3)
and bolts from the top of the fly (4).

4
6748-37
FIGURE 4-27
2
1 FIGURE 4-25
8. At the top front of the outer mid, remove the two
4. Pull the two retract cables up through the holes in the capscrews (1) (Figure 4-28), securing the kickback
bottom of the outer mid and lay them out to the rear. plate. Remove the kickback plate.

5. Turn cylinder rod inner mounting lugs (1) (Figure 4-26),

so they are vertical in order to clear mounting bracket (2)
(Figure 4-26), in the outer mid. 1

FIGURE 4-28
2 9. Remove the screws securing each top (1) and bottom
(2) side wear pads at the front of the outer mid
(Figure 4-29). Remove wear pads, shims, and mounting
angle (3) (top left side only).

6748-22

6748-38 FIGURE 4-26

6. Slide the fly assembly out of the outer mid enough to 1

gain access to the top rear adjustable wear pads on the
2 3
fly through the hole in the top of the outer mid.
FIGURE 4-29

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BOOM TM500E-2 SERVICE MANUAL

DANGER DANGER
Be extremely careful when removing bottom wear pads. The weight of the telescope cylinder is approximately 889
Do not place your hands or fingers in an area that could kg (1980 pounds). Ensure that adequate and properly
cause injury. Use approved tools to remove wear pads. tested lifting devices are used to remove the telescope
cylinder.
10. Lift up on the front of the fly assembly and remove the
wear pads (4) from the pockets in the bottom of the outer 1. Attach a suitable lifting device to the telescope cylinder.
mid. Raise cylinder and remove blocking device (1)
(Figure 4-31) from under the cylinder (2).
11. Continue to pull the assembly from the outer mid section
until access to the rear of the fly is gained to disconnect
the two retract cables.
12. Remove the screws, lockwashers and keeper plate (1)
securing the two fly retract cables (2) (Figure 4-30), to
the rear of the fly.

2 FIGURE 4-30
2
1 FIGURE 4-31
13. Remove the synchronizing cable and sheave assembly
from the top of the outer mid. 2. Slide the telescope cylinder out of the fly section until it is
14. Remove the two fly retract cables from the inside of the just ready to “drop out” of the section. Do not pull the
outer mid. telescope cylinder completely out of the fly section yet.

15. Remove the two bolts securing each lower rear side NOTE: Pull the extend cable along with the telescope
wear pad to the outer mid. Remove wear pads and cylinder (Figure 4-32). Failure to do so will cause
shims. Note location of shims for installation. binding and jamming of the cables in the fly
section.
Remove the Tele Cylinder
Do not attempt to work on the boom without experienced
supervision.

DANGER
To prevent serious injury or death, always wear personal
protective equipment; i.e., a hard hat, eye protection,
gloves and metatarsal boots.
6838-4
FIGURE 4-32

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TM500E-2 SERVICE MANUAL BOOM

3. Remove the capscrews and washers (1) securing the 7. Remove bottom and lower rear side wear pads and
extend cable keeper plate (2) (Figure 4-33), to the rear shims if they are to be replaced. Note location of shims
of the fly. Remove the keeper plate and remove the five for installation.
extend cable ends from the slots in the fly.
Extend Cable Sheave Removal
1. Remove the capscrews and washers securing the cable
retainer (1) (Figure 4-35), to sheave mount (2). Remove
the retainer.
NOTE: If the extend cables are to be reused, be sure that
they are marked before removal to aid in
reassembly.
2. Remove the five extend cables.

1 2 1 NOTE: The boom nose sheave weighs approximately 17.3

FIGURE 4-33 kg (38 pounds).
4. After supporting the weight of the telescope cylinder, 3. Remove the capscrews and washers securing the
remove the capscrews and washers securing the sheave shaft retainer plates (3) (Figure 4-35), from left
cylinder foot weldment (1) to the telescope cylinder (2) and right side of the sheave mount.
(Figure 4-34). Remove the foot weldment.
4. Carefully pull the sheave shaft (4) (Figure 4-35), from
4
the assembly, removing the spacers, and sheave (5).
Note the quantity of the spacers for installation.

4
2

5
6818-34 2 1
FIGURE 4-34 3

5. Completely remove the telescope cylinder from the fly

section.
6. If necessary, remove the capscrews and washers
securing the wear pad(s) and shim to the bottom rear fly 1 3
section. Remove the wear pad(s). 6748-35 FIGURE 4-35

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BOOM TM500E-2 SERVICE MANUAL

BOOM NOSE SHEAVES 3. Carefully pull the upper boom nose sheave shaft (6)
from the boom nose, removing the spacers, and boom
Do not attempt to work on the boom without experienced nose sheaves (4) (Figure 4-36). Note the quantity of the
supervision. spacers for installation.
4. Repeat steps 2 and 3 and remove the lower boom nose
sheave shaft.

DANGER 5. Remove the shim, washer, keyed washer and locknut

from both sheave shafts.
To prevent serious injury or death, always wear personal
protective equipment; i.e., a hard hat, eye protection,
gloves and metatarsal boots.
Boom Nose Sheaves Installation
NOTE: The boom nose sheave weighs approximately 17.4
Boom Nose Sheaves Removal kg (38 pounds).

1. Remove the clip pins from the cable retainer pins (7) and 1. Install the spacers and sheaves (4) onto the sheave
remove the cable retainer pins (3) (Figure 4-36), from shaft while installing the sheave shafts into the lower
the upper and lower part of the boom nose. boom nose (5) (Figure 4-36).

2. Remove the capscrews and washers securing the end NOTE: The lockwasher can be used more than once but
cap (2) to the upper boom nose sheave shaft (6) must be replaced if not in good condition.
(Figure 4-36). Remove the end cap. 2. Install the lockwasher onto the sheave shaft with the
NOTE: The boom nose sheave shafts weigh tabs facing out.
approximately 12.5 kg (27.5 pounds) each. The 3. Install the locknut, washer, keyed washer, and shims (if
boom nose sheaves weigh approximately 17.4 kg necessary) onto the boom nose sheave shaft with the
(38 pounds) each. chamfer side out. Install the end cap (2) (Figure 4-36),
onto the opposite end of the sheave shafts and secure in
place with the two bolts.

3
6
4

4 3

1
6748-13
FIGURE 4-36

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TM500E-2 SERVICE MANUAL BOOM

4. Tighten the locknut until the play in the bearings is

eliminated. Bend the lockwasher tabs to secure the
locknut in place.
5. Repeat steps 1 through 4 for the upper boom nose
sheaves and sheave shaft.
4
6. Install the cable retainer pins (3) into the upper and lower 2
part of the boom nose and secure in place with the clip
pins (7) (Figure 4-36).

BOOM ASSEMBLY PROCEDURE FOR THE

31 M (102 FOOT) BOOM 5
3
Do not attempt to work on the boom without experienced
supervision.
.

1
DANGER 3

To prevent serious injury or death, always wear personal

6748-35 FIGURE 4-37 4
protective equipment; i.e., a hard hat, eye protection, 5. Install the sheave assembly (5), shaft (4) (Figure 4-37),
gloves and metatarsal boots. and spacers (Figure 4-37). Install the shaft with the
lubrication fitting to the LEFT and the notches to the
Extend Cable Sheave Installation Front of the boom.
6. Install the sheave shaft retainer plates (3) (Figure 4-37),
on the left and right side with the capscrews and
washers in each plate.
CAUTION
The extend cable sheave weighs approximately 17.3 kg Install Telescope Cylinder
(38 pounds).
Do not attempt to work on the boom without experienced
supervision.
NOTE: This procedure can be greatly simplified if two
technicians are used. One technician to hold the
sheave in place and the other to insert the spacers
and sheave shaft.
DANGER
1. Clean and inspect the sheave assembly shaft bushing.
To prevent serious injury or death, always wear personal
Replace the bushing if damage is found.
protective equipment; i.e., a hard hat, eye protection,
2. Lubricate the shaft bushing. gloves and metatarsal boots.
3. Determine the number of spacers required for the
NOTE: Apply Loctite 242 to the threads of all attaching
sheave shaft.
hardware except cable ends and cable lock nuts.
As many as six spacers (3 on each side) may be
Apply multipurpose grease (MPG) to all wear
required. If you have placed 3 spacers on the first side,
surfaces.
and find that only two will fit on the second side, that will
be acceptable. It will not be necessary or desirable to Use standard torque values specified in Section 1
remove one spacer from the first side. of this Manual unless otherwise specified.
4. Apply a light coat of lubricant to the sheave shaft (4) NOTE: Wear Pads. When installing upper and lower side
(Figure 4-37). wear pad, use shims as necessary so wear pad is
within 1.52 mm (0.06 inch) from side plate of next
inner section. Use equal number of shims on each
If wear pad shims were previously removed, place
shims in same locations that was noted during
removal.

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BOOM TM500E-2 SERVICE MANUAL

1. Measure and mark the center line of the fly section. This
mark will be used to set the adjustable wear pads after
the section is installed in the outer mid section.
2. Install the lower rear side wear pads and shims on the fly
2
section with two screws each.
1
3. Install the bottom rear wear pad on the fly section with
two screws. 3

4. Install the telescope cylinder sheave mount and sheave

assembly (1) to the telescope cylinder (2) (Figure 4-38).
a. Install the sheave shaft with the grease fitting to left.
b. Do not install the cable retainer with hardware (3)
(Figure 4-38) until the extend cables are reeved
around the sheave
FIGURE 4-39
c. Lubricate the sheave

CAUTION
The five Extend Cables must be marked at both ends
prior to installation. If the cables are not marked, they will
be difficult to install in the correct order.
Do not allow the cables to become entangled or overlap.
2 Cable or boom failure could result.

11. Mark BOTH ENDS of the five extend cables

1
3
(Figure 4-40).
.

6748-32
FIGURE 4-38
5. Attach a suitable lifting device to the telescope cylinder.
Raise the telescope cylinder.
6. Position the sheave end of the telescope cylinder at the
rear of the fly section, with port block turned vertical.
7. Carefully insert the telescope cylinder into the fly section
until the sheave weldment clears the retract cable
weldment.
8. Install the two wear pads on the support foot weldment
with two screws each. Torque screws.
9. Install the cylinder foot weldment (1) (Figure 4-39) to the
telescope cylinder (2) (Figure 4-39) using two bolts.
10. Lower cylinder so the cylinder foot weldment rests on
support foot weldment (3 ) (Figure 4-39) wear pads.

6838-5
FIGURE 4-40

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TM500E-2 SERVICE MANUAL BOOM

15. Slide the telescope cylinder assembly completely into

the fly section.
16. Inspect the extend cables to ensure that they are not
CAUTION crossed or out of sequence.
When adjusting cables, hold the cable end and turn the
nut. do not turn cable. 17. Place blocking under the rear of the telescope cylinder
to aid in assembly (Figure 4-43).
Turning or twisting of the cable while adjusting will result
in damage or failure of cable.
Install cables in their natural untwisted condition.

12. Reeve the five extend cables around the telescope

cylinder sheave.
13. Place the five extend cable dead ends (1) (Figure 4-41),
in the slots at the top of the fly section and secure them
with extend cable keeper plate (2) (Figure 4-41) and two
bolts.

1
4

FIGURE 4-43
18. Temporary tie extend cables to the telescope cylinder to
maintain proper cable alignment during assembly
(Figure 4-42).

Install the Outer Mid Section

2 FIGURE 4-41
Do not attempt to work on the boom without experienced
14. Turn cylinder rod mounting lug ends (Figure 4-42) so supervision.
they are aligned vertically to clear mounting brackets in .
the outer mid section.

DANGER
To prevent serious injury or death, always wear personal
protective equipment; i.e., a hard hat, eye protection,
gloves and metatarsal boots.

NOTE: Before the fly section is installed the center point of

the fly section must be determined. Measurement
from this center point will be used to properly set
the adjustable wear pads

FIGURE 4-42

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BOOM TM500E-2 SERVICE MANUAL

1. Align two straight edge tools with the outer edge of the The pad should extend no more than 1/8 of an inch into
Fly Section at the rear of the section (not the wear pad the outer mid section for the initial installation.
adjustment weldment). The tools should extend past the
NOTE: Use grease to aid in holding the wear pad in place.
wear pad adjustments (Figure 4-44).
.

Align On This Edge

1
6748-25

FIGURE 4-46
FIGURE 4-44
3. Insert the upper wear pad, backing plate and adjusting
a. Measure and note the total width of the boom plate. (3) (Figure 4-46).
section.
a. Attach each wear pad assembly with four washers,
b. Using the measurement obtained determine the four lock washers and four capscrews.
center point of the boom section and clearly mark it
(Figure 4-45). b. Insert the hex head adjusting screws. Do not
tightened at this time
4. Apply lubricant to the wear pad contact areas of the fly
section.
5. To aid in the installation of the fly section into the outer
mid section, apply lubricant to the wear pad contact
areas of the fly section and secure the extend cables to
Measure across section. the telescope cylinder (Figure 4-47).
a. Rotate the port block as shown in (Figure 4-47).

Make Mark At Center Line

FIGURE 4-45

2. Install the lower (brass) wear pads (1) (Figure 4-46), to

the outer mid section. Back out the adjustment set screw
so the pad seats fully into the pocket (2) (Figure 4-46).
FIGURE 4-47

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TM500E-2 SERVICE MANUAL BOOM

CAUTION
Do not allow the cables to become entangled or overlap.
cable or boom failure could result.

6. Attach the fly retract cables to the cable anchors (1)

(Figure 4-48) on the base end of the fly section on both
sides. Install the two cable keepers with two lock
washers and two bolts on each keeper.
7. Feed the threaded end through outer mid and lay out
towards the front of the outer mid section.

1 FIGURE 4-49
1
10. Insert the wear pads and pad holders (1) (Figure 4-50),
on the left and right side of the fly section.
NOTE: The “buttons” on the wear pads may be “shaved 4
down” if needed. Do not cut into the wear pad.
11. Measure and adjust the wear pads until the fly section is
centered ± 1mm (0.04 inch) in the outer mid section.
Apply Loctite and tighten jam nut (2) (Figure 4-50).
.

1
FIGURE 4-48

8. Slide the fly section into the outer mid section until the
2
wear pad adjustment is accessible though the access
plate on top of the outer mid section.

CAUTION
Pull the two fly retract cables through the outer mid as the
fly section is being installed. Do not allow the cables to
become entangled or overlap. Cable or boom failure
could result.
FIGURE 4-50
9. Raise the fly section slightly and insert the bottom wear
pad in to place and secure with retaining bolts. Install the
bolts (1) (Figure 4-49) from the bottom of the outer mid
section.
CAUTION
Do not allow the cables to become entangled or overlap.
Cable or boom failure could result.

12. Slide the fly section the rest of the way into the outer mid
section.

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BOOM TM500E-2 SERVICE MANUAL

FIGURE 4-53

19. Rotate cylinder mounting to facilitate mounting into the

inner mid section (Figure 4-54).

FIGURE 4-51

13. Align cylinder mounting holes with mounting bracket

holes in rear of outer mid section and secure with two
bolts and bushings on each side (Figure 4-51).
NOTE: It is important that the cylinder mount bolts be
properly torqued. The correct torque will allow the
cylinder to “float” in the mount.
14. Remove the block of wood holding the telescope
cylinder.
15. Route the fly retract cables down through the bottom of
the outer mid section. Lay the cables out toward the 6748-31
nose end of the outer mid section. FIGURE 4-54

16. Reeve the fly retract cable around the fly retract cable 20. Install extend cables in to the round keeper plate (1)
sheave (1) (Figure 4-52) and install in the angled slots (Figure 4-55) and (Figure 4-56).
(2) (Figure 4-52) on each side of the outer mid section.

6748-29 FIGURE 4-55

2

CAUTION
6748-34 FIGURE 4-52 Install extend cables in proper sequence. Do not allow the
cables to become entangled or overlap. Cable or boom
17. Lubricate retract cable shaft.
failure could result.
18. Install kickback plate with the capscrews and washers
(1) (Figure 4-53) on inside top of outer mid section.

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TM500E-2 SERVICE MANUAL BOOM

1 FIGURE 4-58

Install the Inner Mid Section

Do not attempt to work on the boom without experienced
supervision.
.
4
DANGER
To prevent serious injury or death, always wear personal
protective equipment; i.e., a hard hat, eye protection,
FIGURE 4-56 gloves and metatarsal boots.

21. Install adjusting bolt (Figure 4-57) to the anchor 1. Install the adjustable brass wear pads (1) and the upper
assembly. wear pads (2) (Figure 4-59). Do not install the bottom
. wear pads at this time.

Permanent Anchor Bolt

Assembly Bolt

FIGURE 4-57
4
22. Temporary secure anchor assembly to the extend 3
cylinder rod. 2
23. Attach the mid retract cables to the anchor point at the
base end of the Outer Mid.
a. Lubricate and install pin through cable ends. Secure
pin (1) (Figure 4-58) with cotter keys.
24. Lay out the threaded end of the mid retract cables
1
through the inner mid section toward the base end.
6748-24 FIGURE 4-59

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2. Attach both mid syncro cable anchor ends (1) 5. Pass the threaded end of the fly retract cables down
(Figure 4-60) with capscrews and bushings to the base thought the bottom of the fly section. Lay the cables out
end of the outer mid section. toward the nose end of the fly section.
6. Reeve the each fly retract cable around the retract
1 sheaves at the base of the outer mid section.
7. Assemble the fly retract sheave (1) assembly as shown
in (Figure 4-62) and (Figure 4-63). Note that the pin has
one thrust washer (2) to the inside of the boom and two
thrust washers (3) to the outside of the boom.
8. Lubricate both sheave assemblies

6748-26

FIGURE 4-60
3. Assemble the mid syncro cable sheave assembly (3)
(Figure 4-59) and lay on top of the outer mid section
about where it will go.
a. Reeve the mid syncro cables (4) (Figure 4-59) 6838-7
3
around the sheaves. FIGURE 4-62
b. The cables should be reeved from the cable anchor
around the outside of the sheave wheels to the
inside of the sheave wheels. The threaded end of
the cable should be laid out down the center of the
Inner Mid section toward the base end.
4. Attach the fly retract cables button ends to the cable
anchor points (1) (Figure 4-61) in the fly section. Use
one keeper plate (2) (Figure 4-61), two capscrews, and
two washers on each anchor to secure the cables. 1

2
2

FIGURE 4-63

9. Install the rear bottom and side and brass wear pads.
FIGURE 4-61
Install shims with the open end facing the base end of
the boom section.

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10. Install adjustment bolts and lock nuts (1) to the upper 13. Assemble the fly retract cable anchor weldments (1) to
adjustable wear pad weldment. Do not install wear pads the retract cables (2). Thread the single nut (3) on the
at this time (Figure 4-64). cable end until there is 1 1/2 inch of thread showing,
then install the locknut (4) (Figure 4-67).
NOTE: There are left and right anchors. Check to make
sure the anchors are in the correct position

1
3 4
1 2

FIGURE 4-64

NOTE: Installation of the Extend Cable Anchor Assembly

will require the use of a bolt longer than the
permanent bolt. The weight of the five extend
cables and anchor assembly will make the 4
installation of the anchor assembly extremely
difficult with out use of a longer bolt (Figure 4-65). FIGURE 4-67

Use bolt Part Number 7099000555 (or equivalent) 14. Install the brass wear pad (1) (Figure 4-68) at the nose
for installation only (Figure 4-65). end of the inner mid section.
.

Permanent Anchor Bolt

Assembly Bolt
FIGURE 4-65

11. Insert assembly bolt into extend cable anchor.

12. Tie the extend cable anchor assembly (1) to the
telescope cylinder (2) (Figure 4-66).

6748-24
1
FIGURE 4-68
15. Pull the outer mid retract cables through the inner mid
section with the threaded end towards the base end of
the section.
NOTE: Always lay out and inspect the cables before
installation. Laying out cables will help eliminate
1 FIGURE 4-66 twists, kinks and make inspection easier.
16. Apply grease to those parts of the inner mid and outer
mid where the wear pads will contact.

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17. Attach the mid retract cables to the Outer Mid section.
(Figure 4-69).
CAUTION
Do not allow the cables to become entangled or overlap.
Cable or boom failure could result.

19. Install bottom wear pads on the inner mid section.

20. Attach fly retract cable anchors (1) to the front of the
inner mid section with the capscrews and washers (2).
(Figure 4-71).

FIGURE 4-69

18. Align the outer mid section with the inner mid section.
Slide sections together (Figure 4-70) until side wear 2 1
pads on the outer mid section (1) engage with the inner FIGURE 4-71
mid section (2). Measure clearance at pads and shim as
required. 21. Continue installing the outer mid section in the inner mid
section. Stop when the upper rear adjustable wear pads
on the inner mid section are accessible.
22. Install the adjustable wear pads (1) (Figure 4-72) to the
top rear of the inner mid section and secure with the
capscrews, washers and offset washers. Install the
keeper plates and bolts.

1 2 FIGURE 4-70

NOTE: Pull the mid retract cables through the base section
as the sections are joined.

FIGURE 4-72

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23. Install kickback plate on inside top inner mid section (1) 26. Install the installation bolt into inner mid anchor
(Figure 4-73). weldment and take up as much slack as possible.
24. Install the mid syncro cable sheave assembly (2) NOTE: Make certain that the extend cable anchor is
(Figure 4-73) to top inside of inner mid section. seating properly into the boom section weldment.
The “ears” on the anchor must fit into grooves
machined into the sides of the inner mid anchor
plate.
27. Carefully clamp the anchor assembly to the inner mid
anchor weldment (Figure 4-75).
a. Remove the installation bolt and replace with the
standard adjustment bolt.
b. Take up the slack on the anchor adjustment bolt and
remove the clamps.
2

4
1

FIGURE 4-73

25. Check to make sure the long cable installation bolt (1)
(Figure 4-74) is installed in the extend cable anchor
assembly.

FIGURE 4-75

28. Adjust the adjustment nut until there is 2.75 inches of

thread showing. Install jam nut.

1
FIGURE 4-74

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29. Attach the telescope cylinder to the inner mid mounting 32. Install retainer capscrew, washer and nut to lock sheave
flanges. Check to ensure bushings are free to rotate assembly pins in place (1) (Figure 4-78).
after bolts are tightened (Figure 4-76).

FIGURE 4-76 View looking up from the

bottom of inner mid section
30. Assemble the mid retract sheave (1) assembly as shown
in (Figure 4-77) and (Figure 4-78). Note that the pin has
one thrust washer (2) to the inside of the boom and two 1
1
thrust washers (3) to the outside of the boom.
NOTE: Insert one thrust washer to the inside and two
thrust washers to the outside of each assembly. FIGURE 4-78

33. Lay out the mid retract cables toward the front of the
2 1 inner mid section.
34. Attach two cables (1) to each anchor (2). Adjust each
cable to 1.75 inches and install locknuts (3)
(Figure 4-79).

1 2
4
3
3
FIGURE 4-77

31. Reeve the mid retract cables (4) on the left and right mid
retract cable sheave assemblies and install as shown in
(Figure 4-77). FIGURE 4-79

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35. Turn telescope cylinder port block so that the test port is
down (Figure 4-80).
.

CAUTION
Failure to properly position the port block will cause
problems when mounting the boom on the crane. The
crane hydraulic system will not function properly if the port
block in installed incorrectly.

4
FIGURE 4-81

4. Connect the mid retract cables (1) to front end of base

section (Figure 4-82).
Test Port FIGURE 4-80

Install the Base Section

Do not attempt to work on the boom without experienced
supervision. 1

DANGER
FIGURE 4-82
To prevent serious injury or death, always wear personal
protective equipment; i.e., a hard hat, eye protection, 5. Install kickback bar between the inner mid section and
gloves and metatarsal boots. the base section (top front of base).

1. Insert inner mid section into the base section until the 6. Install top wear pad adjusting assembly inside base
inner mid section is past the side wear pad access and section at top rear access opening (Figure 4-83).
stop.
2. Install lower front wear pads between sections.
NOTE: Use grease to hold wear pads in place during
assembly.
3. Install brass wear pad through base section access hole
in side of the base section and slide inner mid section
past wear pad and install lock plate (Figure 4-81).

FIGURE 4-83

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CAUTION
Ensure the telescope cylinder port block is correctly
positioned before proceeding. The boom will not function
properly if the port block is not installed as shown in
(Figure 4-84).

CAUTION
There is less than 3 mm of clearance between the sides of
the weldment and the port block during installation.
R e m o v e a n y p l u g s / c a ps t h a t m a y i n t e r f e r e w i t h
installation. FIGURE 4-85

9. Connect mid syncro cables to rear of base section.

10. Adjust cable until there is 76 mm (3 inch) of threads
showing past adjustment nut (Figure 4-86).

Test Port
FIGURE 4-84

7. Carefully guide the port block into the anchor weldment.

FIGURE 4-86
8. Insert two telescope rod end pins. Secure both ends of
each pin with a flat washer, lock washer, and capscrew 11. Plumb port block with tubing (Figure 4-87).
(Figure 4-85).
NOTE: It may be necessary to gently pry the port block to
align the pin holes.

FIGURE 4-87

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12. Disconnect LMI, A2B/cable that was attached to the BOOM DISASSEMBLY FOR THE OPTIONAL
base section cable guide (1) (Figure 4-88) in the 29 M (95 FOOT)
removal of the boom and feed cable through the inner
and outer mid section cable guides (2) (Figure 4-88) and NOTE: The complete boom assembly without the
through the fly section cable guide (3) (Figure 4-88). swingaway boom extension attached weighs
approximately 4900 kg (10,803 pounds)
1. Remove the boom in accordance with the REMOVAL
procedures outlined in this section.
NOTE: See PAT Manual for disconnecting LMI, A2B/
Cable from boom nose and securing cable reel.
2. Remove the bolts and washers securing the telescope
cylinder outer rod to the rear of the base section.
3. Remove the nuts and washers securing the
1
synchronizing cable ends to the base section.
2 Remove the Base Section
3
NOTE: The combined weight of the boom inner mid, outer
mid, and fly sections, including the telescope 4
6818-14 cylinder, is approximately 3680 kg (8110 lb).
FIGURE 4-88 1. Remove the access cover on the top rear of the base
section. Slide the assembly out of the base section
13. Remove the LMI, A2B/cable from boom nose. enough to gain access to the top rear adjustable wear
c. Connect cable connector to side of junction box. pads on the inner mid.

d. Connect “SHD” wire (1) (Figure 4-89) to terminal 1 2. Remove the capscrews, washers, and offset washers
and “CORE” wire (2) (Figure 4-89) to terminal 2. (1) (Figure 4-90) securing each top rear adjustable wear
pad and remove the wear pads, keeper plates and
a. Replace cover to junction box. capscrews from the top of the inner mid. Note location of
wear pads and shims for installation.

11

1
2

FIGURE 4-90

3. On the top front of the base section, remove the two

capscrews securing each kicker plate and remove the
plates.
4. Remove the capscrews securing the outer mid retract
6837 FIGURE 4-89 cable anchor plates to the lower front of the base
section. Remove the cable locknuts and the anchor
14. See PAT manual for proper cable reel tension. plates from the cables.

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12
11

6960-1

21

18

14

9 10

4
13

6
12

7 2

6960-2

19

8 3
5

20

15

16 29 m (95 foot)
17 FIGURE 4-91

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6. Lift up on the front of the assembly and remove the wear

Item Description pads from the pockets in the bottom of the base section.

1 Telescope Cylinder - Rod End 7. Continue to pull the assembly from the base section.
2 Base Section Disconnect Inner Mid Section
3 Telescope Cylinder - Inner Rod
1. At the rear of the inner mid, remove the capscrew and
4 Inner Mid Section cable retainer bushing (1) from the rear of each retract
5 Telescope Cylinder Barrel cable sheave assembly (2) (Figure 4-93).
6 Outer Mid Section
7 Extension Cables
8 Inner Mid Section
9 Sheave Assembly
10 Telescope Cylinder
11 Fly Section Base End
12 Synchronizing Cables
13 Base Section - Rear 4
14 Retraction Cables
15 Sheave
16 Retraction Cable to Fly Section 2
17 Fly Section 1 6960-12

Retraction Cables to Outside Front of Base FIGURE 4-93

18
Section
2. On both sides, remove the capscrews (1) securing each
19 Sheave
retract sheave assembly shaft weldment. Remove the
20 Retract Cables to Outer Mid Section shaft, spacer bushing, sheave assembly, and two thrust
21 Base Section Top and Bottom Wear Pads washers (3) (Figure 4-94). If necessary, remove the
grease fitting from the shaft weldments.
5. Remove the capscrews and washers securing each top
(1) and bottom (2) side wear pads at the front of the base
section (Figure 4-92). Remove wear pads, shims, and
mounting angle (top left side only).

3 2 6960-6

FIGURE 4-94

6960-5 2

FIGURE 4-92

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3. Remove the two capscrews and washers (1) securing capscrews from the top of the outer mid (4)
the cylinder inner rod (2) to the rear of the inner mid (3) (Figure 4-96).
(Figure 4-95).
4. Remove the nuts (4) from the extend cable sled 1
weldment adjusting bolts (Figure 4-95).

3
3 2

4
FIGURE 4-96
8. At the top front of the inner mid, remove the four bolts
and washers (1) securing the synchronizing cable (2)
sheave assembly (3 . Lay the assembly with cables on
top of the outer mid (4) (Figure 4-97).
4

1
6960-13
4 FIGURE 4-95
1
5. Pull the retract cables up through the holes in the bottom
of the inner mid and lay them out to the rear.

Remove the Inner Mid Section

NOTE: Together the boom outer mid and fly sections, and 3
telescope cylinder weigh approximately 2550 kg
(5610 lb).
6. Slide the assembly out of the inner mid enough to gain 3
2
access to the top rear adjustable wear pads on the outer
mid through the hole in the top of the inner mid. 4
FIGURE 4-97
7. Remove the capscrews, washers, and offset washers
(1) securing each top rear adjustable wear pad (2). 9. Remove the capscrews and washers (1) securing the fly
Remove the wear pads, keeper plates (3) and retract cable anchor plates (2) to the lower front of the
inner mid section. Remove the cable locknuts and the
anchor plates (3) from the cables (Figure 4-98).

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14. Remove the two adjusting bolts (1) from the extend
cable sled weldment (2) (Figure 4-100).

7
4
6960-8
5
6 4

2 2 1
3 1 FIGURE 4-98
6960-6
3
10. Remove the capscrews and washers (4) securing each
top (5) and bottom (6) side wear pad at the front of the FIGURE 4-100 4
inner mid (Figure 4-98). Remove wear pads, shims, and 15. Remove the two bolts securing the keeper plate (3) to
mounting angle (top left side only) (7). the bottom of the sled and remove it from the cable ends
11. Lift up on the front of the assembly and remove the wear (Figure 4-100).
pads from the pockets in the bottom of the inner mid. 16. If necessary, remove the retract cables from the inside of
12. Continue to pull the assembly from the inner mid section the inner mid.
until access to the rear of the outer mid is gained to 17. If necessary, remove the two bolts securing the bottom
disconnect the six retract cables. wear pad to the inner mid. Remove wear pad.
13. Remove the cotter pins and pins (1) securing the retract 18. If necessary, remove the two bolts securing each lower
cables (2) to the rear of the outer mid (Figure 4-99). rear side wear pad to the inner mid. Remove wear pads
and shims. Note location of shims for installation.

Remove Outer Mid Section

1. At the rear of the outer mid, remove the capscrew and
cable retainer bushing from above each retract cable
sheave assembly (1) (Figure 4-101).
2. On both sides, remove the capscrews securing each
retract sheave assembly shaft weldment (2)
(Figure 4-101). Remove the shaft, spacer bushing,
sheave assembly, and two thrust washers. If necessary,
remove the grease fitting (3) from the shaft weldments.

1
6960-16
2
FIGURE 4-99

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5. Turn cylinder rod mounting lugs so they are vertical to

clear mounting bracket in the outer mid.
6. Slide the fly assembly out of the outer mid enough to
gain access to the top rear adjustable wear pads on the
fly through the hole in the top of the outer mid.
7. Remove the capscrews washers, and offset washers (1)
securing each top rear adjustable wear pad (2). Remove
the wear pads and wear pad holderfrom the top of the fly
(3) (Figure 4-103).

2 3
1
1
2
3
6960-9
FIGURE 4-101

3. Place blocking (1) under cylinder (2) (Figure 4-102)and

remove the two bolts and washers securing the cylinder
barrel to the rear of the outer mid.

6960-14 FIGURE 4-103

8. At the top front of the outer mid, remove the capscrews

securing the kickback plate (1). Remove the kickback
plate.

2
1 FIGURE 4-102

4. Pull the retract cables up through the holes in the bottom

2
of the outer mid and lay them out to the rear.
FIGURE 4-104
NOTE: Together the boom fly section and telescope
cylinder weigh approximately 1690 kg (3720
pounds).

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9. Remove the capscrews securing each top (1) and 14. If necessary, remove the four fly retract cables from the
bottom (2) (Figure 4-105) side wear pads at the front of inside of the outer mid.
the outer mid. Remove wear pads, shims, and mounting
15. If necessary, remove the two bolts securing the bottom
angle (3) (top left side only).
wear pad to the outer mid. Remove wear pad.
16. If necessary, remove the two bolts securing each lower
rear side wear pad to the outer mid. Remove wear pads
and shims. Note location of shims for installation.

Remove Telescope Cylinder

1. Attach a suitable lifting device to the telescope cylinder.
Raise the cylinder and remove the blocking device from
under the cylinder
1
2. Slide the cylinder out the rear of the fly until the extend
3 cable sheave assembly is aligned with the side access
2 hole in the fly section.
NOTE: The telescope cylinder weighs approximately 899
4 kg (1980 lb).
6960-10 FIGURE 4-105
3. Remove the capscrews and washers (1) securing the
4
10. Lift up on the front of the fly assembly and remove the extend cable keeper plate (2) to the rear of the fly
wear pads (4) (Figure 4-105) from the pockets in the (Figure 4-107). Remove the keeper plate and remove
bottom of the outer mid. the five extend cable ends from the slots in the fly.
11. Continue to pull the assembly from the outer mid section
until access to the rear of the fly is gained to disconnect
the four retract cables.
12. Remove the clip pins and pins (1) securing the four fly
retract cables (2) to the rear of the fly (Figure 4-106).

1 2 1
FIGURE 4-107

4. Lift up on the sheave end of the cylinder and remove the

two lower capscrews securing the support foot
weldment and sheave mounting assembly to the
cylinder barrel. Remove the support foot weldment .
5. If necessary, remove the capscrews securing each wear
pad to the support foot weldment. Remove the wear
pads.

2 6. Continue to pull the cylinder from the fly section until

1 access to the rear of the fly is gained to disconnect the
6960-14 FIGURE 4-106 five extend cables.
7. If necessary, remove the screws securing the bottom
13. If necessary, remove the synchronizing cable and
rear wear pad to the fly. Remove wear pad.
sheave assembly from the top of the outer mid.

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8. If necessary, remove the capscrews (1) securing each NOTE: Apply Loctite 242 to the threads of all attaching
lower rear side wear pad (2) to the fly section (3) hardware except cable ends and cable lock nuts.
(Figure 4-108). Remove wear pads and shims. Note
NOTE: Apply multipurpose grease (MPG) to all wear pads
location of shims for installation.
and the surfaces the wear pads slide on.
NOTE: Use standard torque values specified in Section 1-
INTRODUCTION of this Manual unless otherwise
specified.
NOTE: When installing upper and lower side wear pad,
use shims as necessary so wear pad is within 1.7
mm (0.06 inch) from side plate of next inner
section. Use equal number of shims on each side.

3 Install Telescope Cylinder

1. Measure and mark the center line of the fly section. This
mark will be used to set the adjustable wear pads after
2 the section is installed in the outer mid section.

1 2. If removed from the telescope cylinder (3) assembly,

install the sheave mounting assembly (1) with four
6960-14 capscrews and washers (2). Do not tighten lower two
FIGURE 4-108
capscrews at this time. They will be torqued later.
9. If new cylinder is to be installed, remove the cable
retainer, cables, extend sheave assembly, and sheave 5
mounting assembly from the barrel end of the cylinder. 1
10. If removal of the boom nose sheaves are required, refer
to BOOM NOSE SHEAVES - Removal in this section. 6
11. Refer to BOOM EXTENSION AND RETRACTION
CABLE MAINTENANCE in this section for cable
inspection. 3
4
Boom Nose Sheaves 2
NOTE: Boom nose sheave removal and installation is
identical for both the 31 m (102 foot) boom and the 6748-32
29 m (95 (foot) boom. Refer to BOOM NOSE
SHEAVES in this section. FIGURE 4-109

BOOM ASSEMBLY FOR THE OPTIONAL 29 3. Install the telescope sheave assembly to the telescope
cylinder as follows:
M (95 FOOT) BOOM
a. Using the extend sheave shaft, install the extend
cable sheave assembly with spacer on each side,
CAUTION on the sheave mounting assembly.
When adjusting cables, hold the cable end and turn the b. Install grease fitting (4) (Figure 4-109) in shaft.
nut. do not turn cable. Turning cable while adjusting will
result in damage or failure of cable. c. Lubricate sheave.
4. Route the five extension cables (5) (Figure 4-109) up
and around the extend cable sheave assembly about
one foot on to cylinder. To aid in assembly, secure the
CAUTION cables to the top end of the cylinder by wrapping tape
Install cables in their natural untwisted condition. Do not around the cylinder.
twist cable. Twisting of cable will result in damage or
failure of cable.

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5. Position the cable retainer (6) (Figure 4-109) over the 8. Position the sheave end of the telescope cylinder (with
sheave shaft and secure it to the sheave mounting port block up) at the rear of the fly section. Place the five
assembly with four capscrews and washers. The extend cable dead ends in the slots at the top of the fly
retainer secures the sheave shaft. section and secure them with keeper plate (2),
capscrews and washers (1) (Figure 4-111).
6. Install the lower rear side wear pads and shims (1) on
the fly section with two capscrews (2) each
(Figure 4-110).

1 2 1
FIGURE 4-111

9. Install the telescope cylinder into the fly section until the
sheave end is aligned with the side access hole in the
fly. 4
1 10. Install the two wear pads on the support foot weldment
2 with two capscrews each.

6960-14
11. Lift up on the sheave end of the telescope cylinder and
FIGURE 4-110 remove the two lower capscrews securing the sheave
mounting assembly.
7. Install the bottom rear wear pad on the fly section with
two screws. 12. Install the support foot weldment through the side
access hole and secure with the two removed
capscrews. Torque all four capscrews at this time to
CAUTION standard torque. A 1-1/8” box x 3/4 drive 6” step wrench
The five extend cables must be marked at both ends prior will be required. It can be ordered from Grove using part
to installation. If the cables are not marked, they will be number 9-999-100122. Lower cylinder so it rests on
difficult to install in the correct order. support foot weldment wear pads.
Do not allow the cables to become entangled or overlap. 13. Slide cylinder all the way in. Place blocking under the
Cable or boom failure could result. rear of the telescope cylinder to aid in assembly.
14. Turn rod ends so they are aligned vertically to clear
mounting brackets in outer mid.

Install Outer Mid Section

CAUTION
NOTE: When installing upper and lower side wear pad,
When adjusting cables, hold the cable end and turn the
use shims as necessary so wear pad is within 1.8
nut. do not turn cable.
mm (0.06 inch) from side plate of next inner
Turning or twisting of the cable while adjusting will result section. Use equal number of shims on each side.
in damage or failure of cable.
Install cables in their natural untwisted condition.

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1. Install the lower rear side wear pads and shims (1) on 6. Install a socket head keeper bolt on each side of the half
the outer mid section with two screws (2) each sheave to retain the cable.
(Figure 4-112). Shim per note.
7. Position the front end of the outer mid at the rear of the
fly/telescope cylinder assembly.
8. Using pins, cotter pins, and safety clip (1) attach the four
fly retract cables (2) laying in the bottom of the outer mid
to the lugs in the rear of the fly (3) (Figure 4-114).

6 7 4

1
FIGURE 4-112 3

2. Install the bottom rear wear pad on the outer mid section 2
with two screws.
1
3. Lay four fly retract cables inside the bottom of the outer 6960-14
mid section, threaded ends out the back. FIGURE 4-114

4. Install two extend synchronizing cable sheaves (1) on 9. Slide the fly/telescope cylinder into the outer mid being
the shafts of the sheave mount weld (2). Install a grease careful not to damage any of the cables. As the sections
fitting (3) in each shaft. Lay this assembly on top front of slide together pull the retract cables out the rear of the
outer mid section (Figure 4-113). outer mid. Do not fully slide together.
10. Lift up on the front of the fly and install the bottom front
wear pads (1) (Figure 4-115) in the pockets of the outer
mid.

4
1
2
3
2
FIGURE 4-113

5. Lay out the extend synchronizing cable on top of the 1

outer mid with both threaded ends at the rear and the 6960-10
FIGURE 4-115
loop at the front. Route the looped end through the
inside of the sheaves installed in step 4. Place the 11. Install outer mid front top (4) and bottom (2) side wear
looped end around the fixed half sheave at rear of the pads with two screws each. On top left side attach
outer mid. Be careful to not twist cable. mounting angle (3) with top wear pad screw
(Figure 4-115). Shim as noted during disassembly.

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12. Install kicker plate in top of outer mid with capscrews. 21. Install grease fitting (1) in two shaft weldments. Position
retract cables (2) around sheave assemblies (3)
13. Completely slide assembly together.
(Figure 4-116). Install spacer bushing and install shaft
14. Turn cylinder rod mounting lugs so they are horizontal weldment through mounting lugs in outer mid and the
with port block holding valve being at the top. sheave assembly and spacer bushing (4). Secure each
shaft weldment with a bolt. Apply grease to fittings.
15. Loosen plugs in cylinder port block and manually extend
the inner rod approximately 15 to 20 cm (6 to 8 in). 22. Position cable retainer bushing (5) (Figure 4-116) on top
Tighten plugs. of each sheave assembly and secure with a capscrew.
16. Lift up on end of cylinder to align barrel mounting holes Install Inner Mid Section
with tabs and holes in lugs of outer mid. Secure with two
bolts and washers. 1. Install the lower rear side wear pads and shims on the
inner mid section with two screws each. Shim per note.
17. Remove any blocking under cylinder.
2. Install the bottom rear wear pad on the inner mid section
18. Through the top access hole in the outer mid, position
with two screws.
the two adjustable wear pads (4) on the top rear of the
fly. Install each wear pad holder (5) and loosely install 3. Lay outer mid retract cables inside the bottom of the
each with two capscrews and washers (6) inner mid section, threaded ends out the back.
(Figure 4-114). Install offset washers, capscrews and
washers (7). Using the offset washers, adjust the wear
pads such that the wear pads are within 1 mm (0.03 in)
4
from each side plate of the next outer section. Tighten
the offset washer and capscrews.
19. Route the four fly retract cables through the holes in the
bottom of the outer mid and pull them toward the front of
the assembly. Install the anchor plates on the cables
with cable locknuts. Be careful not to tangle cables.
20. Apply grease to four thrust washers and place one on
each side of the two groove retract cable sheave
assemblies. Grease will keep the thrust washer in place
during installation.
1 4

2 6960-6
3
FIGURE 4-117

4. Position the extend cable sled weldment (2) on the five

large extend cables (2), slots down, and secure the
cables to the sled with keeper plate and two bolts (3)
(Figure 4-117). Be careful not to tangle cables.
5. Install two long adjusting bolts (4) through holes in sled,
heads from the front (Figure 4-117).
6. Temporarily fasten the sled up under the cylinder so it
5 does not interfere with installation.
2 7. Position the front of the inner mid at the rear of the
1 4
6960-9 3 assembly.
FIGURE 4-116

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BOOM TM500E-2 SERVICE MANUAL

8. Using pins and cotter pins (1) (Figure 4-118), attach the 11. Install inner mid front top (2) and bottom (3) side wear
outer mid retract cables (2) laying in the bottom of the pads with two screws each. On top left side attach
inner mid to the lugs in the rear of the outer mid. mounting angle (4) with bottom wear pad screw
(Figure 4-119). Shim per note.
12. Attach fly retract cable anchor plates (5) to front of inner
mid with two bolts each (6) (Figure 4-119).
13. Using four bolts and washers, attach the extend
synchronizing cable sheave assembly laying on top of
the outer mid to top front inside of the inner mid.
14. Through the top access hole in the inner mid, position
the two adjustable wear pads (2) on the top rear of the
outer mid (4). Install each wear pad holder (3) and
loosely install each with two capscrews and washers.
Install offset washers, capscrews, and washers (1)
(Figure 4-120). Using the offset washers, adjust the
wear pads such that the wear pads are within 1 mm
(0.03 in) from each side plate of the next outer section.
Tighten the offset washer and capscrews.
1
6960-16
2
FIGURE 4-118 1

9. Slide the assembly into the inner mid being careful not to
damage any of the cables. As the sections slide together
pull the retract cables out the rear of the inner mid. Do
not fully slide together.
10. Lift up on the front of the assembly and install the bottom
front wear pads (1) in the pockets of the inner mid
(Figure 4-119).
3 2

4
FIGURE 4-120

Connect Inner Mid Section

1. Route outer mid retract cables through the holes in the
bottom of the inner mid and pull them toward the front of
the assembly. Install the anchor plates on the cables
with cable locknuts. Be careful not to tangle cables.
2. While continuing to slide together, route extend cable
4 sled adjusting bolts through mounting holes in rear of
inner mid. Install nuts on the bolts.
2
3 3. Align the cylinder inner rod (1) mounting holes with the
6960-8
tabs and holes in the rear of the inner mid and secure
5 1
6 FIGURE 4-119 with two capscrews and washers (2) (Figure 4-121).

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2
3

1
6960-5

FIGURE 4-121 2
4. Apply grease to four thrust washers and place one on 4 5 FIGURE 4-122
each side of the three groove retract cable sheave
assemblies. Grease will keep the thrust washer in place
during installation.
3. Attach outer mid retract cable anchor plates (4) to front
of base section with two capscrews (5) each
4
(Figure 4-122).
5. Install grease fitting in two shaft weldments. Position
retract cables around sheave assemblies, install spacer 4. Install kicker plate on top of each side of base section
bushing, and install shaft weldment through mounting with two capscrews each.
lugs in inner mid and the sheave assembly and spacer 5. Through the top access hole in the base section,
bushing. Secure each shaft weldment with a capscrew. position the two adjustable wear pads on the top rear of
Apply grease to fittings. the inner mid. Install each wear pad holder and loosely
6. Position cable retainer bushing to the rear of each install each with two capscrews and washers. Install
sheave assembly and secure with a capscrew offset washers, capscrews, and washers. Using the
offset washers, adjust the wear pads such that the wear
7. Loosen plugs in cylinder port block and manually extend pads are within 1mm (0.03 in) from each side plate of the
the outer rod approximately 15 to 20 cm (6 to 8 in). next outer section. Tighten the offset washer and
Tighten plugs. capscrews. Install top access hole cover.
8. Position the front of the base section at the rear of the 6. Continue to slide together and route synchronizing cable
assembly and slide together being careful not to threaded ends through holes in rear of base section.
damage any cables. Install locknuts on cable ends.
Install Base Section 7. Align cylinder outer rod mounting holes with mounting
holes in rear of base section and secure with two bolts
1. Lift up on the front of the assembly and install the bottom and washers.
front wear pads in the pockets of the base section.
8. Reattach the LMI, A2B/ Length cable to the boom nose.
2. Install base section front top (1) and bottom (2) side See PAT manual for proper cable reel tension.
wear pads with two screws each (Figure 4-122). On top
left side attach mounting angle (3) with both wear pad 9. Refer to Section 9 - LUBRICATION section for
screws. Shim per note. lubrication of wear pads and other plates on boom.
10. Install the boom in accordance with the INSTALLATION
procedures outlined in this section.

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BOOM INSTALLATION 7. Remove the hard cap or plugs in the hydraulic lines and
openings and connect the hydraulic lines to the
Do not attempt to work on the boom without experienced telescope cylinder.
supervision.
8. Connect all electrical wiring to the boom.
NOTE: Boom installation procedures are identical for the
standard 31 m (102 foot) boom and the optional 29 9. Elevate the boom slightly with the lifting device so that
m (95 foot) boom. the lift cylinder can be extended approximately 30.48 cm
. (12 in) to allow for insertion of the lift cylinder rod end to
the lift cylinder lift box on the bottom of the boom.
10. Activate the hydraulic system and extend the lift cylinder
DANGER rod enough to slide in the lift box (Figure 4-124).
To prevent serious injury or death, always wear personal
protective equipment; i.e., a hard hat, eye protection,
gloves and metatarsal boots.

NOTE: The complete boom assembly without the

swingaway boom extension attached weighs
approximately 4900 kg (10,803 pounds) .
1. Attach a lifting device to the boom to provide for equal
weight distribution.
2. Raise the boom off of the blocking or cribbing high
enough to clear the crane and lower to crane
superstructure assembly.
3. Align the boom with the superstructure assembly.
4. Insert the boom pivot shaft and thrust washers through
superstructure assembly and boom.
5. Insert the clip pin and retaining pin (1) (Figure 4-123)
6818-32 4
securing the boom pivot shaft (2) on the boom to the 3 1, 2
superstructure assembly. FIGURE 4-124

11. Install the upper lift cylinder shaft (3) (Figure 4-124)
12. Install the bolt (1) and washer (2) (Figure 4-124) to the
side of the lift box (3) and secure the upper lift cylinder
shaft on the boom.
1
13. Remove the boom lifting device.
14. Ensure the Boom is fully retracted.

DANGER
Wear gloves when handling wire rope.

3
SWINGAWAY EXTENSION INSTALLATION
6835
FIGURE 4-123

6. Install the grease fittings (3) (Figure 4-123) on the pivot

shaft and add grease per requirements in Section 9 -
LUBRICATION in this manual. DANGER
To prevent serious injury or death, always wear personal
protective equipment; i.e., a hard hat, eye protection,
gloves and metatarsal boots.

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DANGER DANGER
Boom angles are used to control speed at which When removing the boom extension, ensure that all
extensions swing during erecting and stowage. Improper personnel and equipment are kept clear of the swing path.
boom angles will cause uncontrollable swing speeds of
extension. 4. Raise the swingaway extension to a safe height to move
to the boom and move the extension into place ahead of
NOTE: Tag line used in these procedures is to control the the boom nose.
movement of the boom extension.
5. Using the rope attached to the top of the boom
extension, manually align the boom attachment to the
boom extension anchor fittings (2) (Figure 4-125).

DANGER 6. Move the boom slightly up or down to help align the

boom attachment and boom extension anchor fittings (2)
Before attempting to remove the boom extension; read
(Figure 4-125).
and strictly adhere to all danger decals installed on the
boom/boom nose, boom extension, and stowage 7. Insert the right side attachment pins (1) (Figure 4-125)
brackets. through the boom attachment and boom extension
anchor fittings (2) (Figure 4-125). Install the retainer
4
NOTE: Some illustrations and photos show the standard clips in the attachment pins.
31 m (102 foot). The same boom extension
removal procedure applies to the 29 m (95 foot)
unless otherwise noted.
1. Crane should be set up on outriggers using normal
setup procedures as found in the Operator’s Manual.
1
a. Fully retract boom.
b. Lower boom to horizontal extending over the front of
the crane.
2. Attach a lifting devise to the lifting lugs on the swingaway
extension.
3. Attach a length of rope to the boom extension tip to aid in 2
swinging the boom extension into place ahead of the
boom nose.

6814-4

FIGURE 4-125

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8. Extend the boom approximately 51 to 64 cm (20 to 25”).

Make certain that the boom extension stowage lugs will
line up in front of the guide pins (1) (Figure 4-126) and CAUTION
ramp (2) (Figure 4-127) on the stowage brackets when Do not allow the boom extension to slam into the stowage
the boom extension is positioned to the side of the bracket when swinging into the stowed position.
boom.
10. Using the rope attached to the tip of the boom extension,
manually swing the extension to the side of the boom.
11. Align the stowage lugs on the boom extension with the
guide pins and ramp (2) (Figure 4-127) on the stowage
brackets and fully retract the boom.
12. Install the hitch pin and clip pin (1) (Figure 4-127)
securing the boom extension to the rear stowage
1 bracket.
13. Remove the attachment pins and clip pins (1)
(Figure 4-128) from the anchor and attachment fittings
(2) (Figure 4-128) on the right side of the boom nose and
stow them in the base of the boom extension. Stow left
side attachment pins and clips in outside attachment
6821-3 FIGURE 4-126 fitting on swingaway.

9. Ensure the hitch pin and clip pin (1) (Figure 4-127) are
removed from the rear stowage bracket.

6821-1

FIGURE 4-127
6814-4

FIGURE 4-128

14. On the rear stowage bracket, remove the retainer pin (1)
DANGER
(Figure 4-129) securing the sliding support in the “OUT”
When stowing the boom extension, ensure that all position. Push in on the handle (2) (Figure 4-129) to
personnel and equipment are kept clear of the swing path. push the swingaway against the rear of the boom
15. Disengage the swingaway anchor fittings from the boom
nose attachment lugs. Install the retainer pin (1)
(Figure 4-129) securing the sliding support in the “IN”
position.

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TM500E-2 SERVICE MANUAL BOOM

Extend Cable Adjustment

Do not attempt to work on the boom without experienced
supervision.

DANGER
To prevent serious injury or death, always wear personal
protective equipment; i.e., a hard hat, eye protection,
1 gloves and metatarsal boots.

1. With the boom at any length, extend the boom

6821-2 approximately 150 mm (6 inches) to cause a slack
2 condition in the retract cables.
FIGURE 4-129
2. Set the retract cable adjustment nuts (Figure 4-130) to
16. Slightly raise and/or lower the boom to help control the approximately 1.36 Nm (1 pound-foot).
boom extension.
17. Rig the boom nose and hoist cable as desired. Refer to Mid Retract 4
Section 4 - Set-up and Installation in your Operator’s Fly Retract
Manual.
18. Align the main and auxiliary hoists to the boom per
Section 5 - Hoist and Counterweight in this manual
19. Install the hook block or headache ball.
20. Perform all adjustments and maintenance for the boom.

BOOM CABLE ADJUSTMENT FOR THE 31 M

(102 FOOT) BOOM
Do not attempt to work on the boom without experienced
supervision.

DANGER
To prevent serious injury or death, always wear personal
protective equipment; i.e., a hard hat, eye protection, FIGURE 4-130
gloves and metatarsal boots.
3. Extend the boom fully and then retract the boom
approximately 50 mm (2 inches) each section. The
The extension cables must be adjusted before the retract
upper synchronize extend cables will now be at their
cables can be adjusted. Use the following procedure to
loosest condition.
ensure that all cables are correctly adjusted.

CAUTION
When adjusting cables, use two wrenches. Hold the “flat”
on the cable and turn the adjusting nut.
Do not allow the cables to twist. Cable failure could result.

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BOOM TM500E-2 SERVICE MANUAL

4. At the base end of the base section, adjust the upper

synchronize extend cables a until they are aligned with
the small access hole above the large access hole on
the base section. The cables should not sag below the DANGER
access hole (Figure 4-131).
To prevent serious injury or death, always wear personal
protective equipment; i.e., a hard hat, eye protection,
gloves and metatarsal boots.

1. Retract the boom fully. All sections should stop at the

same time and come to rest on the next inner section.
6838-9 a. If one or more sections do not fully retract, tighten
View Cable Here the retract cable adjustment nuts for retract cables
FIGURE 4-131 of that section.
5. Retract the boom until the extension cable adjustment 2. Extend the boom approximately 150 mm (6 inches).
bolt and locknuts are accessible. Retract the boom. Check to insure that all sections come
to rest at the same time.
6. Lower the boom to a horizontal position.
a. Continue adjusting until all sections “Bottom Out” at
7. Adjust the cables until there is approximately 13 mm (.5 the same time.
inches) of sag as viewed from the access holes in the
boom sides. Check cables to insure that they are tightened equally.
8. Lock all adjustment points with locknuts (Figure 4-132).
BOOM CABLE ADJUSTMENT FOR THE 29 M
(95 FOOT) BOOM
NOTE: For more detailed information concerning
Extend Cable Adjust Nut maintenance of the extension and retraction
cables, refer to Wire Rope in Section 1 -
INTRODUCTION.

Extend Cable Adjustment

Do not attempt to work on the boom without experienced
supervision.

DANGER
To prevent serious injury or death, always wear personal
protective equipment; i.e., a hard hat, eye protection,
gloves and metatarsal boots.

1. With the boom at any length, extend the boom

approximately 150 mm (6 inches) to cause a slack
condition in the retract cables.
2. Torque the retract cable adjustment nuts at the front of
the inner mid and base sections to approximately 1.36
FIGURE 4-132 Nm (1 pound-foot).

Retract Cable Adjustment CAUTION

Do not attempt to work on the boom without experienced When adjusting cables, hold the cable end and turn the
supervision. nut. Do not turn cable. Turning cable while adjusting will
result in damage or failure of cable.

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NOTE: The extension cables must be adjusted properly BOOM MAINTENANCE

before the retract cables can be adjusted.
1. Extend and set the outriggers, ensuring the crane is Functional Test Of The Boom
level. 1. Activate the hydraulic system and check for proper
2. Ensure the boom is over the front and at a horizontal operation and any leaks.
position (boom angle elevation 0 degrees). 2. Ensure the boom will extend and retract properly.
3. Extend the boom fully and then retract the boom 3. Ensure the lift cylinder will not allow the boom to drift
approximately 150 mm (6 inches). down until the operator lowers it.
4. Adjust the two extend synchronizing cables at the top 4. Ensure all electrical components disconnected during
rear of the base section. Adjust until approximately 90 removal are operating properly.
mm (3.5 inches) of threaded cable end is exposed. Lock
in place with jam nuts. Boom Inspection
5. To adjust the five extend cables, fully retract the boom to Do not attempt to work on the boom without experienced
have access to the two extend cable sled adjusting bolts supervision.
at the back of the inner mid section through the rear of
the base section. Adjust these bolts to have 12 mm (0.5
inches) of bolt thread exposed from the sled.
6. Check through the side access holes in the boom, that
4
DANGER
the fly extension cables have approximately 12 mm (0.5
To prevent serious injury or death, always wear personal
in) slack. Lock in place with jam nuts.
protective equipment; i.e., a hard hat, eye protection,
7. Extend each boom section approximately 100 cm (3 ft). gloves and metatarsal boots.
Adjust the six outer mid retract cables at the front of the
base section to have 6 cm (2.5 in) of threaded cable end 1. Visually inspect telescoping sections for adequate
exposed from the retract cable anchor plate. Adjust the lubrication of all wear surfaces.
four fly retract cables at the front of the inner mid section
2. Observe extended sections for evidence of cracks,
to have 7.5 cm (3 in) of threaded cable end exposed
warping, or other damage.
from the retract cable anchor plate.
3. Periodically check security of boom wear pads.
Retract Cable Adjustment
4. Check boom nose sheaves for security and freedom of
1. Extend each boom section approximately 900 mm (35.4 movement.
inches).
Boom Alignment And Servicing
2. Adjust the outer mid retract cables at the front of the
base section to have approximately 65 mm (2.5 inches) Do not attempt to work on the boom without experienced
of threaded cable end exposed from the retract cable supervision.
mounting plate. .
3. Adjust the fly retract cables at the front of the inner mid
section to have approximately 76 mm (2.9 inches) of
threaded cable exposed from the retract cable anchor DANGER
plate. To prevent serious injury or death, always wear personal
4. Fully retract the boom. All sections should bottom out on protective equipment; i.e., a hard hat, eye protection,
the next inner section at the same time. gloves and metatarsal boots.

5. If one or more sections do not fully retract, tighten the Boom alignment is achieved by adjustment of the wear pads
adjusting nut of the retraction cables for the section until located at various points in the boom assembly. Adjustment
the section bottoms out. Repeat until al sections bottom of the wear pads is as follows:
out at the same time.
1. Fully extend the boom horizontally.
6. Check through the side access holes in the boom, that
the tension is the same for all retract cables for a given 2. Lubricate the boom bottom plates (sides and bottom).
section. Lock all adjustments with jam nuts.

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BOOM TM500E-2 SERVICE MANUAL

NOTE: DEFLECTION EXAGGERATED

FOR ILLUSTRATION PURPOSES

Boom Alignment FIGURE 4-133

3. Shim the front lower side wear pads to within 1.52 mm

(0.06 in) from side plate of next inner boom section, then
shim the front upper wear pads in the same manner. Use
equal number of shims on each side. DANGER
To prevent serious injury or death, always wear personal
protective equipment; i.e., a hard hat, eye protection,
CAUTION gloves and metatarsal boots.
When extending and retracting the boom during
alignment, movement should be stopped if a restriction is NOTE: For more detailed information concerning
encountered. re-shim wear pads as necessary to provide maintenance of the extension and retraction
free travel of the affected boom section(s). cables, refer to Wire Rope in SECTION 1 in this
manual.
4. Retract and extend the boom; check for the high point
where the boom has brushed the wear pads at the Inspection
widest point.
Do not attempt to work on the boom without experienced
5. Retract the boom sections to align the high point on the supervision.
boom section with the adjacent wear pads.
6. Add or subtract shims as necessary (Table 4-1).

Table 4-1 DANGER

Example Never handle wire rope with bare hands. Injury to hands
could result.
If the boom deflects to the left:
1 The forward left wear pad would be shimmed in.
The rear left adjustable wear pad would be
2 adjusted out, away from the internal boom
section.
DANGER
To prevent serious injury or death, always wear personal
3 The forward right wear pad will be shimmed out. protective equipment; i.e., a hard hat, eye protection,
4 The right rear adjustable pad adjusted in gloves and metatarsal boots.

7. Attach a weight and extend the boom full length. Check The following information is tak en from a National
for side deflection (Figure 4-133). Consensus standard as referenced by Federal Government
Agencies.
EXTENSION AND RETRACTION CABLE All wire rope will eventually deteriorate to a point where it is
MAINTENANCE no longer usable. Wire rope shall betaken out of service
Do not attempt to work on the boom without experienced when any of the following conditions exist.
supervision. • In running ropes, six randomly distributed broken
wires in one lay or three broken wires in one strand
in one lay.

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TM500E-2 SERVICE MANUAL BOOM

• Wear of one-third the original diameter of outside • 1.19 mm (0.047-in) for diameters 14 to 19 mm
individual wires. Kinking, crushing, bird caging, or (0.5625 to 0.75-in) inclusive.
any other damage resulting in distortion of the rope
• 1.59 mm (0.063-in) for diameters 22 to 29 mm
structure.
(0.875 to 1.125 in) inclusive.
• Evidence of any heat damage from any cause.
• 2.38 mm (0.094-in) for diameters 32 to 38 mm (1.25
• Reductions from nominal diameter of more than: to 1.5 in) inclusive.
• 0.4 mm (0.016-in) for diameters up to and including • In standing ropes, more than two broken wires in
8 mm (0.3125-in). one lay in sections beyond end connections or more
than one broken wire at an end connection.
• 0.79 mm (0.031-in) for diameters 10 and 13 mm
(0.375 and 0.5-in) inclusive.

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BOOM TM500E-2 SERVICE MANUAL

TELESCOPE CIRCUIT TROUBLESHOOTING

Table 4-2

SYMPTOM PROBABLE CAUSE SOLUTION

1. Erratic operation of a. Low hydraulic oil level. a. Replenish hydraulic oil to proper level.
extending
b. Damaged relief valves. b. Repair or replace relief valves.
telescoping
cylinder. c. Air in telescope cylinder. c. Bleed by lowering telescope cylinder
below horizontal.
d. Low engine rpm. d. Increase engine rpm to recommended
setting.
e. Lack of lubrication on boom sections. e. Properly lubricate all boom sections.
f. Extremely tight boom extension f. Inspect and properly lubricate boom
sheaves. extension sheaves.
g. Improper boom alignment caused from g. Reduce and properly hoist load.
side loading.
h. Worn boom wear pads. h. Replace wear pads and properly
lubricate.
i. Distorted boom section. i. Replace distorted section.
j. Damaged telescope cylinder. j. Repair or replace cylinder.
k. Clogged, broken, or loose hydraulic k. Clean, tighten, or replace lines or
lines or fittings. fittings.
l. Damaged control valve. l. Repair or replace control valve.
2. Erratic operation of a. Low hydraulic oil level. a. Replenish hydraulic oil to proper level.
retracting
b. Damaged relief valve. b. Repair or replace relief valve.
telescoping
cylinder. c. Air in cylinder. c. Bleed by lowering telescoping cylinder
below horizontal and cycle telescope
cylinder.
d. Low engine rpm. d. Increase engine rpm to recommended
setting.
e. Lack of lubrication. e. Properly lubricate all boom sections.
f. Check valve malfunctioning. f. Repair or replace check valve.
g. Improper boom alignment caused from g. Reduce and properly hoist load.
side loading.
h. Extremely tight boom retraction h. Inspect and properly lubricate.
sheave.
i. Distorted boom section. i. Replace distorted section.
j. Worn boom wear pads. j. Replace wear pads and properly
lubricate.
k. Bent cylinder rod(s). k. Replace cylinder rod(s) and all cylinder
seals.
l. Scored cylinder barrel. l. Repair or replace cylinder barrel.
m. Damaged piston seals. m. Replace all cylinder seals.
n. Loose or damaged piston(s). n. Replace all seals and re-torque or
replace piston(s).

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SYMPTOM PROBABLE CAUSE SOLUTION

3. Telescope cylinder a. Low hydraulic oil level. a. Replenish oil to proper level.
will not extend.
b. Relief valve malfunctioning. b. Repair or replace relief valve.
c. Excessive load. c. Reduce load.
d. Clogged hose and fittings. d. Replace hose or fittings. (Refer to
Manitowoc CraneCARE Parts Manual).
e. Broken valve spool. e. Replace valve.
f. Damaged piston seals. f. Replace all cylinder seals.
g. Damaged piston(s). g. Replace piston(s) and all cylinder
seals.
h. Bent boom section(s). h. Replace damaged boom section(s).
i. Broken hydraulic pump coupling. i. Replace broken hydraulic pump
coupling.
j. Worn or damaged hydraulic pump j. Repair or replace pump section.
section.
4. Telescope cylinder a. Low hydraulic oil level. a. Replenish oil to proper level.
4
will not retract.
b. Relief valve damaged. b. Repair or replace relief valve.
c. Excessive load. c. Reduce load. (Refer to load chart).
d. Inoperative check valve. d. Replace check valve.
e. Clogged hose and fittings. e. Replace hose or fittings. (Refer to
Manitowoc CraneCARE Parts Manual).
f. Broken valve spool. f. Replace valve section.
g. Broken piston(s). g. Replace piston(s) and all cylinder
seals.
h. Damaged piston seals. h. Replace all cylinder seals.
i. Bent boom section(s). i. Replace damaged boom section(s).
j. Broken hydraulic pump coupling. j. Replace broken hydraulic pump
coupling.
k. Worn or damaged hydraulic pump. k. Repair or replace pump.
l. Broken hydraulic pump shaft. l. Replace pump shaft.

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BOOM TM500E-2 SERVICE MANUAL

LIFT CIRCUIT TROUBLESHOOTING

Table 4-3

Symptom Probable Cause Solution

1. Boom raises a. Low hydraulic oil. a. Replenish hydraulic oil to proper level.
erratically.
b. Low engine rpm. b. Increase engine rpm to recommended
setting.
c. Main relief valve damaged. c. Replace relief valve.
d. Air in cylinder rod. d. Bleed cylinder rod.
e. Bent boom pivot shaft. e. Replace pivot shaft.
2. Boom lowers a. Low hydraulic oil. a. Replenish hydraulic oil to proper oil
erratically. level.
b. Low engine rpm. b. Increase engine rpm to recommended
level.
c. Circuit and/or relief valve inoperative. c. Repair or replace relief valve.
d. Air in hydraulic cylinder. d. Bleed air from cylinder.
e. Damaged hydraulic pump section. e. Repair or replace pump section.
3. Boom raises a. Low hydraulic oil level. a. Replenish hydraulic oil to proper level.
slowly.
b. Low engine rpm. b. Increase and maintain engine rpm.
c. Damaged relief valve. c. Repair or replace relief valve.
d. Extremely cold hydraulic oil. d. Operate unit to bring oil to operating
temperature.
e. Improper hose or fittings, installed. e. Replace hose or fittings. (Refer to
Manitowoc CraneCARE Parts Manual).
f. Operating two functions with in the f. Feather controls to obtain desired
same control valve bank assembly. speed of both functions.
g. Restriction in return hose. g. Replace return hose.
h. Cylinder piston seals leaking. h. Replace all cylinder seals.
i. Scored cylinder barrel. i. Hone or replace barrel.
j. Worn hydraulic pump section. j. Repair or replace pump section.
4. Boom lowers a. Low hydraulic oil level. a. Replenish hydraulic oil to proper level.
slowly.
b. Low engine rpm. b. Increase rpm to recommended level.
c. Damaged relief valve. c. Repair or replace relief valve.
d. Operating two functions within the d. Feather controls to obtain desired
same control valve bank assembly. speed of both functions.
e. Extremely cold hydraulic oil. e. Operate unit to bring oil to operating
temperature.
f. Improper hose or fittings installed. f. Replace hose or fittings. (Refer to
Manitowoc CraneCARE Parts Manual).
g. Restriction in return hose. g. Replace return hose.
h. Cylinder piston seals worn. h. Replace all cylinder seals.
i. Scored cylinder barrel. i. Hone or replace barrel.

4-54 PRELIMINARY Published 10-05-2007, Control # 151-00

TM500E-2 SERVICE MANUAL BOOM

Symptom Probable Cause Solution

Boom lowers j. Worn hydraulic pump section. j. Repair or replace pump section.
slowly. (Continued)
k. Piston rod broken (loose from piston). k. Replace piston rod and all cylinder
seals.
5. Boom will not raise. a. Low hydraulic oil. a. Replenish hydraulic oil to proper level.
b. Main relief valve or circuit relief valve b. Repair or replace relief valve.
damaged.
c. Excessive load. c. Reduce load as required.
d. Worn or damaged hydraulic pump d. Repair or replace pump section.
section.
e. Broken pump shaft. e. Replace pump shaft and seals.
f. Broken pump drive coupling. f. Replace drive coupling.
g. Broken control valve spool. g. Replace control valve.
6. Boom will not a. Low hydraulic oil. a. Replenish hydraulic oil to proper level.
lower.
b. Main relief valve or circuit relief valve
damaged.
b. Repair or replace relief valve. 4
c. Worn or damaged hydraulic pump c. Repair or replace pump section.
section.
d. Broken pump shaft. d. Replace pump shaft and seals.
e. Broken pump drive coupling. e. Replace drive coupling.
f. Broken control valve spool. f. Replace control valve.

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BOOM TM500E-2 SERVICE MANUAL

LIFT CYLINDER MAINTENANCE Lift Cylinder Installation

Lift Cylinder Removal 1. Attach an adequate lifting device to the lift cylinder and
position the cylinder over the attach fitting on the
NOTE: Refer to Section 2 - HYDRAULIC SYSTEM for lift turntable.
cylinder disassembly and assembly procedures.
NOTE: Prior to installing cylinder, measure the distance
Maintenance not requiring removal of the cylinder
between mounting faces on the turntable
barrels, such as packing, may be performed
(Dimension A) (Figure 4-134). Shim as required
without removing the cylinders from the turntable.
per (Table 4-4).
However, all disassembly and assembly should be
conducted in a clean dust-free area. 2. Lower the lift cylinder into the attach fittings on the
turntable and align the lift cylinder bushing with the
1. Extend and set the outriggers and level the crane.
attach fitting holes.
2. Elevate the boom slightly so that the lift cylinder is
3. Install lower pivot shaft (Figure 4-134) with tapped hole
extended approximately 0.3 m (1 ft).
on the right side, side opposite the cab. Shim with thrust
washers as required per (Table 4-4).

Table 4-4
DANGER
The weight of the lift cylinder is approximately 578 kg R.H. L.H.
Dimension A
(1274 pounds). Ensure that adequate and properly tested Shims Shims
lifting devices are used to remove the lift cylinder. ≤ 357 mm ( 14.0 inches) 0 0
358 - 360 mm (14.0 to 14.1 inches) 1 0
3. Ensure the boom is fully supported by placing blocking
or cribbing under the boom. Rest the boom on the 361 - 363 mm (14.2 to 14.3 inches) 1 1
blocking or cribbing.
364 - 367 mm (14.3 to 14.4 inches) 2 1
4. Remove the capscrews and nuts securing the lift 368 - 370 mm (14.4 to 14.5 inches) 2 2
cylinder upper pivot shaft to the boom (Figure 4-134).
≤ 371 mm (14.6 inches) 3 2
5. Remove the capscrews and nuts securing the lift
cylinder lower pivot shaft to the turntable. 4. Install the lift cylinder lower pivot shaft and secure with
the capscrew and locknut. Torque capscrew 212 to 230
6. Attach an adequate lifting/supporting device to the lift
Nm (156 to 170 pounds-foot).
cylinder being removed.
5. Connect the extend and retract hoses to the lift cylinder.
7. Remove the upper pivot shaft. Activate the hydraulic
system and retract the lift cylinder enough to clear the 6. Activate the crane’s hydraulic system and align the lift
upper attach point. cylinder rod end with the attach point on the boom.
Install the upper pivot shaft through the cylinder and
8. Tag and disconnect all the hydraulic lines to the cylinder.
boom attach points. Shut down the engine.
Cap or plug all openings with high pressure fittings.
7. Secure the upper pivot shaft with the capscrew and nuts.
9. Pull the lower lift cylinder pivot shaft out far enough to
Torque capscrews 212 to 230 (156 to 170 pounds-foot).
remove the cylinder.
8. Remove the lifting and supporting devices from the
10. Move the lift cylinder to a clean work area.
boom and lift cylinders. Activate the hydraulic system
Lift Cylinder Disassembly And Assembly and check the lift cylinders for proper operation and any
leaks.
Disassembly and assembly procedures of the lift cylinder
9. Lubricate the pivot shafts. Refer to Section 9 -
holding valve, and control valve are provided in SECTION 2
LUBRICATION.
under Lift Cylinder, Holding Valves and Directional Control
Valves.

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TM500E-2 SERVICE MANUAL BOOM

1 5
5

Dimension A

6997-2
4
Detail A

8 1

6997-1

7
6

9 2653 mm (104 inches) Retracted 2

1994 mm 979 inches) Stroke FIGURE 4-134
See Detail A

Item Description Item Description

1 Telescope Cylinder - Barrel End 6 Turntable
2 Lower Shaft 7 Boom
3 Capscrew 8 Telescope Cylinder - Rod End
4 Nut 9 Upper Shaft
5 Thrust Washer

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BOOM TM500E-2 SERVICE MANUAL

THIS PAGE BLANK

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 SECTION 5
HOIST AND COUNTERWEIGHT
TABLE OF CONTENTS
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Warm-up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Functional Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Hoist to Boom Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Piston Motor and Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Idler Drum and Cable Follower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 5
Idler Drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Cable Follower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Complete Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Hoist Drum Rotation Indicator System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Counterweight Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13

5-i
HOIST AND COUNTERWEIGHT TM500E-2 SERVICE MANUAL

5-ii
TM500E-2 SERVICE MANUAL HOIST AND COUNTERWEIGHT

SECTION 5
HOIST AND COUNTERWEIGHT
DESCRIPTION motor control valve partially closes to restrict the oil leaving
the motor until a balance occurs. This results in the load
One hoist is available; the HP15C-17G (Figure 5-1). The lowering at a uniform speed based on the position of the
hoist incorporates one variable displacement piston motor hoist control lever.
which drives a reduction unit within the hoist.
During stopping, when the hoist down flow ceases, the pilot
The hoist utilizes planetary reduction with a multi-disc pressure holding the motor control valve open decays to
automatic brake that is spring applied and hydraulically zero and the motor control valve spool closes, thus blocking
released. An overrunning clutch allows the hoist to be raised all flow of oil out of the hoist motor. This same pressure
without releasing the brake while at the same time holding decay allows the spring applied pressure released hoist
the load until there is sufficient pressure to release the brake brake to apply when the load is fully stopped. This brake acts
when hoisting down. The hoist motor controls both speed as a “parking brake” and holds the load in the stopped
and torque of the hoist. position.
There are two modes in which the hoist operates. One mode
is high speed. The pilot solenoid valve shifts the selector Warm-up Procedure
spool on the motor to provide minimum motor displacement. A warm-up procedure is recommended at each start-up and
This gives high line speed and low torque. is essential at ambient temperatures below +40°F (4°C).
The second mode is low speed. The pilot solenoid valve The prime mover should be run at its lowest recommended
shifts the selector spool on the motor to provide maximum RPM with the hydraulic hoist control valve in neutral allowing
motor displacement. This gives low line speeds and high sufficient time to warm up the system. The hoist should then
torque. be operated at low speeds, forward and reverse, several
times to prime all lines with warm hydraulic oil, and to 5
THEORY OF OPERATION circulate gear lubricant through the planetary gear sets.
The hoist assembly is controlled by hydraulic remote
controllers located in the superstructure cab. When the
control lever in the cab is moved from neutral, it causes the
main hoist section of the directional control valve to shift the DANGER
valve spool to route hydraulic flow to the hoist motor control Failure to properly warm up the hoist, particularly under
valve. The hoist motor control valve is used to stop or slow low ambient temperature conditions, may result in
the hoist when the load is trying to drive the hoist down too temporary brake slippage due to high back pressures
quickly. The motor control valve is piloted open by the hoist attempting to release the brake, which could result in
down pressure. If the load lowers faster than the flow of oil in property damage, severe personal injury or death.
the hoist down line, the pilot pressure decreases and the

MAINTENANCE

DANGER
If the hoist exhibits any signs of erratic operation, or load
difficulties (i.e. load creeping or chattering), perform
troubleshooting tests and make repairs before continuing
operation, otherwise property damage or severe personal
injury or death could result.

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HOIST AND COUNTERWEIGHT TM500E-2 SERVICE MANUAL

Troubleshooting

Symptom Probable Cause Solution

1. The hoist will not a. The problem could be a plugged or a. Remove the pilot hose and fitting
lower the load or loose pilot orifice. The pilot orifice is a from the brake valve. Use a 5/32 inch
not lower the load small pipe plug with a hole drilled Allen wrench to remove the pilot
smoothly. through it, located behind the pilot port orifice. The diameter of the orifice is
fitting on the brake valve. If it becomes approximately 0.020 inches. Clean
plugg ed, it will prevent th e pilo t and install the pilot orifice tightly in
pressure from the manifold from the brake valve.
opening the brake valve. If it becomes
loose, it will allow an unregulated
amount of oil in to operate the brake
valve which causes erratic brake valve
operation.
b. The friction brake may not be b. Check brake cylinder seal as follows:
releasing as a result of a defective
• Disconnect the swivel tee from the
brake cylinder seal.
brake release port. Connect a hand
NOTE: If the brake cylinder seal is defective, pump with accurate 0 - 2000 psi
there is a possibility of oil leaking from gauge and shut-off valve to the fitting
the hoist vent plug. in the brake release port.
• Apply 1000 psi to the brake. Close
shut-off valve and let stand for five (5)
minutes.
• If there is any loss of pressure in five
minutes, the brake cylinder should be
disassembled for inspection of the
sealing surfaces and replacement of
the seals. Refer to your Shop
Reference and Maintenance Guide.
c. Friction brake will not release as a • Disassemble brake to inspect brake
result of damaged brake discs. discs. Check stack-up height. Refer
to your Shop Reference and
Maintenance Guide.
2. Oil leaks from vent a. Same as 1b. a. Same as 1 b.
plug.
b. Motor seal may be defective as a b. System back pressure must not
result of high system back pressure or exceed 150 psi. Inspect hydraulic
contaminated oil. system for a restriction in the return
line from the control valve to the
reservoir.
Oil analysis may indicate
contamination has worn motor shaft
and seal. Thoroughly flush entire
hydraulic system and install new
filters and oil. Install new motor seal.

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TM500E-2 SERVICE MANUAL HOIST AND COUNTERWEIGHT

Symptom Probable Cause Solution

3. The brake will not a. Excessive system back pressure a. Same as 2 b
hold a load with acting on the brake release port
control lever in
b. Friction brake will not hold due to worn b. Same as 1c
neutral.
or damaged brake discs.
c. Brake clutch is slipping. c. Brake clutch may be damaged or
worn. Disassemble and inspect brake
clutch. Refer to your Shop Reference
and Maintenance Guide.
4. The hoist will not a. The hoist may be mounted unevenly a. Check the shims used to install the
hoist the rated which causes binding of the gear train. hoist. Refer to Hoist Installation in this
load section.
b. System relief may need checked and b. Refer to Pressure Setting Procedures
adjusted. in Section 2 - Hydraulic and Pressure
Settings.
c. Make sure hydraulic system oil c. Same as 4 b
temperature does not exceed 180
degrees F. Excessive oil temperature
increases motor internal leakage.
5. The hoist runs hot. a. The hoist may be mounted unevenly a. Check the shims used to install the
which causes binding of the gear train. hoist. Refer to Hoist Installation in this
section.
b. Make sure hydraulic system oil b. Refer to Pressure Setting Procedures 5
temperature does not exceed 180 in Section 2 - Hydraulic and Pressure
degrees F. Excessive oil temperature Settings.
increases motor internal leakage.
c. Too low or too high oil level in c. Fill/drain to proper level. Refer to
hydraulic reservoir. Section 9 - Lubrication.
d. Excessively worn or damaged internal d. Disassembly hoist to inspect/replace
hoist parts worn pa rts. Refer to your Shop
Reference and Maintenance Guide.
e. Faulty hydraulic cylinder, motor, or e. Replace faulty component.
valve.
6. Hoist chatters a. System relief may need checked and a. Refer to Pressure Setting Procedures
while raising rated adjusted. in Section 2 - Hydraulic and Pressure
load. Settings.

Removal 5. Tag and disconnect the electrical wires to the hoist hi-
speed solenoid valve.
1. If the CE option is provided, remove the hoist covers.
6. Remove the hoist mounting nuts, capscrews, washers,
2. Remove all cable from the hoist drum.
and shims (if shims are used, mark their location).
3. Tag and disconnect the hydraulic lines to the hoist. Cap
NOTE: The HP15C-17G hoist assembly, less the cable,
or plug all lines and openings.
weighs approximately 300 kg (661 pounds).
4. Tag and disconnect the electrical wires to the hoist
7. Using an adequate lifting device, remove the hoist from
rotation indicator sensor box.
the crane.

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HOIST AND COUNTERWEIGHT TM500E-2 SERVICE MANUAL

3 4, 5, 6, 7 6952

FIGURE 5-1

relation to the level positioned between the boom pivot

Item Description shaft bushings.

1 Auxiliary Hoist 6. With the hoist level, check to determine if all the hoist
mounting pads are in contact with the mounting plate by
2 Main Hoist
rocking the hoist.
3 Turntable
7. Keeping the hoist level, use a feeler gauge to determine
4 Capscrew the amount of gap existing between the pads and the
5 Washer mounting plate.
6 Hex Nut 8. Add shims to satisfy any existing gaps. Altering the shim
thickness to fit a tapering gap is acceptable. Install the
7 Shim
capscrews, washers and nuts and torque 413 to 447 Nm
(304 to 329 pounds-foot).
Installation
9. Remove the lifting device from the hoist.
1. Ensure the mounting plate and hoist pads are clean and
free from debris and the hoist has not been damaged 10. Connect the hydraulic lines to the hoist ensuring the
during handling. proper lines are connected to the correct ports as
marked during removal.
2. With the hoist supported by a suitable lifting device,
position the hoist on the mount. 11. Connect the electrical wires to the hoist hi speed
solenoid valve as marked during removal.
3. Check the hoist to boom alignment according to the
HOIST TO BOOM ALIGNMENT procedure (Figure 5-2) 12. Connect the electrical wires to the hoist rotation indicator
in this section. sensor box as tagged during removal.
4. Place a level between the boom pivot shaft bushings. 13. Install the cable, following the procedures outlined under
INSTALLING CABLE ON THE HOIST in Section 4 in the
5. Place a level across the top of the hoist drum and
Operator’s Manual.
determine if the hoist is sitting in the same plane in

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TM500E-2 SERVICE MANUAL HOIST AND COUNTERWEIGHT

MAIN HOIST IS ALIGNED TO THE RIGHT HAND

SHEAVE

LOCATING CENTERLINE WITH

SQUARE

AUXILIARY HOIST IS ALIGNED TO THE CENTER

5
SHEAVE
6019
FIGURE 5-2

Functional Check 3. Ensure the hydraulic connections are secure and free
from leaks.
1. Attach a test weight to the hook and raise and lower the
load several times. Servicing
2. Check the hoist for smooth operation of the hoist motor Remove the large plug from the center of the drum support.
and brake system. Fill with AGMA EO-4 gear lubricant until level with the plug
opening. Check every 1000 hours or 12 months.

PRELIMINARY Published 10-05-2007, Control # 151-00 5-5

HOIST AND COUNTERWEIGHT TM500E-2 SERVICE MANUAL

HOIST TO BOOM ALIGNMENT center point of adjustment to check the fleet angle of the
cable.
Preparation 2. All the cable must be removed from the hoist drum to
Boom alignment must be completed before attempting hoist check the fleet angle. Using mason cord or cat gut
alignment. If the hoist is not properly aligned, the cable can fishing line you will be able to pull the line tight to make
be damaged or fine control could be affected. an accurate measurement of the fleet angle. Find the
centerline of the hoist drum by using a square and
The crane must be set on outriggers fully extended and the drawing a line horizontal on the drum. Put a line vertical
crane must be leveled. The boom must be over the rear on to the horizontal line in the absolute center of the drum
TM/TMS models and over the front on RT/Industrial models. by using a tape measure. With the boom at 0 degree, tie
the line tight to the boom nose and have it in the center
Tools Required of the right hand boom nose sheave.
• Two foot square NOTE: If this special equipment is not available, sufficient
• Mason cord accuracy in locating a centerline may be obtained
by using a steel square against the machine’s inner
• Chalk surfaces of both flanges. It is advisable to avoid
• Protractor using any cast surfaces in this procedure unless a
check from both flanges indicates that the resultant
Procedure line is straight.

The hoist mounting location will determine the alignment 3. Tie the line around the hoist drum so that the line is very
procedure used. Shift one side of the hoist back or forward to tight and the line is crossing the absolute center of the
align the hoist with the boom sheave for cranes that have the drum at the centerline mark you put on the drum.
hoist mounted either directly to the boom or on a mount 4. Using a protractor, lay it on the vertical line on the hoist
attached to the boom. It may be necessary to shim under drum so the string line is in the center of the protractor.
one side of the hoist to make it level. The string line will be at the 90 degree mark on the
The hoist must be checked in two directions, one at 0 degree protractor if the hoist is straight with the boom nose
and the other is above 45 degrees boom angle on any crane sheave. If it is not at the 90 degree mark, the hoist
that the hoist is not mounted directly to the boom, stationary mounting bolts will have to be loosened and the hoist
mounted. moved so it is.

Check the hoist at 0 degree to see if the hoist is aligned to NOTE: This test is for cable leaving gaps while spooling.
the boom nose sheave. The main hoist is aligned to the right
hand sheave and the auxiliary hoist is aligned to the center
sheave (Figure 5-2) CAUTION
Do not alter holes or stop blocks on the crane mounting
NOTE: The hoist cable will have gaps in it during spooling
plate, as very small adjustments result in large angular
if the alignment is not correct.
changes. Extreme care should be taken to avoid over-
NOTE: The hoist is not level if the cable is piling up on one correction.
side of the drum.
5. Elevate the boom above 45 degrees boom angle to
1. The boom must be extended one half of full extension on
check if the hoist is level. Reposition the hoist drum and
all hoist alignments. This length is used because when
tighten the cord so you can have the cord in the center of
the main hoist cable is positioned on the top right hand
the protractor at the 90 degree mark. If the cord is not at
boom nose sheave, the cable must leave the center of
the 90 degree mark, the hoist will have to be shimmed
the drum at a 90 degree angle. The boom has the ability
until the cord is at the 90 degree mark.
to extend, retract, and change the angle of departure
from the drum. Extend the boom half way to provide a NOTE: This test is for cable piling up on one side of the
hoist drum.

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TM500E-2 SERVICE MANUAL HOIST AND COUNTERWEIGHT

PISTON MOTOR AND CONTROL VALVE Installation

Description NOTE: Care must be taken to assure the primary thrust
plate remains properly located in its counterbore
The piston motor is a bent axis, bidirectional, variable when the motor is re-installed. If the winch is
displacement heavy-duty motor. The motor is bolted to the operated with the primary thrust plate wedged
hoist and is geared directly to the hoist planetary. between the primary gears and the planet carrier,
or with a thrust washer out of position severe
The motor control valve is bolted to the motor.
damage to internal winch components could result.
Maintenance 1. Install a new O-ring on the motor pilot then lubricate with
petroleum jelly or gear oil. Engage the motor shaft with
Removal the brake clutch inner race and lower into place.
1. Thoroughly clean the external surfaces of the drum and 2. Apply Loctite No. 242 to the mounting bolts, and install
motor with steam or clean solvent and blow dry. the bolts and lockwashers. Torque the bolts to 102 Nm
(75 pounds-foot).
2. Tag and disconnect the hydraulic lines connected to the
hoist motor and the motor control valve. 3. Connect the hydraulic lines as tagged during removal.
3. Remove the capscrews and lockwashers that secures 4. Fill the drum with oil. Refer to Section 9 - LUBRICATION
the motor and motor control valve to the hoist. in this manual.
4. Place the motor and motor control valve in a clean, dry
suitable work area.

PRELIMINARY Published 10-05-2007, Control # 151-00 5-7

HOIST AND COUNTERWEIGHT TM500E-2 SERVICE MANUAL

IDLER DRUM AND CABLE FOLLOWER 4. Disassemble the cable follower roller as follows.
a. Remove the two bolts and washers securing the
Description angle to the right side of the shaft.
The main and auxiliary hoists are equipped with an idler b. Remove the shims and roller from the shaft.
drum on the forward side of the hoist. The main hoist idler
drum is used to keep the hoist cable from coming in contact c. If necessary, remove the bearing and bearing
with the boom. When the crane is also equipped with an housing from both ends of the roller.
auxiliary hoist, the idler drum on the auxiliary hoist is used to 5. Remove the bolt and locknut securing the arm to the
keep the hoist cable from coming in contact with the main spring attaching lever on each side of the hoist. Remove
hoist. The cable follower is mounted on the rear side of it’s arms and levers from the side plates.
respective hoist. The cable follower applies a downward
spring pressure against the cable onto the hoist drum, to NOTE: Be sure to mark each arm and lever as to what side
ensure that the cable will be uniformly wound onto the hoist (left or right) they were removed from. This will be
drum, and also prevent cable from jumping under abnormal helpful during installation.
line conditions.
Cleaning and Inspection
Maintenance 1. Clean all grease from the shaft, bearing, and roller.
2. Check the shaft, roller, and bearings for cracks, scoring,
Idler Drum or grooving. Replace if necessary.
Removal and Disassembly 3. Check the spring tension. If the springs will not provide
1. Remove the bolt, washer, and lockwasher from the right sufficient tension when adjusted, replace them.
side of the idler roller (Figure 5-3). Assembly and Installation
2. Support the idler roller and withdraw the shaft from the 1. Install the left arm through the bushing on the left side
left side. Take care not to lose the dowel pin on the end. plate. Install left spring attaching lever on the arm and
3. Remove the roller from between the side plates. secure with a bolt and locknut. Apply Loctite 242 to the
bolt threads.
Cleaning and Inspection
2. Repeat step 2 on the right side.
1. Clean all rust and dirt from the shaft.
3. Assemble the cable follower roller as follows.
2. Inspect the shaft and roller for cracks, scoring, or
grooving. Replace if necessary. a. Apply high strength retaining compound Loctite 680
to the bearing housings and the bearings. Install
Assembly and Installation them in both ends of the roller.
1. Position the roller between the side plates b. Install the shaft into the roller with a least one shim
2. Install the shaft through the left side plate and the roller. on each end.
Ensure the flat on the shaft end aligns with the stop c. Position the angle on the right side of the shaft and
welded on the side plate, align the dowel pin. secure with two bolts and washers. Apply Loctite
3. Secure the shaft to the right side plate with a bolt, 242 to the bolt threads.
washer and lockwasher. Apply Loctite 242 to the bolt 4. Position the cable follower roller on the arms and secure
threads. with four bolts and washers. Center the roller between
the hoist drum flanges and tighten the bolts. Tack weld
Cable Follower the bolt heads.
Removal and Disassembly 5. Attach one end of the tension springs to the levers on
1. Loosen the adjusting nuts and remove the tension each side. Install the adjusting rod through the lug on
spring and adjusting rod from both sides of the hoist (see each side plate and connect to the other end of the
Figure 5-3). spring. Install the adjusting nuts on each rod and tighten
enough to take the slack out of the springs.
2. Remove the tack welds from the bolt heads securing the
arm to the cable follower roller. 6. Using a grease gun, apply grease to the fittings on each
side plate bushing.
3. Support the cable follower roller and remove the bolts
and washers securing the arms to the angles on each 7. Adjust the roller as follows.
end of the roller. Remove the cable follower roller.

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TM500E-2 SERVICE MANUAL HOIST AND COUNTERWEIGHT

10

1 9

11
4

3
Item Description
1 Pivot Bracket
2 Drum
3 Follower Roller
4 Arm
6957-1 5 Spring
5
8 6 Spring Adjusting Rod
11
7 Lever
8 Idler Roller
2
9 Nut

10 10 Bracket
9 11 Hydraulic Motor

3
5

6957-2

FIGURE 5-3

PRELIMINARY Published 10-05-2007, Control # 151-00 5-9

HOIST AND COUNTERWEIGHT TM500E-2 SERVICE MANUAL

a. With one layer of cable on the hoist drum, adjust the Remove the idler drum and cable follower assembly
bolts on the front of each side plate (that push from the hoist.
against each arm) so the roller applies pressure on
3. If necessary to completely disassemble or remove any
the layer of cable, and does not interfere with filler/
part of the assembly, refer to the applicable paragraphs
riser protrusions on the hoist drum flanges. Tighten
in this Sub-section.
jam nuts to secure setting.
Installation
b. With a full drum of cable, the adjusting spring length
from eye to eye should not exceed 25.7 cm (10.12 1. Position the idler drum and cable roller assembly on the
in). Adjust rods as necessary and tighten jam nuts to hoist and secure each side plate to the hoist with two
secure this setting. bolts and washers.

Complete Assembly 2. Adjust the tension on the cable follower. Refer to

instructions in paragraph titled Cable Follower -
Removal Assembly and Installation in this Sub-Section.
1. Remove all tension from the springs on each side by
loosening the nuts and jam nuts.
2. Support the weight of the assembly and remove the two
bolts and washers securing each side plate to the hoist.

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TM500E-2 SERVICE MANUAL HOIST AND COUNTERWEIGHT

HOIST DRUM ROTATION INDICATOR Proper circuit operation can be checked for each individual
SYSTEM electrical component. If a malfunction occurs within the
system, repairs should be limited to finding and replacing the
Description faulty component(s). To determine which component is at
fault, refer to the troubleshooting section of your Can-Bus
The hoist drum rotation indicator system (Figure 5-4) is an CD.
electrically operated system that provides the operator with a
touch indication of drum rotation so the operator will know if Rotation Sensor
and at what speed the hoist drum is rotating, even under the The rotation sensor is screwed into the hoist housing and
most distracting conditions. senses the rotation of the primary drive end driven gear.
The rotation indicator system consists of the rotation When installing the sensor, ensure it contacts the top land of
indicator sensor and thumb thumper solenoid. The rotation a gear tooth and not between teeth (Figure 5-4). Screw the
sensor is located on the hoist. The pulsing thumb thumper sensor in until contact is made, then back out 1/2 turn and
solenoid is located in the applicable hoist control lever tighten lock nut.
handle. Actuation of the thumb thumper is controlled by the
Can-Bus system from input supplied by the rotation indicator Thumb Thumper Solenoid
sensor. The thumb thumper solenoid provides feedback proportional
to the hoist line speed by pulsing the rubber button on top of
Maintenance the hoist controller. The thumb thumper will cease operation
at high line speeds to prevent damage to the solenoid.
General
Troubleshooting
NOTE: This machine incorporates a CAN-Bus Multiplex
DANGER system. In order to effectively troubleshoot the
electrical system, you will need a Windows-based
D i s c on n e c t t h e b a t te r i es b e fo r e p e r f o r m i n g a n y
maintenance on this system. Serious burns may result PC, CAN-link service software (9999102409), and 5
from accidental shorting or grounding of live circuits. a connection cable (9999102296). The CAN-link
service software and connection cable may be
ordered from Manitowoc CraneCARE.

PRELIMINARY Published 10-05-2007, Control # 151-00 5-11

HOIST AND COUNTERWEIGHT TM500E-2 SERVICE MANUAL

3 6941-5

Controller

Hoist 6957-3
4
FIGURE 5-4

Item Description Item Description

1 Thumb Thumper 3 Rotation Sensor Connection
2 Controller 4 Two Speed Solenoid Connection

5-12 PRELIMINARY Published 10-05-2007, Control # 151-00

TM500E-2 SERVICE MANUAL HOIST AND COUNTERWEIGHT

COUNTERWEIGHT REMOVAL Removal

Description
Description DANGER
A 1360 kg (3000 pound) or 2495 kg (5500 pound) cast Death or serious injury could result from being crushed by
counterweight (Figure 5-5) is installed at the rear of the a falling counterweight.
turntable.
NOTE: Use of a forklift to remove/install the fixed
counterweight is not recommended.

2, 3, 4, 5

1
5
7
6984

6 2, 3, 4, 5
FIGURE 5-5

NOTE: The counterweight weighs either 1360 kg (3000

Item Description pound) or 2495 kg (5500 pound) depending on
option installed.
1 Cast Counterweight
3. Lower and fully retract the boom
2 Capscrew
4. Shut down crane.
3 Flatwasher
5. Attach an adequate lifting device to the counterweight.
4 Lockwasher
5 Nut 6. Remove the capscrews, washers and nuts securing the
counterweight.
6 Power Plant Tray
7. Use the lifting device to remove the counterweight.
7 Turntable
1. Fully extend and set the outriggers.
Installation
2. Rotate the superstructure so the counterweight is over 1. Fully extend and set the outriggers.
the front of the carrier to gain additional clearance. 2. Shut down crane.
Engaging the pin type turntable lock will aid alignment.

PRELIMINARY Published 10-05-2007, Control # 151-00 5-13

HOIST AND COUNTERWEIGHT TM500E-2 SERVICE MANUAL

NOTE: Use of a forklift to remove/install the fixed

counterweight is not recommended.
CAUTION
3. Attach an adequate lifting device to the counterweight.
When lifting/handling the counterweight, keep the chains/ Lift and install the counterweight onto the
straps vertical to minimize side pull on the lifting lugs. superstructure.

NOTE: The counterweight weighs either 1360 kg (3000 4. Install the capscrews, washers and nuts and secure the
pound) or 2495 kg (5500 pound) depending on counterweight. Torque the capscrews 581 to 629 kg
option installed. (304 to 329 pounds-foot).
5. Remove the lifting device from the counterweight.

5-14 PRELIMINARY Published 10-05-2007, Control # 151-00

 SECTION 6
SWING SYSTEM
TABLE OF CONTENTS
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Swing Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Swing Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Swing Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Swing Gearbox And Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Swing Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Swing Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Torquing Turntable Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15 6
Swivels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Hydraulic Swivel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Electrical Swivel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19

6-i
SWING SYSTEM TM500E-2 SERVICE MANUAL

6-ii
TM500E-2 SERVICE MANUAL SWING SYSTEM

SECTION 6
SWING SYSTEM
INTRODUCTION lock the turntable in a straight ahead position over the front of
machine. Both swing locks are operated from the cab.
Description
Theory of Operation
The purpose of the swing system (Figure 6-2) is to allow the
crane superstructure to rotate atop the carrier frame. The Swing Drive
superstructure swing system provides full 360 degree
rotation in both directions and is equipped with free swing The hydraulic power for the swing drive (Figure 6-2) is
capabilities. The term free swing means that, with the swing supplied by the superstructure engine driven hydraulic pump
brake switch in the off position, the superstructure will swing number 2 through the outrigger selector valve to the swing
freely after the SWING control lever is released until it coasts directional valve. Oil flows from the pump to the hydraulic
to a stop or the swing brake pedal is depressed. Port 5 swivel.

Swing is activated using the control lever in the When the superstructure cab controller is positioned to
superstructure cab. When the swing lever is actuated, select right or left swing, the flow through the control valve is
hydraulic pressure is routed to the swing motor to drive the directed to the swing motor. If the SWING BRAKE selector
gearbox in the appropriate direction. As the gearbox rotates, switch is in the OFF position, the superstructure will rotate in
the pinion gear meshes with the teeth on the swing bearing the desired direction. Shifting the control to neutral and
and rotates the superstructure. The maximum rotation speed depressing the brake pedal will stop the swing.
is 2.0 - 2.5 rpm with no load. Braking is accomplished by
depressing a swing brake pedal which is a proportionate Swing Brake
control valve that provides a controlled braking of the swing
The hydraulic power for the swing brake (Figure 6-2) is
motion. The swing brake can also be controlled by the swing
supplied by pump number 1 through the hoist/telescope/lift
brake selector switch located on the left hand armrest in the
directional valve. With the SWING BRAKE selector switch
superstructure cab.
positioned to ON, the swing brake release valve blocks the
The swing system consists of a hydraulic remote controller, regulated flow to the brake release port and spring pressure
directional control valve, swing drive, swing brake, the brake in the swing brake applies the brake. When the SWING
BRAKE selector switch is positioned to OFF, the regulated
pedal and power brake valve, and a swing brake release
solenoid valve. flow is directed to the brake release port, overcoming the 6
brake spring pressure and releasing the swing brake.
The crane is equipped with a pin type turntable lock as
Regulated is also provided to the power brake valve where it
standard and a 360 degree positive swing lock. The 360
is available for the activation of the swing brake when the
degree positive swing lock meshes with the swing gear teeth
pedal is depressed.
at any point of rotation. The pin type turntable lock will only

PRELIMINARY Published 10-05-2007, Control # 151-00 6-1

SWING SYSTEM TM500E-2 SERVICE MANUAL

2
1
3

7 8, 9, 10 6 5 6953

FIGURE 6-1

Item Description Item Description

1 Swing Motor 6 360° Swing Lock
2 Swing Brake 7 Pinion Guard
3 Swing Gearbox 8 Capscrew
4 Turntable 9 Flatwasher
5 Swing Bearing 10 Bushing

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TM500E-2 SERVICE MANUAL SWING SYSTEM

11
9

8
6

5 12

3
10
4

6
13

6713

FIGURE 6-2

Item Description Item Description

1 Plug 8 Dipstick
2 Plug 9 Breather
3 Plug 10 Plug
4 Elbow 11 Motor
5 Pipe 12 Gearbox and Brake
6 Breather 13 Pinion
7 Plug

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SWING SYSTEM TM500E-2 SERVICE MANUAL

Maintenance
Troubleshooting

Symptom Probable Cause Solution

1. Boom swing a. Damaged relief valve. a. Replace relief valve.
operation erratic in
b. Swing brake dragging (not releasing b. Readjust and/or replace necessary
either direction.
properly). parts.
c. Low engine rpm. c. Increase engine rpm to obtain smooth
swing operation.
d. Low hydraulic oil. d. Replenish hydraulic oil to proper level.
e. Improper movement of control to e. Feather controls to neutral to maintain
neutral. smooth stopping action.
f. Insufficient lubricant on swing bearing. f. Lubricate bearing properly. Refer to
Section 9 - LUBRICATION.
g. Crane not level. g. Level crane using outriggers.
h. Damaged swing motor. h. Repair or replace swing motor.
i. Excessive overload. i. Reduce load. Refer to load capacity
chart.
j. Restricted or partly clogged hydraulic j. Replace hose or fittings.
hose or fittings.
k. Pump cavitation in swing section. k. Tighten suction hose or replace any
damaged fitting. Check hydraulic tank
level.
l. Improperly torqued turntable bolts. l. Torque turntable bolts evenly.
m. Excessive preload on upper and lower m. Adjust as necessary.
pinion shaft bearing.
n. Improperly torqued swing motor n. Torque swing motor attachment bolts.
attachment bolts.
o. Malfunction of the swing box. o. Remove swing box and make
necessary repairs.
p. Worn or damaged pump. p. Repair or replace damaged pump.
q. Damaged swing directional control q. Repair or replace swing directional
valve. control valve.
r. Damaged swing pinion. r. Replace pinion.
s. Damaged turntable bearing. s. Replace turntable bearing.
2. Boom swing a. Crane not level. a. Level crane using outriggers.
operation erratic in
b. Turntable bearing binding due to b. Rotate machine 360 degrees in both
one direction only.
continuous limited swing. (Example: directions several times and lubricate
concrete pourer.) bearing.
c. Restricted hose or fitting. c. Replace hose or fitting.
d. Damaged swing directional control d. Replace swing directional control
valve. valve.
e. Damaged swing pinion. e. Replace pinion.
f. Damaged turntable bearing. f. Replace turntable bearing.

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TM500E-2 SERVICE MANUAL SWING SYSTEM

Symptom Probable Cause Solution

3. Boom will not swing a. Damaged relief valve. a. Remove, clean, and repair or replace
in either direction. relief valve.
b. Damaged swing motor. b. Repair or replace swing motor.
c. Swing brake not releasing properly. c. Repair as necessary.
d. Damaged hydraulic remote control d. Replace hydraulic remote control
valve. valve.
e. Internal damage to swing box. e. Remove swing box and repair.
f. Worn or damaged hydraulic pump. f. Replace pump section.
g. Damaged swing directional control g. Replace swing directional control
valve. valve.
h. Damaged swing pinion. h. Replace pinion.
i. Damaged turntable bearing. i. Replace turntable bearing.
j. Excessive overload. j. Reduce load. Refer to load capacity
chart.
4. Swing operation a. Damaged relief valve. a. Adjust, repair or replace valve.
slow in either
b. Improperly adjusted swing brake. b. Readjust.
direction.
c. Damaged hydraulic remote control c. Replace hydraulic remote control
valve. valve.
d. Improperly lubricated swing bearing. d. Lubricate bearing per
recommendations.
e. Improper size hose and/or fittings e. Refer to your Manitowoc CraneCARE
installed. Parts Manual.
f. Clogged or restricted hydraulic hoses f. Clean or replace damaged parts.
or fittings. 6
g. Worn or damaged output shaft g. Replace bearings.
bearings
h. Worn or damaged swing motor. h. Repair or replace motor.
i. Worn or damaged hydraulic pump. i. Repair or replace pump.
j. Crane not level. j. Level crane.
k. Damaged swing directional control k. Replace swing directional control
valve. valve.
5. Swing operation a. Crane not level. a. Level crane.
slow in one
b. Damaged hydraulic remote control b. Replace hydraulic remote control
direction only.
valve. valve.
c. Damaged swing directional control c. Replace the swing directional control
valve. valve.
d. Clogged or restricted hose. d. Replace hose or fitting.
e. Improperly torqued turntable bearing. e. Torque turntable bearing.

PRELIMINARY Published 10-05-2007, Control # 151-00 6-5

SWING SYSTEM TM500E-2 SERVICE MANUAL

Symptom Probable Cause Solution

6. Swing brake a. Improper brake adjustment. a. Adjust brake.
operation erratic.
b. Air in swing brake system. b. Bleed brake system.
c. Brake pedal not fully retracted. c. Check brake pedal return spring; repair
or replace spring.
d. Dirty or glazed brake disc. d. Clean or replace disc.
e. Malfunction of the swing power brake e. Repair or replace swing power brake
valve. valve.
f. Kinked or bent lines and/or hoses and f. Straighten or replace as required.
fittings.
7. Swing brake a. Damaged swing brake release valve. a. Replace release valve.
system will not
b. Damaged swing power brake valve. b. Repair or replace swing power brake
operate.
valve.
c. Internal damage to the swing brake c. Repair or replace affected parts.
assembly.
d. Loose or restricted brake lines or d. Tighten or replace lines and fittings.
fittings.
8. Swing brake pedal a. Damaged swing power brake valve. a. Repair or replace the swing power
is spongy. brake valve.
b. Loose or restricted brake lines or b. Tighten or replace brake lines and
fittings. fittings.
9. Swing brake drags. a. Damaged swing power brake valve. a. Repair or replace the swing power
brake valve.
b. Damaged swing brake release valve. b. Replace release valve.
c. Internal damage to the swing brake c. Repair or replace affected parts.
assembly.
d. Loose or restricted brake lines or d. Tighten or replace brake lines and
fittings. fittings.
10. Boom swings a. Insufficient hydraulic volume. a. Check delivery of hydraulic pump.
slowly. Ensure sufficient fluid is available to
pump. Check pump drive speed.
b. Damaged relief valve. b. Adjust, repair, or replace valve.
c. Damaged swing motor. c. Repair or replace motor.
11. Swing motor a. Hydraulic remote control valve sticking a. Repair or replace valve.
continues to or valve otherwise damaged.
operate when
b. Control valve sticking or valve b. Repair or replace valve.
swing control is in
otherwise damaged.
neutral.
12. Swing motor a. Improper port connections. a. Reverse port connection.
turning in wrong
direction.
13. Swing motor noisy. a. Air in system. a. Refer to Section 2 - Hydraulic and
Pressure Settings, for removal of air
from the system.
b. Motor binding. b. Repair or replace motor.

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TM500E-2 SERVICE MANUAL SWING SYSTEM

SWING MOTOR
Description CAUTION
Pull straight up on the motor assembly to avoid damaging
The swing motor is mounted on the swing brake housing and the splined shaft.
drives the swing gearbox through the brake assembly. The
swing motor is a hydraulic gerotor type with low speed and
5. Remove the two screws securing the motor and lift the
high torque characteristics. It has only three moving parts,
swing motor free of the flange. Remove and discard the
the commutator valve, the drive, and the gerotor star. The
O-ring from the groove in the swing brake.
motor has two ports for connection to the hydraulic system.

Maintenance Installation

Removal
CAUTION
1. Loosen the latches and remove cover on the right side of Use care when engaging the swing motor drive gear, do
the turntable to gain access to the swing assembly. not force the shaft to engage.
2. Ensure the swing brake and swing lock are engaged.
1. Install a new O-ring in the groove of the swing brake.
3. Clean the port area around the motor. Tag and Position the swing motor on the swing brake, engaging
disconnect the hydraulic hoses from the motor the shaft with the brake input shaft.
assembly. Cap or plug all openings.
2. Apply Loctite 243 to the screw threads. Install the
screws and secure the motor to the brake housing.
CAUTION Torque the screws 85 to 103 Nm (44 to 72 pounds-foot).
Oil can be hot and cause burns. 3. Connect the hydraulic lines to the swing motor as tagged
during removal.
4. Unscrew the drain plug to ensure that all oil has been
removed. Unscrew the filler and level plugs. After the oil 4. Install the cover on the right side of the turntable and
has been drained, replace the drain plug and any other tighten the cover latches.
plugs that may have been removed.
Test
1. Test swing of superstructure in each direction. Stop and 6
start swing several times.
2. Inspect for hydraulic leaks and repair as necessary.

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SWING SYSTEM TM500E-2 SERVICE MANUAL

SWING GEARBOX AND BRAKE 5. Bleed all air from the brake assembly.
Testing
Description
1. With the SWING BRAKE switch in the ON position,
The swing gearbox and brake, used in conjunction with the position the swing control lever in both directions.
swing motor, rotates and stops the superstructure. A pedal Superstructure rotation should not occur.
on the cab floor is used to activate the swing brake. The
swing gearbox is bolted to the superstructure base plate, and 2. Position the SWING BRAKE switch to OFF and swing
its pinion gear meshes with the ring gear of the turntable the superstructure in both directions. Use the swing
bearing to rotate the turntable. brake pedal to stop rotation.

The swing gearbox utilizes double reduction planetary 3. Check for hydraulic leaks and repair as necessary.
gearing. The multi-disc swing brake assembly is an integral
part of the swing gearbox and is located between the swing Gearbox
motor and the swing gearbox. The brake mechanism is a
Removal
disc pack that is hydraulically released and spring applied.
1. Engage the turntable lock pin.
Maintenance
2. Tag and disconnect the hydraulic lines from the swing
NOTE: The swing brake can be removed and motor and swing brake. Cap and/or plug all openings.
disassembled independently of the swing gearbox.
3. If necessary, remove the capscrews and washers
securing the pinion guard. Remove the guard.
Swing Brake
4. Unscrew the three screws securing the pinion gear
Removal
cover. Remove the cover.
1. Engage the turntable lock pin.
5. Remove the gear from the shaft.
2. Tag and disconnect the hydraulic lines connected to the
NOTE: The complete gearbox assembly with motor
swing motor and the brake. Cap and/or plug all
weighs approximately 126 kg (277.7 pounds).
openings.
6. Attach a suitable lifting device to the swing gearbox.
3. Remove the swing motor from the swing brake
Remove the capscrews, flatwashers and bushings
according to the procedures found in this Section under
securing the gearbox to the mounting plate.
SWING MOTOR - REMOVAL.
NOTE: Take note of the swing motor port orientation to
ensure proper installation.
CAUTION 7. Remove the swing gearbox.
Use care when removing the capscrews securing the
brake, as there is tension on the bolts due to internal 8. If necessary, remove the swing motor according to the
brake springs. procedures found in this Section under SWING MOTOR
REMOVAL.
4. Unscrew the screws securing the brake to the gearbox. 9. If necessary, remove the swing brake according to the
Lift the brake using the brake flange, then remove the O- procedures found in this Section under SWING BRAKE
ring. REMOVAL.
5. Cover the opening of the swing gearbox to ensure no 10. Cover the opening of the swing gearbox to ensure no
dirt, dust, etc., gets into the gearbox. dirt, dust, etc., gets into the gearbox.
Installation Installation
1. Install a new o-ring onto the brake housing. 1. If removed, install the swing brake according to the
2. Apply Loctite 243 to the screws. Install brake onto procedures found in this Section under SWING BRAKE
gearbox and secure with the screws. Torque the screws INSTALLATION.
50 to 60 Nm (36.8 to 44.2 pounds-foot). 2. If removed, install the swing motor according to the
3. Install the swing motor into the swing brake according to procedures found in this Section under SWING MOTOR
the procedures found in this Section under SWING INSTALLATION.
MOTOR - INSTALLATION. 3. Attach a suitable lifting device to the swing gearbox and
4. Connect the hydraulic lines to the motor and brake. lift and position the swing gearbox in place on the
mounting plate.

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4. Install the capscrews, flatwashers and bushings. Torque 1. Unscrew the drain plug. To ensure all oil has been
the capscrews 85 to 93 Nm (63 to 69 pounds-foot). removed, unscrew the filler and level plugs.
5. Apply Loctite 243 to screws. Install the pinion gear on 2. After oil is drained, replace the drain plug and any other
the output shaft. Install the cover and secure with three plugs that were removed to drain the oil.
screws. Torque screws 50 Nm (36.8 pounds-foot).
3. Flush the case with a light flushing oil.
6. If removed, install the pinion guard and secure with the
NOTE: Cleaning of the gearbox with a solvent is
capscrews and lockwashers. Torque the capscrews 25
recommended to prevent an accumulation of grit
to 27 Nm (18 to 20 pounds-foot).
and grime. Avoid steam cleaning where moisture
7. Connect the hydraulic lines to the swing brake. and dirt might be driven into the vent of the swing
bearing.
8. Connect the hydraulic lines to the swing motor.
4. To refill with oil, fill through filler plug until it begins to flow
9. Service the gearbox as indicated under SERVICING.
out of the level plug.
Servicing
5. Tighten the level and filler plugs.
As with all highly stressed mechanisms, reasonable
Checking The Oil Level
operating procedures are always required. Normal
maintenance should only consist of proper lubrication and a 1. Check the oil level through level plug.
periodic check of mounting bolt torque values. Lubrication
2. If no oil is visible on the level plug, add oil until the level
consists of maintaining the gearbox oil level. Oil in a new
is between min and max on the level plug.
gearbox should be drained and flushed out after
approximately 250 hours of operation, and replaced with 3. Refer to Section 9 - LUBRICTION.
premium quality SSGL-5 after approximately 500 hours of
operation or each year, whichever occurs first. Operation in Testing
high humidity or polluted air areas will require more frequent 1. Test swing of superstructure in each direction. Stop and
changes to minimize moisture or contaminate accumulation. start swing several times.
Change the oil as follows.
2. Inspect for hydraulic leaks and repair as necessary.

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SWING SYSTEM TM500E-2 SERVICE MANUAL

SWING BEARING
Description
DANGER
The swing bearing is an anti-friction roller bearing that mates
the Superstructure to the Carrier. The bearing inner race is It is mandatory that bearing attaching bolts be inspected
bolted to the Superstructure and the outer race is bolted to for lack of torque and retorqued, as required, after the first
the Carrier. The inner race contains two grease fittings for 300 hours of crane operation. The bolts may loosen in
lubrication of the bearing which are hosed to two fittings at service due to vibration, shock-loads, and temperature
the front right side of the turntable center section. changes, therefore, periodic inspection should be
accomplished every 500 hours thereafter, ensuring the
Maintenance bolts are properly torqued.

General KNOW YOUR TORQUE WRENCH! Flexible beam type

wrenches, even though they might have a pre-set feature,
The swing bearing is the most critical maintenance point of must be pulled at right angle and the force must be applied at
the crane. It is here, at the centerline of rotation, that the center of the handle. Force value readings must be made
stresses of loads are concentrated. In addition, the bearing while the tool is in motion. Rigid handle type, with torque
provides the only attachment between the superstructure limiting devices that can be pre-set to required values,
and carrier. Therefore, proper care of the bearing and eliminate dial readings and provide more reliable, less
periodic maintenance of the turntable-to-bearing attach bolts variable readings.
-IS A MUST -to ensure safe and efficient operation.
NOTE: If multipliers and/or special tools are used to reach
hard to get at areas, ensure torque readings are
Torquing Turntable Bolts
accurate.
General
Torque wrenches are precision instruments and must be
handled with care. To ensure accuracy, calibrations must be
made on a scheduled basis. Whenever there is a possibility
that a torque wrench may have been either overstressed or
DANGER damaged, it should immediately be removed from service
Failure to maintain proper torque of the turntable bearing until recalibrated. When using a torque wrench, any erratic or
attaching bolts will result in damage to the crane and jerking motion can result in the application of excessive or
possible injury to personnel. improper torque. ALWAYS use a slow, even movement and
STOP when the predetermined value has been reached.
Maintaining proper torque value for bolts is extremely If it is reported by the crane operator or suspected that the
important for structural strength, performance, and reliability crane has been overloaded beyond the capacities specified
of the crane. Variations in torque can cause distortion, above the bold line on the cranes’ capacity chart, then all
binding, or complete separation of the superstructure from turntable bolts must be inspected for looseness and
the carrier. retorqued to specifications.
Turntable bolts should be torqued according to the
CAUTION procedures outlined in this section.
Repeated re-torquing may cause bolts to stretch. If bolts When using step wrenches, calculated wrench settings are
keep working loose, they must be replaced with new bolts valid only when the following conditions are met.
of the proper grade and size.
1. Torque wrenches must be those specified and forces
Proper identification of bolt grade is important. When marked must be applied at the handle grip. The use of handle
as a high strength bolt (grade 8 and metric grade 10.9), the extensions will change applied torque to the bolt.
serviceman must be aware of bolt classifications and that he 2. All handles must be parallel to the step wrench during
is installing a high strength heat-treated tempered final tightening. Multiplier reaction bars may be
component and the bolt must be installed according to misaligned no more than 30 degrees without causing
specifications. Special attention should be given to the serious error in torque.
existence of lubricant and plating that will cause variation
from dry torque values. When a high strength bolt is 3. Multiplier bar handles must be propped or supported
removed, or un-torqued, the bolt must be replaced with a within the outer 1/4 of the handle length, or serious
new bolt of the same classification. under or over tightening will occur.

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TM500E-2 SERVICE MANUAL SWING SYSTEM

35 36 1 2
34 3
4
33

32 5

31 6
35 36 1 2
30 34 3 7
33 4
32 5
31 6 8
29
30 7
28 29 8
9
28 9
27 10
27 26 11 10
25 12
26 24 13 11
23 14
22
25 21 1615 12
20 19 18 17

24 13

23 14
22 15 6750-2
21
20 19 18 17 16 FIGURE 6-3

The inner race of the bearing is secured to the turntable by multiplier, backlash adapter, necessary extensions, and
36, 1 inch, grade 8 bolts. The outer race of the bearing is torque wrench.
secured to the carrier frame by 36, 7/8 inch, grade 8 bolts.
3. Return to bolt 1 and torque all bolts sequentially in a
Torque Values clockwise direction to the final torque of 1162 to 1259
Nm (857 to 929 pounds-foot). The same tools are used
Torque all inner race turntable bolts (Figure 6-3) to a final
as in step 1.
torque of 1162 to 1259 Nm (857 to 929 pounds-foot).
Outer Race Torquing
6
Torque all outer race turntable bolts (Figure 6-3) to a final
torque of 769 to 834 Nm (567 to 615 pounds-foot). 1. Extend and set the outriggers. Fully elevate the boom.
Tools Required 2. Torque eight bolts 615 to 667 Nm (454 to 492 pounds-
foot) using the following sequence pattern; 36, 18, 10,
(Figure 6-4) lists the complete set of special tools required to
28, 5, 23, 14, and 32. Tools used are the socket,
torque the turntable bolts.
multiplier, backlash adapter, necessary extensions, and
Inner Race Torquing torque wrench.

1. Extend and set the outriggers. Fully elevate the boom. 3. Return to bolt 1 and torque all bolts sequentially in a
clockwise direction to the final torque of 769 to 834 Nm
2. Torque eight bolts 930 to 1008 Nm (686 to 743 pounds- (567 to 615 pounds-foot). The same tools are used as in
foot) using the following sequence pattern; 36, 18, 10, step 1.
28, 5, 23, 14, and 32. Tools used are the socket,

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SWING SYSTEM TM500E-2 SERVICE MANUAL

7 1 3
6
5

Orders for special tools Description Grove Part Number Quantity Required
shall be referred to: 1. 1 1/2” Socket 3/4” Drive 9-999-100143 1
2. 4 to 1 Torque Multiplier (1/2” Input 3/4” Output) 9-999-100134 1
Manitowoc/Grove CraneCARE 3. Backlash Adapter 9-999-100141 1
1565 Buchanan Trail East 4. 1/2” Drive Torque Wrench 9-999-100136 1
Shady Grove, PA 17256-0021 5. 10” Extension 3/4” Drive 9-999-100138 A/R
Phone: (717) 597-8121 6. 13” Extension 3/4” Drive 9-999-100137 A/R
Fax: (717) 593-5929 7. Tool Box (Optional) 9-999-100146 1

Special Turntable Bolt Torquing Tools

FIGURE 6-4

Removal NOTE: The counterweight weighs either 1360 kg (3000

pounds) or 2495 kg (5500 pounds).
1. Fully extend and set the outriggers enough to take up
the slack in the pads. 6. Remove the counterweight and hoist(s) following
procedures outlined in Section 5 - HOIST and
NOTE: Do not raise the machine on the outriggers. COUNTERWEIGHT.
2. Ensure the boom is in the travel position and the
turntable lock pin is engaged.
3. Elevate the boom slightly and shut down the engine. DANGER
4. Tag and disconnect the battery cables from the It is mandatory that the hydraulic oil be drained from the
batteries. hydraulic reservoir, the counterweights are removed and
the two front sheet metal sections be removed to reduce
NOTE: The 31 m (102 foot) boom assembly weighs
the weight of the powerplant tray before removal. Failure
approximately 5792 kg (12,769 pounds) with
to do so could cause injury or death to personnel.
stowed boom extension. The 30 m (95 foot) boom
weighs approximately 4906 kg (10,816 pounds).
NOTE: It will be necessary to remove the powerplant tray
Removal of the swingaway boom extension will assembly before removing the turntable.
simplify boom removal, therefore, the above weight
NOTE: The powerplant tray assembly weighs
is for the boom without the swingaway boom
approximately 1900 kg (4189 pounds). Make sure
extension attached. The lift cylinder weighs
the sling is capable of lifting the tray and its
approximately 578 kg (1274 pounds).
components.
5. Remove the boom and lift cylinder following the
procedures outlined in Section 4, BOOM.

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TM500E-2 SERVICE MANUAL SWING SYSTEM

7. Attach special sling with hooks (Grove Part Number

9999102462) to the lugs on the powerplant tray
asembly. Make sure the load is centered in the sling.
DANGER
Ensure the superstructure is fully supported before
proceeding.
DANGER
Make sure all personnel stand clear of the powerplant tray NOTE: It will be necessary to rotate the superstructure
during removal. Do not allow personnel to ride on the sling while attached to the lifting device. Outer race bolts
or on suspended loads. Failure to do so could result in can only be removed from the swing drive side of
injury or death. the turntable.
15. Remove the 36 bolts and washers securing the turntable
8. Remove the capscrews, washers, nuts and shims
bearing outer race to the carrier.
securing the powerplant tray assembly to the turntable.
Remove the powerplant tray.
9. Tag and disconnect all water and oil lines from the
bottom of the swivel. Cap or plug all lines and openings. DANGER
10. Locate the connectors and ground wire that joins the Ensure that any blocking material used is capable of fully
swivel wiring harness to the receptacles and ground supporting the weight of the superstructure and will not
stud on the carrier. allow it to tilt or shift. Failure to do so may result in death or
injury to personnel.
11. Disconnect the swivel wiring harness connectors from
the carrier wiring receptacles. Remove the ground wire 16. Carefully lift the superstructure, using care not to
from the ground stud. damage the swivel assembly, and set it on blocking that
12. Remove the clamp securing the swivel wiring harness to will not allow the superstructure to tilt or shift, or rest on
the hydraulic swivel assembly. the swivel. Leave the lifting device attached.

13. Coil the wiring harness and secure it to the swivel to NOTE: If the same bearing is to be used again, mark the
prevent damage to the harness during turntable position of the bearing on the superstructure so it
removal. can be installed in the exact position it was before
removal.
NOTE: The swivel assembly will be removed with the
NOTE: The bearing weighs approximately 260 kg (573
6
turntable.
pounds). Ensure the bearing lifting device is
capable of supporting the weight.
17. Place an adequate lifting device under the bearing and
DANGER remove the 36 bolts and washers securing the turntable
Ensure the lifting device is capable of fully supporting the bearing to the superstructure.
weight of the superstructure. Ensure the superstructure 18. Using the lifting device, remove the turntable bearing
will not tilt or slide during lifting and moving. Failure to do from under the superstructure.
so may result in death or injury to personnel and damage
to equipment. Inspection
NOTE: If a lifting device capable of lifting the entire Check the bearing teeth for chipping or cracking. If any
superstructure is not available, superstructure evidence of these is found, replace the bearing. Ensure the
weight may be reduced by removing various bolt holes are free of dirt, oil, or foreign material.
components such as the hoist(s).
Installation
14. Attach a suitable lifting device to the four superstructure
lifting lugs (two near the boom pivot shaft bushings and
two near the lower lift cylinder pivot shaft bushings).
Take in cable or chain to remove slack. Do not pull up on
the superstructure. DANGER
Anytime a turntable bolt has been removed, it must be
replaced with a new bolt.

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SWING SYSTEM TM500E-2 SERVICE MANUAL

NOTE: If the same bearing is to be used again, align the drives so that pinion is centered within cutout in base plate
marked teeth on the pinion shaft and the marked and motor ports face towards the outboard side as shown.
teeth on the bearing.
NOTE: Installation is in the travel position. Ensure the
swing lock is disengaged before attempting to mate CAUTION
the bearing to the superstructure. Do Not Clamp Over Pinion.
1. Using an appropriate lifting device, position the turntable • Using shims, set backlash by moving the swing drive
bearing under the superstructure. If the same bearing is assemblies toward the bearing in order to mesh the
being used, position it as marked prior to removal. pinion with the ring gear teeth (Figure 6-5).

2. Install 36 new bolts and washers securing the bearing to • Check tooth engagement squareness and vertical
the superstructure. Refer to Inner Race Torquing in this tooth engagement.
Sub-Section. • Remove backlash shims and recheck backlash.
3. Using an appropriate lifting device, align the
superstructure over the carrier in the travel position and 5. Plug the swivel wiring harness connectors into the
carefully lower the superstructure, being careful not to carrier receptacles. Secure the ground wire to the
damage the swivel assembly, into position on the carrier ground stud using a washer, lockwasher, and nut.
bearing plate. 6. Install the clamp securing the swivel wiring harness to
NOTE: It will be necessary to rotate the superstructure the hydraulic swivel.
while attached to the lifting device. Outer race bolts 7. Connect all hydraulic lines to the ports on the bottom of
can only be installed from the swing drive side of the swivel as tagged during removal.
the turntable.
NOTE: The powerplant tray assembly weighs
4. Install 36 new bolts and washers. Refer to Outer Race approximately 1900 kg (4189 pounds).
Torquing in this Sub-Section.
8. Attach special sling with hooks (Grove Part Number
NOTE: If a new bearing is being installed, a new pinion 9999102462) to the lugs on the powerplant tray
gear must also be used. Align the high point asembly. Make sure the load is centered in the sling.
(maximum eccentricity) on the bearing with the
new pinion gear high point (Figure 6-5).

Pinion Maximum Eccentricity Point DANGER

Make sure all personnel stand clear of the powerplant tray
during removal. Do not allow personnel to ride on the sling
or on suspended loads. Failure to do so could result in
injury or death.

NOTE: Add shims between powerplant tray and turntable

weldment as required.
9. Install the powerplant tray assembly to the turntable and
secure with capscrews, washers, nuts and shims.
10. Service the hydraulic reservoir. Refer to Section 9 -
LUBRICATION.
11. Install the two front sheet metal sections.

.0.20 Thick Shim NOTE: The counterweight weighs either 1360 kg (3000
By Full Width to Tooth Bearing pounds) or 2495 kg (5500 pounds).
6750-3
Engagement (.040) Backlash)
12. Install the counterweights. Refer to Section 5 - HOIST
FIGURE 6-5 AND COUNTERWEIGHT.

Orient ring gear such that its point of max eccentricity (“high 13. Install the boom and lift cylinder following the procedures
point”) is located between the swing drives. Position swing outlined in Section 4, BOOM.
14. Reconnect the batteries.

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TM500E-2 SERVICE MANUAL SWING SYSTEM

Testing NOTE: If the superstructure does not turn freely after

bearing and pinion replacement, contact your local
Activate the crane and check for proper function. dealer.

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SWING SYSTEM TM500E-2 SERVICE MANUAL

SWIVELS swivel retainer plate which engages the carrier frame lugs
with capscrews and hex nuts. This allows the spool to remain
Description stationary with the carrier as the case rotates with the
superstructure.
The swivel assembly (Figure 6-6) consists of a 2 port
hydraulic swivel and a 10 conductor slip ring electrical The electrical swivel center or collector ring assembly is
swivel. Solid connections cannot be used to transfer oil, secured by setscrews to a center post which is bolted to the
heater hot water and electricity between the carrier and spool of the hydraulic swivel. This allows the collector ring
superstructure due to the continuous 360 degree swing. The assembly to remain stationary with the carrier. The outer
use of swivels efficiently accomplishes this function. portion or brush assembly is mounted on two studs which
are located on the mounting plate assembly which is
The barrel portion of the hydraulic swivel is attached to the retained to the water swivel barrel by a bolt. This allows the
turntable bottom plate by four capscrews and nuts. The spool brush assembly to rotate with the superstructure around the
portion of the swivel rides upon a thrust ring at the top of the stationary collector core.
swivel case. The spool portion is held stationary with the
carrier by bolts, and bolt retainer plates attached to the

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TM500E-2 SERVICE MANUAL SWING SYSTEM

11, 12

15, 16

18
17
4, 5

13

15, 16 1, 2

6, 7

10
14

6
6959 8, 9

FIGURE 6-6

Item Description Item Description

1 Capscrew 10 Swivel Bracket
2 Washer 11 Slip Ring Assembly
3 Plate 12 Cover
4 Capscrew 13 Center Post
5 Washer 14 Hydraulic Swivel
6 Capscrew 15 Capscrew
7 Jam Nut 16 Washer
8 Capscrew 17 Bushing
9 Nut 18 Turntable Base Plate

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SWING SYSTEM TM500E-2 SERVICE MANUAL

Hydraulic Swivel 6. Tag and disconnect the hydraulic lines from the spool of
the hydraulic swivel. Cap or plug all lines and openings.
Description 7. If necessary, remove the electrical swivel. Refer to
Each of the ports on the spool and case of the swivel is ELECTRICAL SWIVEL in this Section.
stamped with the port number. The function of each port is NOTE: The hydraulic swivel weighs approximately 36 kg
described below. (79.3 pounds). The hydraulic and electrical swivel
combined weigh approximately 66.1kg (446
pounds).
Max Test Pressure
Port # Function
kPa (bar) (psi) 8. On the bottom of the swivel, loosen the capscrew and
1 13,789 (137.8) (2000) Extend nut on the swivel bracket to allow removal of the swivel
from the frame plates.
2 13,789 (137.8) (2000) Retract
NOTE: If removing the swivel by lowering it, position an
Theory of Operation adequate supporting device beneath the swivel,
otherwise the swivel can be removed through the
The hydraulic swivel allows oil to flow from the pumps to top of the frame.
various crane functions on the superstructure. All oil is
9. Remove the capscrews, washers, and bushings
routed into the spool portion of the swivel where, through a
securing the swivel barrel to the turntable base plate.
series of internally drilled passages, oil is transferred to
Remove the swivel.
circumferential channels on the spool exterior. These
channels correspond with a mating port on the outer case of Installation
the swivel. Each channel is separated by a series of nylon
and O-ring seals that prevent transfer of oil and pressure. NOTE: The hydraulic swivel weighs approximately 36 kg
Return flow from the crane superstructure is accomplished in (79.3 pounds). The hydraulic and electrical swivel
the same manner through another set of ports. combined weighs approximately 66.1kg (146
pounds).
Maintenance 1. Install the swivel.
Removal 2. Secure the hydraulic swivel to the turntable base plate
with the bushings, capscrews and washers. Torque the
1. Extend and set the outriggers. Ensure the crane is level
capscrews 714 to 743 Nm (526 to 548 pounds-foot).
and the boom is over the front.
3. Tighten the capscrews and nuts on the swivel bracket.
2. Elevate the boom and note at what boom angle, you
have the most clearance between the lift cylinder and 4. If removed, install the electrical swivel. Refer to
the turntable side plate. Shut down the engine. ELECTRICAL SWIVEL in this Section. Connect the
swivel wiring harness connectors to the carrier
3. Measure the distance from the top of the lift cylinder to
receptacles and the yellow ground wire to the mounting
the base of the boom section where the lift cylinder
bracket on the carrier frame. Use the bolt and star
attaches. Cut two pieces of 10 x 10 cm (4 x 4 in) oak to
washers taken off at removal and refer to Grove
fit.
Engineering Specification A-829-100386 for proper
NOTE: It might be necessary to raise the boom slightly to electrical termination of grounds.
allow installation of the blocking.
5. Connect the hydraulic lines to the spool of the hydraulic
NOTE: This blocking is to add extra support for the boom. swivel as tagged during removal.
Any seepage or leakage in the holding valves or
6. Connect the hydraulic lines to the hydraulic swivel case
internally in the cylinders will allow the boom to
as tagged during removal.
settle over a period of time.
7. Remove the blocking material from the lift cylinder.
4. Use the oak blocking to block between the barrel of the
lift cylinder and the boom base section. 8. Activate all systems; cycle all functions and observe for
proper operation and any leakage.
5. Tag and disconnect the hydraulic lines from the case of
the hydraulic swivel. Cap or plug all lines and openings.

6-18 PRELIMINARY Published 10-05-2007, Control # 151-00

TM500E-2 SERVICE MANUAL SWING SYSTEM

Electrical Swivel 7. Tag and disconnect the connectors from the receptacles
at the fuse panel at the superstructure cab.
Description 8. Loosen the cover holddown latch and remove the cover
The swivel assembly consists of a 10 conductor slip ring and from the electrical swivel.
cover assembly. 9. Loosen the capscrews securing the electrical swivel
Each brush set incorporates two brushes, leads, and clips mounting tube to the center post on the water swivel.
which are attached to a brush holder assembly. The brush 10. Remove the capscrew and jam nut securing the
set leads are formed into harnesses which are routed electrical swivel case to the plate on the case of the
through the mounting plate on the swivel. The collector ring hydraulic swivel.
leads are formed into one harness which is routed downward
through the center of the hydraulic swivel. Extending from
the base of the hydraulic swivel, the collector ring leads are CAUTION
also formed into connectors which plug into receptacles from When withdrawing the wiring harness through the center
the chassis power supply. of the hydraulic swivel, ensure the wires do not get caught
The electrical swivel also incorporates a slew potentiometer. and damaged.
The potentiometer controls functions in the load moment
indicating, working area definition, and rear axle oscillation 11. Remove the swivel and wiring harness from the crane.
lockout systems.
Installation
Theory of Operation 1. Route the collector core wiring harness through the
center of the hydraulic swivel.
The electrical swivel is located on top of the 2-port swivel and
transfers electricity between the carrier and superstructure. NOTE: The boom should be centered directly over the
Wiring harnesses transmit the electricity between the carrier front of the crane before adjustment is made to the
and superstructure. slew potentiometer.
2. Slide the electrical swivel mounting shaft onto the center
Maintenance post.
Removal 3. Ensure the threaded hole on the bottom of the electrical
1. Perform steps 1 through 4 of HYDRAULIC SWIVEL - swivel base is aligned with the mounting hole in the plate
REMOVAL in this section. on the swivel case. Install the capscrew through the hole
in the plate and install the jam nut. Screw the capscrew
6
into the hole in the electrical swivel base until the
capscrew head is approximately 6.0 mm (0.23 in) from
the bracket. Tighten the nut against the electrical swivel.
DANGER
D i s c on n e c t t h e b a t te r i es b e fo r e p e r f o r m i n g a n y 4. Apply medium strength Loctite to the setscrews securing
maintenance on the electrical system. Serious burns may the electrical swivel to the center post and tighten them 5
result from accidental shorting or grounding of live to 6 Nm (44 to 53 pounds-inch)
circuits.
5. Install the swivel cover and secure with cover latch.
2. Disconnect the batteries. Refer to Section 3 - 6. Connect the wiring harness connectors to the
ELECTRIC SYSTEM. receptacles at the superstructure cab fuse panel.
3. Locate the connectors which join the collector ring 7. Install the clamp securing the harness to the hydraulic
harness to the receptacles for the carrier. swivel assembly.
4. Tag the connectors and their receptacles with numbers. 8. Connect the batteries.
Disconnect the connectors from the chassis wiring
receptacles.
CAUTION
5. Remove the clamp securing the wiring harness to the
It is imperative that the slew potentiometer be adjusted
hydraulic swivel assembly.
anytime work is done to the electrical swivel.
6. Secure the connectors and wires from each of the
numbered connectors so the harness can be withdrawn 9. Activate all systems, cycle all functions, and observe for
through the center of the hydraulic swivel. proper operation. Adjust the slew potentiometer in

PRELIMINARY Published 10-05-2007, Control # 151-00 6-19

SWING SYSTEM TM500E-2 SERVICE MANUAL

accordance with SLEW POTENTIOMETER NOTE: If the superstructure swings past the house lock pin
ADJUSTMENT procedures in this Sub-Section. engaged position, step 4 must be repeated.
Preventive Maintenance 5. Loosen the three screws that secure the slew
potentiometer to the mounting plate.
It is recommended that a normal inspection of the electrical
swivel collector ring and brush assembly be established. An 6. Rotate the body of the slew potentiometer until the slew
example of this could be at approximately 100 to 150 engine angle indicates 0.6 ± 0.1 degree.
operating hours. When this time limit is reached, perform the
NOTE: The slew angle indication in step 6 may not be
following.
obtainable due to limited wire length on the
1. Check the collector ring and brush assembly for any p o t e n t i o m e t e r, o r t h e e l e c t r i c a l t e r m i n a l s
corrosion, pitting, arcing, and wear. interference with one of the three mounting screws.
If this occurs, reposition the collar set screwed to
2. Check the collector ring setscrews and ensure they are
the potentiometer shaft and repeat steps 4 thru 6.
tight.
7. Tighten the three screws that secure the slew
3. Check the brush and arm assembly springs. Ensure
potentiometer to the mounting plate. Install the electrical
they are holding the brushes firmly against the collector
swivel cover.
rings.
8. Disengage the house lock pin and swing approximately
Slew Potentiometer Adjustment 10 degrees to the left (counterclockwise). Slowly swing
1. Rotate the superstructure over the front and engage the back to the right and engage the house lock pin.
house lock pin. NOTE: If the superstructure swings past the house lock pin
2. Set the LMI console to read slewing angle as follows: engaged position, step 8 must be repeated.

NOTE: Refer to the PAT Load Moment Indicator BCS 9. If the angle indicated on the console does not exceed ±
Operator’s Handbook for detailed instructions. 1.0 degree, proceed to step 10. If the indicated angle
exceeds ± 1.0 degree, return to step 4.
• Complete the LMI console setup according to the
crane’s current operating configuration. 10. Disengage the house lock pin and swing approximately
10 degrees to the right (clockwise). Slowly swing back to
• Press limits LIM.
the left and engage the house lock pin.
• Press 4 for slew angle/work area definition limits.
NOTE: If the superstructure swings past the house lock pin
• Press 1 for slew angle. engaged position, step 10 must be repeated.
• Press 2 or 3 to display slewing angle. 11. If the angle indicated on the console does not exceed ±
3. Remove the electrical swivel cover. 1.0 degree, proceed to step 12. If the indicated angle
exceeds ± 1.0 degree, return to step 3.
12. Disengage the house lock pin and swing approximately
CAUTION 10 degrees to the left (counterclockwise). Slowly swing
Do not attempt to rotate the slotted shaft in the center of back to the right and engage the house lock pin.
the slew potentiometer.
NOTE: If the superstructure swings past the house lock pin
4. Disengage the house lock pin and swing the engaged position, step 12 must be repeated.
superstructure approximately 10 degrees to the right 13. Verify the angle indicated on the console does not
(clockwise). Slowly swing back to the left and engage exceed ± 1.0 degree. If the indicated angle exceeds ±
the house lock pin. 1.0 degree, return to step 3.

6-20 PRELIMINARY Published 10-05-2007, Control # 151-00

 SECTION 7
POWER TRAIN
TABLE OF CONTENTS
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Engine Drive Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Electronic Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Engine Wait To Start /Battery Discharge Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Engine Warning/Electrical System Diagnostic Indicator . . . . . . . . . . . . . . . . . . . . . . 7-6
Engine Stop/Module Off Line Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Fault Code Flashing Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Injection Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Air Intake System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Air Cleaner Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Filter Element Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Element Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
Duct Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
Water Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
Effects of Cooling System Neglect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
Rust Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
Engine Antifreeze/Coolant Fill Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
Cooling/SCA Maintenance Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15 7
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
Pressure Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
Component Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
Engine Water Jacket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
Fans and Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
Hoses and Clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
Test Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
Antifreeze/Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
Radiator Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18

7-i
POWER TRAIN TM500E-2 SERVICE MANUAL

7-ii
TM500E-2 SERVICE MANUAL POWER TRAIN

SECTION 7
POWER TRAIN
ENGINE in the engine’s intake air stream to aid in cold starting and
reduce white smoke at start-up. In the preheat mode, the
Description engine should not be cranked until the WAIT-TO-START
indicator on the superstructure cab front console turns off.
NOTE: Carrier engine information can be found in the The WAIT-TO-START lamp is illuminated during the preheat
engine manufacturer’s manual shipped with the time that takes place when the ignition switch is in the ON
crane. position during cold weather starting. The ECM checks
The superstructure engine is a Cummins QSB3.3 intake manifold temperature to determine how long to
(Figure 7-1) diesel engine. This Service Manual does not energize the air heater before extinguishing the WAIT-TO-
include detailed information on the engine itself. A separate START indicator. Once the engine is started, the electric air
manual as prepared in detail by the engine manufacturer, is heating element will be energized again for a time period
supplied with this Service Manual. However, a short determined by intake air temperature.
description and maintenance of certain components of the
fuel system, air intake system, and water cooling system is Maintenance
provided in this section.
Engine Removal
The engine is electronically controlled by the Electronic
Control Module (ECM), it is the control center of the system. 1. Set the outriggers. Refer to Section 3 - OPERATING
It processes all of the inputs and sends commands to the fuel CONTROLS and PROCEDURES in the Operator’s
systems as well as vehicle and engine control devices. Manual.

Superstructure engine speed is controlled by the foot throttle 2. Remove the engine covers and hood support.
pedal in the superstructure cab. It controls engine RPM 3. Disconnect the air filter tubing at the engine and air
which increases or decreases proportionately with the cleaner. Remove and lay aside.
amount of foot pressure applied to the pedal. The foot
throttle pedal is electrically connected to the superstructure 4. Disconnect the exhaust tubing.
control module which sends the signal to the engine ECM via 5. Tag and disconnect the engine electrical harness
the J1939 data link. connector and battery cables.
The superstructure engine and its components are installed 6. Disconnect the lines to the grid heater panel.
in the powerplant tray located on the turntable. Access to the
engine is gained by removing the engine covers. 7. Remove the capscrews and washers securing the ECM
hangar. Remove the hangar with ECM.
The air intake filter is mounted above the engine. The muffler
is mounted on the left side of the hood behind the rear 8. Drain the engine coolant system.
fender.
9. Drain the engine lubrication system. 7
10. Tag and disconnect all lines from the radiator.
Disconnect the coolant level sensor harness from the
DANGER engine harness and tie up excess harness so it is out of
the way. If necessary to remove the radiator, refer to
Do not spray starting fluid into the air inlet. The spray will
RADIATOR - Removal in this section.
contact the heater elements and could explode causing
personal injury. 11. Tag and disconnect any other lines and tubing
necessary for removal of the engine.
To aid in starting the engine in cold weather, the engine is
equipped with electric air heating elements that are located

PRELIMINARY Published 10-5-2007, Control # 151-00 7-1

POWER TRAIN TM500E-2 SERVICE MANUAL

1 Rear of Superstructure

See Detail D

See Detail C
6955-5

3, 4, 5

7, 8, 9

6955-6
Detail D 6955-4 Detail C
3, 4, 5
FIGURE 7-1

7-2 PRELIMINARY Published 10-5-2007, Control # 151-00

TM500E-2 SERVICE MANUAL POWER TRAIN

See Detail A
Rear of Superstructure 6955-7
See Detail B

3, 4, 5

3, 4, 5

6955-8
6955-9
Detail A
Detail B
7
FIGURE 7-1 continued

Item Description
1 Engine DANGER
2 Powerplant Tray The lifting device must be able to support the combined
weight of the engine and transmission.
3 Capscrews
4 Washers NOTE: The engine weighs approximately 415 kg (915
5 Nuts pounds).

6 ECM Hangar 12. Attach to the engine a lifting device capable of

supporting the weight of the engine.
7 Washers
13. With the lifting device supporting the weight of the
8 Nuts
engine, remove the capscrews, washers and nuts
9 Capscrews securing the engine to the powerplant tray (Figure 7-1).

PRELIMINARY Published 10-5-2007, Control # 151-00 7-3

POWER TRAIN TM500E-2 SERVICE MANUAL

14. Using the lifting device, lift the engine from the crane.
15. If a new engine is to be installed, remove all CAUTION
components, fittings, etc., from the old engine and install Do not apply sealant to the inside of the hydraulic suction
them on the new engine in the same locations. hoses.
NOTE: Ensure that the same grade hardware, torque
values, and Loctite as were installed by the factory 5. Apply a moderate coat of Permatex® Type No. 2 to the
are used. male hose adapter and install the hydraulic hoses. Do
not apply sealant to the inside of the hydraulic hose, and
Engine Installation push it onto the male adapter. This can result in excess
sealant being pushed ahead of the male adapter and
being exposed to the hydraulic oil.
6. If removed, install the radiator. Refer to RADIATOR -
DANGER Installation in this section. Connect all hoses and
The lifting device must be able to support the combined electrical harnesses to the radiator as tagged during
weight of the engine and transmission. removal.
7. Install the hood support and engine covers.
NOTE: Use the same grade hardware, torque values, and
Loctite that were used by the factory. 8. Connect the battery cables and engine electrical
harness connector in accordance with the identification
NOTE: Apply medium strength sealant (Loctite 242) to marks made during removal.
engine attaching hardware.
9. Connect the air filter tubing at the engine and the air
1. With all components and fittings installed on the new filter. Connect the exhaust tubing to the engine.
engine, lift the engine into the powerplant tray on the
superstructure turntable. 10. Service the engine lubrication system and engine
cooling system. Refer to Section 9 - LUBRICATION.
2. Install the nuts, washers and capscrews and secure
engine (Figure 7-1). Torque capscrews 25 to 27 Nm (18 11. Start the engine. Check all hoses and fittings for leaks.
to 20 pounds-foot). Recheck all fluid levels.

3. Remove the lifting device. Engine Drive Belts

4. Connect all lines and tubing to the engine and all other The proper operation of engine belt-driven components such
components in accordance with the identification marks as the alternator, fan, and water pump depend on the proper
made during removaL. condition and tension of the engine drive belt.
NOTE: Belt tension is maintained with an automatic belt
tension device.

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TM500E-2 SERVICE MANUAL POWER TRAIN

OK OK OK

Missing Material Traverse Cracks Longitudinal Cracks Intersecting with

Transverse Cracks must be Replaced

FIGURE 7-2

The engine drive belt should be inspected visually on a daily engine pulleys, incorrectly installed belt, or by oil, grease, or
basis. The drive belt should be inspected for cracks, frayed hydraulic fluid on the belt.
areas, and glazed or shiny surfaces (Figure 7-2). A drive belt
Refer to the engine manufacturer’s manual for any special
that is glazed or shiny indicates belt slippage.
tools or belt tension specifications.
Engine drive belt damage can be caused by various factors
such as incorrect tension, incorrect belt size, misaligned

PRELIMINARY Published 10-5-2007, Control # 151-00 7-5

POWER TRAIN TM500E-2 SERVICE MANUAL

ELECTRONIC CONTROLS Engine Stop/Module Off Line Indicator

Engine Wait To Start /Battery Discharge The engine stop/module off line indicator is located on the
top left side of the front console. The top portion of the switch
Indicator is the stop indicator. It illuminates red when energized by a
The engine wait to start indicator is located on the top left signal from the engine ECM that signifies a serious engine
side of the front console. The top of the switch illuminates problem that requires the vehicle and the engine to be
amber for a period of time when the ignition switch is turned stopped as soon as safely possible. In addition, a warning
to the on position. The engine should not be cranked until the buzzer will also sound.
wait to start indicator turns off. In addition to alerting the operator of system faults, the stop
The bottom of the switch illuminates red and a warning light, in conjunction with the warning light, is used in the
buzzer sounds for a battery discharge condition. diagnostic operation of the engine control system. The
diagnostic mode begins when the ignition and engine
Engine Warning/Electrical System diagnostic switch is on and the engine is not running. The
Diagnostic Indicator amber light flashes at the beginning of a fault code
sequence, the red light flashes the three-digit or four-digit
The engine warning/electrical system diagnostic indicator is code for the active and the amber light flashes again to
located at the top left side of the front console. The top separate the previous red light sequence from the next one.
portion is the warning indicator. It illuminates amber when Each code will be flashed twice before moving to the next
energized by a signal from the engine ECM that signals the code. When all codes have been flashed, the sequence will
operator of an engine problem which must be corrected. begin again. If no codes are present, both the warning and
stop lights will remain on.
In addition to alerting the operator of system faults, the
warning light, in conjunction with the stop light, is used in the The bottom portion is the module off line indicator. This
diagnostic operation of the engine control system. The indicator will illuminate solid red and a buzzer will sound
diagnostic mode begins when the ignition and engine whenever communication with one of the crane’s electronics
diagnostic switch is on and the engine is not running. The modules is lost. The vehicle should be stopped as soon as
amber light flashes at the beginning of a fault code safely possible. The crane must be restored to proper
sequence, the red light flashes the three-digit or four-digit condition before operating again.
code for the active fault and the amber light flashes again to
separate the previous red light sequence from the next one. Fault Code Flashing Sequence
Each code will be flashed twice before moving to the next
code. When all codes have been flashed, the sequence will The ENGINE WARNING light (yellow) flashes at the
begin again. If no codes are present, both the warning and beginning of a fault code sequence. There will be a short 1-
stop lights will remain on. or 2-second pause after which the number of the recorded
fault code will flash in the ENGINE STOP light (red). To
The bottom portion of the switch is the electrical system interpret the flash code, count the first sequence of red
diagnostic indicator. There are three conditions for this flashes for the first digit and after a two second delay, count
indicator as follows: the second sequence of red flashes for the second digit.
a. On solid with buzzer sounding - There is an When the number has finished flashing in red, the ENGINE
interruption of communication over the main canbus WARNING light (yellow) flashes again. The lamps flash each
control line between the crane’s electronic control fault code 3 times before advancing to the next code. To skip
modules. Proper crane operating condition shall be to the next fault code, move the ENGINE DIAGNOSTIC
restored as quickly as possible. IDLE switch in either position (+/-) to see other fault codes. If
only one active fault is recorded, the control system will
b. Flashing with buzzer sounding - An undesirable continuously display the same fault code when pressing the
condition with the crane’s joysticks has been ENGINE DIAGNOSTIC IDLE switch. Reference the engine
detected. Proper crane operating condition shall be manufacturers service manual for explanation and correction
restored before performing any hydraulic function. of the fault codes.
c. Flashing without buzzer - An undesirable
component or electrical system condition has
occurred.

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TM500E-2 SERVICE MANUAL POWER TRAIN

FUEL SYSTEM Fuel Tank

Description The fuel tank should be kept filled, especially overnight, to
reduce condensation to a minimum. Refer to the applicable
The superstructure fuel system consists of the fuel tank with engine manual for the recommended schedule for draining
fuel level sender, fuel filter and injection fuel pump. any water or sediment from the tank.
Removal
Fuel Tank
1. Position a suitable container under the fuel tank and
The fuel tank (Figure 7-3) is located in the superstructure
drain all fuel from the tank.
power plant tray beside the hydraulic tank. The fuel tank has
a draw capacity of 114 liters (30.1 gallons). The supply and 2. Tag and disconnect the lines from the tank.
return lines are on the side of the tank. Surplus fuel from the
3. Disconnect the electrical lead from the fuel level sender
engine is provided to the bottom of the fuel tank below the
unit.
fuel level. The tank is equipped with a non-vented filler cap,
chain-attached to the tank, and a fuel level sender unit which 4. Support the weight of the tank, loosen and remove the
provides a signal to a fuel quantity gauge on the front capscrews and washers securing the fuel tank in the
console in the superstructure cab. powerplant tray. Remove the tank.
5. If a new tank is to be installed, remove the fittings and
Injection Fuel Pump
fuel level sender from the tank and install them in the
The fuel oil is finely atomized as it is injected into the cylinder new tank.
and ignited by the heat of the compression. It is metered
Installation
also, before injection, to meet the load requirements
imposed upon the engine. Surplus fuel, returning from the 1. Position the new tank in the powerplant tray and secure
injectors, is bypassed back to the fuel tank or to the inlet side with the capscrews and washers. Torque the capscrews
of the pump. The continuous flow of fuel through the injectors 85 to 93 Nm (63 to 69 pounds-foot).
helps to cool the injectors and to purge air from the system.
2. Connect the electrical lead to the fuel level sender unit.
Maintenance 3. Connect the lines to the fittings on fuel tank in
accordance with the identification marks made during
NOTE: The entire fuel system must be maintained air tight
removal.
to prevent loss of prime.
4. Service the tank.

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POWER TRAIN TM500E-2 SERVICE MANUAL

2
1

7 3, 4

6955-11

Rear of Superstructure

FIGURE 7-3

Item Description Item Description

1 Fuel Tank 5 Oil Cooler
2 Fuel Level Sensor 6 Fuel Filter
3 Capscrews 7 Powerplant Tray
4 Washers

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TM500E-2 SERVICE MANUAL POWER TRAIN

AIR INTAKE SYSTEM Check For Filter Restriction

As a dry cleaner element becomes loaded with dust, the
Description vacuum on the engine side of the air cleaner (at the air
The engine air intake system consists of an air cleaner and cleaner outlet) increases.
associated piping for channelling the air from the The vacuum is generally measured as restriction in
atmosphere to the engine turbocharger intake. kilopascals or inches of water. The engine manufacturer
The air cleaner is the dry-type with a replaceable element places a recommended limit on the amount of restriction the
and is located above the engine on the powerplant tray. engine will stand without loss in performance before the
(Figure 7-4). A service indicator, designed to indicate red element must be cleaned or replaced. Cummins allows a
when servicing is required, is installed at the air cleaner vacuum of 6.2 kPa (25 inches of water) maximum with a dirty
outlet. air cleaner at maximum governed RPM.

On the Cummins QSB3.3 engine there are electric air A service indicator on the air cleaner housing will indicate
heating elements that are located in the engine’s intake air when the filter needs to be cleaned or replaced. Reset the
stream. These elements heat the intake air when starting the indicator each time the air cleaner is serviced. If the
engine in cold ambient conditions. Startability and white indicator’s accuracy is suspect, a water manometer is the
smoke control are enhanced by the use of an intake air most accurate and dependable method of measuring
heater. A WAIT-TO-START indicator is located on the front vacuum.
console in the superstructure cab to indicate when to crank To use the manometer, hold it vertically and fill both legs
the engine. approximately half full with water. One of the upper ends is
connected to the restriction tap on the outlet side of the air
Maintenance cleaner by means of a flexible hose. The other end is left
open to the atmosphere.
Air Cleaner Checks
Maximum restriction in the air cleaner occurs at maximum air
Dust passing the air cleaner can cause rapid engine wear. All flow. On this turbocharged diesel engine, the maximum air
connections between the air cleaner and the engine must be flow occurs only at maximum engine power.
tight and sealed. If these connections are well sealed, and
there is still evidence of dust leakage, check the following With the manometer held vertically and the engine drawing
places for possible trouble (Figure 7-4). maximum air, the difference in the height of the water
columns in the two legs, measured in inches or centimeters,
NOTE: Dust that gets by the air cleaner system can often is the air cleaner restriction. Restriction indicators are
be detected by looking for dust streaks on the air generally marked with the restriction at which the red signal
transfer tubing or just inside the intake manifold flag locks up.
inlet.
If the initial restriction on a new or clean filter reads above the
1. Inspect the air cleaner outlet tube for damage. maximum allowed for the engine, check the following items.:
2. Ensure the element gasket washer is not damaged and
the washer’s rubber face seals against the element.
1. Ensure the air cleaner inlet is not plugged.
7
2. Inspect the air cleaner outlet to be sure it is not plugged
3. Inspect the element gasket for damage. by paper, rags, etc.
4. Check for structural failures and replace damaged parts. 3. Ensure the correct size connections are used between
5. Inspect the restriction indicator tap for leaks. the air cleaner and the engine.
4. Ensure all inlet accessories are the correct size and are
not plugged by any foreign object.

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POWER TRAIN TM500E-2 SERVICE MANUAL

Rear of Superstructure
4
5
1

2 7

6823

6955-10

FIGURE 7-4

Filter Element Replacement

Item Description
1 Hood CAUTION
2 Mounting Bands Never service the air cleaner while the engine is running.
3 Air Cleaner
1. Unlatch the latches, open the air cleaner body and
4 Air Restriction Indicator withdraw the element as follows:
5 Air Intake Tube a. RELEASE THE SEAL GENTLY. The filter element
6 Powerplant Tray fits tightly over the outlet tube, creating the critical
7 Engine seal on the inside diameter of the filter endcap. The
filter should be removed gently to reduce the
amount of dust dislodged. There will be some initial
resistance, similar to breaking the seal on a jar.
Gently move the end of the filter up and down and
side to side or twist to break the seal (Figure 7-5).

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TM500E-2 SERVICE MANUAL POWER TRAIN

FIGURE 7-7
FIGURE 7-5

b. AVOID DISLODGING DUST FROM THE FILTER. 5. Install the cover on the air cleaner body with the two
Gently pull the filter off the outlet tube and out of the arrows pointing up. Secure the cover with the latches.
housing (Figure 7-6). Avoid knocking the filter
6. Check all connections and ducts for an air tight fit. Make
against the housing.
sure that all clamps, bolts, and connections are tight.
Check for holes in piping. Leaks in the air intake system
may send dust directly to the engine.

Element Cleaning
Washing in a water-detergent solution or blowing out with
compressed air are two accepted methods for cleaning the
element of the air cleaners. If the element contains
substantial amounts of soot or oil fumes, washing in water
works better than compressed air. If the contaminant is found
to be mostly loose dust, either method works equally well.
FIGURE 7-6
Elements that are cleaned with compressed air can be put
2. Clean the element as outlined in ELEMENT CLEANING. back into service immediately. Elements cleaned by washing
Replace the element after six cleanings or annually, must be dried before returning them to service.
whichever comes first.
NOTE: Some elements are partially covered by a plastic
3. Inspect all parts of the intake system and air cleaner. Be sleeve with fins. The covered portion can be
sure to clean the sealing surface of the outlet tube and cleaned with water or air without removing the
the inside of the outlet tube. sleeve. Use a stiff fiber (not wire) brush to remove
oil and grease deposits from the sleeve and fins.
4. Install the cleaned or new element into the air cleaner
body as follows:
Never remove the sleeve and fins from the
element.
7
a. INSPECT THE FILTER FOR DAMAGE. Always
Cleaning With Compressed Air
look for filter damage, even if a new filter element is
being installed. Pay special attention to the inside of
the open end (sealing area). Do not install a
damaged filter.
b. INSERT THE FILTER PROPERLY. The seal area is
on the inside of the open end of the primary filter. A
new filter has a dry lubricant to aid installation. The
critical sealing area will stretch slightly, adjust itself
and distribute the sealing pressure evenly. To
complete a tight seal, apply pressure at the outer
rim of the filter, not the flexible center (Figure 7-7).
No cover pressure is required to hold the seal.
FIGURE 7-8

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POWER TRAIN TM500E-2 SERVICE MANUAL

CAUTION
Pressure at the air nozzle must not exceed 690 KPA
(100 PSI).

1. Direct a jet of clean, dry air from the inside of the filter
element, perpendicular to the pleats (Figure 7-8).
2. Move the air jet up and down along the pleats, slowly
rotating the element, until no more dust is being
removed. Do not rupture the element with the nozzle or
the air jet.
Cleaning With Water FIGURE 7-10

CAUTION
Heated air (maximum temperature 71°C [160°F]) must
have circulation. Do not use light bulbs for drying
elements.

7. Mechanized drying methods can be used.

Inspection
Element
FIGURE 7-9

1. The elements can be cleaned by washing with water and

a good non-sudsing detergent. Direct a jet of clean, dry
air from the inside of the filter element. Wash the
element after the loose dust and soot are removed.

CAUTION
Never use gasoline or solvents to clean the elements. FIGURE 7-11

2. Dissolve the detergent in a small amount of cool water.

3. Add warm water (approximately 38°C [100°F]) to get the CAUTION
proper proportions of detergent and water (about one Do not touch the inside of the filter with a bare light bulb.
cup of detergent to five gallons of water).
4. Soak the element for at least 15 minutes. After cleaning the filter element, inspect the element for
damage. Look for dust on the clean air side, the slightest
5. Agitate the element for about two minutes to loosen the rupture, or damaged gaskets. A good method to use to
dirt (Figure 7-9). detect ruptures in the element is to place a light inside the
element and look toward the light from the outside
(Figure 7-11). Any hole in the element will pass dust to the
CAUTION engine and cause unnecessary engine wear. Replace the
Water pressure from a hose or tap should not exceed element if holes are evident.
276 kPa (40 PSI).
Air Cleaner Body
6. Rinse the element with clean water until the water Before installing the filter element, remove foreign material
coming through the element is clean. Air-dry the element (leaves, lint or other foreign matter) that may have collected
thoroughly before using (Figure 7-10). inside the air cleaner body. Inspect the inside of the body for
dents or other damage that would interfere with air flow or

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TM500E-2 SERVICE MANUAL POWER TRAIN

with the fins on the element or inside the body. Repair any Check the condition of the valve and lips frequently and keep
body dents, being careful not to damage the sealing them clean (Figure 7-12). The valve lips should be open only
surfaces. Be sure to clean the sealing surface of the outlet when the engine is shut down, or running at low idle speed. If
tube and the inside of the outlet tube, taking care not to the valve is turned inside out, check for a clogged air cleaner
damage the sealing area on the tube. inlet. Malfunction of this valve does not reduce the air
cleaner effectiveness, but does allow the element to get dirty
Vacuator Valve
faster and reduces serviceable life. If a valve is lost or
Vacuator valves are designed to expel loose dust and dirt damaged, replace it with a new valve of the same part
from the air cleaner body automatically, thus lengthening the number.
element service life. The valve lips must point straight down
and be kept free from debris to operate effectively. Mud and Duct Work
chaff can lodge in these lips periodically and hold them open
1. Check the intake pipe cap and screen for accumulation
during engine operation.
of leaves, trash, and other debris that could restrict air
flow. Repair the screen or replace the cap if any large
holes are found in the screen.
2. Check all mounting hardware for security to eliminate
possible vibration of intake piping. Such vibration leads
to early failure of hoses, clamps, and mounting parts,
and can cause hoses to slip off the connecting pipes,
allowing un-filtered air into the engine air intake.
3. Check hoses for cracks, chafing, or deterioration, and
replace at the first sign of probable failure.

FIGURE 7-12

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POWER TRAIN TM500E-2 SERVICE MANUAL

WATER COOLING SYSTEM Most of these problems can be traced to overheating;

however, an engine that is running too cold can be just as
Description troublesome.

The cooling system consists of a charge air cooler/radiator Overheating

(Figure 7-13), surge tank, engine cooling circuit, charge air An engine that is overheating may lead to troubles such as
cooler circuit, the connecting hoses and connecting tubes. the following:
Cooling system capacity is approximately 19.8 liters (21
quarts). The radiator consists of three sections; the top 1. Burned valves.
section is the charge air cooler, the middle section is the 2. Pinging or knocking.
engine water cooler, and the bottom section is the hydraulic
oil cooler. The temperature is controlled by a 88°C (190°F) 3. Excessive fuel consumption.
thermostat located between the top of the engine and the top
4. Poor lubrication - increased engine wear.
of the radiator. At all times, the antifreeze/coolant should be
properly inhibited against corrosion. It is recommended that 5. Sticking valves.
a mixture of AFC-50/50 blended ethylene-glycol, low silicate,
6. Short injector life.
fully formulated, engine antifreeze/coolant concentrate and
water which does not require a pre-charge of supplemental 7. Engine hot spots.
coolant additives (SCA) for use in initial fill of heavy duty
8. Need for higher grade fuel.
liquid cooled internal combustion engines be used at all
times. Overcooling
The crane is equipped with a superstructure cab hot water The following engine troubles result when an engine is
heater. Hot water is supplied by the engine coolant system to overcooled:
the cab heater.
1. Excessive fuel consumption.
Maintenance 2. Sludge formation in crankcase.

General 3. Corrosive acids formed in crankcase.

4. Excessive fuel deposits in the exhaust system.
The cooling system includes the radiator, surge tank,
thermostat, the fan, and water pump. Radiator hoses are
also included in this group.
Rust Prevention
The cooling system is often neglected because the effects or To keep engines operating at newness efficiency, all forms of
damage that result from an improperly maintained system rust formation must be prevented. The formation of rust in
usually occur gradually. The cooling system needs to be the cooling system is a result of the interaction of water, iron,
maintained with the same attention as other systems. and oxygen, and can only be prevented by maintaining full
strength corrosion protection at all times.
The circulation of water through the cooling system relies
entirely upon the water pump. The water pump draws water For maximum rust, freeze, and boiling point protection, an
from the radiator and forces it through the water jacket and AFC-50/50 blended, f ully formu lated e xtended life
cylinder head. There it accumulates heat and flows to the antifreeze/coolant should be maintained at all times.
right radiator tank. Then the water flows across through the
radiator core and is cooled by air from the fan. This process Engine Antifreeze/Coolant Fill Procedure
of removing heat from water as it circulates holds the engine 1. Fill the system with an AFC-50/50 blended, fully
to its efficient operating temperature. formulated extended life antifreeze/coolant. Fill to the
The following paragraphs point out several facts about bottom of the surge tank filler neck. Fill slowly. Flow
cooling system components, the effects of cooling system exceeding 12 l/min (3 gpm) can give a false reading.
neglect, and procedures to be followed for cooling system 2. Wait one minute and recheck the antifreeze/coolant
maintenance. level. Refill as necessary repeating step.

Effects of Cooling System Neglect 3. Run the engine through two (2) thermal cycles and
recheck the antifreeze/coolant level. Refill as necessary
Whenever an engine does not perform at top efficiency, a repeating step 1.
neglected cooling system may be at fault even though the
part directly responsible is not a part of the cooling system.

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10 3 7
6

5 Rear of Superstructure
11

44

FIGURE 7-13 7
Cooling/SCA Maintenance Summary
Item Description
The cooling system level should be checked every 10 hours
1 Charge Air Cooler/Radiator/Hydraulic Oil Cooler of operation or daily, whichever comes first.
2 Surge Tank 6 Months or 500 Hours
3 Charge Air Cooler Hose • Check SCA (Supplemental Coolant Additives) Levels
4 Radiator Hose (use Fleetguard kit # CC2626).
5 Heater Hose If SCA levels are less than 1.2 Units/Gal, add cummins DCA-
6 Wire Guard 4 to maintain desired level.

7 Engine 1 Year or 1000 Hours

8 Coolant Level Sensor • Test coolant for contamination condemning.
9 Radiator Supports Condemning limits are:
10 Pet Drain Cock Valve Sulfate level greater than or equal to 1500 ppm.

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POWER TRAIN TM500E-2 SERVICE MANUAL

Chloride level greater than or equal to 200 ppm. 7. If clogging of the core is relieved but not fully corrected,
allow the engine to cool, pressure-flush the system (see
The ph level is less than 6.5
Pressure Flushing) and repeat the cleaning operation.
Oil or fuel contamination can be identified by odor or color.
8. If clogging of the core, indicated by low temperature
If condemned, flush the system using a mixture of sodium spots on core, is not relieved, the radiator core must be
carbonate and water or an equivalent commercially available removed for mechanical cleaning. Mechanical cleaning
flushing agent. Refill system with fully formulated extended requires removal of the upper and lower tanks, and
life coolant. Refer to Section 9 - LUBRICATION. rodding out the accumulated rust and scale from the
water passages of the core.
NOTE: Remove the radiator cap when draining the system
to ensure proper draining.
Pressure Flushing
Cleaning 1. Disconnect both radiator hoses that connect the radiator
to the engine.
2. Clamp a convenient length of hose to the radiator core
outlet opening, and attach another suitable length of
DANGER hose to the radiator inlet opening to carry away the
The cooling system is pressurized and injury can result flushing stream.
when removing the radiator cap at operating temperature.
3. Connect the flushing gun to compressed air and water
Use proper protection to remove the radiator cap.
pressure, and clamp the gun nozzle to the hose
attached to the radiator outlet opening.
1. Coolant shut-off valves to heaters and other accessories
should be open to allow complete circulation during 4. Fill the core with water. Turn on air pressure in short
cleaning, flushing, and draining. Run the engine with blasts to prevent core damage.
radiator covered if necessary until temperature is up to
5. Continue filling the radiator with water and applying air
operating range 71 to 82 °C (160 to 180 °F). Stop the
pressure as above until the water comes out clear.
engine, remove the radiator cap, and drain the system
by opening the drain cocks on the radiator and engine 6. Clamp the flushing gun nozzle firmly to a hose attached
block. securely to the engine water outlet opening. Fill the
engine block with water, partly covering the water inlet
2. Allow the engine to cool, close the drain cocks, and pour
opening to permit complete filling.
the cleaning compound into the surge tank according to
the directions. Fill the system with water. 7. Turn on compressed air to blow out water and loose
sediment. Continue filling with water and blowing out
3. Place a clean drain pan to catch the overflow, and use it
with air until flushing stream comes out clear.
to maintain the level in the radiator. Do not spill the
solution on the vehicle paint. 8. For badly clogged water jackets that do not respond to
regular pressure flushing, remove the engine cylinder
4. Replace the radiator cap and run the engine at moderate
head and core hole plugs, and with a suitable length of
speed, covering the radiator if necessary, so the system
small copper tubing attached to the flushing gun nozzle,
reaches a temperature of 82 °C (180 °F) or above, but
flush the water jackets through the openings.
does not reach the boiling point. Allow the engine to run
at least two hours, or according to recommendations of 9. When the vehicle is equipped with a water heater
the manufacturer of the cleaning compound, at 82 °C connected to the cooling system, flush the heater,
(180 °F) so the cleaning solution may take effect. Do not following the same procedure as for the radiator core.
drive the vehicle or allow the liquid level in the radiator to
10. After completing the flushing operation, clean out the
drop low enough to reduce circulation.
surge tank overflow pipe; inspect the water pump; clean
5. Stop the engine as often as necessary to prevent boiling. the thermostat and the radiator cap control valves.
Check the thermostat for proper operation before
6. With the engine stopped, feel the radiator core with bare
installation.
hands to check for cold spots, and then observe the
temperature gauge reading. When there is no change in 11. Blow insects and dirt from the radiator core air
temperature for some time, drain the cleaning solution. passages, using water, if necessary, to soften
obstructions.

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Component Inspection become clogged, if the cooling system does not receive the
proper maintenance.
Radiator/Surge Tank
1. Core Plugs - These are sometimes mistakenly called
1. Side Tanks - Look for leaks, particularly where the tank is freeze plugs. They do not provide protection against
soldered to the core. Vibration and pulsation from freezing expansion, but are only present because of
pressure can fatigue soldered seams. engine block casting methods. Remove and replace
2. Filler Neck - The sealing seat must be smooth and core plugs that show signs of leaking or rusting through.
clean. Cams on filler neck must not be bent or worn so Use an installation tool for core plug replacement.
as to allow a loose fitting cap. Ensure the overflow tube 2. Drain Plugs - The water jacket of each engine has one or
is not plugged. more drain plugs. These should receive seasonal care
3. Radiator Cap - This is the pressure-setting type. Its and be kept free of rust and scale.
purpose is to hold the cooling system under a slight 3. Gaskets - Gaskets must be in good condition to prevent
pressure, increasing the boiling point of the cooling both internal and external leaks. If there are external
solution and preventing loss of solution due to leaks around gaskets, there may also be internal leaks
evaporation and overflow. into the engine. Proper tightening of the head bolts with
The cap has a spring-loaded valve, the seat of which is a torque wrench is essential for preventing leaks around
below the overflow pipe in the filler neck. This prevents the the head gasket.
escape of air or liquid while the cap is in position. When the
cooling system pressure reaches a predetermined point, the Water Pump
cap valve opens and will again close when the pressure falls The pump should be checked carefully for leaks and proper
below the predetermined point. lubrication. Replace or rebuild if leaking, cracked, or worn.
When removing the pressure type cap, perform the
operation in two steps. Loosening the cap to its first notch Fans and Belts
raises the valve from the gasket and releases the pressure The fan should be checked for cracked or broken blades.
through the overflow pipe. In the first stage position of the
cap, it should be possible to depress the cap approximately 3 Refer to ENGINE DRIVE BELTS in this Section.
mm (0.13 in). The prongs on the cap can be bent to adjust
this condition. Care must be taken that the cap is not too Thermostat
loose as this would prevent proper sealing.
The thermostat is of the nonadjustable type and is
incorporated in the cooling system for the purpose of
retarding or restricting the circulation of coolant during
engine warm up. Engine overheating and loss of coolant is
DANGER sometimes due to an inoperative thermostat. To check for
Loosen cap slowly and pause a moment to avoid possible t h i s c o n d i t i o n , r e m o v e t h e t h e r m o s ta t a n d t e s t b y
burning by hot water or steam. Continue to turn the cap to submerging it in hot water and noting the temperature at
the left until it can be removed. which the thermostat opens and closes. Use an accurate 7
high temperature thermometer for making this test.
4. Tubes are very small and can become easily clogged by
rust and scale. The general condition of the cooling Hoses and Clamps
system and operating temperature are indications as to
Hoses and their connections must be checked regularly
whether or not tubes are clean. Another good test is to
because they are often the source of hidden trouble. Hoses
feel the core for cold spots.
may often times appear in good condition on the outside
5. Fins are thin metal sheets that dissipate heat picked up while the inside will be partially deteriorated. If there are any
by the tubes. They should be kept free of bugs, leaves, doubts about a hose doing its job, replacement should be
straw etc., so as to allow the free passage of air. Bent made. The clamps should be inspected to make sure they
fins should be straightened. are strong enough to hold a tight connection.

Engine Water Jacket Test Equipment

The water jacket permits coolant to be circulated around the The antifreeze/coolant concentration must be checked using
cylinder walls, combustion chamber, and valve assemblies. a refractometer. “Floating ball” type density testers or
Some of these coolant passages are small and can easily hydrometers are not accurate enough for use with heavy
duty diesel cooling systems.

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POWER TRAIN TM500E-2 SERVICE MANUAL

Antifreeze/Coolant 5. Remove the capscrews and washers securing the

support plate on each side of the radiator.
Heavy duty diesel engines require a balanced mixture of
water and antifreeze/coolant. Fill the system with a AFC-50/ NOTE: The radiator assembly weighs approximately 50 kg
50 blended, fully formulated extended life antifreeze/coolant (110 pounds).
at all times. Refer to Section 9 - LUBRICATION. Do not use 6. Attach an adequate lifting device to the radiator
more than 50 percent antifreeze/coolant in the mixture assembly.
unless additional freeze protection is required. Never use
more than 68 percent antifreeze/coolant under any 7. Remove the capscrews and washers securing the
condition. Antifreeze/coolant at 68 percent provides the radiator to the mount bracket and remove the radiator
maximum freeze protection; antifreeze/coolant protection assembly from the powerplant tray.
decreases above 68 percent.
Installation
Radiator Removal and Installation 1. Position the radiator assembly in the powerplant tray
using a lifting device. Secure the radiator to the mount
Removal bracket with the capscrews and washers.
1. Set the outriggers and position the boom to over the 2. Secure the support plates to each side of the radiator
side. using with the capscrews and washers.
2. Open the drain cock at the end of the hose coming from 3. Attach the fan guards to the shroud with the capscrews
the water pump and drain the coolant into a suitable and washers.
container. Dispose of in accordance with local and EPA
regulations. 4. Connect all hoses to the radiator assembly as tagged
during removal.
3. Tag and disconnect all hoses from the top, middle, and
bottom sections of the radiator assembly. 5. Ensure the drain cock is closed.

4. Remove the capscrews and washers attaching the left 6. Service the engine coolant system, transmission oil
and right hand fan guards to the shroud. system, and the hydraulic system as necessary. Start
the engine, operate all systems and check for leaks.

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 SECTION 8
UNDERCARRIAGE
TABLE OF CONTENTS
Driveshaft and Shaft Phase Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Driveshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Half-Round End Yoke 12-point Bolt Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Maximum Driveshaft Operating Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Driveshaft Phase Angles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Center Bearing Shaft Phase Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Main Shaft Phase Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Interaxle Driveshaft Phase Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Design and Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Driveshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Driveshaft Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Construction of a Driveshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Example of Spline Galling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Universal Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Input Yoke. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Half-Round End Yoke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Driveshaft Center Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Correcting Universal Joint Operating Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Typical Chart to Record Driveshaft/Yoke Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Cutaway View of Center Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Typical Axle Housing Shims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Balancing a Driveshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Driveshaft Angles and Phasing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Driveshaft Arrows Lined Up “in phase” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Driveshaft Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Causes of Universal Joint Operating Angle Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
Vibration-related Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
First Order Vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
Second order vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
Lubrication Related Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
Typical Lack of Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
Typical Trunnion Brinelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
Typical End Galling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
Bearing Cup Rotation Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
Driveshaft, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
Removal (Half-round End Yoke Style) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
Universal Joint, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
8
Assembly (Half-round) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
Driveshaft, Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
Installation, Half-Round End Yoke Style . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14
Driveshaft, Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14
Lubrications for Universal Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14
Initial Lubrication and Relube Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14
Driveshaft Support Bearing Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
Driveshaft Maintenance Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
Universal Joint, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
Universal Joint, Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18

8-i
UNDERCARRIAGE TM500E-2 SERVICE MANUAL

U-Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18
Slip Splines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18
Driveshaft Angles, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19
Tools: Electronic Protractor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19
Preparing the crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19
Pinion Angles, Correcting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20
Wheel Bearing Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21
Adjusted Wheel End Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21
Crane Hub Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21
Nut Adjustment Torque Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22
Wheel Bearing Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22
Jam Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22
Determining Acceptable End Play Using a Dial Indicator . . . . . . . . . . . . . . . . . . . 8-22
Steering Linkage and Wheel Alignment Information . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
Wheel Alignment Measurement Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
Design & Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24
Steering Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24
Tie Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24
Tie Rod Arms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-25
Steering Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-25
Draglink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-25
Steering Gear and Pitman Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-25
Steering Column / Steering Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-26
Steering Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-26
Wheel Alignment Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-26
Checking Air Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27
Checking Lug Nut Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27
Front Suspension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27
Rear Axle and Rear Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27
Front Wheel Alignment Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27
Caster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27
Camber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-28
Toe-In / Toe-Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-29
Turning Angles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-29
Rear Wheel Alignment Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-30
Thrust Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-30
Tandem Scrub Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-31
Typical Wear Patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-31
Incorrect Tire Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-31
Incorrect Camber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-31
Incorrect Toe and Axle Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-31
Dual-Wheel Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-32
Incorrect Caster and Wheel Imbalance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-32
Cuts In the Tire Tread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-32
Spot Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-32
Feathered Edges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-33
Cupping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-33
Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-33
Ball Joint Wear Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-33
Toe Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-34
Turn Angle Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-35
Caster Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-35
Drive Axle Thrust Angle Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-36
Important Safety Information Before Making Ride Height Adjustment . . . . . . . . . . . . . 8-38

8-ii
TM500E-2 SERVICE MANUAL UNDERCARRIAGE

Shock Absorbers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-38

Air Spring Inflation And Deflation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-38
Air Spring Inflation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-38
Air Spring Deflation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-38
Support Beam And Cross Brace Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-38
Cross Brace Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-38
Ride Height Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-38
Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-40
Lateral Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-40
Axle Pinion Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-41
Drive Axle Alignment Inspection Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-41
Ride Height Alignment Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-42
Ride Height Pinion Angle Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-44
Adjustment Of 1.5 Degrees Or Less . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-44
Adjustment Of More Than 1.5 Degrees . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-44
Steering Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-44
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-45
Steering Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-45
Steering Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-45
Steering Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-45
Test and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-46
Special Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-46
Special Tools And Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-46
Special Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-46
Hydraulic Flow Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-46
Design and Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-47
Steering Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-47
Steering Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-47
Power Steering Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-48
Steering Geometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-48
Fluid Reservoir and Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-49
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-49
Tests and Adjustments Steering Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-51
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-51
Testing Pump Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-51
Testing Pump Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-51
Testing Steering Gear Internal Leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-52
Steering Knuckle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-52
Adjusting Steering Gear Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-52
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-52
Replacing Power Steering Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-52
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-52
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-53
Replacing Steering Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-53
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-53 8
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-53
Replacing Steering Fluid Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-54
Changing Power Steering Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-54
Bleeding Steering Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-54
Overhauling Steering Assist Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-55
Preparation Before Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-55
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-55
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-55
ABS System General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-56
Anti-Lock Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-56
ABS System Electronic Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-56
Anti-Lock Brake System Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-56

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UNDERCARRIAGE TM500E-2 SERVICE MANUAL

Traction Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-57

Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-57
Tooth Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-58
Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-58
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
ABS Fault Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-65
Test and Adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-65
Traction Control Valve Function Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-65
Traction Control Valve Differential Pressure Check . . . . . . . . . . . . . . . . . . . . . . . 8-66
Traction Control Valve Solenoid Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-66
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
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-70
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-71
Wheel Speed Sensor, Replacement (Rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-72
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-72
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-72
Front Modulator Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-73
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-73
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-73
Rear Modulator Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-74
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-74
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-74
ATR Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-75
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-75
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-75
ABS Electronic Control Unit Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-76
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-76
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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

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TM500E-2 SERVICE MANUAL UNDERCARRIAGE

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
Initial Start-up Procedure for AL-6 / EC-16 or AL-7 / EC-17 ECU . . . . . . . . . . . . . . . . . 8-90
Section I - ABS Warning Lamp Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-91
Section II - Inspection for Illuminated LEDs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-92
Section III - Inspection for Illuminated LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-93
Section IV - Inspection for Illuminated LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-94
Section V - Testing for Power to the ABS ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-95
Section VI A - Testing the Modulator Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-96
Section VI B - Testing the Modulator Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-97
Section VII A - Testing the Wheel Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-98
Section VII B - Testing the Wheel Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-99
Section VIII - Testing for False Indication Caused by ABS Warning Lamp Relay . . . . 8-100
Section IX - Testing for False Indication Caused by Wheel Speed Components . . . . 8-101
Section X - Testing TCS Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-102
Section XI - Testing Traction Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-103
Section XII - Testing J1922 Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-104
Outriggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-105
Outrigger Circuit Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-105
Outrigger Beam Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-108
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-108
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-108
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-111
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-111
Wear Pad Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-111
Extension Cylinder Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-112
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-112
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-113
Stabilizer Cylinder Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-113
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-113
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-113 8
Outrigger Control Valve Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-114
Pilot Operated Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-114
Outrigger Selector Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-114
Outrigger Control Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-114

8-v
UNDERCARRIAGE TM500E-2 SERVICE MANUAL

8-vi
TM500E-2 SERVICE MANUAL UNDERCARRIAGE

SECTION 8
UNDERCARRIAGE
DRIVESHAFT AND SHAFT PHASE ANGLES Maximum Driveshaft Operating Angle
This information covers the function, specifications, and
service of driveshafts and universal joints for your crane. Normal
Information also includes recommended shaft phase angles Angles Driveshaft
Maximum Operating Angles
for optimum driveline performance. RPM
5000 3.25°
SPECIFICATIONS 4500 3.67°
Driveshaft 4000 4.25°
3500 5.00°
Universal Joint Journal Cross Dimensions
3000 5.83°
2500 7.00°
2000 3.67°
1500 1.50°

Driveshaft Phase Angles

Center Bearing Shaft Phase Angle

α Center Bearing
Crane Model Axle Shaft Phase
Angle
TM500E-2 All 0°

FIGURE 8-1 Main Shaft Phase Angle

α Main Shaft
NOTE: Measure the diameter (A) and the span, or length Crane Model Axle
Phase Angle
(B) of the journal cross to determine universal joint
TM500E-2 All 0°
size or series.

Series A B
Interaxle Driveshaft Phase Angle
1710HD 1.30" 32.94 mm 5.78" 146.84 mm

Half-Round End Yoke 12-point Bolt

Specifications 8
The 12-point head bolt should be alloy steel equivalent to
SAE Grade 8, high strength bolt. These bolts have a nylon
patch for locking. The 1/2" - 20 thread bolt should be torqued
at 115 - 135 ft-lb (156 -183 N·m).

FIGURE 8-2

PRELIMINARY Published 10-05-2007, Control # 151-00 8-1

Undercarriage TM500E-2 SERVICE MANUAL

The interaxle driveshafts are designed to have a particular DESIGN AND FUNCTION
phase angle as shown in the following table. If the shaft is
phased correctly, it should not be changed. Driveshafts
If the shaft is not phased properly, it should be properly The driveshaft is a steel tube that transmits power from the
phased and rebalanced. It is very important to have the transmission output shaft to the differential. To accommodate
balancing operation done before reinstalling the newly the various types of model, wheel base and transmission
phased shaft, to eliminate vibration and wear problems combinations, driveshafts differ in length, diameter and type
associated with the shaft. of splined yoke. Each shaft is installed in the same manner. A
NOTE: If the shaft is phased, there are “timing” marks near universal joint and splined yoke are located at the
the splines. transmission rear extension. The slip yoke differential
assembly moves up and down. The spline is lubricated
To check the phasing, hold the end yoke vertically, internally through a grease fitting. An oil seal prevents
away from you, and look down the length of the leakage and protects the slip yoke from dust, dirt and other
s h a f t . Tu r n t h e e n d y o k e c l o s e s t t o y o u harmful materials.
counterclockwise to find the proper angle or the
proper number of spline teeth. Since the driveshaft is a balanced unit, it should be kept
completely free of undercoating and other foreign material
which would upset shaft balance.

Typical Driveshaft and Universal Joint Assembly

FIGURE 8-3

On models that use a two-piece or three-piece shaft, the

shaft is supported near its splined end in a rubber-cushioned
Item Description
ball bearing (commonly referred to as the center bearing)
1 Transmission which is mounted in a bracket attached to a frame
2 Yoke crossmember. The center bearing is permanently lubricated
and sealed.
3 Driveshaft Tubing
4 Center Bearing Driveshaft Function
5 Universal Joint The basic function of the driveshaft is to transmit power from
one point to another in a smooth, continuous action. In trucks
6 Seal
and construction equipment, the driveshaft is designed to
7 Slipshaft Spline send torque through an angle from the transmission to the
axle (or auxiliary transmission).
8 Differential

8-2 PRELIMINARY Published 10-05-2007, Control # 151-00

TM500E-2 SERVICE MANUAL UNDERCARRIAGE

The driveshaft must operate through constantly changing UNIVERSAL JOINTS

relative angles between the transmission and axle. It must
also be capable of changing length while transmitting torque.
The axle of a crane is not attached directly to the frame, but Exploded View of Universal Joint
rides suspended by springs in an irregular, floating motion.
This means the driveshaft must be able to change length and
operating angles when going over bumps or depressions.
The universal joints permit the driveshaft to operate at
different angles, while slip joints permit lengthening or
shortening of the driveshaft.

Construction of a Driveshaft

FIGURE 8-5

Item Description
1 Trunnion
2 Seal

FIGURE 8-4 3 Bearing

4 Washer
Example of Spline Galling 5 Bearing Cap
To transmit required torque loads, the driveshaft must be The simple universal joint is basically two Y-shaped yokes
durable and strong. Forged steel and high-strength end connected by a crossmember called a “spider.” The spider is
yokes are used to provide the necessary rigidity required to shaped like an “X,” and has arms that extend from it called
maintain bearing alignment under torque loads. trunnions. The spider allows two yokes/shafts to operate at
an angle to each other.
Anti-friction bearings are used to withstand oscillating loads
while the driveshaft is rotating at high speeds. The needle This type of universal joint is designed to make disassembly
roller bearings on the cross trunnions carry large loads and and reassembly a comparatively simple matter. No hand
are used because of their high capacity in a limited space. fitting or special tools are required. The journals and needle
bearing assemblies are the parts most subject to wear. When
The bearing assembly inside-diameter crowning and tapered
it becomes necessary to replace bearings, remove the
thrust pads distribute load more evenly to significantly
driveshaft from the crane.
reduce end galling. Bearing assemblies are individually
sealed to retain lubricants and keep foreign material out. If The procedure used to remove a driveshaft is shown in
lubricants become contaminated with water or abrasive Figure 8-6
material, needle roller bearing life is seriously affected.
After disassembling a universal joint, check the fit of each
Abrasive material is a major problem for cranes operating in bearing on its respective journal. If looseness is evident, the
extremely moist and dirty environments. To combat this
problem, synthetic rubber seals are used for increased
journal cross and all four bearing assemblies and journal
cross are in serviceable condition. Clean bearings and
8
component life, ability to withstand high temperatures, and reassemble universal joint with bearings and journals in their
result in less critical relubrication cycles. original positions.
The sliding splines between slip joint and permanent joint
must support the driveshaft and be capable of sliding under
Input Yoke
full torque loads. To aid in this axial or slip movement, There are three possible fastening designs that are used for
Glidecote was developed to reduce sliding friction, reducing the rear axle input yoke. Of the three types, the full- and half-
thrust under high torque. This non-metallic coating also round fastening systems are the most often used. Unless
prevents spline galling and extends spline life. specified otherwise, this series cranes are typically equipped
with the half-round yoke. A picture of each yoke type is
provided in this section for reference.

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Undercarriage TM500E-2 SERVICE MANUAL

Half-Round End Yoke NOTE: Both sides of the axle must be changed to balance
the pinion and universal joint angles. Also,
remember that changing the pinion angle may
affect the rear axle lube level(s).
If unusual universal-joint operating angle problems are
experienced, consult your authorized Manitowoc dealer.

Cutaway View of Center Bearing

FIGURE 8-6

Item Description
1 Half-round End Yoke
2 Bearing Strap
3 Bolts
4 To the Axle

DRIVESHAFT CENTER BEARING

If replacing the center bearing, it is not necessary to pack it
with grease. However, chassis lubricant should be packed
within the dust shields to form a dam to help prevent water
FIGURE 8-7
and dirt from reaching the bearing. The dust shields are
staked into position.
Item Description
Correcting Universal Joint Operating Angles
1 Rubber Mount
The recommended method for correcting severe universal
joint operating angles depends on the crane’s suspension or 2 Bearing
driveshaft design. 3 Shield

Typical Chart to Record Driveshaft/Yoke 4 Grease Area

Angles Typical Axle Housing Shims
The front leaf-spring suspensions (9500 Lower Camber Flat
Leaf model), axle shims (thin wedges) can be installed
between the spring and axle housing. This will tilt the axle
housing to raise the pinion up and correct the universal joint
operating angles. Shims are available in a range of sizes to
change the pinion angle of the rear axle.
The rear tandem suspensions (Hendereckson PAZ-460 Air
AT54) use torque or radius rods to control the pinion angles.
Various methods are used: shims between the torque rod
and axle; adjustable torque rods; and eccentric bushings in
the radius rod leaf eye. FIGURE 8-8
Generally, adding or removing a 1/4" (6 mm) shim from a
torque rod changes the pinion angle 0.75°. A 0.75° change in
the pinion angle changes the universal joint operating angle
about 0.25°.

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Balancing a Driveshaft The simple one-plane angle found in most installations

confines all driveline slopes to one plane, usually the vertical
Rebuilding the driveshaft assembly includes replacing worn plane.
cross and bearing assemblies with a new kit. These kits
replace the part of a driveshaft most subject to wear in The other type of driveshaft angle is the compound angle in
operation. The potential off-center condition present in the two planes. This is found in driveshaft designs where offset
cross and bearing assemblies makes it desirable to balance exists in both the vertical and horizontal planes.
every assembly after installing new cross and bearing kits.
When the tubing is bent or twisted or the tube fittings are High angles combined with high RPM reduce U-joint life. Too
distorted, it will be necessary to replace the driveshaft large and unequal U-joint angles can cause vibration and
assembly. contribute to U-joint, transmission and differential problems.
Improper U-joint angles must be corrected.
Driveshaft Angles and Phasing
Ideally, the operating angles on each end of the driveshaft
Proper driveshaft angles and correct phasing of the yokes should be equal to or within 1° of each other, have a 3°
are very important in maintaining long life and quiet running ma x im um o pe rat ing a ng l e an d ha ve at lea s t 0. 50 °
driveshafts. continuous operating angle.

When in phase, the slip yoke lugs (ears) and tube yoke lugs The main factor in determining maximum allowable
(ears) are in line. Normally, this is the ideal condition and operating angles is RPM. As a guide to maximum normal
gives the smoothest running driveshaft. There should be an operating angles, see Maximum Driveshaft Operating Angle
alignment arrow stamped on the slip yoke and on the tube on page 8-1
shaft to ensure proper phasing when assembling these
components. If there are no alignment marks, they should be Driveshaft Arrows Lined Up “in phase”
added before disassembly of the driveshaft to ensure proper
reassembly.
Be careful not to change or re-mark a driveshaft assembly
manufactured out-of-phase for special applications. Locate
the arrows marked for the out-of-phase driveshaft and do not
change them. Do not replace an out-of-phase driveshaft with
a driveshaft that is in phase.
Phasing is relatively simple on a two-joint set. Be sure that
the slip yoke lugs and the tube yoke lugs are in line.
Driveshaft angles are a little more complicated. The U-joint FIGURE 8-9
operating angle is the angle formed by two yokes connected
by a cross and bearing kit. There are two kinds of U-joint
angles.

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Undercarriage TM500E-2 SERVICE MANUAL

DRIVESHAFT TROUBLESHOOTING

Fault Reason Remedy

Vibration
Low-gear shudder U-joint angle too large for continuous Reduce U-joint continuous running
running angle.
Worn U-joint Replace U-joint.
Install 2-piece driveshaft with center
Incompatible driveshaft
support bearing.
Driveshaft weight not compatible with
Use larger diameter tube.
engine/transmission mounting
Shim drive train components to equalize
Driveshaft too long for speed
U-joint angles.
Shim drive train components to equalize
Unequal U-joint angles
U-joint angles.
Inspect U-joint flex effort for looseness,
Excessively loose U-joint for speed torque to specification, straighten and
balance shaft.
Driveshaft out of balance; not straight
torsional and/or inertial excitation; Consult component manufacturer;
secondary couple load reaction at center replace shaft bearing.
support bearing. Improper phasing
Check driveshaft for correct yoke
Inadequate torque on bearing plate cap
phasing. Torque bearing cap screws to
screws
specifications.
Premature Wear
Use Spicer alignment bar to check for
Low-mileage U-joint wear End yoke cross hole misalignment
end-yoke cross-hole misalignment.
Repeated U-joint wear Check U-joint operating angles with a
spirit level protractor, or the Spicer
Excessive angularity Anglemaster™ Electronic Driveshaft
Inclinometer; reduce excessive
operating angles.
Lubricate according to specifications;
Contamination and abrasion
Replace U-joint kit.
End galling of cross trunnion and Torque bearing retention method to
Excessive U-bolts torque on retaining nuts
bearing assembly specifications.
Contamination and abrasion Replace U-joint kit.
Improper lubrication Lubricate according to specifications.
Reduce U-joint continuous running
Excessive continuous running load
Needle rollers brinelled into bearing U-joint operating angles.
cup and cross trunnion Excessive torque load (shock loading) Continuous operation at high angle or
angle high speed.
Realign to proper running angle,
Broken cross and bearing Worn or damaged seals
minimum 0.50.

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CAUSES OF UNIVERSAL JOINT LUBRICATION RELATED PROBLEMS

OPERATING ANGLE CHANGES The most common reasons for U-joint wear are lack of
• Suspension changes, worn bushings in the spring lubrication, inadequate lube quality, inadequate initial
hangers, worn bushings in the torque rods, incorrect air lubrication or failure to lubricate properly and often enough.
spring height.
Typical Lack of Lubrication
• Revisions in the components of the driveshaft.
• Stretching or shortening of the chassis.
• Adding an auxiliary transmission or transfer case in the
main driveshaft.
• Worn engine mounts.

VIBRATION-RELATED PROBLEMS
Driveshaft assemblies can be the source of first order
vibrations (one excitation per revolution) and second order
vibration (two excitations per revolution).

First Order Vibration

First order vibration results from an imbalance in the FIGURE 8-10
driveshaft assembly caused by improper balancing
procedures, loss of the driveshaft balancing weights, Generally, failure to lubricate properly can lead to one of two
excessive runout, poor spline fit or undercoating on the problems: brinelling or end galling. Brinelling is indicated by
driveshaft. grooves made by the needle roller bearings on the trunnion
of the cross. Brinelling can also be caused by too much
Driveshaft vibration problems due to an imbalance or first torque for the capacity of the U-joint used. End galling is a
order excitation are crane-speed sensitive since driveshaft displacement of metal at the end of the trunnion and can also
speed is directly related to crane speed by the rear axle ratio. be related to angularity problems. Both of these problems
In the case of conditions as a “sloppy” spline fit, imbalance can be caused by lack of lubrication.
may be engine-torque sensitive in that the torque causes the
spline to center itself differently than if no torque were Typical Trunnion Brinelling
present.

Second order vibration

Second order vibration occurs when the driveshaft transmits
torque through an angle at each end. The excitation level is
related to both the amount of angle the U-joints operate
through and the amount of torque transmitted. A second
order driveshaft excitation is sensitive to crane speed, torque
and jounce. Driveshaft angles must be set in the optimum
position to accommodate various loads and rear-axle windup
during acceleration. 8
To determine if the driveshaft is the source of a vibration,
drive the crane and note the speed range at which the
vibration occurs and the vibration frequency (using a Reed
tachometer). Determine the driveshaft speed by placing the FIGURE 8-11
transmission in direct drive and reading the driveshaft RPM
with an engine tachometer. If it is determined that the
vibration is related to first order excitation of the driveshaft,
balance the driveshaft.

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Undercarriage TM500E-2 SERVICE MANUAL

Typical End Galling REPAIR

Driveshaft, Removal

! DANGER
Before working on a crane, set the parking brakes, place
the transmission in neutral, and block the wheels. Failure
to do so can result in unexpected crane movement and
can cause serious personal injury or death.

! DANGER
Do not go under the crane while the engine is running. Do
not engage or disengage driven equipment by hand from
FIGURE 8-12
under the crane when the engine is running. Do not work
on a shaft (with or without a guard) when the engine is
Failures which are not a result of lubrication film breakdown running. Rotating shafts can snag clothes, skin, hair, and
are associated with the installation, angles and speeds, and hands, etc. Failure to follow these instructions can result
manufacturing discrepancies. in serious personal injury or death.
Driveshaft failures through torque, fatigue and bending are
associated with overload, excessively high U-joint angles
and driveshaft lengths excessive for operating speeds.
! WARNING
Driveshaft Troubleshooting on page 8-6 is intended to
Driveshafts are very heavy. Install a support strap when
provide probable causes and corrections for typical
servicing a driveshaft. Failure to install a support strap can
driveshaft problems. Through normal crane maintenance
result in personal injury.
and recognition of discrepancies, this may enable service
technicians to make the corrections necessary to ward off a
serious breakdown. Removal (Half-round End Yoke Style)
For half-round end yoke assembly, install a nylon support
BEARING CUP ROTATION strap. Remove the strap retaining bolts one end at a time and
TROUBLESHOOTING release the driveshaft.

Some bearing “creep” is normal on the half-round (quick-

disconnect) U-joints and is not detrimental to performance.
However, excessive bearing rotation can cause premature
component wear. The root causes of rotation are:
• Intermixing components that are not manufactured by
Spicer.
• Improper torque on retaining strap bolts. See
Half-Round End Yoke 12-point Bolt Specifications on
page 8-1.
• Failure to firmly seat U-joints in the end yoke saddles
FIGURE 8-13
before the strap bolts are tightened. See Half-Round
End Yoke 12-point Bolt Specifications on page 8-1.
• Dirty bearing saddles. Grease, paint, or other foreign Item Description
matter in the end yoke saddles will increase the risk of
bearing cup rotation. 1 Half-round End Yoke
2 Bearing Strap
3 Bolts
4 To the Axle

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Universal Joint, Replacement

Tools: Removing Cap Locking Tabs

• No-Go Wear Gauge

• Alignment Bar

! DANGER
Driveline components should be assembled according to
proper procedures. Do not use worn out or damaged
driveline components. Do not use driveline components in
a non-approved application. Failure to follow these
instructions can result in serious personal injury or death.

! WARNING
Driveshafts are very heavy. Install a support strap when
servicing a driveshaft. Failure to install a support strap can
result in personal injury.

Disassembly
1. Place the driveshaft in a bench vise, clamping on the
tube adjacent to the cross and bearing assemblies being
removed.

! WARNING
Do not distort the tube with excessive pressure.
FIGURE 8-14
2. Completely remove the cross and bearings from both
ends of the driveshaft by disassembling the bearing
assemblies from the slip yoke and tube yoke (and flange
yoke where applicable).

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Undercarriage TM500E-2 SERVICE MANUAL

Checking Yoke Alignment with Alignment Bar

Removing Cross

FIGURE 8-15
FIGURE 8-16

3. After removing the cross and bearings at both ends,

inspect the cross hole surfaces for damage or raised Assembly (Half-round)
metal. Raised metal can be removed with a rat-tail or
half-round file and emery cloth. Place each end of the driveshaft, less cross and bearing kits,
into a bench vice. Check the paint markings placed on the
4. Check the yoke lug cross holes with a No-Go Wear tube and slip yoke assembly before removing from the crane
Gauge and then use an Alignment Bar to inspect for to be sure they are lined up or in phase.
damage by sliding through both cross holes
simultaneously. The alignment bar identifies yoke lugs
that have taken a set because of excessive torque. Driveshaft Phasing
Raised metal or distorted lugs can cause premature
cross and bearing problems.
5. At this time, clean the cross holes of the yokes on the
transmission and axle and inspect with an alignment bar
gauge as described in step 4. If, after properly cleaning
the cross holes, the alignment bar will not pass through
simultaneously, the yoke lugs are distorted and the yoke
or yokes must be replaced. 1. Correct Phasing
2. Incorrect Phasing FIGURE 8-17

1. Remove the cross and bearings from the box and

remove all four bearing assemblies. Rotate the cross to
inspect for presence of the one-way check valve in each
lube hole of all four trunnions. Then position the cross
into the end yoke with its lube fitting in line as near as
possible with the slip spline lube fitting. Keep the lube
fitting on the in board side.
NOTE: The Zerk fitting must be on the compression side
when driving forward.

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Reinstalling Bearing Cap on Trunnion

Reinstalling the Cross Into the End Yoke

FIGURE 8-17

2. Apply an anti-seize compound to the outside diameter of

the four bearing assemblies. Move one end of the cross
to cause a trunnion to project through the cross hole
beyond the outer machined face of the yoke lug. Place a
bearing assembly over the trunnion diameter and align it FIGURE 8-18
to the cross hole. Holding the trunnion in alignment with
the cross hole, press bearing flush to face of end yoke 3. When the bearing assembly is completely seated, put
by hand. the lock plate tab in place. Insert the “Grade 8” cap
screws that are furnished with the kit through the cap
NOTE: Make sure to lubricate the bearing cap before screw holes in both the lock strap and bearing assembly.
installing. Thread with hand or wrench into tapped holes in yoke.
Projecting the trunnion through a cross hole Do not torque the bolts.
beyond the machined surface of the lug will provide 4. If bearing assembly binds in cross hole, tap with ball
a surface to help align the bearing assembly with peen hammer directly in center of bearing assembly
the cross hole. plate. Do not tap outer edges of bearing plate.

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 Undercarriage TM500E-2 SERVICE MANUAL

Figure 1 Figure 2

Tapping in Bearing Cap Reinstalling Bearing Cap Bolts

FIGURE 8-19

FIGURE 8-20
NOTE: Exact fit of all driveshaft components is extremely
important. The correct parts and clean mating
surfaces are essential for safe operation and good
repair. 7. Repeat installation process for cross and bearing kit at
the opposite end of the driveshaft. Make sure to position
5. Move the cross laterally to the opposite side and through
the cross in the yoke so that the lube fitting is in line with
the cross hole beyond the machined surface of the yoke
the lube fitting at the other end.
lug. Place a bearing assembly over the cross trunnion
and slide it into the cross hole, seating the plate to the 8. For flange yoke applications, install the flange yoke,
face of the lug. bearing assemblies and bolts at this time.
6. Put the lock plate tab in place and thread the bolts with
hand or wrench into tapped holes in yoke. ! CAUTION
Using a new cross with a worn bearing assembly, or a
worn cross with a new bearing assembly will cause rapid
wear, making another replacement necessary in a short
time. Always replace the cross, four bearing assemblies
and bolts as a unit.

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Driveshaft, Installation • Cross should flex and be free from excessive bind. A
slight drag is the most desirable condition on a new
cross and bearing kit. Excessive looseness is
! DANGER undesirable and will result in an unbalanced driveshaft.

Before working on a crane, set the parking brakes, place • Mounting flanges and pilots should be free from burrs,
the transmission in neutral, and block the wheels. Failure paint and foreign substances which would not allow
to do so can result in unexpected crane movement and proper seating at assembly.
can cause serious personal injury or death.
Journal Cross and Bearing Assembly

! DANGER
Do not go under the crane while the engine is running. Do
not engage or disengage driven equipment by hand from
under the crane when the engine is running. Do not work
on a shaft (with or without a guard) when the engine is
running. Rotating shafts can snag clothes, skin, hair, and
hands, etc. Failure to follow these instructions can result
in serious personal injury or death.

! DANGER
Driveline components should be assembled according to
proper procedures. Do not use worn out or damaged
driveline components. Do not use driveline components in
a non-approved application. Failure to follow these
instructions can result in serious personal injury or death.

! WARNING
Driveshafts are very heavy. Install a support strap when
servicing a driveshaft. Failure to install a support strap can
result in personal injury.
A - “00” Series
Installation, Half-Round End Yoke Style B - “10” Series FIGURE 8-21
The installation of a driveshaft does not present any unusual
mechanical difficulties. Before installation, check the
driveshaft for the following items: Item Description

• Damage or dents on the driveshaft tubing. 1 One-way Check Valve

• Splines should slide freely with slight drag from slip shaft
2 Spherical End Rollers 8
seal. 3 Crowned Bearing Races
4 Double Lip Seal

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Undercarriage TM500E-2 SERVICE MANUAL

1. Place straps over the bearing assemblies, thread

special self-locking cap screws into tapped holes and
torque bolts to specification. See Half-Round End Yoke
12-point Bolt Specifications on page 8-1.
2. Lubricate the cross and bearing assemblies.

MAINTENANCE
Driveshaft, Lubrication
To avoid lubrication-related problems:
Lube all fittings, including those that are often over-looked,
out of sight, dirt covered or difficult to reach.
• Note how some lube fittings appear different from
FIGURE 8-22 regular chassis lube fittings and require a needle-nose
attachment for the grease gun.
• Use correct lube technique.
• Use recommended lubricant, such as NLGI Grade 2 with
Item Description extreme pressure additives and high temperature
1 Half-round End Yoke resistance.

2 Bearing Strap • Lubricate new U-joints when installing into the driveshaft
yokes.
3 Bolts
• Observe recommended lubrication cycle. See
4 To the Axle
Half-Round End Yoke 12-point Bolt Specifications on
page 8-1. One of the most common causes of U-joint
and slip yoke problems is lack of proper lubrication.
! DANGER Properly sized U-joints that are adequately lubricated at
Do not reuse half-round, self-locking retaining bolts more recommended intervals will normally meet or exceed
than five times. Follow instructions explicitly to prevent crane operation requirements. Relubrication flushes the
danger of serious personal injury or death from loss of joints, removing abrasive contaminants from the
driveshaft function. If in doubt regarding the number of bearings.
times the bolts have been removed, replace with new
bolts. Lubrications for Universal Joints
For normal application, use a good-quality, lithium-based,
1. Place the bearing assemblies on the cross trunnion and extreme-pressure (E.P.) grease that meets NLGI Grade 2
seat the bearing cup into the end yoke shoulders. specifications. Grades 3 and 4 are not recommended
NOTE: The proper procedure for installing the U-joints is to because of their reduced viscosity. For severe applications,
install the bearing cups into the yoke and firmly use a good-quality, lithium-based (or equivalent) E.P. grease
seat the cups with a soft hammer blow. with an operating temperature range of 315 to 325°F (157 to
163°C). In addition, the grease should meet the NLGI Grade
Bearing caps should be held in place by clips or 2 specifications.
tape so they will not fall off when installing the
driveshaft. Initial Lubrication and Relube Cycle
Replacement universal joint kits contain only enough grease
! DANGER to protect needle roller bearings during storage. It is
therefore necessary to completely lubricate each
DO NOT pull the U-joint into the bearing saddles by replacement kit before assembly into the yokes. Each cross
drawing down the strap with the bolts. This can cause lube reservoir should be fully packed with a recommended
distortion of the strap and improper seating of the U-joint grease and each bearing assembly should also be wiped
bearing cups. This can also result in a loss of clamping with the same grease. Fill all cavities between the needle
force, allowing the cups to rotate excessively. rollers and apply a liberal grease coating on the bottom of
each bearing assembly.

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Too much grease can cause hydraulic “lockup,” making

installation difficult. Relube the kits after installing into the Center Bearing Lubrication
yokes and before placing into service. Do this through the
lube fitting, using the same grease.
Relubrication cycles vary, depending on crane service
requirements and operating conditions. Relube splines at the
intervals recommended in Driveshaft Maintenance Interval
below.
NOTE: “On-highway” is defined as all applications that
operate less than 10% of the time on gravel, dirt, or
unimproved roads. If higher than 10% operating
time, follow off-highway recommendations.
For extended linehaul tractors, use “10” series (1610, 1710,
1760, and 1810) U-joints and Glidecote slip splines.

Driveshaft Support Bearing Assemblies FIGURE 8-24

When replacing a shaft support bearing assembly, be sure to
fill the entire cavity around the bearing weather proof grease Driveshaft Maintenance Intervals
to shield the bearing from water and contaminants. Put
enough grease in to fill the cavity to the extreme edge of the
Service miles (km) Time/Month
slinger surrounding the bearing. Lubricants must be
waterproof. 5,000 – 8,000 miles
City 3
(8,000 – 13,000 km)
Bearing Cap Lubrication 10,000 – 15,000 miles
On Highway 3
(16,000 – 24,000 km)
On/Off 5,000 – 8,000 miles
3
Highway (8,000 – 13,000 km)
10,000 – 15,000 miles
Linehaul 1
(16,000 – 24,000 km)

City is defined as all applications that require a minimum of

90% of operation time within the city limits.
On Highway is defined as all applications that operate less
than 10% of the time on gravel, dirt, or unimproved roads.
On/Off Highway is defined as all applications operating
primarily on paved roads, but requiring more than 10% of
FIGURE 8-23 operating time on gravel, dirt or unpaved roads.
Linehaul is defined as 100% of operation time on smooth
concrete or asphalt.
8
UNIVERSAL JOINT, CHECKING

! DANGER
Before working on a crane, set the parking brakes, place
the transmission in neutral, and block the wheels. Failure
to do so can result in unexpected crane movement and
can cause serious personal injury or death.

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Undercarriage TM500E-2 SERVICE MANUAL

2. If the end yokes are tight, check for excessive radial

looseness at the transmission output and rear axle input
! DANGER shafts at their respective bearings. Transmission output
Do not go under the crane while the engine is running. Do shaft radial play should not exceed 0.001" (0.025 mm).
not engage or disengage driven equipment by hand from Rear axle input shaft radial play should not exceed
under the crane when the engine is running. Do not work 0.003 – 0.007" (0.076 – 0.178 mm) for a new axle and
on a shaft (with or without a guard) when the engine is 0.013 – 0.017" (0.33 – 0.43 mm) for a rebuilt axle using
running. Rotating shafts can snag clothes, skin, hair, and reused components.
hands, etc. Failure to follow these instructions can result
in serious personal injury or death. Checking End Yokes for Looseness
The driveshaft and universal joints generally require little
maintenance, but periodic inspection is recommended for
proper driveshaft balance and universal joint lubrication.To
keep a crane operating smoothly and economically, carefully
inspect the driveshaft at regular intervals.
If the area around the caps appears to be excessively dry, it
may indicate a need for bearing relubrication or universal
joint replacement. A failing universal joint often squeaks on
start-up or “clunks” with direction change.
Vibrations and problems with the U-joint and shaft support
(center) bearing are caused by such things as loose end FIGURE 8-26
yokes, excessive radial (side-to-side or up-and-down)
looseness, slip spline radial looseness, bent shaft tubing or
missing plugs in the slip yoke. 3. Check for excessive looseness across the ends of the
bearing assemblies and trunnions. This looseness
1. Check the output and input end yokes on both the should not exceed 0.006" (0.152 mm) maximum.
transmission and rear axle(s) for looseness. If loose,
disconnect the driveshaft and retorque the retaining nut
to specification. If a yoke replacement is required, Checking Cap for Looseness
always install a new retaining nut when replacing the
yoke. Also, if the retaining nut is damaged, it must be
replaced. Most self-locking retaining nuts are only used
once.

Inspection of Input and Output Yokes

FIGURE 8-27

4. Check the slip spline for excessive radial movement.

FIGURE 8-25 Radial looseness between the slip yoke and the tubes
shaft should not exceed 0.007" (0.178 mm).

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Checking Slipshaft Splines for Looseness Checking Driveshaft for Runout

FIGURE 8-30

8. Place an axle stand next to the driveshaft and position a

dial indicator with a magnetic base onto the axle stand.
Set the dial indicator probe up against the driveshaft and
set it at zero. Rotate the driveshaft and read the runout.
The best way to check the driveshaft balance is to set a
FIGURE 8-28 dial indicator and take the highest reading, place a
weight on the low side, then spin the driveshaft and
5. Place an axle stand next to the driveshaft at the slip check for balance. Do not use more than 5 oz (150 g).
yoke. Position a dial indicator with a magnetic base onto
the axle stand. Set the dial indicator to zero against the 9. Check to see that the end plug is not loose or missing. If
yoke and read off the movement. it is, have it repaired or replaced. Loose or missing plugs
indicate that there is not enough slip movement in the
6. Check the shaft for damage, bent tubing or missing driveshaft.
balance weights. Any buildup of foreign material, such
as undercoat or concrete on the shaft, should be Closed length of the driveshaft may be too great,
removed. requiring a change in the driveshaft length. Continued
use of a long driveshaft can lead to failures of the
transmission or rear axle bearing, as well as other
Checking Driveshaft for Damage journals and bearings.

Checking Slipshaft End Plug

8
FIGURE 8-29

7. If a runout reading is required, take the reading with the

driveshaft in the crane, the rear axle jacked up, and the
transmission in neutral. This allows driveshaft rotation by
hand to check the dial indicator reading. Take the runout
reading at various locations; runout should not exceed a
maximum of 0.025" (0.64 mm).

FIGURE 8-31

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UNIVERSAL JOINT, LUBRICATION 3. Release seal tension by loosening the bolts holding the
bearing assembly that does not purge. It may be
necessary to loosen the bearing assembly
! DANGER approximately 1/16" (0.625 mm) minimum. If loosening it
does not cause purging, remove the bearing assembly
Before working on a crane, set the parking brakes, place to determine cause of blockage.
the transmission in neutral, and block the wheels. Failure
to do so can result in unexpected crane movement and
can cause serious personal injury or death. Loosening Bearing Cap

! DANGER
Do not go under the crane while the engine is running. Do
not engage or disengage driven equipment by hand from
under the crane when the engine is running. Do not work
on a shaft (with or without a guard) when the engine is
running. Rotating shafts can snag clothes, skin, hair, and
hands, etc. Failure to follow these instructions can result
in serious personal injury or death.

U-Joints
1. Use the proper lubricant to purge all four seals of each
U-joint. This flushes abrasive contaminants from each
bearing assembly and ensures all four are filled. Pop the
seals.

Lubricating U-joint

FIGURE 8-33

4. Retorque bolts to specification.

Slip Splines
The lubricant used for U-joints is satisfactory for slip splines.
Glidecote and steel splines both use a good E.P. grease
meeting NLGI Grade 2 specifications.
Lubricate splines at the intervals recommended in Driveshaft
FIGURE 8-32 Maintenance Intervals on page 8-15
1. Apply grease gun pressure to the lube fitting until
2. If any seals fail to purge, move the driveshaft from side
lubricant appears at the pressure-relief hole in the plug
to side and then apply gun pressure. This allows greater
at the slip yoke end of the spline.
clearance on the thrust end of the bearing assembly that
is not purging. 2. Now cover the pressure-relief hole with your finger and
continue to apply pressure until grease appears at the
NOTE: Because of the superior sealing capability of the
slip yoke seal.
seal design on your crane, there will occasionally
be one or more bearing assembly seals that will not
purge.

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! CAUTION
Factory set phase angles are vitally important to the
quality of the ride, the reduction of driveline vibration and
major component life. Under no circumstances should the
phasing of any component of the driveshaft system be
changed or tampered with in any way. Doing so could
cause severe vibration, decreased U-joint life and/or
damage to axles or transmissions.

Preparing the crane

1. Inflate the tires to normal operating pressure.
FIGURE 8-34 2. Park the crane on a flat and level surface, front to rear
and side to side. Do not level the crane by jacking up the
front or rear axles. Do not apply the parking brakes, and
! CAUTION make sure the rear air-suspension ride height is correct,
if applicable.
In cold temperatures, be sure to drive the crane
immediately after lubricating. This activates the slip spline 3. Jack up one rear wheel, just enough to clear the floor.
and removes the excessive lubricant. Failure to do so can
cause the excess lubricant to stiffen in the cold weather Procedure
and force the plug out. The end of the spline would then 1. Rotate the rear wheel by hand until the output yoke on
be open to collect contaminants and cause the spline to the transmission is vertical, then lower the rear wheel to
wear and/or seize. the floor. Check the driveshaft angles in the same
loaded or unloaded conditions as when the vibration or
DRIVESHAFT ANGLES, CHECKING noise occurred.
2. To determine driveshaft angles, an electronic protractor,
Tools: Electronic Protractor or equivalent, is required. To use the electronic
protractor, place it onto the component to be measured.
A display module will show the angle and in which
! DANGER direction it slopes.
Before working on a crane, set the parking brakes, place
the transmission in neutral, and block the wheels. Failure Checking Driveshaft Angle
to do so can result in unexpected crane movement and
can cause serious personal injury or death.

! DANGER
Do not go under the crane while the engine is running. Do
not engage or disengage driven equipment by hand from
under the crane when the engine is running. Do not work 8
on a shaft (with or without a guard) when the engine is
running. Rotating shafts can snag clothes, skin, hair, and
hands, etc. Failure to follow these instructions can result
in serious personal injury or death. FIGURE 8-35

3. Always measure the slope of the drive train going from

front to rear. A component slopes downward if the rear is
lower than the front. A component slopes upward when
it is higher at the rear than at the front.

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4. Check and record the angle on the main transmission. 8. To determine the universal joint operating angles, simply
This reading can be taken on the end yoke lug with the find the difference in the slopes of the components.
bearing cap assembly removed; or on a flat, machined
9. When the slopes are in the same direction on two
surface on the transmission parallel or perpendicular to
connected components, subtract the smaller reading
the output-shaft yoke lug plane. Record the reading.
from the highest reading to find the universal joint
operating angle. When the slopes are in the opposite
Checking Transmission Yoke Angle direction on two connected components, add the
readings to find the universal joint operating angle.
10. Compare the universal joint operating angles to the
instructions in Maximum Driveshaft Operating Angle on
page 8-1.

Pinion Angles, Correcting

Parts: Shim kit, including shims of the following
measurements: 1.0°, 1.5°, 2.0°, 2.5°, 0.5°.
1. Set ride height to 8.00" (20 cm) from center line of axle to
bottom of frame rail at the center axle. As a reference
point, the highest portion of the center axle housing
should be 5.25" (13.35 cm) below the rail as shown in
FIGURE 8-36 the illustration. Be sure the crane is in a level flat
surface.
5. Check the driveshaft angle between the transmission
and the forward rear axle.
Be sure to remove any rust, scale or sound-deadening
compounds from the tube shaft to obtain an accurate
measurement.
6. Check the forward rear axle input yoke angle. This can
be done by removing a bearing cap assembly and
measuring the angle on the yoke lug, or measuring at a
flat, machined surface on the rear axle parallel or
perpendicular to the input-shaft yoke lug plane.

Checking Front Axle Yoke Angle

FIGURE 8-38

2. Measure the forward pinion angle with respect to the

frame rail. This should be 3.5° as illustrated above.
3. If the angle is not correct, it should be adjusted using
washers and the required shim provided in the shim kit.
When adjusting the pinion angle, install washers at the
1.25" diameter bolt hole at the top of the axle seats.
Install required shims with thick side to the rear of the
axles. The shims should be located on the right and left
FIGURE 8-37 sides between the top axle seats and the radius leaf
springs. Torque bolts to 330 ft-lb.
7. If applicable, measure the output-yoke angle of the NOTE: If the U-bolts do not have 2 - 3 threads of the bolt
forward rear axle through the shaft yoke. This is the showing after torquing to 330 ft-lb, the existing
angle of the interaxle driveshaft between the tandem U-bolt must be replaced with a longer U-bolt.
axles and the input yoke angle of the rear-rear axle.

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4. Using an electronic protractor, measure the rear pinion

angle with respect to the frame rail. Note that the correct
angle depends on the axle model. Repeat step 3 to
Wheel Bearing Adjustment, Non-Unitized Hubs
adjust the rear angle pinion as necessary.

WHEEL BEARING ADJUSTMENT

Introduction
This information includes component specifications and
procedures for front and rear wheel bearing adjustments.

Adjusted Wheel End Systems

This system on your crane is characterized by having the
bearings, seals and lubricant all pre-installed. Bearing
adjustment is preset in the hub assembly. Unitized wheel end
components are not serviceable and should not be
disassembled.

Crane Hub Unit

The unitized hub and bearing combination for the front axle
system is also referred to as the crane hub unit. The unit FIGURE 8-39
contains bearings which are lubricated for the life of the
component. This unit has no serviceable parts and requires
no adjustment.
200 ft-lb (270 N·m) while
Initial Adjusting Nut Torque
rotating wheel
Nut Adjustment Torque Specifications
Initial Back Off One full turn
NOTE: Never use an impact wrench when tightening or
loosening lug nuts or bolts during the adjustment 50 ft-lb (68 N·m) while
Final Adjusting Nut Torque
procedure. rotating wheels

BACK OFF JAM NUT TORQUE Acceptable End Play

Threads Torque
Axle Type Final Back-off Nut Size
Per Inch Specifications
12 1/6 Turn*
Install Cotter Pin to Lock Axle Nut in Position
Steer (Front) 18 1/4 Turn*
Non-Drive 14 200 - 300 ft-lb 0.001 - 0.005"
1/2 Turn Less than 2-5/8" (67 mm) (0.025 - 0.127 mm) as
18 (270 - 405 Nm)
measured per
300 - 400 ft-lb procedure with dial
Drive 12 Dowel Type Washer
(405 - 540 Nm)
1/4 Turn
200 - 275 ft-lb
indicator
8
16 Tang Type Washer**
(270 - 375 Nm)
Trailer
12 300 - 400 ft-lb
1/4 Turn 2-5/8" (67 mm) and over
16 (405 - 540 Nm)
* If dowel pin and washer (or washer tang and nut flat) are not aligned, remove the washer, turn it over, and reinstall. If
required, loosen the inner (adjusting) nut just enough for alignment.
** Bendable type washer lock only: Secure nuts by bending one wheel nut washer tang over the inner and outer nut. Bend
the tangs over the closest flat perpendicular to the tang

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REPAIR 6. Assemble the wheel bearings, hub and drum on the

spindle. Install the nut on the spindle and tighten. See
Wheel Bearing Adjustment Nut Adjustment Torque Specifications on page 8-21.
NOTE: If using the 4-piece system, install only the
adjusting (inner) nut at this time. Rotate the hub
! WARNING and drum assembly while tightening the inner nut.
Before working on a crane, set the parking brakes, place NOTE: Note: For further information on wheel bearing
the transmission in neutral and block the wheels. Failure adjustment refer to the vendor literature covering
to do so can result in unexpected crane movement and the front and rear axles.
can cause serious personal injury or death.
1. Back off the nut one full turn.
2. Turn the hub and drum one turn. Retorque the nut while
! WARNING turning. See Nut Adjustment Torque Specifications on
page 8-21.
Never work under or around a crane unless it is supported
on jack stands of adequate rating. Failure to use adequate 3. Determine axle type and threads per inch of the spindle.
jack stands can result in the crane falling, which can 4. Back off the nut according to Wheel Bearing Adjustment
cause serious personal injury or death to anyone under on page 8-22.
the crane.
Jam Nut Torque
Install the locking components as necessary.
! WARNING
Determining Acceptable End Play Using a
Never work under or around a crane unless it is supported
on jack stands of adequate rating. Failure to use adequate Dial Indicator
jack stands can result in the crane falling, which can Wheel end play is the free movement of the hub and drum
cause serious personal injury or death to anyone under assembly along the spindle.
the crane.
NOTE: Wheel end play measurement is made with the
brake drum attached or removed.
1. Ensure that the brake drum attached to the hub
! CAUTION fasteners is tightened to the required specifications.
Never work under or around a crane unless it is supported
2. Adjust the dial indicator so that its plunger or pointer is
on jack stands of adequate rating. Failure to use adequate
against the end of the spindle with its line of action
jack stands can result in the crane falling, which can
approximately parallel to the axis of the spindle.
cause serious personal injury or death to anyone under
the crane. NOTE: Magnetic-based indicators are NOT recommended
for use during the wheel adjustment procedure.
NOTE: Before servicing the crane, disable the TCS by
disconnecting the harness at the TCS control 3. The dial indicator stand attaches to the hub of the steer
valve. axle by threading into the tapped holes used to attach
the hub cap. For directions on how to attach the dial
The following procedure applies to your crane’s wheel indicator stand to the hub of the drive axle, review the kit
bearing fastening system: instructions.
5. Pack the wheel bearings with grease. Use the same 4. Push and pull the hub and drum assembly. Read
type (petroleum or synthetic) as requested for filling the bearing end play as the total indicator movement.
drive axle and front hub assembly. Bearing end play is required to be in the range:

0.001 - 0.005"
! CAUTION (0.025 - 0.127 mm)
Measured with drum removed

Do not mix petroleum and synthetic lubricants when 0.001 - 0.004"

lubricating wheel bearings. This practice reduces bearing Measured with drum installed
(0.025 - 0.102 mm)
life.

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NOTE: Measurements less than 0.001" (0.025 mm) are STEERING LINKAGE AND WHEEL
allowed only if end play movement can be detected ALIGNMENT INFORMATION
on the dial indicator. Measurements of zero end
play are not allowed unless a customer has
specifically requested preloaded bearings.

Measuring Wheel End Play with Tire Assembly

FIGURE 8-42

The steering linkages connect the main parts of the steering

together. It is important that the main components are lined
up according to their timing marks or designed straight-
ahead positions before adjustments are made to the
linkages.

WHEEL ALIGNMENT MEASUREMENT

SPECIFICATIONS

Toe-In
Unloaded cranes,
1/16 ± 1/32" (1.6 ± 0.8 mm)
maximum
Loaded cranes,
1/32 ± 1/32" (0.8 ± 0.8 mm)
maximum

FIGURE 8-40
Caster
For all axles later than
+2 to +4.5°
1992

Measuring Wheel End Play without Tire Assembly

Camber
Right and left sides
(non-adjustable value), +3/16 to -11/16° (final reading)
axle under load
8
Rear Axle Thrust Angle
Deviation from straight-
0.0 ± 0.09°
ahead, maximum

FIGURE 8-41

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DESIGN & FUNCTION

Steering Linkage Overview

5
5

4
3
FIGURE 8-43
6996

Steering Assembly
! WARNING
Item Description Do not compensate for damage to a steering component,
1 Steering Shaft like a bent steering arm, by adjusting the linkage. The
steering geometry is compromised, which can lead to
2 Draglink
unstable steering resulting in an accident. Always replace
3 Tie Rod a damaged steering component with a new part.
4 Steering Arm
Tie Rod
5 Tie Rod Arm
The tie rod (2) connects the tie rod arms (1). Toe in
Steering linkages connect each main component in the adjustment is made by the tie rod turnbuckle. The ends of the
steering system. Do not make adjustments to a linkage tie rod are articulated by ball joints. To check for ball joint
before making sure one of the main components connected wear, see Ball Joint Wear Inspection on page 8-33. To adjust
by the linkage is aligned. The other component can then be toe-in, see Toe Adjustment on page 8-34.
aligned by adjusting the linkage. The main components in
the steering system are:
• Steering Wheel
• Steering Gear
• Steering Knuckles

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NOTE: Make sure the same type of arm is used when

replaced.

FIGURE 8-45

Draglink
FIGURE 8-44 The draglink connects the pitman arm to the steering arm.
The link is articulated with ball joints on either end. To adjust
Tie Rod Arms the draglink, one ball joint must be removed. The draglink is
then lengthened or shortened to achieve straight-ahead
Tie rod arms (1) are bolted to or are part of the steering position for both the wheels and the steering gear. Make sure
knuckles. The right tie rod arm is a mirror image of the left. If the draglink goes back in the same position after adjustment
a steering arm has suspected damage, do not try to or replacement. To check for wear, see Ball Joint Wear
straighten it. Make sure the same type of arm is used as Inspection on page 8-33.
replacement.
Steering Gear and Pitman Arm
Steering Arms
The pitman arm converts the output torque from the steering
The steering arm converts the draglink or assist ram cylinder gear into the control force applied to the draglink. The pitman
force into a turning movement through the kingpin and arm is either secured to the steering gear output shaft with
knuckle. The steering arm is either bolted to or is part of the splines or with a key. Timing marks will be found if the shaft
steering knuckle. If a steering arm has suspected damage, has splines. The timing marks must line up for the steering
do not try to adjust the linkage to compensate for the gear to be in the straight-ahead position.
damage or try to straighten a bent arm. Only replacement
with a new arm or steering knuckle is allowed.
8

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WHEEL ALIGNMENT OVERVIEW

The term “front wheel alignment” has been used for many
years, but since the opportunities for misalignment are not
limited to the front wheels, the rear wheels are just as
important when it comes to wheel alignment.
Proper alignment means that all the wheels on the crane are
aimed in the same direction. Wheel angles must be set
according to manufacturer specifications in order to provide
maximum tire life in a crane that tracks straight and true
when driving along a straight and level road. The settings
should be checked periodically, depending on crane use.
While effects of misalignment show clearly in tire wear, the
effects of fuel consumption are harder to quantify. Fuel
c on s u m p ti o n i s aff e ct e d b y m an y fa c t or ; h ow e v er,
misalignment increases the rolling resistance, which is a
major cause of fuel consumption. It is recommended that
initial chassis wheel alignment be performed no later than 90
days from crane-in-service date. Perform additional
realignment:
• If drive comments indicate a handling problem.
• If inspections indicate irregular tire wear.
FIGURE 8-46 • Every 12 months of crane service.

Before checking the front wheel alignment, make sure the

When the steering gear is in the straight-ahead position, the following steps are verified or inspected:
pitman arm is pointing straight down. This way, the pitman
arm has the same travel for left- and right-hand turning.

Steering Column / Steering Shaft

The steering wheel is connected to the steering gear with the
steering column and a steering shaft. The shaft is indexed on
the steering gear input shaft with splines that give 10° of
adjustment increments. The other end of the shaft connects
to the steering column end with splines. If the shaft needs
replacement or is removed/installed, note the orientation of
the yokes before removal. At installation, the shaft needs to
go back with the same yoke orientation.

Steering Wheel
The steering wheel is fastened to the steering shaft with a
nut. To adjust straight-ahead position, remove nut, lift
steering wheel off from the shaft, and reposition on the shaft
in a straight-ahead position. The wheel can be adjusted in
10° adjustment increments. Make sure the steering gear is in
the straight-ahead position (centered on the pressure point)
before repositioning the steering wheel.

FIGURE 8-47

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CHECKING LUG NUT TORQUE

Front Suspension
• All fasteners are tightened to specified torque.
• Leaf springs have no wear or damage.
• Shock absorbers have no wear or damage.

Rear Axle and Rear Suspension

1. All fasteners are tightened to the specified torque.
2. Leaf springs have no wear or damage.
3. Leaf spring bushings have no wear or damage.
4. Torque rods, if used, are correctly adjusted.
5. Frame is not bent.
FIGURE 8-48 6. Rear axle, especially a tandem axle, is correctly aligned.

CHECKING AIR PRESSURE FRONT WHEEL ALIGNMENT

TERMINOLOGY
• Wheels and Tires
• Tires are inflated to the specified pressure. Caster
• Front tires are of the same size and type. Caster is the rearward or forward tilt of the kingpin (A) from
the vertical (V). The purpose of this inclination is to keep the
• Lug nuts are tightened to the specified torque. front wheels always pointing straight ahead. The greater the
• Wheels are balanced. caster, the greater the self-centering action. To overcome
this action, more torque must be used at the steering wheel.
• Wheels are not bent or damaged.
If the caster is out of adjustment, it can cause problems in
straight line tracking. If the caster is different from side to
side, the crane pulls to the side with the less positive caster.
If the caster is equal but neutral or negative, the steering will
be light and the crane will wander and be difficult to keep in a
straight line. If the caster is equal but too positive, the
steering will be heavy and the steering wheel may “kick”
when you hit a bump. Caster has little effect on tire wear.
It is important to set caster to achieve the best compromise.
Too much caster produces hard steering; too little causes
wander. Caster typically has a positive value.

FIGURE 8-49

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FIGURE 8-50

Caster is adjusted by increasing or decreasing the thickness

of a wedge-shaped shim that is placed between the bottom
of the spring and the front axle beam.

Camber
Camber is the outward or inward inclination (A) of the wheel
from the vertical (V). Outward camber reduces strain on the
kingpins and wheel bearings by placing the major part of the
load on the inner wheel bearing. Camber is positive if the
upper part of the wheel is inclined outward.
The camber angle is set by the axle manufacturer and
should not be changed. If inspection finds the angle to be out FIGURE 8-51
of specification and tires and suspension fasteners are within
If the camber is different from side to side, it can cause a
specification, check the kingpin inclination to determine if the
axle beam or the knuckle is bent and needs to be replaced. pulling problem. The crane will pull to the side with the more
positive camber. Kingpin Inclination (KPI)
Kingpin inclination is the inward tilt (A) of the upper end of the
! DANGER kingpin which makes it easier to steer the wheels. Vibration
Replace damaged or out-of-specification axle from the road surface is also lessened and not transmitted to
components. Do not bend, repair or recondition axle the steering wheel.
components by welding or by heat-treating. A heated, The KPI is set at the factory and should not be changed. If
bent axle beam reduces axle strength, affects crane the camber is out of specification and the KPI is correct,
operation. Serious personal injury and damage to replace the knuckle. If the camber is out and the KPI is also
components can result. out, there is a strong indication that the axle beam may need
to be replaced.
Measurement (B) is the scrub radius, defined as the distance
between the KPI and the vertical lines where they are
intersecting the ground. This distance must be the same
from side to side or the crane will pull strongly at all speeds.
Different type/size wheels, tires on right and left side, or a tire
that is low on air will give a different scrub radius from the left
to the right.

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Toe-In / Toe-Out
Toe is the degree to which the wheels are out of parallel,
either in or out, resulting from angling the wheels away from
the parallel. It is the difference between measurements A
and B in the illustration. Typically, the wheels are adjusted to
a slight toe-in, since the wheels tend to turn outward when
the crane is driven. Toe will change depending on crane
speed.

FIGURE 8-53

Incorrect toe adjustment will result in tire wear. Excessive

toe-in wears the outside shoulder of the tire; excessive toe-
out wears the inside shoulder. The further away from the
parallel, the more severe the wear.
When adjusting the toe, be aware that a loaded axle requires
a different measurement from an unloaded axle.

Turning Angles
Turning angle is the difference in the angles of the wheels in
FIGURE 8-52 a turn. When a crane is steered through a turn, the outer
wheel travels a wider arc than the inner wheel. This enables
the wheels to follow the same center in the turning circle (A).
The angles are measured at the maximum turn angle (full
lock).

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FIGURE 8-55

FIGURE 8-54 Thrust Angle

Generally speaking, the front wheels point straight ahead

only about 30% of the driving time. This is because the driver
must take corrective action to keep the crane on a straight
line, turning the steering wheel right or left. This counteracts
the effects of uneven roads, side winds and other factors. If
the wheels have different rolling centers, tire wear outside
the straight-ahead sector will be significant. This is because
the wheels will strive to move either farther apart or closer
together.
The turning radius angles are accomplished by the angle of
the steering arm. This arm allows the inside wheel to turn
sharper than the outside wheel.

Rear Wheel Alignment Overview

The rear wheel angles are simpler than the front wheel
angles since there is no steering involved. However, if the
rear wheels are out of alignment, steering will be
compromised. It very important that the wheels track true to
the direction of travel. There is an ideal line of direction called
Geometric Centerline (GC) that goes through the crane
through the center of the frame. The GC is not the same as
the center of the frame since the frame may be distorted and
not aligned properly.
The GC of a crane is established by drawing an imaginary
line from the midpoint of the front axle to the midpoint of the FIGURE 8-56
rearmost axle. The GC is not based on frame rail or
crossmember reference points.

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Thrust angle is the direction that the rear wheels are pointing TYPICAL WEAR PATTERNS
compared to the GC. If the thrust angle (C) is not zero, then
the crane will “dog track” and the steering wheel will not be Incorrect Tire Pressure
centered. If the thrust angle is positive (as in illustration), the
crane tends to pull to the right and the driver has to Too high air pressure (A) gives rapid wear in the middle of
compensate by turning the steering wheel to the right. The the tire.
result is wear on the inside of one front tire and wear on the Too low air pressure (B) gives rapid shoulder wear.
outside of the other.
If both of the tandem axles are pointing in the same direction
away from the GC, it gives the same symptoms described
above.
The best solution is to first center the rearmost axle to the
GC, then the forward rear axle (if a tandem) and last, align
the wheels on the front axle(s).

Tandem Scrub Angle

Tandem scrub angle is the angle (D) formed by the two thrust
lines of a tandem axle crane if the axles are misaligned in
opposite directions. This misalignment may not be noticed in
the steering wheel if the axles are off by the same value. This
causes wear on all the tandem tires. When the axles are off
by different values (as in illustration), the driver has to
compensate by turning the steering wheel, and all the tires
experience wear.

FIGURE 8-58

Incorrect Camber
Incorrect camber gives abnormal wear on one-half of the tire.

FIGURE 8-59

FIGURE 8-57
Incorrect Toe and Axle Alignment
The best solution is to first center the rearmost axle to the Incorrect toe has a “scrubbing” effect on the front wheels that
GC, then the forward rear axle (if a tandem) and last, align shows in rapid shoulder wear or across the tire.
the wheels on the front axle(s). Incorrect axle alignment has a “scrubbing” effect on all
wheels.

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Incorrect Caster and Wheel Imbalance

Incorrect caster or wheel imbalance shows as spot wear that
is either in the middle of the tire or extends to the shoulder.
This rapidly wears the mechanical parts of steering linkage,
kingpin and wheel bearing.

FIGURE 8-60

a. Incorrect toe-in
b. Incorrect toe-out
c. Out-of-line axles
a. Caster angle
d. Steering arm defect
b. Imbalance
FIGURE 8-62
Dual-Wheel Mounting
Cuts In the Tire Tread
Cuts are due to poor roads, air pressure too high or incorrect
tire type for the application.

FIGURE 8-61 a. Cuts b. Flanking Cuts c. Rubber flaking

a. Excessively crowned roads, different types of tire, FIGURE 8-63

different circumference or off-center loading give
faster wear on one tire. Spot Wear
b. Too low air pressure, mismatched rims for the tire
Sudden braking, locking brakes or out-of-round brake drums
type and dimension, excess flexing in the tire wall,
give spot wear.
or different types of tires in inner and outer tires can
cause contact wear.

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Cupping
Cupping is a normal occurrence that depends on the tread
pattern - the higher the load, the greater the wear.

FIGURE 8-66

REPAIR INFORMATION
Ball Joint Wear Inspection
FIGURE 8-64

! WARNING
Feathered Edges
Park the crane on a level surface. Block the wheels to
Normal occurrence on non-driving wheels on good roads prevent the crane from moving. Support the crane with
and high mileage. safety stands. Do not work under a crane supported only
by a jack. A jack can slip and fall over. Serious personal
injury and damage to components can result.

! WARNING
Do not use a wrench or other object to apply leverage
when inspecting sockets. Applying leverage can give
skewed results and damage components.

NOTE: Inspection of the ball joint should be done before it

is lubricated.
1. Make sure the ball joint is seated tightly in the steering
arm or tie rod arm taper and that the nut is tight.
2. With the engine on, lightly rock the steering wheel back 8
and forth while checking for looseness in any threaded
joint or any movement of the ball joint nut. Any
looseness requires repair.
3. With the engine off and front wheels straight ahead,
push and pull the socket in and out by hand (using
approximately 100 lb [50 kg] of pressure) in the direction
of the ball joint. If NO axial movement is detected, the
socket is operable. Any axial movement detected by
hand requires replacement of the ball joint.
FIGURE 8-65

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FIGURE 8-67
FIGURE 8-68
Toe Adjustment
5. Lower the crane to the floor. Do not measure toe with the
This repair information covers Arvin Meritor axles. For other
front axle raised off the ground. The weight of the crane
manufacturers’ axles, refer to their repair information.
must be on the front axle when toe is measured. Move
the crane backward and then forward 10 ft (3 m).
! WARNING 6. Place the trammel bar at the back of the tires. Raise the
Park the crane on a level surface. Block the wheels to trammel bar pointers so they are at the same height as
prevent the crane from moving. Support the crane with the spindles.
safety stands. Do not work under a crane supported only
by a jack. A jack can slip and fall over. Serious personal
injury and damage to components can result.

1. Park the crane on a level surface. Block the wheels to

prevent the crane from moving. Set the parking brake.
2. Place a jack under the front axle and raise the front
wheels just off the ground. Support the crane with safety
stands of adequate rating.
3. Use paint or chalk to mark the center area of both front
tires around the complete outer surface.
4. Place a pointer of a trammel bar in the center of the tire
tread. Rotate the tire. Make sure a straight line is
inscribed on the tire surface (1) all around the FIGURE 8-69
circumference. Repeat for the other tire.
7. Align the pointers with the marks on the tires and lock
them in place.

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TURN ANGLE ADJUSTMENT

! CAUTION
Do not exceed the maximum turn angle specified. If the
angle is exceeded, the steering arms, tie rod and tie rod
ends will be damaged.

Use an alignment machine to check the angles. Refer to the

alignment equipment manufacturer’s procedures.
1. Place a 1/8" (3 mm) spacer (1) between the stop bolt
and the boss (2) on the axle beam.

FIGURE 8-70

8. Bring the trammel bar to the front of the tires without

disturbing the pointer setting. Align one pointer with the
inscribed line of one tire. Check where the pointer on the
other tire is pointing. If it is pointing outside the inscribed
line, the wheels are toed-in. If it is pointing inside the
inscribed line, the wheels are toed-out. Note
measurement between pointer and inscribed line.

FIGURE 8-72

2. Turn the steering wheel until the boss on the axle beam
touches the spacer in front of the stop bolt. Measure the
maximum turn angle.
3. If the maximum turn angle does not meet specifications,
correct the maximum angle. After an adjustment has
been made to the maximum angles, a readjustment of
the steering gear poppet valves must be made.
4. When the maximum turn angle is correct:
• Loosen the stop bolt jam nut.
• Insert the 1/8" (3 mm) spacer and adjust the stop
bolt to the spacer.
FIGURE 8-71 • Tighten a 3/4" jam nut to a torque of 65-85 ft-lb
8
(85-115 Nm) and a 1/2" jam nut to 50-75 ft-lb
9. Check the measurement against the toe specification (68-100 Nm).
given for the axle. Make adjustments as needed (see
step 10). CASTER ADJUSTMENT
10. Loosen the clamp nut and bolt on each side of the tie 1. Measure the caster angle with alignment equipment.
rod. Turn the rod until the specified toe distance is
obtained. Tighten the clamp fasteners to the specified 2. To change the caster angle, a wedge needs to be added
torque. Repeat the above procedure to check the between the axle and the spring seat. If there already is
measurement. Repeat until toe measurement is within a wedge installed, change to a different wedge.
specification.

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3. Jack up the front of the crane and place jack stands 7. Compare the measurements. When the thrust angle is
under the frame. Lower the front so the axle is hanging square to the geometric centerline of the frame, the
free but with the jack in place supporting the axle beam. measurements are equal. If one is greater than the
other, adjust the rear suspension. Suspensions have
4. Loosen the U-bolt nuts on the side where the wedge is
different arrangements for adjusting axle position. Refer
placed. Lower the axle enough to install the wedge.
to the suspension manufacturer information for
Tighten the U-bolt nut to the specified torque. Remove
adjustment procedure.
jack stands and lower crane to the ground.
5. Measure the camber angle again.

DRIVE AXLE THRUST ANGLE

ADJUSTMENT
This information uses standard alignment tools but can also
be performed with computerized alignment equipment.

! DANGER
Before working on a crane, set the parking brake, place
the transmission in neutral and block the wheels. Failure
to do so can result in unexpected crane movement and
can cause serious personal injury or death.

1. Drive the crane into a work station with a level floor.

Drive in as straight as possible. Do not set any brakes.
Instead, chock the wheels to avoid binding the springs
and suspension.
FIGURE 8-73
2. Check runout on the wheels. Any lateral runout
measured at the wheel or the tire wall can affect the 8. Adjust and re-measure both sides until the
accuracy of this method. The method does not allow for measurements are equal. Now the front drive axle is
lateral runout in wheel rim on cast spoke wheels. If there square to the frame. The maximum difference between
is excessive lateral runout on cast spoke wheels, use a the two measurements should not be more than 1.4" (6
dial indicator and align the wheel. mm).
3. Attach a sturdy string (2) to the frame (at any convenient 9. Set the rear drive axle to the front drive axle using a
place) behind the forward drive wheel on the left side of trammel bar such that the spacing on the left and the
the crane. right side are equal within 1/8" (3 mm). Use the
4. Loop the string through the tire tread at the approximate machined dimple in the center of the hub to position the
centerline of the hub at the 3 o’clock position. Stretch the trammel bar.
string out to the front of the crane. 10. When the adjusting has been completed, take the crane
5. Keep tension on the string and hold it parallel to the floor. out on the road for a test drive. Verify the measurement
Have an assistant check the rear tire. Hold a tape upon return.
measure to the frame at a 90° angle at the same height
as the string (1). Slowly walk the string in toward the
frame until the assistant tells when the string contacts
the front part of the tire wall (2). Read off the distance
from the frame on the tape measure. If the frame is not
accessible, measure to the center of the front axle hub.
Record this measurement.
NOTE: Center the front axle before using it as a reference
for the measurement.
6. Repeat the procedure on the other side of the crane and
record that measurement. FIGURE 8-74

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Wheel Alignment Troubleshooting Guide

Symptom Possible Cause Symptom Possible Cause
Pull Left / Right Uneven Tire Pressure Vibration Wheel Imbalance
Uneven Tread Wear Defective Tire
Mismatched Tires Brake Drum Imbalance
Uneven Camber Drive Shaft Imbalance
Brake Drag Defective U-Joints
Suspension/Frame Sag Defective Wheel Bearings
Unbalanced Power Assist Improper Tire Inflation
Bent Wheel Spindle Drive Train Misalignment
Worn Suspension Components Defective Shock Absorbers or Mounting
(front/rear)
Excessive Tandem Scrub Excessive Wheel and Tire Runout (axial)
Centerline Steering Steering Gear Fasteners Loose Loose Steering Excessively Loose Wheel Bearings
Error Excessive Steering and/or Worn Steering and Suspension
Suspension Play Components
Rear Wheel Misalignment Loose Steering Mounting
Excessive Play in Steering Gear Excessive Internal Steering Gear Wear
Loose/Worn Steering Shaft Coupling
Incorrect Front Toe
Steering Gear Misadjusted
Shimmy Excessive Positive Caster Noise (abnormal) Defective Wheel Bearing
Loose/Rubbing Suspension or Steering
Wheel Imbalance
Components
Defective Suspension and Coarse Tread Pattern
Steering Components
Worn Tires Incorrect Wheel Alignment (all wheels)
Excessive Wheel and Tire Incorrect Turning Angle
Runout (lateral)
Underinflated Tires Overinflation
Steering Gear Loose Driveline Misalignment
Excessive Wheel Bearing Play
Tire Ply Separation or Blister
Improperly Tightened Wheel
Fasteners
8

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Wheel Alignment Troubleshooting Guide (Continued)

Symptom Possible Cause Symptom Possible Cause
Excessive Road Excessive Positive Caster Hard Steering Low Tire Air Pressure
Shock Low Tire Air Pressure Steering Gear Binding
Worn Tires Power Steering Fluid Low
Wrong Type Tire Excessive Positive Caster
Wrong Shock Absorbers Power Steering Pressure Low
Worn Shock Absorbers Steering/Suspension Components not
Springs Worn or Sagging Lubricated (binding)

Braking Instability Brakes Incorrectly Adjusted

Contaminated Brake Linings
Defective Suspension
Components
Incorrect Wheel Alignment
Excessive Negative Caster
Uneven or Low Tire Pressure

IMPORTANT SAFETY INFORMATION Air Spring Inflation

BEFORE MAKING RIDE HEIGHT Inflate the suspension slowly and make sure that the rubber
ADJUSTMENT bladder of the airspring inflates uniformly and is not binding.
Failure to do so can cause damage to the upper air spring
Shock Absorbers mounting bracket and void warranty.
The shock absorbers are the rebound travel stops for the
suspension. Anytime the axle is suspended, it is mandatory
Air Spring Deflation
that the shock absorbers remain connected. failure to do so If the air spring is being removed, it is mandatory to lubricate
can cause the air springs to separate from the piston and the lower air spring fasteners with penetrating oil and remove
result in premature air spring failure. with hand tools to prevent damage to the lower air spring
mounting stud. Failure to do so can cause component
Air Spring Inflation And Deflation damage.
Air spring assemblies must be deflated prior to loosening any
clamp group hardware. Unrestricted air spring assemblies
Support Beam And Cross Brace Assembly
can violently shift. Do not inflate air spring assemblies when Do not strike suspension components with a hammer.
they are unrestricted. Air spring assemblies must be however, the support beam and cross brace joint requires
restricted by suspension or other adequate structure. Do not blunt force on the support beam at the joint to dislodge the
inflate beyond pressures recommended by air spring two components. All blunt force must be applied flush to the
manufacturer. thickest part of the support beam at the inboard corner joint.
failure to strike the support beam squarely may result in
component damage and premature failure.

! CAUTION Cross Brace Assembly

Improper use or over inflation may cause air spring Improper jacking methods can cause structural damage and
assemblies to burst, causing property damage and/or result in loss of vehicle control, severe personal injury or
severe personal injury. death do not use the suspension cross brace as a jacking
Prior to and during deflation and inflation of the air point.
suspension system, ensure that all personnel and
equipment are clear from under the vehicle and around RIDE HEIGHT ADJUSTMENT
the service area. Failure to do so can cause serious
The ride height suspension is equipped with a height control
personal injury, death, or property damage.
valve located on the front drive axle.

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1. Drive the vehicle onto a level surface.

1
2. Free and center all suspension joints by slowly moving
vehicle back and forth several times without using the
brakes. When coming to a complete stop, make sure the 2
brakes are released. End with all wheels positioned
straight ahead. Try to roll to a stop without the brakes 3
being used. Do not set the parking brake.
4
3. Chock front wheels and verify the air system is at full 7
operating pressure when adjusting ride height.
NOTE: It is very important that the leveling valve be cycled 5
completely before and after any ride height
adjustments. This cycling of the leveling valve
will help to make the adjustment as accurate as Torque 13.5 to 16.2 Nm
possible. (10 to 12 pounds-foot) 6

4. Detach the upper rubber grommet of the height control

valve linkage from the upper stud and exhaust the
suspension system air by lowering the height control 8
valve linkage arm. FIGURE 8-75

! WARNING Item Description

1 Rubber Grommet
Prior to and during deflation and inflation of the air
suspension system, ensure that all personnel and 2 5/16 inch Hex Nut
equipment are clear from under the vehicle and around 3 Leveling Valve Arm
the service area, failure to do so can cause serious
personal injury, death, or property damage. 4 5/16 Inch Locknut
5 5/16 Inch Washer
5. Prior to deflating or inflating the air system, refer to air
spring cautions and warnings in section titled, 6 Height Control Valve
IMPORTANT SAFETY INFORMATION BEFORE 7 Height Control Valve Linkage Assembly
MAKING RIDE HEIGHT ADJUSTMENT
8 Adjustable Valve Arm Joint
6. Cycle the air system. Disconnect the leveling valve
arm from the rubber grommet. Lower the leveling
valve arm to exhaust the air in the air springs and
deflate the suspension. Reconnect the leveling valve
arm(s) to the rubber grommet to inflate the
suspension (Figure 8-82).
Bottom of the Frame Rail
7. Measure the suspension ride height. Measure from the
bottom of the frame rail to the axle centerline. The ride
height measurements are shown in (Figure 8-76).
Axle Centerline
8

7019-2

FIGURE 8-76

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NOTE:
• Ride height measurement from bottom of To set neutral position, align hole with hole on
frame to axle centerline (average of weld bead height control valve cover.
on front and rear of axle at the clamp group).
• All ride heights to be taken on the axle
attached to the height control valve.
8. If the ride height is not within this range it will be
necessary to adjust the ride height.

Adjustment Procedure
1. If an adjustment is required, verify that the air system is
at full operating pressure.

7019-3
! WARNING
Prior to and during deflation and inflation of the air
suspension system, ensure that all personnel and
FIGURE 8-77
equipment are clear from under the vehicle and around
the service area, failure to do so can cause serious 9. Tighten the clamp(s) on the adjustable valve arm joint
personal injury, death, or property damage. with a screwdriver until securely fastened
(Figure 8-75). Remove the dowel from the height
2. Prior to deflating or inflating the air system, refer to air control valve.
spring cautions and warnings in section titled,
IMPORTANT SAFETY INFORMATION BEFORE 10. Cycle the height control valve leveling arm as stated in
MAKING RIDE HEIGHT ADJUSTMENT step number 3.

3. Disconnect the height control valve leveling arm from 11. Recheck the ride height.
the rubber grommet. Lower the leveling valve arm to 12. Repeat steps 3 through 10 until the ride height is within
exhaust the air from the air springs and deflate the rear specification.
suspension.
NOTE: It is very important that the leveling valve(s) be
4. Refill the suspension by raising the height control valve cycled completely before and after any ride height
arm by hand, so that the air springs are above the proper adjustments. The cycling of the leveling valve will
ride height. help to make the adjustment more accurate.
5. Lower the leveling valve arm to exhaust the air system
until the suspension is at proper ride height. Lateral Alignment
6. Use a 1/8 inch wooden dowel rod (golf tee) to set the 1. 1. Use a work bay with a level floor. Drive the vehicle
neutral position for the height control valve by aligning slowly, straight ahead. Try to slacken or loosen the
the hole in the leveling arm with the hole in the height suspension as the vehicle is positioned. End with all
control valve cover, as shown in (Figure 8-77). Use a wheels positioned straight ahead. Try to roll to a stop
metal rod or nail as this may cause damage to the without the brakes being used. DO NOT set the
height control valve. parking brake. Chock the front wheels of the vehicle.

7. Adjust the extension rod so the rubber grommet can be 2. Measure from the outside of the frame rail to the rim
reconnected to the height control valve arm at the proper flange of the inner tire. Record the measurement.
height. Check the rubber components for any tearing or 3. Measure the same distance on the opposite side of the
damage, replace as necessary. same axle. Record the measurement.
8. Connect the height control valve arm to the rubber 4. Subtract the two measurements to get a difference
grommet(s). between the two. If the difference is greater than 3mm
(1/8 inch) it will be necessary to correct the lateral
alignment. Adding or removing shims that are located
between the transverse torque rod and frame rail
accomplishes this. A general rule of thumb is to use a

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shim with a thickness that is half of the difference shown in (Figure 8-78). Check that the pinion angle is within
between the two measurements. the range specified by the vehicle manufacturer.
NOTE: EXAMPLE: If the lateral alignment is out of Drive Axle Alignment Inspection Procedure
specification by 6mm (1/4 inch), remove or
install a 3mm (1/8 inch) shim as needed. Proper alignment is essential for maximum ride quality,
performance, and tire service life. The recommended
The mounting fasteners used with the straddle mount alignment procedure is described below. This procedure
transverse torque rods are furnished by the vehicle should be performed if excessive or irregular tire wear is
manufacturer. It is important to check the locknuts for observed, or any time the QUIK-ALIGN connection is
proper torque during preventive maintenance service loosened or removed.
intervals. Follow the vehicle manufacturer's
specifications for tightening torque values. 1. Use a work bay with a level surface.

All torque rods need to be inspected for looseness as 2. Relax the suspension by slowly moving the vehicle back
follows: and forth several times in a straight line without using the
brakes. This will slacken or loosen the suspension as
With the vehicle shut down, a lever check can be made the vehicle is positioned. End with all wheels positioned
with a long pry bar placed under each rod end and straight ahead.
pressure applied.
3. DO NOT set the parking brake. Chock the front wheels.
Visually inspect torque rod bushings for torn or shredded
rubber, inspect for bent, cracked, or broken torque rods 4. Verify and maintain the air system at full operating
and also for end hubs that have an elongated “oval” pressure.
shape. Any of these conditions require component 5. Verify the vehicle is at the correct ride height. Correct as
replacement. necessary. Refer to Ride Height Adjustment in this
Rod ends can be renewed by pressing out the worn section.
bushing, and installing a replacement bushing. In the 6. Verify all suspension components are in good condition.
event of structural damage the entire torque rod Repair or replace any worn or damaged suspension
assembly should be replaced. The torque rods are made components before proceeding with the alignment
to a specified length or a two-piece transverse torque process.
rod can be cut and welded to the desired length (if
available). 7. Ensure all drive axle tires are the same size.

NOTE: NOTE It is recommended that Grade 8 bolts and 8. If axle alignment equipment is not available, using C-
Grade C locknuts be used for all torque rod clamps, securely clamp a six-foot piece of straight bar
attachments. stock or angle iron across the lower frame flange Select
a location for the angle iron as far forward of the drive
Axle Pinion Angle axle as possible where components will not interfere.
9. Accurately square the straight edge to the frame using a
carpenter’s square.
10. Using a measuring tape, measure from the straight edge
to the forward face of the front drive axle arms at the
centerline on both sides of the vehicle.
11. Calculate the difference between measurements.
8
a. If the front drive axle is within vehicle manufacturer’s
specifications, proceed to check the rear drive
axle (Step 12).
b. If alignment of the front drive axle IS NOT within the
7019-4 FIGURE 8-78
vehicle manufacturer’s specifications, then the
Drive axle pinion angles are established by the vehicle alignment of this axle MUST be corrected
manufacturer. If it is necessary to fine tune the pinion angle BEFORE measuring the rear drive axle
see the Alignment & Adjustments Section of this publication. alignment (step 7). Correct the alignment of this
To check the pinion angle, verify first that the suspension is axle by following the proper Alignment
at the proper ride height. Refer to Ride Height Adjustment in Instructions.
this Section. Install a digital protractor on the axle housing as

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NOTE: Since the remaining drive axle(s) will be aligned Ride Height Alignment Instructions
relative to the front drive axle, it is essential that the
front drive axle is aligned within the vehicle
manufacturer’s specifications prior to the alignment 9
of the remaining drive axle(s).
8
12. Using a trammel bar, measure the distance from the 7
spindle center of the front drive axle to the spindle center
of the rear drive axle on both sides of the vehicle.
13. Calculate the difference between measurements.
a. If the measurements are within the vehicle
manufacturer’s specifications, then the rear drive 3
axle alignment is acceptable. Proceed to check the 4 5 6
pinion angles of the drive axles.
b. If alignment of the rear drive axle IS NOT within the 2
vehicle manufacturer’s specifications, then the
alignment of this axle MUST be corrected BEFORE
checking the drive axle pinion angles (step 14).
Correct the alignment of this axle by following the
proper Alignment Instructions procedure as
determined by the ride height of the suspension. 1
7019-5
14. Repeat steps 12 and 13 for any remaining drive axle(s). FIGURE 8-79
Be sure all remaining drive axles are aligned relative to
the front drive axle.
Item Description
15. After all drive axles are aligned, check the pinion angle
of each drive axle with a digital protractor. Refer to the 1 Pivot Bushing
vehicle manufacturer specifications for the required 2 Support Beam
pinion angles (Figure 8-78).
3 Pivot Bolt Locknut
a. If all pinion angles are within the vehicle
4 Washer
manufacturer’s specifications then proceed to step
16. 5 Eccentric Collar

b. If any pinion angle is out of the vehicle 6 Concentric Collar

manufacturer’s specifications it must be corrected. 7 Washer
Follow the Pinion Angle Adjustment Procedure
8 Pivot Bolt
for the suspension model as determined by the
ride height of the suspension. 9 Frame Hanger
16. Recheck measurements to confirm adjustments. Repeat NOTE: The eccentric collars (with the square drive feature)
steps 10 through 15 until the correct alignment and are located on the outboard side of the frame
pinion angles are achieved. hangers with the concentric collars on the
17. When all drive axle alignments and pinion angles are
inboard side. The total range of fore/aft axle
within the vehicle manufacturer’s specifications then the adjustment is 1.0".
alignment procedure is complete. NOTE: A suspension equipped with eccentric QUIK-
ALIGN collars on both sides of an axle can be
adjusted on both sides. A suspension equipped
with an eccentric QUIK-ALIGN collar on only one
side of the axle can be adjusted only on the side
that has the eccentric QUIK-ALIGN collar.

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5. On the side being adjusted, remove the old QUIK-

ALIGN fastener and replace it with a new QUIK-ALIGN
! WARNING fastener. Snug to the new QUIK-ALIGN fastener to 50/
Do not assemble the quik-align joint without the proper 100 foot pounds. This will hold the eccentric flanged
fasteners. Failure to do so can cause loss of vehicle collar in place against the frame hanger face, and within
control, property damage or personal injury. Ensure that the adjustment guide, but loose enough to permit the
the quik-align fasteners torque value is sustained. Failure QUIK-ALIGN eccentric flanged collar to rotate freely.
to do so can cause loss of vehicle control resulting in
personal injury or property damage.
! WARNING
1. Support the frame at ride height. Prior to and during deflation and inflation of the air
suspension system, ensure that all personnel and
equipment are clear from under the vehicle and around
! WARNING the service area, failure to do so can cause serious
Prior to and during deflation and inflation of the air personal injury, death, or property damage.
suspension system, ensure that all personnel and
equipment are clear from under the vehicle and around 6. Prior to deflating or inflating the air system, refer to air
the service area. Failure to do so can cause serious spring cautions and warnings in section titled,
personal injury, death, or property damage. IMPORTANT SAFETY INFORM.ATION BEFORE
MAKING RIDE HEIGHT ADJUSTMENT
2. Prior to deflating or inflating the air system, refer to air 7. Inflate the suspension by connecting the height control
spring cautions and warnings in section titled, valve linkage to the height control valve arm. Verify the
IMPORTANT SAFETY INFORM.ATION BEFORE air springs inflate uniformly without binding.
MAKING RIDE HEIGHT ADJUSTMENT
8. Verify correct ride height.
3. Disconnect the height control linkage assembly from the
height control valve arm. Lower the height control valve NOTE: When adjusting the alignment of an axle, the
arm to exhaust the air in the air springs and deflate the fasteners connecting the longitudinal torque rod to
rear suspension. the frame hanger, above the QUIK-ALIGN collar
being adjusted, must be loose at the frame hanger.
4. Using the measurements from the Drive Axle Alignment This will allow the longitudinal torque rod to move
Inspection Procedure, Step 11, determine which QUIK- freely with the axle while the alignment is adjusted.
ALIGN collar will need adjusting to correct the axle Failure to do so will result in bushing preload in all
alignment. rubber connections on that side of the axle,
NOTE: If the axle can be adjusted on both sides, begin the shortening component life.
adjustment on the side that is furthest out of 9. On the side of the axle being adjusted, loosen the
specification. fasteners connecting the longitudinal torque rod to the
frame hanger. Remove any existing shims from this
NOTE: Use a new QUIK-ALIGN pivot bolt kit for any axle
alignment or disassembly of the QUIK-ALIGN connection. Leave connection loose at this time.
connection. This ensures that the proper clamp 10. Use a QUIK-ALIGN socket tool and impact gun, or a 12
load is applied to the connection, so that the joint mm (1/2 inch) square drive breaker bar to rotate the
will not slip in service. QUIK-ALIGN eccentric collar to align the axle
(Figure 8-80).
8

FIGURE 8-80

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11. Once the correct axle alignment is achieved, use a 2. Install or remove shims as required in equal amounts, to
calibrated torque wrench to tighten the 25 mm (1 both sides of the axle, to achieve the proper pinion angle
inch)QUIK-ALIGN locknuts 712 to 779 Nm (525 to 575) (Figure 8-81). Increase the pinion angle install shims. To
pounds-foot torque. decrease the pinion angle remove shims.
12. Fill any gap between the frame hanger and longitudinal NOTE: A general rule of thumb is, 1/8 inch change in the
torque rod with shims. shim pack thickness will increase or decrease the
pinion angle by 1/2 degree.
13. Tighten the longitudinal torque rod fasteners to 373 to
440 Nm (275 to 325 pounds-foot) torque. 3. Tighten the fasteners connecting the longitudinal torque
rod to the frame hanger to 373 to 440 Nm (275-325
14. Re-check the ride height and the axle alignment to verify
pounds-foot) torque.
they are within the vehicle manufacturer’s specifications.
4. 4. Re-check the pinion angle and verify it is within the
15. Return to the Drive Axle Alignment Inspection
vehicle manufacturer’s specifications.
Procedure, Step 12, for the remaining drive axles.

Ride Height Pinion Angle Adjustment Adjustment Of More Than 1.5 Degrees
If an adjustment of more than 1.5 degrees is required, it will
Adjustment Of 1.5 Degrees Or Less be necessary to replace the bottom cap with a bottom cap
that will achieve the desired pinion angle. After replacement
NOTE: When correcting the pinion angle of an axle the
of the bottom cap perform the drive axle alignment
correction must be in equal amounts on both sides
procedure.
of the axle. However, the total number of shims per
side may differ due to axle alignment.
STEERING HYDRAULIC SYSTEM
1. Loosen the fasteners connecting the longitudinal torque
rods to the frame hangers. This steering hydraulic system information is described from
the standpoint of what is specific to your Manitowoc crane.
To find information concerning steering linkage or wheel
Add or remove
shims to maintain
alignment, refer to Steering Linkage and Wheel Alignment
or adjust pinion Information on page 8-23.
angle.

FIGURE 8-81

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Reservoir

Assist Ram
Steering Gear

Pump

FIGURE 8-82
FIGURE 8-82

SPECIFICATIONS

Steering Gear
Item Specification
Ratio 20.4:1
Steering wheel travel 4.75 turns

Steering Pump
Item Specification
Pressure output (max) 2175 psi (14.996 MPa)
Regulated flow 7 gpm (26.5 L/min)
8
Steering Fluid
Item Specification
Fluid type ATF Dexron II® or Dexron III®
Fluid capacity, without ram assist 4.0 qt (4.0 L)
Fluid capacity, with ram assist 4.0 qt (4.0 L)

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Undercarriage TM500E-2 SERVICE MANUAL

Test and Adjustment

Item Specification
Power steering system test temperature 125 - 135° F (50 - 55°C)
Power steering pump pressure (minimum)
Power steering system flow (minimum)
Steering gear internal leakage (maximum) 1.0 gpm (3.8 L/min)

Special Torque Chart

Item Specification
Steering Pump Mounting Bolt 34 ±1 ft-lb (46 ± 1 N·m)
Pitman Arm Pinch Bolt 295 ±45 ft-lb (400 ±60 N·m)
Steering Gear Mounting Bolt 3/4" bolt 337 ±12 ft-lb (457 ±16 N·m)
7/8" - 9 bolt 460 ±45 ft-lb (624 ±61 N·m)
7/8" - 14 bolt 500 ±50 ft-lb (678 ±68 N·m)
Drag Link Ball Joint Nut 150 ±22 ft-lb (203 ±30 N·m)
Steering Shaft U-joint Pinch Bolts 69 ±6 ft-lb (94 ±8 N·m)
Steering Cylinder Piston Lock Nut 160 ft-lb (217 N·m)
Steering System Manual Bleed Screw 45 in.-lb (5.08 N·m)

SPECIAL TOOLS AND EQUIPMENT Hydraulic Flow Meter

Special Equipment
In some cases, use of a special tool is necessary in order to
carry out the troubleshooting or repair procedure. The
following tools are recommended for use in the procedures
described in this manual.

FIGURE 8-83

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DESIGN AND FUNCTION

Steering Hydraulic System
The steering hydraulic system is a high-pressure, power-
assisted control system that enables the driver to easily steer
even with high front axle loads. For very high loads, a power
steering assist ram cylinder is added to the system.
The system consists of a pump driven by the engine, a
steering gear and a power steering fluid reservoir standard
fluid reservoir with a 4 quarts (4 liters) capacity and an assist
ram Figure 8-82.
The active controls in the system is the hydraulic control FIGURE 8-85
valve in the pump and the steering gear control valve. The
pump control valve regulates the flow and maximum Item Description
pressure. As long as the system is not loaded, the pump
sends the fluid flowing in a loop through the system. When 1 Circular Rotor
the steering gear control valve diverts the flow to assert 2 Oval Chamber
pressure on the top or bottom of the steering gear piston, the
pump control valve allows pressure to build to the preset 3 Vanes
relief pressure when the control valve opens and ends the 4 Intake
pressure build-up.
5 Oval Chamber
Steering Pump 6 Output
A vane type pump has a circular rotor (1) with several vanes
(3) that can slide in and out of the rotor grooves. The rotor
and vanes are located inside an oval-shaped chamber (2).
As the rotor spins, centrifugal force and hydraulic pressure
force the vanes against the inside wall of the chamber. As a
vane moves past the intake opening, fluid is trapped
between the vanes and the wall (5). The chamber walls
narrow, pressure increases, and fluid is deposited at the
output opening (6). The narrowing walls will then completely
push the vane in so no fluid is transported away from the
output area.
The pump housing also contains the control valve which
FIGURE 8-84 regulates both flow and pressure, and acts as a pressure
relief valve.
The vane-type steering pump (Figure 8-84) is driven by the
engine. The steering fluid both lubricates and cools the
pump. Fluid is circulated through the hydraulic system as
long as the steering wheel is not turned.
8

FIGURE 8-86

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Item Description
1 Delivery Channel
2 Orifice
3 Delivery Line
4 Control Valve
5 Connection Channel
6 Spring
7 Relief Valve
8 Relief Valve
9 Fluid Flow
10 Pump Suction
The principles of control valve function is as follows: During
normal operation, fluid passes through the delivery channel FIGURE 8-87
(1), through an orifice (2), and out the delivery line (3) to the
steering gear. Fluid is also delivered to the rear of the control
The input shaft is split into two parts, input and worm shaft,
valve (4) through the connection channel (5). Due to the
that are connected by a torsion bar. The control valve is fixed
orifice, pressure in the rear of the control valve is slightly
to the upper part of the worm shaft. The threaded part of the
lower than in the delivery channel. As pump output pressure
worm shaft is inserted into the piston. The circular movement
increases and flow volume lessens, the delivery channel
of the worm shaft is transferred to the piston through a set of
pressure increases enough to overcome the force of the
recirculating balls.
spring (6) forcing the valve open to allow some of the fluid to
flow back (9) to the suction side of the pump (10). When the steering wheel is turned, the upper part of the input
shaft turns slightly more than the worm shaft because of the
In the event that fluid flow stops (e.g., steering wheels forced
torsion bar flexing as it tries to overcome the force of moving
against a curb or stuck in a rut), the pressure in the
the piston. Depending on the load on the front axle, the input
connection line will be equal to the delivery line pressure,
shaft will have a larger or smaller twist in relation to the worm
and the spring will force the valve back to its normal position.
shaft. The difference in movement between the shafts
This action causes the pressure to quickly rise in the blocked
translates to a corresponding movement of the valve in the
hydraulic system until the relief valve (7,8) opens to let fluid
control valve body so fluid is sent to either the top or the
flow in a closed loop inside the pump.
bottom of the piston to help with the steering effort. The
NOTE: Never force the pump to operate in a blocked torsion bar is also responsible for the valve returning to the
position for more than 5 seconds. The high center position.
pressure and low volume of fluid circulating, will
make the temperature increase very quickly. After 5 Steering Geometry
seconds, the heat will start destroying the fluid’s
For a crane to have good road characteristics and correct
lubricating properties resulting in severe pump
steering without steering wheel vibrations, it is important that
damage.
all the parts of the steering system are correctly adjusted in
To help prevent damage when the steering wheel is turned to relation to each other. See Steering Linkage and Wheel
a full lock, the steering gear has two off-load valves (or Alignment Information on page 8-23 for more information.
poppet valves), one for each turn, to minimize excessive
The steering gear center position should always be checked
mechanical loads and to allow some fluid to circulate instead
after replacement of the steering gear, front spring, pitman
of being trapped.
arm, or drag link. It should also be checked every time the
crane shows signs of unstable steering or pulling.
Power Steering Gear
The steering gear main parts are: input shaft, control valve, In its center position, the steering gear has a so-called
piston, sector shaft, and off-load valves (poppet valves). The pressure point. This is a designed “tight spot” to minimize
gear also has a pitman arm attached to the sector shaft. vibrations when driving straight ahead.

The unloading valves (poppet valves) should always be

checked and adjusted after the turning angles have been

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set, and before or in conjunction with, checking the hydraulic

function.

Fluid Reservoir and Filter

The reservoir contains the power steering fluid and filter for
the system. The standard reservoir size is 4 quarts (4 liters)
capacity reservoir. The recommended fluid type is Dexron II®
or Dexron III®.
The filter is mounted on the return line located inside the
reservoir. if it were installed on the suction line, a clogged
filter would cause a restriction in the pump suction line. The
filter is held in place by a yoke and a spring which exert
pressure on the upper cover. A relief valve is located below
the filter. In the event that the filter gets clogged, the
increased fluid pressure will lift the filter up from the valve to
let fluid flow directly into the reservoir, thereby preventing a
filter rupture. Bypassing fluid is unfiltered which will cause
increased wear to the entire power steering system.
FIGURE 8-88

The reservoir is mounted such that it is the highest point in

the system. Any air in the system will tend to migrate up and
be dissolved out of the fluid in the reservoir. This makes the
hydraulic system easy to bleed.

TROUBLESHOOTING
The troubleshooting table is intended as a guide to assist the
technician in discovering the possible cause of the crane
steering problem. The table is not intended to cover all the
possible problems in the steering system or their exact
remedy. The table should not be used in place of good
troubleshooting technique and experience, but as a
timesaving tool to help locate possible causes and possible
cures of steering problems.

Steering Hydraulic System Troubleshooting Guide

Complaint Possible Cause Remedy
Steering heavy in both Fluid level low and/or air in power steering Add fluid and bleed steering system. Check for
directions system leakage. Check the pump drive shaft seal.
Incorrect fluid in power steering system Replace with the correct fluid.
Steering shaft universal joint binding
Abnormally high steering resistance in front
Replace steering shaft.
Check and correct tire pressure. Ensure steering
8
wheel linkage knuckles do not bind.
Insufficient pressure and fluid flow in the Check hydraulic function. Overhaul power
power steering pump steering pump.
Excessive internal leakage in steering gear Overhaul steering gear.
Steering heavy in one Unloading too early Check and adjust unloading mechanism.
direction Incorrectly adjusted and/or faulty valves or
Overhaul steering gear.
seals in steering gear

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Steering Hydraulic System Troubleshooting Guide (Continued)

Complaint Possible Cause Remedy
Steering heavy with Insufficient pressure and fluid flow in power Check hydraulic function. Check and/or replace
rapid steering wheel steering pump pump driveshaft seal.
turns Check and correct leakage. Check and/or replace
Air in power steering system
pump driveshaft seal. Bleed steering system.
Steering wheel has stiff Abnormally high steering resistance in front Check and correct tire pressure. Ensure steering
return-to-neutral after wheel linkage knuckles do not bind.
steering Too little camber Adjust camber.
Excessive friction or dirt in steering shaft or Clean, repair, or replace components as
steering column components necessary.
Difficult to maintain Fluid level too low and/or air in the power Add fluid and bleed steering system. Check for
straight course steering system leakage.
Incorrect tire equipment Ensure front wheels have same type of tires.
Pressure point incorrectly adjusted Adjust steering gear pressure point.
Steering incorrectly adjusted Adjust steering gear center position.
Excessive play in steering shaft U-joints or
Replace steering shaft or steering rod ball joints.
steering rod ball joints
Loose steering gear mounting bolts Tighten bolts to correct torque.
Incorrect toe setting Adjust toe.
Stiff kingpins Replace kingpins and their bushings.
Impact felt in steering Fluid level too low and/or air in power steering Add fluid and bleed steering system. Check for
wheel system leakage.
Steering gear mounting bolts loose Tighten bolts to the correct torque.
Steering gear pressure point setting incorrect Adjust pressure point.
Excessive play in steering shaft U-joint(s) Replace steering shaft.
Excessive play in steering rod ball joints Replace worn ball joints or steering rods.
Faulty shock absorbers Replace shock absorbers.
Fault in steering gear Repair/replace steering gear.
Vibration in steering Imbalance in front wheels or front brake
Balance front wheels and front brake drums.
gear drums
Unusual noise in power Fluid level too low and/or air in the power Add fluid and bleed the system. Check for
steering system steering system leakage.
Incorrect fluid in power steering system Replace with the correct fluid.
Fault in power steering pump Repair/replace power steering pump.
Fault in steering gear Repair/replace steering gear.
Steering wheel turns by
Control valve mechanism in steering gear
itself to one stop to the Repair/replace steering gear.
faulty
other

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TESTS AND ADJUSTMENTS STEERING Testing Pump Pressure

HYDRAULIC SYSTEM NOTE: Potential pump damage. Never leave the shut-off
valve fully closed for more than 5 seconds. Leaving
Preparation the shut-off valve fully closed too long could result
in excessive fluid temperature and pump damage.

! CAUTION 1. Close the shut-off valve and read the pressure gauge.
Immediately open the shut-off valve.
A faulty steering pump high pressure relief valve may
cause excessive system pressure. Closing the high NOTE: Refer to the pump manufacturer's service literature
pressure shut-off valve on the tool may cause severe for specifications.
pump damage or high pressure hoses to rupture. Monitor
2. If pump pressure was below the minimum accepted
the pressure closely when closing the shut-off valve. If
pressure, repair or replace the pump.
pressure rises rapidly or exceeds the rated pump
pressure, immediately open the valve. Failure to follow 3. Allow the fluid to cool to 125 - 135°F (50 - 55°C) before
these precautions could result in severe equipment performing other tests or shutting off the engine.
damage or personal injury.
Testing Pump Flow
1. Ensure the engine is idling and fluid temperature is
between 125 - 135°F (50 - 55°C). Note the flow rate
displayed by the tool.
NOTE: Potential equipment damage. The following steps
must be performed in rapid succession. Leaving
the shut-off valve closed for too long could result in
excessive fluid temperatures and pump damage.
2. Fully close the shut-off valve. When the pump relief
pressure is reached, verify that the flow rate is zero.
Immediately open the shut-off valve. Verify that the flow
rate rapidly returns to the value noted in step 1.
3. Allow the fluid temperature to return to 125 - 135°F
(50 - 55°C). Set the engine to maximum governed
speed and note the fluid flow rate.
4. Potential equipment damage. The following steps must
be performed in rapid succession. Leaving the shut-off
valve closed for too long could result in excessive fluid
FIGURE 8-89 temperatures and pump damage.
5. Fully close the shut-off valve. When pump relief
pressure is reached, verify that the flow rate is zero.
1. Install a steering system analyzer tool in the high Immediately open the shut-off valve. Verify that the flow
pressure fluid line between the pump and the steering rate rapidly returns to the value noted in step 3.
gear (Figure 8-89). The analyzer should include a
pressure gauge, flow meter, and a shut-off valve.
6. Allow the fluid to return to 125 - 135°F (50 - 55°C).
8
7. Repeat steps 4 and 5 two additional times.
2. Place a thermometer in the fluid reservoir (Figure 8-89).
8. If the flow rate did not immediately return to the noted
3. Start the engine and warm the hydraulic system by
flow rate, the pump is malfunctioning and should be
partially closing the shut-off valve until the pressure
repaired or replaced.
gauge reads 1000 psi (6.9 MPa). When the fluid
temperature reaches 125 - 135°F (50 - 55°C), open the
shut-off valve.

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TESTING STEERING GEAR INTERNAL Adjusting Steering Gear Relief Valve

LEAKAGE The design of the relief valve is different depending on
steering gear used. Refer to the manufacturer’s service
Steering Knuckle information for correct procedure.

! CAUTION
You must read and understand all precautions and
guidelines before performing this procedure. If you are not
properly trained and certified in this procedure, ask your
supervisor for training before you perform it.

• Perform adjustment of steering gear poppet valves in

accordance with the appropriate manufacturer ’s
manual.
• Make sure the wheels are aligned according to crane
specification.

REPAIR
1 - 1/8" (3 mm) Think Bar
2 - Front Axle
FIGURE 8-90
Replacing Power Steering Pump
This procedure includes replacing steering fluid and the filter.
1. Place a socket or a 1/8" (3 mm) thick bar over the left
wheel stop bolt. Removal
2. Ensure fluid temperature is between 125 - 135°F 1. Disconnect the two fluid lines from the pump.
(50 - 55°C).
2. Drain the steering fluid.
NOTE: Potential pump damage. Never hold the steering
wheel at full lock for more than 10 seconds. Pump 3. Dispose of used fluid according to state and local
damage could result. regulations.

3. Turn the steering wheel to the right until the left spindle 4. Plug or cap all openings to prevent contamination.
contacts the socket on the left stop bolt. Verify that the
pump pressure equals the relief pressure value from the
pump pressure test. Read the steering gear leakage
flow meter.
4. Return the steering wheel to the neutral position.
5. Move the socket to the right wheel stop bolt.
6. Ensure the fluid temperature is between 125 - 135°F
(50 - 55°C).
NOTE: Potential pump damage. Never hold the steering
wheel at full lock for more than 10 seconds. Pump
damage could result. FIGURE 8-91
7. Turn the steering wheel to the left until the right spindle
contacts the socket on the right stop bolt. Verify that the Item Description
pump pressure equals the relief pressure value from the 1 Mounting Bracket
pump pressure test. Read the steering gear leakage
flow meter. 2 O-ring

8. Return the steering wheel to neutral position. 3 Pump Drive Gear

9. If internal leakage is greater than 1.0 gpm 3.8 L/min), 4 Washer

repair or replace the steering gear. 5 Mounting Bolt

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5. Remove the two mounting bolts with washers 7. Remove the pitman arm according to the manufacturer’s
(Figure 8-91) and pull the pump away from the engine. procedure.
6. Clean the gasket surfaces on the engine and on the 8. Remove the hydraulic hose fittings from the steering
pump. gear.

Installation Installation
7. If necessary, transfer the hose fittings from the removed 1. Install the hose fittings on the new steering gear using
pump or install new fittings on the pump to be installed. new sealing washers.
Ensure the fittings are properly oriented.
8. For spline driven pumps, place a gasket on the pump.
For gear driven pumps, install an O-ring (2) on the pump.
9. Install the pump on the engine. Tighten the bolts to a
torque of 34 ± 1 ft-lb (46 ± 1 N·m).
10. Connect the two hydraulic hoses to the pump. Bind the
hoses together using a tie strap to prevent them from
rubbing on the frame.
11. Replace the steering fluid filter. Fill the reservoir with
power steering fluid and bleed the system. See Bleeding
Steering Hydraulic System on page 8-54. Verify there is
no leakage in the system.

REPLACING STEERING GEAR

Removal
1. Park the crane with the steering wheel turned to a
straight-ahead position.
2. Disconnect the pressure and return hoses from the gear.
Allow fluid to drain into a drip pan. Plug the ends of the
FIGURE 8-92
hoses to avoid contamination.
NOTE: Dispose of used fluid according to state and local 2. Set the steering gear timing by turning the input shaft to
regulations. find the pressure point. The pitman arm should point
straight down (Figure 8-92). Refer also to the
3. Remove the U-joint pinch bolt at the end of the steering
manufacturer’s service information for timing mark
shaft. Use a pry bar to loosen and remove the U-joint
location.
from the steering gear input shaft.
3. Install pitman arm so that the timing marks are aligned
4. Remove the cotter pin and nut from the drag link.
on pitman arm and sector shaft.
Discard the cotter pin.
4. Tighten the pitman arm pinch bolt to 295 ± 45 ft-lb
5. Use a ball joint removal tool to separate the drag link
(400 ±60 N·m).
from the pitman arm.
5. Install the steering gear on the crane using the correct
8
spacers and mounting bolts. Tighten bolts to
! CAUTION specification.
Use caution when removing the steering gear. A steering
gear weighs approximately 100 lb (50 kg). Use a floor jack Bolt Size Specification
placed under the steering gear to help in lowering to the 3/4" bolts 337 ± 12 ft-lb (457 ± 16 N·m)
ground. Failure to use a jack may result in bodily harm. 7/8" - 9 bolts 460 ± 45 ft-lb (624 ± 61 N·m)
6. Remove the steering mounting bolts. Lower the steering 7/8" - 14 bolts 500 ± 50 ft-lb (678 ± 68 N·m)
gear to the ground.

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Undercarriage TM500E-2 SERVICE MANUAL

6. Install the drag link ball joint into the end of the pitman 6. Refill the reservoir if necessary. Install the reservoir
arm. Tighten the nut to a torque of 150 ± 22 ft-lb cover.
(203 ±30 N·m).
7. Dispose of the old filter responsibly.
7. Continue to tighten the nut until the slots in the
castellated nut line up with the cotter pin hole. Never Changing Power Steering Fluid
loosen the nut to align the holes. Secure with a new
1. Jack up the front of the crane and place it on jack stands
cotter pin.
of adequate rating.
8. Replace the steering shaft U-joint bolt with a new
2. Place a drain pan under the steering gear.
original equipment bolt.
3. Turn the steering wheel to the full left position. Remove
9. Ensure the timing marks on the steering gear are
the plug from the bottom of the steering gear.
aligned, then install the steering shaft U-joint on the input
shaft with the steering wheel pointing straight ahead. 4. Start the engine and let it idle for a maximum of 10
Tighten the pinch bolt to a torque of 69 ±7 ft-lb seconds, then shut it off.
(94 ±8 N·m).
5. Turn the steering wheel from full left to full right until all
10. Install the hydraulic hoses and tighten the fittings. fluid has run out of the gear.
11. Fill the reservoir with steering fluid and bleed the 6. Install the plug in the steering gear.
system. See Bleeding Steering Hydraulic System on
7. Fill the reservoir with power steering fluid of type Dexron
page 8-54. Verify that no leaks are in the system.
II® or Dexron III®.
12. Set the steering gear relief valves according to the
steering gear manufacturer’s service procedure. 8. Bleed the steering system in accordance with the
service procedure in See Bleeding Steering Hydraulic
13. Perform a road test of the crane steering system. Refill System on page 8-54.
fluid reservoir, if necessary.
Bleeding Steering Hydraulic System
REPLACING STEERING FLUID FILTER
1. Fill the fluid reservoir nearly full.
NOTE: When changing the fluid filter, place a finger under
2. Start and run the engine for 10 seconds, then shut it off.
the bottom hole as it comes off the return line to
Check the reservoir and refill, if necessary. Repeat this
prevent contaminants from dislodging from the filter
step at least three times.
and draining into the reservoir.
3. Equipment damage. Never allow the fluid level to drop
1. Remove the reservoir cover.
significantly or run the reservoir dry. This may introduce
2. Press down and turn the filter locking device to unlock it. air into the system which could result in damage to the
steering gear.
3. Lift out the existing filter while placing a finger under the
lower hole to prevent dirt from falling back into the 4. Start the engine and let it idle for two minutes, then shut
reservoir. it off. Check the reservoir and refill if necessary.
4. Transfer the locking device to the new filter and place it 5. Start the engine. Steer the crane from full left to full right
in the reservoir. several times. Add fluid as necessary to maintain fluid
level at the “full” line on the dipstick.
5. Secure the filter by pressing down the locking device
and turning until it snaps into place. NOTE: Automatic bleed systems should now be free from
trapped air. Manual bleed systems continue at
step 5.

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Disassembly
NOTE: Always clamp the stationary end housing into the
vise when servicing a hydraulic cylinder. Never
clamp a cylinder in the center barrel area as
distortion can result.
1. Place the cylinder in a vice.
2. Remove cylinder retainer ring using a spanner wrench
inserted in the holes provided in the head (may have to
use sharp pointed object to start retainer removal
through the slotted barrel).
3. Remove the shaft assembly from the barrel, pulling in a
straight line, so as not to scar the internal parts.
4. Insert shaft into a soft jawed vice so the head and piston
can be removed. Be sure the shaft and vice are both
clean before using.
5. Remove nut at the end of the shaft and remove head
and piston from the rod.
6. Remove all seals from the head and piston using a non-
sharp seal tool. These tools are available from various
1 - Automatic Bleed Plug - Do Not Remove seal suppliers.
2 - Manual Bleed Screw FIGURE 8-93 7. Clean all oil and debris from the head, piston, shaft,
collar and barrel using solvent, rags and an air hose.
NOTE: NEVER turn steering wheel with bleed screw 8. Inspect all parts for any wear or damage, if damage is
loosened. found replace with new part.
1. With the engine idling, steer from full left turn to full right
turn several times. Assembly
2. Stop steering and loosen the manual bleed screw 1. Install new seals on the head and piston using a non-
approximately one turn. Allow air and aerated fluid to sharp seal tool.
escape until only clear fluid is seen. 2. Place a small amount of oil on the inside seals of the
3. Close the bleed screw and refill the reservoir. head and install it on the shaft by slipping head over the
piston end of the shaft, being very careful not to damage
4. Repeat steps 5 through 8 four additional times until all the inside seals.
air is removed.
3. Place a small amount of oil on the inside seals of the
5. Tighten bleed screw to 45 in.-lb (5.08 N·m). piston and install it on the shaft by slowly twisting the
piston on over the threads of the shaft, being very
OVERHAULING STEERING ASSIST careful not to damage the inside seals.
CYLINDER 4. Install shaft nut. Tighten 3/4” nut to 160 ft-lb (217 N·m).
Preparation Before Disassembly 5. Apply grease to the outside seals of the head and piston.
8
NOTE: Cleanliness is of utmost importance when working 6. Install the shaft into the barrel of the cylinder and push in
with hydraulic system components. Even the until groove of the head lines up with the slot in the
smallest piece of dirt can cause damage to the barrel.
system. 7. Install the cylinder retainer with the use of the spanner
Thoroughly clean the outside of the steering assist cylinder wrench.
before disconnecting any hydraulic fittings or hoses. 8. Cycle the cylinder using air to check for proper
Remove the cylinder from the crane and drain the hydraulic operation.
fluid from the cylinder. Finish cleaning the steering assist
cylinder and dry before placing on the work bench. 9. If the cylinder is to be stored, pour fluid into the cylinder
ports and plug the ports to prevent rust.

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ABS SYSTEM GENERAL INFORMATION ABS System Electronic Control Unit

Anti-Lock Brake System The ABS ECU requires a 12 VDC, 5 amp and 30 amp fuse.

This information covers the design, function, operation, and

service procedures for the Anti-Lock Braking System for your
ABS ECU
crane.

! DANGER
Do not work under or around a crane unless the wheels
are securely chocked. Failure to chock the wheels can
result in the crane rolling, which can cause serious bodily
injury or death.

FIGURE 8-94
! DANGER
Do not work under a crane supported only by jacks. Jacks Inputs
can slip out from under the truck or fall over, causing Wheel speed 100 pulses per wheel
personal injury or death. Always use jack stands under information revolution, variable voltage
the truck.
Enabled or disabled via dash
Traction control
switch

! DANGER
Outputs
If placing a crane with Traction Control System (TCS) on
Modulator valve signal Pulsating on/off
jacks when servicing, the ABS must be disabled. If the
ABS is not disabled and one of the wheels starts to spin, Traction control solenoid On/off
the TCS will compensate and the crane may come off the J1939 Data Link Reduces engine torque
jack. The ABS should be disabled by disconnecting the
ABS connector at the pass-through to the cab. Diagnostic information to
J1587 Data Link
instrument cluster
ABS warning light, wheel spin
Dash lights
warning light
! DANGER
Pneumatic components store compressed air and can Anti-Lock Brake System Description
separate violently during disassembly or removal. Before The Anti-Lock Braking System (ABS) is an electronically
servicing any part of the pneumatic (air) system, controlled system that continually monitors wheel speed and
completely release the air pressure. Failure to do so can controls wheel braking during extreme braking situations.
result in serious personal injury or death. The ABS is an important component of the foundation brake
system. Its purpose is to prevent wheels from locking up
It is best to avoid welding on a crane or components attached when the brakes are applied with great intensity under
to it. Voltage and current spikes associated with welding normal road conditions or when applied normally on slippery
could damage the vehicle’s electrical system. If welding must road surfaces.
be preformed on any structure or in contact with the vehicle,
follow the recommendations below: The ABS works in conjunction with the standard crane
braking system. The ABS monitors the crane wheel speed at
• Disconnect both negative (-) and positive (+) battery all times and helps control braking during hard braking or
cables. Ensure the cables remain separated and are not slippery road conditions. The ABS improves the crane’s
in contact with the crane chassis. stability and control by reducing wheel lock during braking.
• Disconnect the electrical harnesses for engine ECU, The ABS electronically monitors the rotational speed of both
crane ECU, ABS ECU and all other ECUs on the crane. front wheels and the wheels on the rear axle. The wheel
• Disconnect the main crane harness at the pass-through rotation signals are sent to an Electronic Control Unit (ECU)
to the cab. which sends signals to the ABS modulator valves if it detects

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that a wheel has locked up or is about to lock up. The Wheel rotation is determined by an electronic sensor
modulator valves control the pressure in the brake assembly mounted in the brake spider. A signal is generated by the
air chambers. sensor as high spots on a tooth wheel pass by the sensor.
The tooth wheel is either mounted on or is part of the wheel
hub.

FIGURE 8-95

When the ECU senses that a wheel or set of wheels is about while the wheel on ice attempts to maintain optimum braking
to lock during braking, a signal is sent to the appropriate during the entire stop.
solenoid modulator valve to intermittently open and close it.
This opening and closing occurs rapidly (up to 15 times per TRACTION CONTROL SYSTEM
second) to reduce brake pressure and ensure that the wheel
returns to rotating while still maintaining most of the brake Some cranes are equipped with a Traction Control System
capacity. (TCS or ATC) included with the ABS. The TCS prevents the
drive wheels from spinning on a slippery surface (such as on
If the brakes are applied and the wheel speed sensors detect ice or loose gravel), or when accelerating from a standstill.
an impending wheel lockup, the ECU controller will The TCS uses the ABS ECU for control, but requires
immediately begin to compensate using the ABS additional control valves to automatically apply brake force to
modulator(s) at the affected wheel(s). The rear axle brakes the spinning wheels to increase traction.
are controlled independently from the front axle brakes, so
that brake application pressure at an individual wheel is Components
adjusted solely on the basis of its behavior on the road
surface on which it is traveling. The ABS consists of the following components: 8
Although each steering axle brake is under the control of an • Tooth wheel (4 or 6)
individual modulator, the ECU controller does not treat these
• Magnetic sensor (4 or 6)
brakes independently. The ECU uses a modified individual
control for the steering axle brakes. This is done in order to • Modulator valve (4)
minimize “steering wheel pull” in the event that each wheel is
traveling on a different road surface, such as when there is • Electronic Control Unit (ECU)
ice close to the curb and a dry crown. Essentially, the ECU • Fuses and relays
controls the brake force difference between the two brakes.
The wheel on dry pavement is initially given less braking • ABS warning lamp
force and is brought up to optimum braking during the stop, • Wheel spin indicator lamp

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• Connectors Sensor
• TCS switch (if TCS is installed)
The sensor is a magnetic inductor that allows current to flow
• Traction control valve (if TCS is installed) through it from the ECU when one of the wheel teeth is in
front of it. It continuously provides wheel speed information
Tooth Wheel to the ECU whenever the ignition is on, regardless of
whether or not the crane is in motion.
The tooth wheel is an alloy ring that resembles a gear. It
normally has 100 teeth cut into its surface. The purpose of The sensors are installed in brackets that are bolted to the
the teeth is to cause a pulsating current flow in the sensor brake spider. Each sensor is held in the bracket by a spring
circuit. As each tooth passes near the sensor, it causes a clip. It is installed such that the sensor is as close to the tooth
small current to flow in the sensor. When the gap between wheel as possible.
two teeth is in front of the sensor, the current flow stops.
The standard ABS has four sensors. On all cranes equipped
As the tooth wheel rotates, the starting and stopping of the with ABS, each front wheel has a sensor, and there is one
current flow is seen by the ECU as pulses. The greater the sensor for each complete set of rear wheels.
speed of the tooth wheel past the sensor, the more pulses
are registered per second, which is a direct indication of
wheel speed.

The tooth wheel is manufactured either as a ring that is

pressed onto the wheel hub, or is machined as an integral
part of the hub itself.

FIGURE 8-97

FIGURE 8-96

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ATR-1 Relay Valves

The relay valve is used to control the rear axle service
brakes and perform the standard relay function on trucks
with ABS but without ATC. For more information, refer to the
appropriate brake system manual.
The relay valve is a specialized service brake relay valve
combined with a traction control solenoid. It contains air and
electric components to provide both service braking and
traction control functions. The relay valve provides added
crane braking control and reduces the number of times ABS
is actually needed.
All air connections on the relay valve are identified with cast,
embossed letters for ease of identification and installation
(see the Relay Valve Connections table).

Relay Valve Connections

Identification Air Line Connection
SUP Supply to reservoir
DEL Delivery to service actuators
Service to brake valve rear service
SER
delivery

FIGURE 8-98

Item Component
1 Spider Mounting Bolts
2 Sensor Bracket
3 Sensor
4 Spring Clip
5 Tooth Wheel

Modulator Valve 8
The modulator valve section includes general information
about the Modulator Valve. FIGURE 8-99

Anti-Lock Modulator Valve Item Component

For more information on the M-30 modulator valve, refer to 1 Service
the Bendix Service Data Sheet SD-13-4830 available at 2 Delivery
www.bendix.com.
3 Supply
4 ATC Solenoid
5 ATC Solenoid Connector

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Electronic Control Unit (ECU) LEDs identify the faulty component: TRC for traction control
components, MOD for modulator, SEN for sensor and ECU.
The ECU is the brain of the system. It receives wheel speed The final LED, which is the only green LED, is marked VLT.
information from the sensors and sends signals to the ABS This LED indicates whether the ECU is receiving 12 volts.
modulator valves. The VLT LED is on during normal conditions.
The ECU is powered from the 12-volt battery bus through a The ECU houses a magnetic switch that is used to erase
relay. The relay is only energized when the ignition switch is faults from memory as they are repaired. A fault is erased
on so that the ECU only receives power when the ignition is from memory (ECU reset) by holding a magnet next to the
on. ECU where it is labeled RESET (just below the VLT LED).
The ECU compares the wheel speed of each wheel to the The magnet must be capable of lifting a 3 oz weight in order
speed of the other wheels to determine if any one wheel is to perform the reset function. While the magnet is held
locked up (i.e., not spinning or spinning slower in relation to against the ECU all LEDs will illuminate. If the magnet is held
the other wheels). This comparison is performed many times against the ECU for more than 20 seconds, the ECU will
each second. If any wheel is determined to be locked up enter a Self-Configuration mode.
while the other wheels are spinning, the ABS sends signals There may not be an LED from each group lighted when a
to the modulator valve for the locked wheel to reduce its fault is detected. An LED in the FRT, MID and RER group will
braking force until it starts to spin again. This series of events only light if the fault is with a sensor or an ABS modulator
may occur up to 15 times each second, giving the modulator valve. The same is true for the RHT and LFT group LEDs.
valve the appearance of having a pulsating action. The TRC will be the only red LED lit if the problem is in the
If the Traction Control System (TCS) feature is installed, the traction engine control circuit.
ECU provides signals to the ATR valve to control driving
wheel spin. The ATR valve is energized to apply air to the
brake chambers on the set of drive wheels that are spinning.
This action will slow the drive wheels to a speed consistent
with crane speed to increase the traction of those wheels.
If the engine is equipped with electronic controls, the ECU
will also send a signal through a J1939 or J1922 Data Link to
the engine ECU to reduce engine torque during wheel spin
conditions. Above 25 mph, the ECU will only send the engine
signal; no braking will occur.

FIGURE 8-101

When power is applied to the ECU a start-up self-check

sequence is activated. The status of the sequence is evident
from the LEDs. The start-up LED sequence is as follows.
1. All LEDs flash on.

FIGURE 8-100 2. All LEDs flash off.

3. SEN, FRT and MID or RER LEDs are on.
The ECU has built-in diagnostic capabilities and is equipped
with a series of light-emitting diodes (LEDs) that are visible 4. TRC LED is on if J1922 engine control is disabled.
from the outside. These LEDs are used in troubleshooting 5. LEDs return to normal fault status. (If no faults, only
the faults in the anti-lock brake system.The LEDs are marked green VLT will light.)
so that the technician can determine the location of a
problem detected by the ECU. The designations are grouped ECU Connections
to aid in determining the problem location and component.
The ECU controls the ABS/ATC. It is contained in a die-cast
The first three LEDs identify which axle has the faulty aluminum housing which is environmentally protected by a
component and are labeled FRT for front, MID for middle and self-healing silicone compound.
RER for rear. The next two LEDs identify the side of the
crane with the fault: RHT for right, LFT for left. The next four

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An LED display and a magnetically actuated reset switch are

incorporated in the housing for troubleshooting and
diagnostic purposes.
Two electrical connectors are used to connect the ECU to
ABS components. These connectors, one 30-pin and one
18-pin Packard Electric 150 series Metri-pack, are located in
the controller housing opposite the diagnostic display.
FIGURE 8-103

30-pin Metri-Pack 150 Series (pull-to-seat) Connector (for

detail, see the 0-pin connector table)

30-pin Connectors
Pin Function
A1 Ground
FIGURE 8-102 A2 Ground
A3 Ground
18-pin Metri-Pack 150 Series (pull-to-seat) Connector (for B1 Battery Voltage +12V
detail, see the 18-pin connector table)
B2 Data Link + (J1922/A)

18-pin Connectors B3 Data Link - (J1922/B)

Pin Function C1 Right Front Modulator Common

A1 Right Rear Modulator Common C2 ATC Lamp

A2 Not Used C3 Auxiliary Output

A3 Not Used D1 Right Front Modulator Hold

B1 Right Rear Modulator Hold D2 Not Used

B2 Right Mid Wheel Sensor Signal D3 Not Used

B3 Right Mid Wheel Sensor Return E1 Right Front Modulator Exhaust

C1 Right Rear Modulator Exhaust E2 Not Used

C2 Left Mid Wheel Sensor Signal E3 Warning Lamp

C3 Left Mid Wheel Sensor Return F1 Left Front Modulator Exhaust

D1 Left Rear Modulator Exhaust F2 ATC Enable Switch

D2 Traction Solenoid Source F3 Not Used

D3 Traction Solenoid Ground G1 Left Front Modulator Hold

E1 Left Rear Modulator Hold G2 Data Link + (J1587/A)

E2 Right Rear Wheel Sensor Signal G3 Data Link - (J1587/B)

E3 Right Rear Wheel Sensor Return H1 Left Front Modulator Common 8

F1 Left Rear Wheel Modulator Common H2 Right Front Wheel Sensor Signal

F2 Left Rear Wheel Sensor Signal H3 Right Front Wheel Sensor Return

F3 Left Rear Wheel Sensor Return J1 Left Front Wheel Sensor Signal
J2 Left Front Wheel Sensor Return
J3 Chassis Ground
K1 Retarder Disable
K2 Battery Voltage +12V
K3 Battery Voltage -12V

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In addition to the two housing-mounted connectors, the ECU The J1922 Data Link provides I/O connections between the
also uses a 2-pin Deutsch DT series connector for ATC. The engine ECU and the ECU. It is present only if the engine
2-pin connector is linked to a traction solenoid, which is ECU supports J1922. If the J1922 is not used, a10kW
located in the upper portion of the traction relay valve resistor is installed in the circuit to prevent false electrical
assembly. signals in the ECU.

Inputs The following outputs are used for ATC:

• The ECU controls the WHEEL SPIN dash warning lamp
Wheel speed information is provided to the ECU via a wiring
to advise the driver of the condition of the ATC system.
harness from individual wheel speed sensors. The ECU is
able to simultaneously receive, and individually interpret, • A connection to the ATC solenoid is provided via a 2-pin
speed signals from up to six wheel speed sensors. D e u ts c h D T s e r i e s c o n n e c t o r a s s h o w n i n t h e
illustration.
Power is supplied to the ECU from the ignition switch
through a relay. • A connection for the ATC/OFF switch. The switch allows
the ATC to be turned on or off manually.
Outputs
Configuration Information
The modulators allow the ECU to modify driver-applied air
pressure to the service brakes. The modulator is an Configuration of the ECU is available at all times via the
electrically controlled air valve located near the service J1587 Data Link using the MPSI Pro-Link ® 9000. The
actuator(s) it controls, and is the last air valve through which information is also displayed by the LEDs at power-up, as
air passes on its way to the brake actuator. A wiring harness follows:
connects the modulator to the ECU. Solenoid valves
contained in the modulator provide the electrical interface 1. All LEDs flash on.
between the ECU electronics and the air brake system. 2. All LEDs are off.
A dash lamp and its electrical relay are connected to, and 3. SEN, FRT and MID or RER LEDs are on.
controlled by, the ECU and serve as a means of advising the
driver of the condition of the ABS system. 4. TRC LED is on if J1922 engine control is enabled.

A connection to the engine or transmission retarder allows 5. TRC and MOD LEDs are on if differential braking is
the ECU to temporarily disable the retarder during certain enabled.
modes of operation. This function is not always used. 6. LEDs return to normal fault status.
The Data Link (SAE standard J1587) enables the ECU to NOTE: The green VLT LED will be off during steps 3, 4
“report” its operating condition to a specialized, external and 5.
computer in response to certain commands it receives.
Pass-through Connector
Data Link + Data Link - All ABS/ATC connections to the cab are through a 19-pin
Deutsch HD30 Series connector located in the pass-through
panel. This connector is accessible on the left-hand side
engine tunnel, once the hood is tilted open.

FIGURE 8-104

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ABS Pass-through Connector

5 Battery Voltage
6 Battery Voltage
7 ATC Enable Switch
8 Not Used
9 Retarder Relay Ground
10-12 Not Used
13 Battery Voltage
14-19 Not Used

ABS Warning Lamp

At crane start-up, the amber ABS warning lamp will flash.
When the system has successfully completed a self-check
cycle, the light will remain on. At approximately 7 mph (11
km/h), the ABS light will go off, indicating that the ABS
system is functional.
FIGURE 8-105 If a problem is detected at start-up, the amber ABS warning
lamp will not flash, but will remain on. If the lamp stays on, or
ABS Pass-through Connector comes on at any other time, this indicates a failure in the
Pin Description ABS system.

1 ABS Warning Relay Lamp Ground NOTE: An ABS failure means ONLY the ABS portion of the
crane’s braking system is malfunctioning. The
2 ATC (Wheel Spin) Lamp Ground
standard air braking will still be in effect.
3 Data Link + (J1587/1708)
In conventional models the ABS lamp is located in the
4 Data Link - (J1587/1708) instrument cluster.

Wheel Spin (ATC) Indicator and ABS Lamp in Data Link Instrument Cluster

ABS Warning Lamp Wheel Spin Indicator

FIGURE 8-106
8
ABS Lamp in Instrument Cluster

ABS Warning Lamp

FIGURE 8-107

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Undercarriage TM500E-2 SERVICE MANUAL

AUTOMATIC TRACTION CONTROL controlling wheel spin. The lamp will flash on and then off
when the ignition switch is turned on. The lamp will also stay
on if a fault is detected in the ATC circuits.
! DANGER
If placing a crane with ATC on jacks when servicing, the
ABS must be disabled. If the ABS is not disabled and one
of the wheels starts to spin, the ATC will compensate and
the crane may come off the jack, which could result in
personal injury or death. ABS is disabled by switching the
ATC/OFF switch to the OFF position.

The ABS on a crane may also be configured for traction

control. The Automatic Traction Control System (ATC) uses
the same wheel sensors as the ABS to determine if one set
of drive wheels is spinning much more rapidly than those on
the other side. If the ATC determines that a wheel is spinning
and the crane speed is below 25 mph (40 km/h), it opens the
relay valve to apply some braking force to stop the wheels
from spinning. FIGURE 8-108
If the crane speed is above 25 mph (40 km/h), the system
sends a signal to the Engine Electronic Control Unit (EECU) If the ATC is not installed, the lamp in the Data Link
to reduce the engine RPM to be consistent with crane speed. instrument cluster indicates times when one or more drive
This action helps reduce the amount of wheel spin and gives wheels are spinning relative to the steer axle wheels. If ATC
the driver greater crane control. is installed, the ATC lamp will come on if the drive wheels are
spinning during acceleration. The ATC lamp indicates when
The ATC option includes an additional switch. In the wheel spin is being controlled by ATC. On a tandem
NORMAL (DOWN) position, the ATC operates normally to suspension only one drive axle is monitored. It is possible
increase traction to the spinning wheels. When placed in the under certain conditions that the ABS/ATC system will not
OFF (UP) position, the ATC does not apply braking force to sense the spin of wheels on the non-monitored axle.
the spinning wheels.
An ATC disable switch is located on the crane dash. Its
ATC Lamp and Switch location may vary on the dash, depending on the options
installed on the crane. This switch, labeled ATC/OFF, is
The ATC lamp is installed on all cranes equipped with the normally in the ATC position. It can be switched to the OFF
ATC option. In cranes with a non-Data Link instrument position in situations where slightly more wheel spin is
cluster, the lamp is labeled WHEEL/SLIP. In models with the desirable to keep the crane from bogging down. If the switch
Data Link cluster, it is labeled WHEEL SPIN. is off, the ATC lamp on the dash will illuminate to remind the
The ATC warning light on the instrument cluster has several driver that the ATC has been disabled.
functions. If the ATC switch is in the OFF position, the ATC If the lamp stays on when the ATC switch is in the ATC
light will come on to remind the driver that ATC is off. If ATC position, there is a possible malfunction in the ATC.
is installed, the light will come on while the ATC system is

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the system has been repaired and the fault has been cleared
from the system memory.
NOTE: When the system detects a fault, it deactivates the
anti-lock braking function for the wheel that has the
fault. For example, if a fault is detected in the right
front modulator, the ABS function for that wheel will
be disabled. However, normal braking ability is still
available for this wheel. ABS function is still
available for the remaining wheels.
The ABS ECU has the ability to store the details of faults that
it detects within its own memory so that the technician can
easily locate the problem.
The details of the fault are stored in the system memory and
will remain there until the fault has been repaired and the
technician clears the fault memory. If the fault is intermittent,
the details of the fault are stored only as long as the fault
symptom is present. When the symptom disappears, the
system returns to normal.
FIGURE 8-109
Following detection of any fault, the ABS warning light will go
on and stay on until the ignition is switched to OFF. If the fault
is temporary, the warning light will go out normally when the
crane reaches 7 mph (11 km/h). If the fault still exists, the
ABS Self-tests warning light will remain on until the fault is repaired and is
The ABS has a variety of self-monitoring features. When the cleared from the memory.
ignition switch is on, the ABS warning light in the instrument
The ABS can store the details of several faults within its
cluster energizes to tell the operator that the system is memory. The ECU LEDs will indicate ONLY ONE fault at a
powered and that it is conducting self-tests. Two tests are time, even if there are multiple faults. The faults must be
performed by the system at this point.
repaired and removed from memory one at a time in the
The first test energizes and deenergizes the modulator order they are displayed when using the ECU LEDs to
isolation solenoids to ensure the circuits and valves are troubleshoot. The instrument cluster may display multiple
functional. In the second test, the operation of the exhaust codes, but faults can be repaired in any order. The ABS
portion of the modulator valves is tested, also by energizing warning light will not go out while the crane is being driven
and deenergizing them. until all faults have been corrected and removed from
memory.
One additional self-test is performed by the ABS. This test
occurs once the crane begins moving. As the crane starts to
speed up from a standstill, the ABS monitors the output from
TEST AND ADJUSTMENTS
each of the wheel speed sensors and verifies that they are NOTE: Unless otherwise stated, there must be air
reading correctly and within the correct range compared with pressure in the brake system to perform the valve
the other wheels. If the test is satisfactory, the ABS warning tests described below.
light goes out when the crane speed reaches approximately
7 mph (11 km/h). If the test is not satisfactory, the warning Traction Control Valve Function Check
light will remain lit. 8
ABS Fault Detection ! DANGER
During operation, the ABS continuously monitors the system PERSONAL INJURY HAZARD! Before working on a
for faulty conditions. The system components are checked to crane, set the parking brakes, place the transmission in
ensure that they are in working order. If the ABS detects that neutral and block the wheels. Failure to do so can result in
a fault has occurred, as determined by the absence of unexpected crane movement and can cause serious
correct signals from one of the ABS components, the system personal injury or death.
illuminates the ABS warning lamp. This lamp will stay on until

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12. Make a slow brake application up to 20 psi (140 kPa) at

the traction control valve service port while observing
! DANGER the pressure at the delivery port. Verify that the delivery
PERSONAL INJURY HAZARD! Never disconnect an air port pressure rises to 5 to 10 psi (35 to 70 kPa).
system component unless all system pressure has been 13. Release the brakes.
depleted. Failure to deplete system pressure before
disconnecting hoses or components may result in them 14. Make a slow brake application up to 60 to 70 psi (415 to
separating violently and causing serious bodily injury or 480 kPa) at the traction control valve service port while
death. observing the pressure at the delivery port. Verify that
the delivery port pressure rises to 20 to 25 psi (140 to
170 kPa).
NOTE: Delivery pressure should be approximately one-
! DANGER third of service pressure.
Exhaust gases contain deadly poison. When testing a
15. Release the brakes.
crane with the engine running, conduct the test outdoors
or use a properly vented exhaust hose. 16. Make a full brake application and verify both service and
delivery pressures register the same pressure.
NOTE: If any of the desired results for the tests below are
not met the valve should be repaired or replaced. 17. If the differential pressure test is not to be performed,
deplete the air from the system, remove the test gauges
1. Drain air pressure from all crane reservoirs. and restore the system to normal.
2. Install a tee at the traction control valve service port and
one of the delivery ports. Connect a test gauge at each
Traction Control Valve Differential Pressure
tee. Check
3. Connect the tractor service and emergency glad hands 1. Apply 10 psi (70 kPa) pressure to the traction control
to dummy connectors or to a trailer. valve service port. Note the pressure at the delivery port.

4. Start the crane and build system air pressure to normal. 2. Subtract the delivery port value from 10 psi (70 kPa).
This is the differential pressure.
5. Make five full brake applications and check the test
gauge fittings for leaks. Tighten if necessary. 3. Verify the differential pressure is correct for the valve
part number. If it is incorrect, the valve should be
6. Activate the system park control and trailer supply dash repaired or replaced.
control valves for tractor/trailer operation.
4. Deplete the air from the system and remove test
7. Apply and release the brakes several times — checking gauges.
for prompt application and release at each wheel.
5. Restore the system to normal.
8. If prompt application and complete release occur at
some but not all wheels, test the ABS modulator valve Traction Control Valve Solenoid Check
between the traction control valve and the brake
actuator. 1. Disconnect the two-pin solenoid connector from the wire
harness.
9. If a sluggish response or incomplete release is noted at
all wheels, inspect for system leakage or a kinked or 2. Measure the solenoid coil resistance. Verify that it is 10
obstructed air line leading to or from the traction control to 12 ohms.
valve. 3. Using a portable power supply, energize the valve and
10. Apply and hold a full-pressure brake application and verify that a full brake application occurs. Remove the
make sure that full pressure is delivered to the brake power and verify that the brakes fully release.
chambers. 4. If the coil resistance is incorrect, or the brakes do not
11. Set the dash-mounted trailer air supply valve for bobtail apply and release properly, the valve should be
tractor operation (Yellow knob OUT). replaced.
5. Reconnect the electrical connector to the valve.

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SYSTEM DIAGRAMS

ABS System Schematic, Modulator Valves and Sensors

FIGURE 8-110
8

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System Schematic Detail 30-pin Connector

The following charts provide detail for ABS System Circuit
30-pin Connector
Schematic, Modulator Valves and Sensors above. Number
730 J1 - Left Front W.S. Signal
30-pin Connector
731 J2 - Left Front W.S. Return
Circuit
30-pin Connector ABS J3 - Chassis Ground (ECU Case)
Number
772 K1 - Retarder Disable (Sink)
ABS A1 - Power Ground High (Current)
777B K2 - Battery Voltage (Power - High Current)
ABS A2 - Power Ground High (Current)
777C K3 - Battery Voltage (Power - High Current)
ABS A3 - Power Ground (Electronics)
777A B1 - Battery Voltage (Electronics)
404 B2 - Engine Control Serial A (J1922) 18-pin Connector
405 B3 - Engine Control Serial B (J1922) Circuit
18-pin Connector
Number
754 C1 - Right Front Modulator Common (Sink)
761 A1 - Right Rear Modulator Common (Source)
C2 - Traction Lamp (Sink; Illuminated =
774 — A2 - Future Relay Ground
Disabled)
— C3 - Auxiliary Output — A3 - Auxiliary Output
753 D1 - Right Front Modulator Hold (Source) 760 B1 - Right Rear Modulator Hold (Source)
— D2 - Not Used 755 B2 - Right Mid Wheel Spin Signal
— D3 - Not Used 756 B3 - Right Mid Wheel Spin Return
752 E1 - Right Front Modulator Exhaust (Source) 759 C1 - Right Rear Modulator Exhaust (Source)
— E2 - Not Used 735 C2 - Left Mid Wheel Spin Signal
778 E3 - Warning Lamp (Sink) 736 C3 - Left Mid Wheel Spin Return
732 F1 - Left Front Modulator Exhaust (Source) 739 D1 - Left Rear Modulator Exhaust (Source)
773 F2 - Traction Enable Switch (-12V Disables) 780 D2 - Traction Solenoid Source
— F3 - Not Used 781 D3 - Traction Solenoid Ground
733 G1 - Left Front Modulator Hold (Source) 740 E1 - Left Rear Modulator Hold (Source)
400 G2 - Diagnostic Serial A (J1587) 757 E2 - Right Rear Wheel Spin Signal
401 G3 - Diagnostic Serial B (J1587) 758 E3 - Right Rear Wheel Spin Return
734 H1 - Left Front Modulator Common (Sink) 741 F1 - Left Rear Modulator Common (Source)
750 H2 - Right Front W.S. Signal 737 F2 - Left Rear Wheel Spin Signal
751 H3 - Right Front W.S. Return 738 F3 - Left Rear Wheel Spin Return

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ABS System Schematic,

Relays and Connectors

FIGURE 8-111

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REPAIR INFORMATION 4. Verify proper sensor adjustment by driving the crane.

This allows the ABS to perform an additional self-test.
ABS Sensor Adjustment (ABS Self-tests on page 8-65) Once the crane reaches
approximately 7 mph (11 km/h), the ABS warning lamp
1. Slide the notched end of an ABS sensor adjustment tool will go out if the sensor is properly adjusted.
through the opening in the brake spider until it rests
against the sensor. (The tool will go in the hole at a slight 5. To check wheel speed sensor resistance, see Section
angle.) VII B - Testing the Wheel Speed Sensor on page 8-99.

Wheel Speed Sensor Replacement (Front)

! DANGER
PERSONAL INJURY HAZARD! Before working on a
crane, set the parking brakes, place the transmission in
neutral and block the wheels. Failure to do so can result in
unexpected crane movement and can cause serious
personal injury or death.

! DANGER
Do not work under a crane supported only by jacks. Jacks
can slip out from under the truck or fall over, causing
personal injury or death. Always use jack stands under
the truck.

Removal
1. Park the crane on a level surface. Apply the parking
brake, place the transmission in neutral and block the
rear wheels. Make sure crane ignition is in the OFF
position.
FIGURE 8-112 2. Raise the wheel where the faulty sensor is located.
Place jack stands of adequate rating under the axle.

NOTE: It is not necessary to remove the wheel or drum to 3. Remove the wheel from the axle.
adjust sensors using the adjustment tool. 4. If equipped with spring brakes, release the brakes. Back
off the slack adjuster.

CAUTION 5. Remove the brake drum, cam rollers, return spring and
Sensor damage may result. DO NOT use a screwdriver or brake shoes.
sharp instrument to adjust the sensor. Use of a sharp
instrument could permanently damage the sensor. CAUTION
Sensor damage may result. DO NOT pull on the sensor
cable to remove it, as this may permanently damage the
CAUTION sensor. DO NOT use any device to pry the sensor from its
mounting block, as this may damage the steel casing on
Sensor damage may result. DO NOT use a hammer to
the sensor and can void any existing warranty.
drive the sensor into position. Hammering the sensor
could permanently damage it.
6. Remove the mounting bolts for the sensor bracket. Cut
the tie straps along the sensor cable. Remove the
2. Press the sensor toward the wheel hub until the sensor
P-clips at the S-cam tube, bracket and frame rail. Using
contacts the tooth wheel.
a slight twisting motion, remove the sensor from its
3. Remove the sensor adjustment tool. mounting block. Use extreme care not to damage the
tooth wheel or the sensor.

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7. Remove the sensor spring clip from the mounting block.

8. Disconnect any fasteners that hold the sensor cable and
the hose clamp to other components.
9. Disconnect the sensor from the crane wiring at the
connector closest to the sensor.

Installation
NOTE: Spring clip must be installed with the flange stops
facing the inboard side of the crane.
1. Push the sensor spring clip all the way into the mounting
block.
2. Insert the sensor cable through the brake spider
housing, around the S-cam tube and bracket, up the
brake chamber airline, and route the cable along the
frame rail.
3. Connect the sensor cable connector.
4. Install the sensor into the bracket and spring clip. Install
the bracket and sensor onto the spider assembly.
Tighten the bracket to a torque of 130 ±10 ft-lb (175
±15 N·m).
5. Install the P-clip on the S-cam tube and bracket. Fasten
the sensor cable to the brake air line using a tie strap.
Install P-clip inside the frame rail.

CAUTION
Sensor damage may result. DO NOT use a screwdriver or FIGURE 8-113
sharp instrument to insert or adjust the sensor. DO NOT
use a hammer to drive the sensor into position. Use of a
sharp instrument or hammer can permanently damage
the sensor. Item Component
6. Using an ABS sensor adjustment too adjust the sensor 1 Spider Mounting Bolts
against the tooth wheel, and install the rubber grommet. 2 Sensor Bracket
7. Install the brake lining onto the spider housing. Install the 3 Sensor
return spring, S-cam rollers and brake drum. 4 Spring Clip
8. Install the wheel and tighten wheel nuts to a torque of 5 Tooth Wheel
475 ±25 ft-lb (645 ±35 N·m).
12. Readjust the brakes.
9. Adjust the front axle brakes.
10. Remove the jack stand(s) from under the crane.
13. Verify proper sensor adjustment by driving the crane. 8
This allows the ABS to perform an additional self-test.
11. Lower the crane and remove the wheel blocks. (ABS Self-tests on page 8-65) Once the crane reaches
approximately 7 mph (11 km/h), the ABS warning lamp
will go out if the sensor is properly adjusted.

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Wheel Speed Sensor, Replacement (Rear)

! DANGER
PERSONAL INJURY HAZARD! Before working on a
crane, set the parking brakes, place the transmission in
neutral, and block the wheels. Failure to do so can result
in unexpected crane movement and can cause serious
personal injury or death.

! DANGER
Do not work under a crane supported only by jacks. Jacks
can slip out from under the truck or fall over, causing
personal injury or death. Always use jack stands under
the truck.

Removal
1. Park the crane on a level surface. Apply the parking
brake, place the transmission in neutral and block the
rear wheels. Make sure crane ignition is in the OFF
position.
2. Using an adequate lift, raise the wheel where the faulty
sensor is located. Place jack stands of adequate rating
under the axle. FIGURE 8-114
3. Using a wheel lift, remove the wheel from the axle.
4. If equipped with spring brakes, release the brakes. Back Item Component
off the slack adjuster.
1 Spider Mounting Bolts
5. Remove the brake drum, cam rollers, return spring and
2 Sensor Bracket
brake shoes.
3 Sensor
6. Remove the mounting bolts for the sensor bracket. Cut
the tie straps along the sensor cable. Remove the P- 4 Spring Clip
clips at the S-cam tube, bracket and frame rail. Using a 5 Tooth Wheel
slight twisting motion, remove the sensor from its
mounting block. Use extreme care not to damage the Installation
tooth wheel or the sensor.
NOTE: Spring clip must be installed with the flange stops
7. Remove the sensor spring clip from the mounting block. facing the inboard side of the crane.
8. Disconnect any fasteners that hold the sensor cable and 1. Push the sensor spring clip all the way into the mounting
the hose clamp to other components. block.
9. Disconnect the sensor from the crane wiring at the 2. Insert the sensor cable through the brake spider
connector closest to the sensor. housing, around the S-cam tube and bracket, up the
10. Pull the sensor cable through the hole in the frame rail. brake chamber airline, and route the cable along the
frame rail.
CAUTION 3. Connect the sensor cable connector.
Sensor damage may result. DO NOT pull on the sensor 4. Install the sensor into the bracket and spring clip. Install
cable to remove it, as this may permanently damage the the bracket and sensor onto the spider assembly.
sensor. DO NOT use any device to pry the sensor from its Tighten the bracket to a torque of 165 ±18 ft-lb (225
mounting block, as this may damage the steel casing on ±25 N·m).
the sensor and can void any existing warranty.

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5. Install the P-clip on the S-cam tube and bracket. Fasten Removal
the sensor cable to the brake air line using a tie strap.
Install P-clip inside the frame rail. 1. Park the crane on a level surface, apply the parking
brake and block the wheels. Make sure the crane
ignition is off and the transmission is in neutral.
CAUTION
Sensor damage may result. DO NOT use a screwdriver or 2. Disconnect the electrical connector from the valve.
sharp instrument to insert or adjust the sensor. DO NOT
3. Identify and label or mark modulator valve air lines for
use a hammer to drive the sensor into position. Use of a
later reinstallation.
sharp instrument or hammer can permanently damage
the sensor. 4. Disconnect the air supply and delivery lines from the
valve.
6. Using an ABS sensor adjustment tool adjust the sensor
against the tooth wheel, and install the rubber grommet.
7. Install the brake lining onto the spider housing. Install the
return spring, S-cam rollers and brake drum.
8. Install the wheel and tighten nuts to a torque of 475
±25 ft-lb (645 ±35 N·m).
9. Adjust the rear axle brakes.
10. Remove the jack stands from under the crane.
11. Lower the crane and remove the wheel blocks.
FIGURE 8-115
12. Readjust the brakes.
13. Verify proper sensor adjustment by driving the crane. 5. Remove the valve mounting screws and nuts.
This allows the ABS to perform an additional self-test.
(ABS Self-tests on page 8-65) Once the crane reaches 6. Remove the valve.
approximately 7 mph (11 km/h), the ABS warning lamp
7. Note the orientation of the fittings in the valve, then
will go out if the sensor is properly adjusted.
remove the fittings.
Front Modulator Valve Replacement
Installation
1. Install the proper fittings on the valve in the original
! DANGER orientation. Use tape or paste-type thread sealant on
PERSONAL INJURY HAZARD! Before working on a fittings to reduce the probability of leakage.
crane, set the parking brakes, place the transmission in 2. Mount the valve on the crane using two bolts and nuts.
neutral and block the wheels. Failure to do so can result in Tighten the nuts to a torque of 18 ft-lb (24 N·m).
unexpected crane movement and can cause serious
personal injury or death. 3. Connect the air supply line to port 1 of the valve.
Connect the delivery line to port 2.

! DANGER
8
PERSONAL INJURY HAZARD! Pneumatic components
store compressed air and can separate violently during
disassembly or removal. Before servicing any part of the
pneumatic (air) system, completely release the air
pressure. Failure to do so can result in serious personal
injury or death.

FIGURE 8-116

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Undercarriage TM500E-2 SERVICE MANUAL

4. Connect the modulator valve electrical connector.

5. Build up air pressure in the crane’s air system.
6. Release the parking brakes.
7. Apply normal brake pressure and verify that the air
passes freely through the ABS modulator valve and that
there are no air leaks.

Rear Modulator Valve Replacement

! DANGER
PERSONAL INJURY HAZARD! Before working on a FIGURE 8-117
crane, set the parking brakes, place the transmission in
neutral and block the wheels. Failure to do so can result in 6. Remove the valve mounting screws and nuts.
unexpected crane movement and can cause serious 7. Remove the valve.
personal injury or death.
8. Remove the two service brake chamber airline(s) from
the valve.

! DANGER 9. Note the orientation of the fittings in the valve, then

remove the fittings.
PERSONAL INJURY HAZARD! Pneumatic components
store compressed air and can separate violently during Installation
disassembly or removal. Before servicing any part of the
pneumatic (air) system, completely release the air 1. Install the proper fittings on the valve in the original
pressure. Failure to do so can result in serious personal orientation. Use tape or paste-type thread sealant on
injury or death. fittings to reduce the probability of leakage.
2. Connect the air line(s) for the service brake chamber(s)
Removal to the valve.
1. Park the crane on a level surface, apply the parking 3. Route the service brake chamber air line(s) through the
brake and block the wheels. Make sure the crane frame and to the service brake chamber(s). Connect the
ignition is off and the transmission is in neutral. air line(s) to the chamber(s). Install the P-clips and tie
straps to hold the air line(s) in place.
2. Disconnect the electrical connector from the valve.
4. Mount the valve on the crane using two bolts and nuts.
3. Identify and label or mark modulator valve air lines to
Tighten the nuts to a torque of 18 ft-lb (24 N·m).
simplify installation.
5. Connect the supply line from the relay valve to port 1 of
4. Remove the air line(s) from the service brake
the modulator valve.
chamber(s) supplied by the valve. Remove the P-clips
and plastic tie straps that hold the air line(s) in place.
NOTE: Due to the non-rotating fittings at the valve, the
service brake chamber air line(s) must be removed
with the valve.
5. Disconnect the supply air line that comes from the relay
valve.

FIGURE 8-118

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6. Connect the valve electrical connector. Installation

7. Build up air pressure in the crane’s air system. 1. Install the proper fittings on the valve in the original
8. Release the parking brakes. orientation. Use tape or paste type thread sealant on
fittings to reduce the probability of leakage.
9. Apply normal brake pressure and verify that the air
passes freely through the ABS modulator valve and that 2. Mount the valve on the crane using two cap screws and
there are no air leaks. nuts. Tighten the nuts to a torque of 18 ft-lb (24 N·m).
3. Connect the air supply lines to the ATR valve as follows:
ATR Valve Replacement
a. Control air line to port 1
b. Service air line to port 2
! DANGER
c. Delivery air line to port 3
PERSONAL INJURY HAZARD! Before working on a
crane, set the parking brakes, place the transmission in d. Supply line to port 4
neutral and block the wheels. Failure to do so can result in
unexpected crane movement and can cause serious
personal injury or death.

! DANGER
PERSONAL INJURY HAZARD! Pneumatic components
store compressed air and can separate violently during
disassembly or removal. Before servicing any part of the
pneumatic (air) system, completely release the air
pressure. Failure to do so can result in serious personal
injury or death.

Removal
1. Park the crane on a level surface, apply the parking
brake and block the wheels. Ensure the crane ignition is
off and the transmission is in neutral.

! DANGER FIGURE 8-119

Components in any air brake system may be under high
pressure. Before disconnecting any air lines, be sure all
air pressure is released. Failure to do so may result in the Item Component
sudden, possibly explosive release of air pressure, 1 Control
causing parts to strike you with considerable force, 2 Service
resulting in serious personal injury.
3 Delivery
2. Bleed the air pressure from the crane’s air brake system. 4 Supply 8
3. Identify and label or mark the ATR valve air lines for 5 ATC Solenoid
proper reinstallation. 6 ATC Solenoid Connector
4. Disconnect the electrical connector from the valve.
4. Connect the valve electrical connector.
5. Disconnect the air lines from the valve.
5. Build up pressure in the crane’s air system.
6. Remove the valve mounting bolts and nuts.
6. Release the parking brakes.
7. Remove the valve.
7. Apply air pressure to the service brakes and verify that
8. Note the orientation of the fittings in the valve, then there are no air leaks and that the system is working
remove the fittings. properly.

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Undercarriage TM500E-2 SERVICE MANUAL

ABS Electronic Control Unit Replacement

ECU Normal Power Sequence
a) All LEDs on
CAUTION
b) All LEDs off
Damage to electronic components may result. Turn the
crane ignition switch off before disconnecting or c) SEN, FRT and RER LEDs on
connecting any electrical components. Failure to d) TRC LED on (if J1922 engine control is enabled)
deenergize circuits may result in electronic equipment
TRC and MOD LEDs on (if differential braking is
damage. e)
enabled)
f) LEDs indicate actual fail status
Removal
1. Ensure the crane ignition is off. 10. IF the LEDs indicate there are faults in the system,
troubleshoot them in accordance with the
2. Disconnect all connectors from the ECU.
troubleshooting procedure and make any required
3. Unbolt the ECU mounting bracket from the crane by repairs. (ABS Troubleshooting on page 8-76)
removing the two mounting nuts from the front of the
crossmember. Remove the ECU and bracket. ABS TROUBLESHOOTING
4. Remove the four bolts and nuts that hold the ECU to its
bracket.
General
There are three methods to troubleshoot the ABS:
Installation
• Use the diagnostic display on the Data Link Instrument
1. Verify the crane ignition is off. cluster.
2. Bolt the replacement ECU to its mounting bracket. • Use the MPSI Pro-Link 9000. (Data Link Instrument
Tighten the bolts to a torque of 65 ±15 in-lb (7.3 Cluster - Diagnostic Display on page 8-77)
±1.7 N·m).
• Use the ECU LEDs. (ECU LEDs on page 8-87)
3. Install the ECU mounting bracket on the crossmember
and install the mounting nuts. Tighten the bolts to a General Safety Information
torque of 213 ±36 in-lb (24 ±4 N·m).
4. Connect all electrical connectors to the ECU. Tighten the
connector screws to a torque of 10 ±3 in-lb (1.15 ! DANGER
±0.35 N·m). PERSONAL INJURY HAZARD! Before working on a
crane, set the parking brakes, place the transmission in
5. Turn the crane ignition on.
neutral and block the wheels. Failure to do so can result in
6. Turn the TCS switch off. unexpected crane movement and can cause serious
personal injury or death.
7. Configure the ECU by holding a magnet over the point
labeled RESET on the LED side of the ECU for at least
20 seconds.
NOTE: The LEDs will flash while self-configuration is ! DANGER
taking place. Power should not be removed from Exhaust gases contain deadly poison. When testing a
the ECU during self-configuration. crane with the engine running, conduct the test outdoors
8. Verify that the LEDs flash to indicate self-configuration is or use a properly vented exhaust hose.
occurring.
9. When self-configuration is complete, verify that the ECU
carries out its normal power on sequence as listed ! WARNING
below. HOT ENGINE! Keep yourself and your test equipment
clear of all moving or hot engine parts. A hot engine can
cause serious burns or can permanently damage test
equipment.

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Brake SIDs (Subsystem IDs) Text Message

CAUTION 15 ABS relay, diagonal 2 Diag2Rly
Damage to electronic components may result. Turn the
crane ignition switch off before disconnecting or 18 ABS, dif 1 - ASR valve ASRValv1
connecting any electrical components. Failure to 19 ABS dif 2 - ASR valve ASRValv2
deenergize circuits may result in electronic equipment
damage. MPSI Pro-Link 9000
Data Link Instrument Cluster - Diagnostic The MPSI Pro-Link 9000 is a hand-held electronic diagnostic
instrument. When used with the MPC cartridge and Bendix
Display ABS application card (for the AL-7) or with the Bendix ABS
The integrated multifunction display of the Data Link cartridge (for the AL-6), the Pro-Link tool provides easy
Instrument Cluster can be used to display diagnostic diagnosis of faults within the ABS, including:
messages from the ABS. The system uses the SAE J1708/
• a faulty input;
1587 Data Link and is installed on all models.
• a faulty command; or
Refer to the Instruments, Dixson Data Link Cluster service
manual for more information. • a faulty reaction to a command.

To view diagnostic messages: In addition, the Pro-Link 9000 provides the ability to run a
series of component tests on the ABS/ATC system.
1. Stop the engine.
2. Turn ignition key on.
AL-6
3. Press the MODE button on the dash until the “DIAG” The MPSI Pro-Link 9000 is available from Kent-Moore. The
indicator and the message “REQUEST?” are displayed. Bendix ABS cartridge is required to use the Pro-Link 9000 on
the Bendix ABS model AL-6.
4. Press the RESET button to activate the diagnostic
routines.
The multifunction display requests the diagnostic information
stored in the engine, transmission, ABS brake system and
any other system present on the SAE J1708/1587 Data Link. MPSI Pro-Link 9000
As the codes are received, they will be displayed in short text
messages, along with “ACTIVE” or “INACTIVE” status.

Diagnostic Messages

Brake SIDs (Subsystem IDs) Text Message

1 ABS sensor, axle, 1, left Sens L#1
2 ABS sensor, axle, 1, right Sens R#1
3 ABS sensor, axle, 2, left Sens L#2
4 ABS sensor, axle 2, right Sens R#2
5 ABS sensor, axle 3, left Sens L#3 Bendix ABS
6 ABS sensor, axle, 3, right Sens R#3
Cartridge 8
7 ABS valve, axle 1, left Valv L#1
8 ABS valve, axle 1, right Valv R#1
FIGURE 8-120
9 ABS valve, axle 2, left Valv L#2
10 ABS valve, axle 2, right Valv R#2
11 ABS valve, axle 3, left Valv L#3 AL-7
12 ABS valve, axle 3, right Valv R#3 The Pro-Link 9000/MPC tool is available from MPSI. The
13 ABS retarder control relay RtdrRly Bendix ABS application card is required to use the Pro-Link
9000 with MPC cartridge on the Bendix ABS model AL-7.
14 ABS relay, diagonal 1 Diag1Rly

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Undercarriage TM500E-2 SERVICE MANUAL

Key Description
This key is used to “back out” of functions
FUNC Key
MPSI Pro-Link 9000 and menus.

Cleaning: The keypad can be cleaned with a damp cloth or

mild cleaner. DO NOT immerse the Pro-Link/MPC tool in
fluids, as doing so will permanently damage the unit.

Push Button
A red push button is located on the left side of the Pro-Link/
MPC tool. The function of this push button is determined by
the specific application card plugged into the MPC cartridge.
MPC Data The tool will instruct you when to press this button.
Cartridge
Installing and Removing the MPC Cartridge
Application Card With the MPC cartridge installed in the Pro-Link tool, you can
use the Bendix ABS application card.
FIGURE 8-121 To Install the MPC Cartridge:
1. Disconnect the crane adapter (containing the 12-volt
Readout Window power feed) from the crane.
The Pro-Link 9000 uses a liquid crystal display (LCD).The 2. Seat the cartridge on the back of the Pro-Link tool. Do
readout contains 4 display lines with 20 characters each and not hold the cartridge at an angle. It must sit flat. It can
can include letters, numbers and special symbols. The be inserted only one way.
display includes a built-in backlight so the display can be
read in any light. 3. Slide the cartridge forward until it clicks into place. The
cartridge may be left in place indefinitely.
When the readout window shows a menu, the first three
display lines show the menu title and other helpful
information. The last display line shows the first menu
choice. Press the up or down arrow key to display the next
menu item.

Press ENTER to select the menu item that is displayed on

the bottom line of the screen, or press FUNC to return to the
previous menu (next higher level).

Keypad
The keypad features 16 keys, which are sealed to prevent
contamination from grease and fluids.

Key Description
The 10 numeric keys are arranged and
Numeric Keys
used like a calculator.
The up and down arrow keys are used to
scroll through the lines of the display. FIGURE 8-122
Each touch of the key moves the display
Arrow Keys To Remove the MPC Cartridge:
up or down one line. The right and left
arrow keys are used to move between 1. Place your thumbs on the slanted surface of the
choices provided by the display. keyboard and your fingers on the cartridge.
This key is used to select a menu item,
2. Make a motion similar to snapping your fingers. The
ENTER Key confirm an answer or instruct the tool to
retention latches will release the outer end of the MPC
go to the next step.
cartridge.

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3. Continue sliding the cartridge straight out until the edge

board is clear of the connector in the Pro-Link tool.
Power/Data Cable, Earlier Version
Non-Volatile Memory
The MPC cartridge has a non-volatile memory. This means
that data is not lost when the Pro-Link/MPC tool is
disconnected from the crane’s power source.

FIGURE 8-124

Power/Data Cable, Later Version

FIGURE 8-123

When the Pro-Link/MPC tool is connected to an external

power source (using the power cable in conjunction with the
data cable), the Pro-Link/MPC tool recognizes that it is not
communicating with an ECU. The FUNC key is still active,
and you can access stored data for review and printing. This
includes “MPC Utilities” and “Recall Data.”

MPSI Power/Data Cable

The data and power cable must be connected to the crane or
an external 12-volt power source before the Pro-Link/MPC
tool can function.
FIGURE 8-125
Connecting the Power/Data Cable
Earlier cables consisted of a single assembly; both the data
cable and power cable are attached by a single molded
connector. Fuse 8
Later versions have two separate cables. In both cases, the The standard power cable contains a replaceable fuse inside
power cable includes a cigarette lighter adapter. the cigarette lighter adapter. There also is a fuse inside the
MPC cartridge that can be reset.
1. Locate the crane power/data cable (part number 501002
or J-38500–2). The cable has a large, 15-pin connector
Application Cards
with two thumbscrews. Note that part 501002 is a two-
piece cable and permits the removal of the power cable Application cards are specific to the crane’s computer
(containing the cigarette lighter adapter). system. Before beginning work on the crane, check the
identification label on the application card to make sure you
2. Plug the connector into the top of the Pro-Link/MPC tool.
are using the correct crane application.
3. Tighten the two thumbscrews to secure the cable.

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Installing the Application Card:

Slide the application card into the PCMCIA card slot on the
MPC cartridge. The card will seat into the MPC cartridge only Diagnostics
one way. Do not force the card into place. Connector

FIGURE 8-127

FIGURE 8-126

Application cards can be inserted or removed while the Pro-

Link is powered. Removal of the application card will halt the
system. Reinserting the application card will reboot the Pro-
Link tool.

When correctly seated, the eject button to the left of the

PCMCIA card slot will pop out. If the card seats but the eject
button does not pop out, the card has been inserted upside
down. Pressing the eject button will remove only a properly
inserted card.
NOTE: The “Write Protect” (W/P) switch must be in the
OFF position for the application card to work
properly.

USING THE PRO-LINK 9000 FIGURE 8-128

Bendix ABS Application Card and MPC

Item Component
Cartridge (with AL-7 ECU)
1 Diagnostic Connector:
Perform the following steps to determine faults using the Pro-
Bussed Electrical Center, crane Interface
Link 9000: 2
Module
1. Insert the MPC cartridge into the Pro-Link 9000. (See 3 Transmission ECU
Installing and Removing the MPC Cartridge on page
8-78) 4 Terminating Resistor Connector
5 ABS ECU
2. Plug the male end of the data cable into the Pro-Link
9000. Tighten the thumbscrews to secure the cable.
4. Turn the crane ignition switch on.
3. Remove the dust cap from the crane diagnostics
5. Verify that the Pro-Link 9000 powers up properly.
connector and connect the data cable to the diagnostics
connector (1) on the crane. 6. Insert the Bendix ABS application card into the MPC
cartridge. (See Application Cards on page 8-79)

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NOTE: From this display, you can also use the up or down previous screen. (Refer to the Pro-Link/MPC
arrows to choose either MPC UTILITIES or LOAD operator’s manual for more detailed information
ALL APPLICATIONS for the MPC UTILITIES Menu about these functions.)
Structure. (For more information, refer to the Pro-
Link/MPC operator’s manual.)
7. With BENDIX ABS/ATC v1.0 on the bottom line of the
display, press ENTER to continue to the “Bendix ABS/
ATC Application Menu Structure.”
NOTE: To exit to the previous menu, press FUNC.
8. With the Bendix ABS/ATC application running, you can
choose from the following main options. (For a flow chart
showing application options, see MPC Application Menu
Structure on page 8-83.)
• Diagnostic Codes 10. Return to the Bendix ABS/ATC main option menu. (You
may need to press the FUNC key.) The DIAGNOSTIC
• Data List CODES menu option should be on the bottom line of the
• Reset ECU display.
• Test System
• System Configuration
• ECU Information
Use the up or down arrows to scroll to the desired
option. With the DIAGNOSTIC CODES option on the
bottom line of the display, press ENTER to continue.
NOTE: To exit to the main menu options, press the FUNC
key.

11. Using the up or down arrow keys, scroll to the DATA

LIST option.
To select the DATA LISToption, press ENTER. This lets
you view data list parameters in sequence of operation.
Press FUNC to exit back to the main option menu.

9. The DIAGNOSTIC CODES menu lets you choose from

the following diagnostic functions:
• ACTIVE FAULTS
• FAULT HISTORY 8
• CLEAR FAULT HISTORY
• CLEAR ACTIVE FAULTS 12. Using the up or down arrow keys, scroll to the RESET
ECU option.
NOTE: As with all menu options, use the up or down arrow
to scroll to the desired function, and press ENTER To select the RESET ECU option, press ENTER. This
to begin the function. To end use of a function, function lets you reset the ABS ECU. Press FUNC to exit
press the FUNC key. This will return you to the back to the main option menu.

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• EDIT CONFIGURATION
• SELF CONFIGURATION
Press FUNC to exit back to the main option menu.

13. Using the up or down arrow keys, scroll to the TEST

SYSTEM option.
To select the TEST SYSTEM option, press ENTER. This
function lets you test the operation of components of the 15. Using the up or down arrow keys, scroll to the ECU
ABS/ATC system. These include: INFORMATION option.
• PULSE MODULATOR To select the RESET ECU option, press ENTER. This
• TEST MODULATOR function displays information about the ECU being
tested. Press FUNC to exit back to the main option
• RETARDER RELAY
menu.
• TRACTION LAMP
16. Press the FUNC key when finished to end the session.
• WARNING LAMP
17. When troubleshooting is complete, turn the crane
• DISABLE TRACTION ignition to OFF, remove the application card from the
Press FUNC to exit back to the main option menu. MPC cartridge and disconnect the power/data cable
from the diagnostics connector in the crane. Replace the
14. Using the up or down arrow keys, scroll to the SYSTEM diagnostics connector dust cap.
CONFIGURATION option.
To select the SYSTEM CONFIGURATION option, press
ENTER. This function lets you view and edit the
configuration of the ABS ECU system.
This includes:
• VIEW CONFIGURATION
• VIEW TIRE SIZE
• VIEW SYSTEM SETUP

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MPC APPLICATION MENU STRUCTURE

The application menu structure will assist you in locating
specific functions of the Bendix ABS/ATC application card.

FIGURE 8-129

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Undercarriage TM500E-2 SERVICE MANUAL

Using the Bendix ABS Cartridge (with AL-6 4. Turn the crane ignition switch on.
ECU) 5. Verify that the Pro-Link 9000 powers up properly by
observing the display.
Perform the following steps to determine faults using the Pro-
Link 9000.
1. Insert the Bendix ABS cartridge into the Pro-Link 9000/
MPC tool.
2. Plug the male end of the data cable into the Pro-Link
9000. Tighten the thumbscrews to secure the cable.
3. Remove the dust cap from the crane diagnostics
connector and connect the data cable to the diagnostics
connector (1) on the crane.

6. Verify that the Pro-Link establishes communication with

Diagnostics the ABS.
Connector
7. Verify that the information displayed matches the crane
configuration (four sensors or six sensors). If it does not,
refer to the MPSI Pro-Link 9000 manual for the Bendix
ABS/ATC System to change the Pro-Link 9000 test
configuration.

FIGURE 8-130

8. Press ENTER to access the function selections menu.

9. If the ABS/ATC does not have brackets around it, press

the left arrow to place brackets around ABS/ATC, then
press ENTER.
FIGURE 8-131

Item Component
1 Diagnostic Connector: WXR
2 Bussed Electrical Center, crane Interface Module
3 Transmission ECU
4 Terminating Resistor Connector
5 ABS ECU

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10. With the DIAGNOSTIC CODES menu displayed, press 16. If clearing ACTIVE FAULTS was successful, repeat the
ENTER to go to the faults menu. clearing process for FAULT HISTORY; otherwise, repeat
the entire process to repair and clear ACTIVE FAULTS.
11. When the ABS MENU appears, use the up and down
arrow keys to scroll to ACTIVE FAULTS or FAULT 17. Press FUNC several times to return to the function
HISTORY, then press ENTER. selections menu.

18. When troubleshooting with the Pro-Link 9000 is

12. If there are any faults of the type selected, the Pro-Link
complete, turn the crane ignition to OFF, then disconnect
9000 will display them one at a time.
the Pro-Link 9000. Replace the diagnostics connector
The last line of the display provides information dust cap.
regarding the fault. In the example, A1 refers to the
number of the active fault assigned by the ECU. “H1” System Testing Using the Pro-Link 9000
would refer to the first fault stored in the fault History. (AL-6)
DEV refers to the device number of the faulty
component, such as 11 for Left Front Sensor or 22 for There are several tests that can be run on the Bendix system
Right Rear Modulator. FLT identifies the specific type using the MPSI Pro-Link 9000. The available tests are:
fault such as 01 for sensor open or 80 for shorted • crane voltages
modulator.
• ABS modulator valves
• Traction control valve
• ABS/wheel spin dash warning lamps
• Sensors
• Engine Data Link
• Retarder relay
• Retarder Data Link

13. Correct the active faults using appropriate service Preparing for Testing
procedures or other repair method. Perform the following steps to set up the Pro-Link 9000 to
14. Press the FUNC key to return to the fault selection run system tests:
menu. 1. Insert the Bendix ABS cartridge into the Pro-Link 9000.
15. Use the up or down arrow keys to select CLR ACTIVE 2. Plug the male end of the data cable into the Pro-Link 8
FAULTS or CLR FAULT HISTORY, then press ENTER. 9000. Tighten the thumbscrews to secure the cable.
The screen will appear as shown:
3. Connect the female end of the data cable to the Data
Link connector on the crane.
4. Turn the crane ignition switch on.
5. Verify that the Pro-Link 9000 powers up properly by
observing the display.

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NOTE: ATC on the MPSI Pro-Link 9000 display refers to 11. When the ABS selections menu appears, use the down
the Traction Control System. arrow key to scroll to TEST SYSTEM. Then press
ENTER.
6. Verify that the Pro-Link establishes communication with
the ABS.
7. Verify that the information displayed matches the crane
configuration (four sensors, four valves). If it does not,
change the Pro-Link 9000 test configuration. (Refer to
the MPSI Pro-Link 9000 manual for the Bendix ABS/
ATC System.)

12. Use the up and down arrow keys to scroll to the test of
your choice, then press ENTER to run the test.
13. When the system testing is complete, press FUNC to
return to the selections menu. Use the up or down arrow
keys to scroll to DATA LIST, then press ENTER.
14. The Pro-Link 9000 will display the current value of four
8. Press ENTER to access the function selections menu. parameters. Press the down arrow to view additional
parameters. The status of the following parameters can
be displayed by the Pro-Link 9000:
• L FRONT MP
• R FRONT MPH
• L REAR MPH
• R REAR MPH
• L MIDDLE MPH
• R MIDDLE MPH
9. If ABS/ATC does not have brackets around it, press the • BATT VOLTAGE
left arrow to place brackets around ABS/ATC, then press
ENTER. • TRACTOR LAMP

10. With the DIAGNOSTIC CODES menu displayed, press • WARNING LAMP
ENTER to go to the faults menu. • RETARDER RELAY
• ENGINE IDLE
• SBEND RELAY
• ENGINE DATA LINK
• RETARDER DATA LINK

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15. At any time, press FUNC to move back to the previous error condition is detected within the system by the ECU, one
menu (one level higher). or more of the LEDs will light to show the location and
component associated with the fault.
16. When all testing is complete, turn the crane ignition
switch to OFF before disconnecting the Pro-Link 9000. There are 10 LEDs plus a magnetically activated reset
switch in the ECU diagnostics. The LEDs are software driven
ECU LEDS and are either on, off or flashing, depending on their
monitoring function.
The condition of specific ABS/TCS components is provided
by a series of LEDs on the side of the ECU housing. If an

Label Identifies Color Signifies

FRT Steer Axle Red Fault detected on a steering axle ABS component or its wiring
Fault detected on a forward drive axle ABS component or its
MID Forward drive axle Red
wiring
RER Rear drive axle Red Fault detected on a rear drive axle ABS component or its wiring
RHT Right side of crane Red Fault detected in a component that is on the right side of the crane
LFT Left side of crane Red Fault detected in a component that is on the left side of the crane
TRC Traction control Red Fault detected in a TCS component or circuit
Fault detected in an ABS modulator valve or its wiring or with an
MOD ABS modulator valve Red
ATR-2 traction control valve
SEN ABS wheel speed sensor Red Fault detected in an ABS wheel speed sensor
ECU ECU electronic controller Red The ECU has detected a failure in its own circuitry.
Indicates that the voltage is supplied to the ECU and that the
VLT Voltage supply to ABS Green voltage is in the correct range (11 to 17 VDC). This LED flashes if
voltage is present but out of range.

Diagnosing Faults Using the ECU LEDs

The troubleshooting diagrams and flowcharts in this section
provide a method to help locate a fault that is indicated by the
ECU LEDs.

Technicians experienced in troubleshooting Bendix ABS

problems may begin troubleshooting using the quick
r e f e r e n c e f l o w c h a r ts o n t h e n e x t t w o pa g e s . L e s s
experienced technicians should begin troubleshooting using
the Initial Start-Up Procedure flowchart.

When a fault has been identified and corrected, reset the

ECU diagnostics by passing a small magnet over the point
labeled RESET on the ECU. (The magnet must be strong
enough to pick up a 3 oz weight.) If additional faults exist,
8
repeat the troubleshooting process. FIGURE 8-132

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Troubleshooting Quick Reference

This index is presented for the benefit of personnel experienced in troubleshooting Bendix full-crane wheel control anti-lock
with traction control. It provides a quick reference to specific sections that provide testing procedures and values.

NOTHING ON - GO TO
Section V - Testing for
Power to the ABS ECU
on page 8-95

FLASHIG ON - GO TO ON (Not Flashing) - GO

Section V - Testing for TO Section II - Inspection
Power to the ABS ECU for Illuminated LEDs on
on page 8-95 page 8-92

ONE FROM THIS ONE FROM THIS

GROUP ON GROUP ON

ONE FROM THIS ONE FROM THIS

ONE OR GROUP ON GROUP ON
MORE ON
ON - GO TO Section VI A -
Testing the Modulator ON - GO TO Section VII A -
GO TO Section IV - Valve on page 8-96
Inspection for Testing the Wheel Speed
ON Illuminated LEDs Sensor on page 8-98
(Not Flashing) on page 8-94

ON - GO TO Section XII -
ON - GO TO Section X - Testing J1922 Circuit on
Testing TCS Lamp on page 8-104
page 8-102

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Component Troubleshooting Quick Reference Chart

Check the pins shown on the ECU 30-pin connector that correspond to the combination of red LEDs to the left (arrows
show the red label combination).

NOTE: All contacts described above should not have any continuity to ground. Pin A1, A2, A3 or J3 of 30-pin
connector and Pin B1, K2 and K3 are power to ABS ECU.

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INITIAL START-UP PROCEDURE FOR AL-6 / EC-16 OR AL-7 / EC-17 ECU

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SECTION I - ABS WARNING LAMP TESTING

NOTE: For more detailed information, refer to Electrical Schematics, System Group 370.

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SECTION II - INSPECTION FOR ILLUMINATED LEDS

NOTE: For more detailed information, refer to Electrical Schematics, System Group 370.

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SECTION III - INSPECTION FOR ILLUMINATED LEDS

NOTE: For more detailed information, refer to Electrical Schematics, System Group 370.

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SECTION IV - INSPECTION FOR ILLUMINATED LEDS

NOTE: For more detailed information, refer to Electrical Schematics, System Group 370.

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SECTION V - TESTING FOR POWER TO THE ABS ECU

NOTE: Note: For more detailed information, refer to Electrical Schematics, System Group 370.

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SECTION VI A - TESTING THE MODULATOR VALVE

NOTE: Note: For more detailed information, refer to Electrical Wiring and Circuit Diagrams.

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SECTION VI B - TESTING THE MODULATOR VALVE

NOTE: For more detailed information, refer to Electrical Schematics, System Group 370.

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SECTION VII A - TESTING THE WHEEL SPEED SENSOR

NOTE: For more detailed information, refer to Electrical Schematics, System Group 370.

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SECTION VII B - TESTING THE WHEEL SPEED SENSOR

NOTE: For more detailed information, refer to Electrical Schematics, System Group 370.

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SECTION VIII - TESTING FOR FALSE INDICATION CAUSED BY ABS WARNING

LAMP RELAY
NOTE: For more detailed information, refer to Electrical Schematics, System Group 370.

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SECTION IX - TESTING FOR FALSE INDICATION CAUSED BY WHEEL SPEED

COMPONENTS

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SECTION X - TESTING TCS LAMP

NOTE: For more detailed information, refer to Electrical Schematics, System Group 370.

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SECTION XI - TESTING TRACTION CONTROL VALVE

NOTE: For more detailed information, refer to Electrical Schematics, System Group 370.

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SECTION XII - TESTING J1922 CIRCUIT

NOTE: For more detailed information, refer to Electrical Schematics, System Group 370; to reset ABS ECU, hold a
magnet against ECU “RESET” for at least 20 seconds.

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OUTRIGGERS the outrigger control manifolds are mounted on their

respective outrigger boxes.
Outrigger Circuit Description There are three sets of outrigger selector controls.One on
The outrigger circuit consists of four extension cylinders, four each side of the crane and one in the cab on the front
stabilizer cylinders, an outrigger selector valve, front and rear console.
outrigger control manifolds, and pilot operated check valves. Sight bubble levels are mounted on each side of the crane
The extension cylinders are mounted in the outrigger beams and in the crane cab. The sight bubble level provides the
and the outrigger beams are mounted in their respective operator with a visual indication of crane level attitude.
outrigger boxes. The stabilizer cylinders are mounted on the
end of each outrigger beam. The outrigger selector valve is NOTE: Refer to Section 3 - OPERATING CONTROLS and
mounted on the right side of the superstructure frame and PROCEDURES in the Operator ’s Manual for
operation of the outrigger switches.

Troubleshooting
Symptom Probable Cause Solution
1. Slow or erratic operation of a. Damaged relief valve. a. Remove relief valve; clean or
outrigger extension cylinders. replace.
b. Low hydraulic oil. b. Replenish oil to proper level.
Refer to Section 9 -
LUBRICATION
c. Sticking solenoid valve spool. c. Repair or replace valve spool.
d. Improper ground to base of d. Ground properly.
solenoid.
e. Damaged O-rings and swivel e. Remove swivel and replace
O-rings.
f. Directional selector switch f. Clean or replace switch.
sticking.
g. Collector ring dirty or glazed. g. Clean and deglaze collector
ring.
h. Damaged wiring to solenoid. h. Replace wiring.
i. Weak brush springs on i. Replace brush springs.
collector ring.
j. Damaged extension cylinder j. Remove extension cylinder
(internal parts). and repair as necessary.
k. Bent cylinder rods. k. Replace piston rods and
seals.
l. Excessive material on l. Clean outrigger beams.
outrigger beams. 8
m. Binding outrigger beam. m. Repair or replace outrigger
beam.
n. Damaged outrigger valve. n. Repair or replace valve.
o. Damaged valve coil. o. Replace coil.
p. Main hydraulic pump p. Replace or tighten hose or
cavitation. fitting.

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Troubleshooting (Continued)
Symptom Probable Cause Solution
Slow or erratic operation of q. Partially shifted hydraulic q. Disassemble, clean, and
outrigger extension cylinders. spool in selector valve or polish spool and valve
(continued) manifolds. housing with very fine emery
cloth (water paper).
r. Insufficient voltage for r. Solenoids require a minimum
operation of solenoid valve. of 9.5 volts to energize. Check
outrigger wiring and electrical
coupling collector rings.
s. Damaged piston seals. s. Replace all cylinder seals.
t. Worn or damaged hydraulic t. Repair or replace pump
pump section. section.
u. Scored cylinder barrel. u. Repair or replace extension
cylinder.
v. Cracked or damaged piston. v. Replace rod weld and all
cylinder seals.
w. Piston loose on piston rod. w. Replace all cylinder seals and
torque piston locknut.
2. Sticking spool. a. Dirt in the system. a. Change oil and flush system.
b. Distortion caused by tie bolts b. Retorque tie bolts.
being overtorqued.
c. Flow in excess of valve rating. c. Limit flow through valve to that
recommended. Check pump
output and cylinder ratio.
d. Pressure in excess of valve d. Check relief valve setting or
rating. pump compensation with that
recommended.
e. Electrical failure. e. Check wiring and solenoids.
3. External leakage. a. Damaged O-ring or quad a. Check for chipped packings
rings. and replace.
b. Loose tie bolts. b. Retorque tie bolts.
c. Damaged solenoid. c. Replace damaged parts.
4. Solenoid failure. a. No current. a. Check power source of at
least 85% of coil rating.
b. Damaged solenoid assembly. b. Replace solenoid.
c. Short in solenoid. c. Replace coil.
d. Loss of solenoid force. d. Decrease time of solenoid
energization, decrease cycle
rate.

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Troubleshooting (Continued)
Symptom Probable Cause Solution
5. Outrigger stabilizer cylinder slow a. Low in hydraulic oil. a. Replenish oil to proper level.
or erratic.
b. Damaged main relief valve. b. Repair or replace valve.
c. Damaged holding valve seals. c. Replace holding valve seals.
d. Bent cylinder rod. d. Replace cylinder rod and
seals.
e. Bent outrigger housing. e. Repair or replace outrigger
housing.
f. Excessive material on beams. f. Clean outrigger beams.
g. Sticking solenoid valve spool. g. Repair or replace valve spool.
h. Damaged wiring to solenoid. h. Repair or replace wiring.
i. Weak brush springs on i. Replace brush springs.
collector rings.
j. Collector ring dirty or glazed. j. Clean or deglaze collector
ring.
k. Directional selector switch k. Clean or replace switch.
sticking.
l. Main hydraulic pump l. Replace or tighten hose and
cavitation. fittings.
m. Worn or damaged hydraulic m. Repair or replace pump
pump section. section.
6. Outrigger stabilizer cylinder a. Damaged piston seals. a. Replace all cylinder seals.
retracts under load.
b. Damaged holding valve seals. b. Replace seals.
c. Damaged holding valve. c. Replace valve assembly.
d. Scored cylinder barrel. d. Repair or replace cylinder.
e. Cracked or damaged piston. e. Replace piston and all
cylinder seals.
7. Outrigger stabilizer cylinder a. Damaged piston seals. a. Replace all cylinder seals.
extends while machine is
b. Scored cylinder barrel. b. Replace jack cylinder.
traveling.
c. Cracked or damaged piston. c. Replace piston and seals.
d. Piston loose on cylinder rod. d. Replace seal and retorque.
8. Outrigger system will not activate a. Hydraulic oil low. a. Replenish system.
(from stowed or extended and
down position).
b. Loose or broken wire on b. Repair or replace wiring. 8
switch.
c. Clogged, broken, or loose c. Clean, tighten, or replace
lines or fittings. lines or fittings.
d. Damaged relief valve or d. Repair or replace valve.
damaged control valve.

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Troubleshooting (Continued)
Symptom Probable Cause Solution
9. Outrigger system activates, but a. Clogged, broken, or loose a. Clean, tighten, or replace
selected outrigger will not stow or hydraulic lines or fittings. lines or fittings.
extend and lower as desired.
b. Loose or broken wire on b. Repair or replace wiring.
control switch or solenoid
valve.
c. Damaged solenoid valve. c. Repair or replace valve.
d. Damaged control switch. d. Replace switch.
e. Damaged hydraulic cylinder. e. Repair or replace cylinder.
10. Outriggers will not set. a. Improper sequence of a. Activate individual control
activation. switch; then activate system
control switch.
11. Two outriggers activate from a. Damaged solenoid valves. a. Repair or replace.
single control switch.
12. The two outriggers will not stow. a. Hydraulic lock. a. Recycle individual
outrigger(s).
13. Individual outrigger will not set or a. Damaged piston seals. a. Replace seals.
stow.
b. Damaged check valve. b. Repair or replace valve.
c. Loosen or broken wire on c. Repair or replace wiring.
control switch or solenoid
valve.
d. Damaged solenoid valve. d. Repair or replace valve.

Outrigger Beam Description Removal

The outrigger beam assembly Figure 8-133 consists of an 1. On the stabilizer cylinder end of the beam, remove the
outrigger beam, a stabilizer cylinder, a extension cylinder, set screw from the side adjustable wear pad and back off
and the required hoses and mounting hardware. the wear pad from the outrigger box.
2. Remove the cover from the opposite end of the outrigger
Theory of Operation box. Remove the setscrew from the side adjustable wear
When the outrigger extension is activated, it extends or pad and back off the wear pad from the beam.
retracts the outrigger beam within the outrigger box. The
3. Remove the setscrews from the bottom adjustable wear
outrigger beam can be extended to the mid-extend position
pads and back off the wear pads leaving approximately
by allowing the lock pin to ride on the top of the beam while
6 mm (0.23 in) protruding to keep the bottom of the
it’s extending. The lock pin will automatically drop into the
beam off the outrigger box.
hole when the beam reaches the mid-extend position.
4. Extend the outrigger slightly to facilitate attaching a
The stabilizer cylinder is mounted to the end of the beam and
lifting device to the outrigger beam.
applies force to the outrigger beam vertically. This sequence
of events provides for lifting and stabilizing the crane for
operation.
DANGER
Be sure any blocking material used is capable of
supporting the weight of the outrigger beam. Do not allow
it to tilt or slide. Failure to do so could result in death or
injury to personnel.

5. Place blocking material under the outrigger beam.

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11, 12

14
1

5
15

16
2, 3

13
7 9
8

4
6759-3

14
6
FIGURE 8-133 10

Item Description Item Description

1 Outrigger Box 9 Lock Nut
2 Cotter Pin 10 Set Screw
3 Clevis Pin 11 Cotter Pin
4 Side Wear Pad and Set Screw 12 Clevis Pin
5 Lock Pin 13 Extension Cylinder
6 Bottom Wear Pad Assembly 14 Stabilizer Cylinder
7 Capscrew 15 Outrigger Beam 8
8 Plate 16 Wear Pad

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5 4

7
2

8
FIGURE 8-133 continued

Item Description Item Description

1 Stabilizer Cylinder 5 Stabilizer Cylinder Retract Port
2 Extension Cylinder 6 Extension Cylinder Retract Port
3 Outrigger Beam 7 Extension Cylinder Extend Port
4 Stabilizer Cylinder Extend Port 8 Wear Pad

NOTE: Outrigger removal and installation

similar for both front and rear
outriggers. 6120-1
NOTE: Lifting belts or straps should be used
for lifting purposes so as to avoid
nicking or scratching the bottom
edges of the outrigger beam.

FIGURE 8-134

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6. Tag and disconnect the hydraulic lines at the cylinder 4. Attach a suitable lifting device of straps or belts instead
barrel end of the extension cylinder. Cap all lines and of chains to prevent nicking the bottom edges of the
fittings. outrigger beam.
NOTE: Do not allow the end of the outrigger extension 5. Slide the beam into the outrigger housing and align the
cylinder to fall when the cylinder mounting shaft is cylinder bushing with the mounting hole.
removed. Use blocking to limit the drop or an
6. Apply anti-seeze compound to the clevis pin. Secure the
adequate soft support to cushion any distance the
cylinder barrel to the housing with the clevis pin and
rod will drop.
cotter pin.
7. Remove the cotter pin and clevis pin securing the
cylinder barrel end of the extension cylinder to the
outrigger housing. Carefully extend the outrigger beam CAUTION
until the extension cylinder is free of the housing and Be sure that the piston side of all outrigger cylinders are
carefully lay the end of the cylinder on the bottom of the connected to the solenoid valve bank. Reversal of port
outrigger beam or leave on blocking. connection of the rod and piston sides could result in
8. After attaching a suitable lifting device of straps or belts severe damage to the cylinders as very high pressure
Figure 8-134 instead of chains to prevent nicking the intensification will occur.
bottom edges of the outrigger beam, pull the outrigger
beam out of the outrigger box, re-adjusting the lifting
attachment to prevent the extension cylinder from sliding
out of the outrigger beam when the beam clears the CAUTION
outrigger box. During initial start-up and checking of the outrigger
operation, each control switch must be operated before
operating the selector valve. If hydraulic lines are
reversed to one or more cylinders, this will prevent
DANGER damage to the cylinders.
Be sure any blocking material used is capable of
7. Connect the hydraulic lines as tagged prior to removal.
supporting the weight of the outrigger beam. Do not allow
it to tilt or slide. Failure to do so could result in death or 8. Install the side adjustable wear pad in the outrigger box.
injury to personnel.
9. Adjust the wear pads, refer to WEAR PAD
ADJUSTMENT in this Sub-Section.
NOTE: The outrigger beam assembly weighs
approximately 374 kg (824 pounds). 10. Install the end cover.
9. Position the outrigger beam on the blocking material. NOTE: At installation, be sure that the outrigger stabilizer
cylinder hydraulic hoses are not trapped against
Inspection the outrigger box when the beam is fully retracted.
Inspect the outrigger beams for bends, evidence of cracks,
Wear Pad Adjustment.
or other damage. Check the outrigger beam internally for
hydraulic fluid, which may indicate a leaking cylinder, loose NOTE: When adjusting wear pads, refer to Wear Pad
connection, or damaged hydraulic line. Adjustment Figure 8-135.

Installation 1. Adjust the bottom wear pads until a gap of 3 mm (0.11 in)

NOTE: Apply anti-seeze compound on clevis pins and

is obtained between the top of the beam and the top of
the outrigger box. Install and lock setscrew against wear
8
setscrews during installation. pad.
1. Apply grease (EPMPG) to the bottom of the outrigger 2. Adjust outrigger box side wear pad until a gap of 2 mm
beam. (0.07 in) is obtained between beam and shims welded in
top and bottom of box. Install and lock set screw against
2. If removed, install the side adjustable wear pad in the
wear pad.
outrigger beam.
3. Adjust outrigger beam side wear pad until a gap of 2 mm
3. Install the bottom wear pads with approximately 6 mm
(0.07 in) is obtained between shim welded on beam and
(0.23 in) protruding. This will prevent the beam side
side of box. Install and lock set screw against wear pad.
plates from riding on the bottom of the box Figure 8-135.

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Undercarriage TM500E-2 SERVICE MANUAL

Adjust wear pad for 2 mm (0.07inch)

gap with opposing shim

6, 7

4
3
5 3
The wear pad needs to be 6 mm (0.23 inch) above 1, 2
the of bottom of the outrigger box before installing 1, 2
outrigger beam.

FIGURE 8-135

NOTE: Refer to Cylinders in Section 2 - HYDRAULIC AND

PRESSURE SETTINGS for Disassembly and
Item Description
Assembly of the cylinder.
1 Lock Nut
2 Set Screw Removal
3 Cap Screw 1. Remove the outrigger beam. Refer to OUTRIGGER
BEAM - REMOVAL in this section.
4 Plate
2. Remove the cotter pin and clevis pin securing the rod
5 Wear Pad
end of the extension cylinder to the outrigger beam.
6 Set Screw
3. Pull the extension cylinder from the outrigger beam until
7 Wear Pad the hydraulic hoses on the rod end of the cylinder can be
accessed. Tag and disconnect the hoses from the rod
Extension Cylinder Description end of the cylinder. Cap or plug all openings.
Two outrigger extension cylinders are utilized within each 4. Remove the cylinder.
outrigger box assembly. The extension cylinders provide the
force for the outrigger beam’s horizontal movement. The
cylinder weighs approximately 42 kg (92.5 pounds).

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TM500E-2 SERVICE MANUAL UNDERCARRIAGE

Installation NOTE: Refer to CYLINDERS in Section 2 - HYDRAULIC

and PRESSURE SETTINGS for Disassembly and
1. Place the cylinder in the beam. Assembly of the cylinders.
NOTE: Keep hydraulic fittings and hoses close to angles
shown Figure 8-136 and as low as possible to Removal
prevent rubbing with the beam top plate and side 1. Extend the outrigger beam slightly for improved access
plate, and for proper tracking during beam to the stabilizer cylinder; shut down the engine.
extension and retraction.
2. Tag and disconnect the hydraulic hoses from the
Fittings
stabilizer cylinder. Remove the fittings from the ports.
Outrigger Beam
Cap or plug all openings.
3. Remove the nut and washer and remove the cylinder
Hoses cap.
4. Place a jack capable of supporting the weight of the
stabilizer cylinder at the base of the cylinder barrel. Jack
up the cylinder just enough to relieve any pressure on
the cylinder retaining pin.
5. Remove the cotter pins securing the cylinder retaining
pin and remove the cylinder retaining pin and cylinder
cap retaining bracket.
6. Jack the stabilizer cylinder up just enough to insert the
retaining pin back into the cylinder. Insert the retaining
NOTE: Keep hydraulic fittings and hoses close to pin into the lugs on the cylinder and secure the pin in
angles shown and as low as possible to place with the cotter pins.
prevent rubbing with the beam top plate and
side plate, and for proper tracking during
beam extension and retraction. CAUTION
FIGURE 8-136 Use a nylon strap to remove the cylinder. This will ensure
the retaining pin is not damaged.
2. Position the extension cylinder so the hydraulic ports on
the rod end of the cylinder can be accessed. Connect 7. Fasten a nylon strap onto the cylinder retaining pin and
the hydraulic hoses to the ports as tagged during use an adequate lifting device to lift the stabilizer
removal. cylinder out of the tube on the beam assembly.
3. Push the cylinder into the outrigger beam. Align the
cylinder rod with the clevis in the beam. Apply anti-seeze
Installation
to the clevis pin and secure in place with the clevis pin 1. Apply grease (EPMPG) to the ID of the stabilizer
and cotter pin. cylinder support tube.
4. Install the outrigger beam. Refer to OUTRIGGER BEAM 2. If removed, install wear ring in groove in bottom of
- INSTALLATION in this section. support tube and in groove at top on stabilizer cylinder.
Functional Check 3. Place a jack beneath the cylinder tube on the outrigger
1. Activate the hydraulic system; extend and retract the beam. Using the same method as described under 8
outrigger. REMOVAL, lower the stabilizer cylinder into the cylinder
tube on the outrigger beam until the retaining pin is just
2. Observe the operation of the outrigger beam. above the tube. Position the jack so that it will support
the cylinder in this position. Remove the lifting device
3. Check the hydraulic connections for any evidence of
from the cylinder.
leakage.
4. Remove the retaining pin and cotter pins from the
Stabilizer Cylinder Description cylinder.
Four stabilizer cylinders are used on the crane, one at the 5. Lower the jack until the holes in the cylinder rod align
end of each outrigger beam. The stabilizer cylinders provide with the holes in the outrigger beam.
the force for the outrigger beam’s vertical movement. The
cylinder weighs approximately 64.6 kg (142.4 pounds).

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Undercarriage TM500E-2 SERVICE MANUAL

6. Apply anti-seeze compound to the retaining pin. Secure Testing Pilot Operated Check Valve For Leakage
the cylinder and cylinder cap retaining bracket to the
1. Fully extend and set the outriggers.
support tube with the retaining pin and cotter pins.
7. Install the cylinder cap.
8. Install the fittings in the cylinder ports and connect the
CAUTION
hoses as tagged during removal. When performing step number 2, remove hose to adapter
connection slowly. Trapped pressure may exit between
Functional Check the outrigger cylinder and the work port pilot operated
check valves in the outrigger selector valve.
1. Activate the hydraulic system.
2. Extend and retract the stabilizer cylinder. 2. Remove the piston side cylinder hose from the
suspected leaking stabilizer cylinder (see Figure 8-27).
3. Check for smooth operation of the cylinder.
Oil will flow until the cavity in the cylinder port block
4. Check all hydraulic connections and hoses for evidence empties. Once the port block cavity empties, oil should
of leakage. stop flowing from the piston side port.
Outrigger Stabilizer Cylinder Internal Leak Test a. If oil stops flowing, the cylinder’s pilot operated
check valve is sealing properly.
Use the following procedure to troubleshoot and diagnose an
internal leak, a leaking pilot operated check valve or a b. If oil continues to flow out the piston port, the
thermal contraction on an outrigger stabilizer cylinder. cylinder’s pilot operated check valve is leaking.
If oil flow is not noticed from either port, the cylinder and pilot
operated check valve are functioning properly, and any
cylinder contraction during normal operation can be
DANGER attributed to thermal contraction of the oil.
Perform the following procedures with the crane
positioned on a firm level surface with outriggers fully Outrigger Control Valve Description
extended and set, and the crane in the travel position
There are four valve assemblies responsible for controlling
Remove hoses from one cylinder at a time.
the outrigger system, the outrigger selector valve, the front
and rear outrigger control manifolds, and the pilot operated
Checking Cylinder For Internal Piston Seal Leak check valves.
1. Fully extend and set the outriggers. NOTE: For a more detailed description and maintenance
of the valves, refer to Valves in Section 2 -
HYDRAULIC and PRESSURE SETTINGS.
CAUTION
When performing step number 2, remove hose to adapter Pilot Operated Check Valve
connection slowly. Trapped pressure may exit between
the outrigger cylinder and the work port pilot operated The pilot operated check valves are located in the outrigger
check valves in the outrigger selector valve. stabilizer port blocks. The check valve provides two
functions; the first function is a holding valve, the second
2. Remove the rod side cylinder hose from the suspected function provides a thermal relief of the stabilizer.
leaking stabilizer cylinder. Oil will flow until the cavity in
the cylinder port block empties. Once the port block Outrigger Selector Valve
cavity empties, oil should stop flowing from the rod side
The outrigger selector valve is mounted on the right side of
port.
the superstructure frame. Refer to Section 2 - HYDRAULIC
Check for the following conditions: and PRESSURE SETTINGS.
a. If oil stops flowing, the cylinder’s internal piston seal Outrigger Control Manifold
is sealing properly.
The front and rear outrigger control manifolds are located
b. If oil continues to flow out the rod port, the cylinder’s
on the respective outrigger boxes. Each manifold consists of
internal piston seal is leaking.
four 2 way solenoid valves.
3. After determining the condition of the cylinders internal
piston seal, let the rod side hose disconnected and
continue to test the pilot operated check valve.

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 SECTION 9
LUBRICATION
TABLE OF CONTENTS
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Arctic Conditions Below -18°C (0°F). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Surface Protection For Cylinder Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Carrier Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Superstructure Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
Boom, Boom Extension, and Boom Accessories Lubrication . . . . . . . . . . . . . . . . . . . . . 9-9
Wire Rope Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11

Published 2-20-2007, Control # 101-00 9-i

TM500E-2 SERVICE MANUAL LUBRICATION

SECTION 9
LUBRICATION
GENERAL lube requirements is to maintain a job log indicating crane
usage. The log must use the engine hourmeter to ensure
Following the designated lubrication procedures is important coverage of lube points that will receive attention based on
in ensuring maximum crane lifetime and utilization. The their readings. Other lubrication requirements must be made
procedures and lubrication charts in this section include on a time basis, i.e. weekly, monthly, etc.
information on the types of lubricants used, the location of
the lubrication points, the frequency of lubrication, and other All oil levels are to be checked with the crane parked on a
information. level surface in transport position, and while the oil is cold,
unless otherwise specified.
The service intervals specified are for normal operation
where moderate temperature, humidity, and atmospheric On plug type check points, the oil levels are to be at the
conditions prevail. In areas of extreme conditions, the bottom edge of the check port.
service periods and lubrication specifications should be On all hoists with a check plug in the drum, the fill plug shall
altered to meet existing conditions. For information on be directly on top of the hoist, and the check plug level.
extreme condition lubrication, contact your local Grove
Distributor or Manitowoc CraneCARE. All grease fittings are SAE STANDARD unless otherwise
indicated. Grease non-sealed fittings until grease is seen
extruding from the fitting. One ounce(28 grams) of EP-MPG
CAUTION equals one pump on a standard one pound (0.45 kg) grease
gun.
Chassis grease lubricants must not be applied with air
pressure devices as this lubricant is used on sealed Over lubrication on non-sealed fittings will not harm the
fittings. fittings or components, but under lubrication will definitely
lead to a shorter lifetime.
On sealed U-joints, care must be exercised to prevent
rupturing seals. Fill only until expansion of the seals first
CAUTION
becomes visible.
The multipurpose grease installed during manufacture is
of a lithium base. Use of a noncompatible grease could Unless otherwise indicated, items not equipped with grease
result in damage to equipment. fittings, such as linkages, pins, levers, etc., should be
lubricated with oil once a week. Motor oil, applied sparingly,
Arctic Conditions Below -18°C (0°F). will provide the necessary lubrication and help prevent the
formation of rust. An Anti-Seize compound may be used if
In general, petroleum based fluids developed especially for rust has not formed, otherwise the component must be
low temperature service may be used with satisfactory cleaned first.
results. However, certain fluids, such as halogenated
hydrocarbons, nitro hydrocarbons, and phosphate ester Grease fittings that are worn and will not hold the grease
hydraulic fluids, might not be compatible with hydraulic gun, or those that have a stuck check ball, must be replaced.
system seals and wear bands. If you are in doubt about the Where wear pads are used, cycle the components and
suitability of a specific fluid, check with your authorized relubricate to ensure complete lubrication of the entire wear
Grove distributor or Manitowoc CraneCARE. area.
NOTE: All fluids and lubricants may be purchased by
contacting the Manitowoc CraneCARE Parts
Surface Protection For Cylinder Rods
Department. Steel cylinder rods include a thin layer of chrome plating on
Regardless of temperature and oil viscosity, always use their surfaces to protect them from corroding. However,
suitable start-up procedures to ensure adequate lubrication chrome plating inherently has cracks in its structure which
during system warm-up. can allow moisture to corrode the underlying steel. At typical
ambient temperatures, hydraulic oil is too thick to penetrate 9
these cracks. Normal machine operating temperatures will
LUBRICATION POINTS allow hydraulic oil to warm sufficiently to penetrate these
A regular frequency of lubrication must be established for all cracks and if machines are operated daily, protect the rods.
lubrication points. Normally, this is based on component Machines that are stored, transported, or used in a corrosive
operating time. The most efficient method of keeping track of environment (high moisture, rain, snow, or coastline

PRELIMINARY Published 10-05-2007, Control # 151-00 9-1

LUBRICATION TM500E-2 SERVICE MANUAL

conditions) need to have the exposed rods protected more corresponds to the index number shown on the Lubrication
frequently by applying a protectant. Unless the machine is thru . Lube description and symbols are found in (Table 9-1)
operated daily, exposed rod surfaces will corrode. Some and (Table 9-2).
cylinders will have rods exposed even when completely
retracted. Assume all cylinders have exposed rods, as SAFETY
corrosion on the end of the rod can ruin the cylinder.
To lubricate many of the locations the engine will need to be
It is recommended that all exposed cylinder rods be started. After positioning areas of the unit for lubrication the
protected using Boeshield® T-9 Premium Metal Protectant. engine must be turned off and the moved areas stable before
Manitowoc CraneCARE has Boeshield® T-9 Premium Metal approaching.
Protectant available in 12 oz. cans that can be ordered
through the Parts Department.
Cylinder operation and inclement weather will remove the
Boeshield® protectant; therefore, inspect machines once a WARNING
week and reapply Boeshield® to unprotected rod Movement of the superstructure and the boom may
The following describe the lubrication points and gives the create a crushing and/or pinching hazard. Failure to
lube type, lube interval, lube amount, and application of observe this warning could result in death or serious injury
each. Each lubrication point is numbered, and this number if the message is ignored.

Table 9-1
Carrier Lube Symbol Chart

Symbol Description Lube Specification

EP-MPG Extreme Pressure Multipurpose Grease - Lithium Soap Base, NLGI Grade 2. A6-829-003477
Semi-Synthetic Gear Lubricant - SAE Grade 80W-90, API Service Designation
SSGL-5 A6-829-012964
GL-5.
AFC 50/50 Blended Fully Formulated Antifreeze/Coolant, SAE J1941 A6-829-101130
EO Engine Oil - SAE 15W-40, API Service Classification CI-4 or better A6-829-103483
ASC Anti-Seize Compound A6-829-003689
BAS Black Anti-Seize Moly Lubricant A6-829-009568
AGMA EP-4 Extreme Pressure Gear Lubricant A6-829100213
TranSynd™ Automatic Transmission Fluid A6-829-101690

Table 9-2
Superstructure Symbol Chart

Symbol Description Lube Specification

EP-MPG Extreme Pressure Multipurpose Grease - Lithium Soap Base, NLGI Grade 2. A6-829-003477
SSGL-5 Semi-Synthetic Gear Lubricant A6-829-012964
AFC - 50/50 50/50 Blended Fully Formulated Antifreeze/Coolant, SAE J1941, ASTM D6210 A6-829-101130
Hydraulic Oil - Must meet John Deere Standard JDM-J20C (Anti-brake chatter)
HYDO A6-829-006444
and ISO 4406 cleanliness level 17/14
EO-15W/40 Engine Oil - SAE 15W-40, API Service Classification CI-4 or better A6-829-003483
EP-OGL Open Gear Lubricant, CEPLATTYN 300 Spray, NLGI Class 1-2 A6-829-102971
AGMA EP-4 Extreme Pressure Gear Lubricant. A6-829-100213

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TM500E-2 SERVICE MANUAL LUBRICATION

3. Transmission
Lube Type - TranSynd™ - Automatic Transmission Fluid
CAUTION
The following lube intervals are to be used as a guideline Lube Interval -
only. Actual lube intervals should be formulated by the • Initial fluid and filter change at 500 hours, thereafter
operator to correspond accordingly to conditions such as at 1000 hours maximum or 18 months, whichever
continuous duty cycles and/or hazardous environments. occurs first
• Drain fluid when transmission is at operating
CARRIER LUBRICATION temperature 71° to 93° (169° to 200°)
NOTE: Carrier Lube Capacities will be added at a later Lube Amount - Capacity -
date upon availability.
1. Carrier Engine Crankcase
Lube Type - EO - 15W40 CAUTION
Axle fluid levels shall be adjusted to bottom of fill plug
Lube Interval - threads. Check with crane on level ground, at it’s normal
• Check fluid level every 10 hours or daily ride height.; cold or room temperature oil only.
• Drain, fill and replace filter every 500 hours, 6
• Application - Fill through dipstick opening only. Fluid
months or 9,000 miles; whichever interval occurs
levels shall be adjusted by indicating arrows dipstick
first.
markings or to filler plugs.
Lube Amount - Capacity -
• Clean magnetic drain plug when changing lubricant.
Application - Fill to full mark on dipstick. • Initial main filter change required at 5000 miles/200
2. Engine Cooling System hours.

Lube Type - AFC 4. Drive Line Slip and U-Joints

Lube Interval - Lube Type - EP-MPG

• Check coolant level every 10 hours or daily; Refer to Lube Interval - 500 hours or 16,090 km (10,000 mi);
S e r v ic e M a nu a l S e c t i o n 7 - P o w e r Tra i n fo r whichever interval occurs first.
additional information.
Lube Amount - Until grease extrudes
• Drain and fill per engine service manual.
Application - 2 grease fittings
Lube Amount - Capacity -
5. Fuel Tank
Lube Interval - Check fluid level and fill every 10 hours or
CAUTION daily, whichever interval occurs first
Improper filling of the engine coolant system can result in
6. 90 Degree Miter Box
engine damage.
Lube Type - EP-MPG
Application -
Lube Interval - 1000 hours or 12 months; whichever
a. Open petcock in upper radiator tube to vent air interval occurs first.
during initial fill.
Lube Amount - Until grease extrudes
Fill slowly. Flows exceeding 12 l/min (3 gpm) can
give a false level. When coolant squirts out, close Application - 2 grease fitting
petcock, then fill radiator to bottom of filler neck with 7. Power Steering Reservoir
mixture of 50% AFC and 50% water.
Lube Interval - Check and fill every 10 hours or daily
Run engine through two (2) thermal cycles.
Lube Amount -
9
Wait 1 minute and recheck coolant level and refill as
required. Application -

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LUBRICATION TM500E-2 SERVICE MANUAL

3
2 1
22
21 22
6, 7
16 4 4 5 21
16 4

15

8
23 23 13, 14 11 12 9, 10 7017-1
18 19, 20 17
19, 20

Truck Carrier

FIGURE 9-1

Item Description
Item Description 20 Rear Axle Brake Camshafts
1 Engine Crankcase 21 Outrigger Beams
2 Engine Coolant System 22 Jack Cylinder Support Tubes
3 Transmission 23 Jack Cylinder Barrels
4 Drive Line Slip
8. Steer Connecting Rods
5 Fuel Tank
Lube Type - EP-MPG
6 90 Degree Miter Box
Lube Interval - 1000 hours
7 Power Steering Reservoir
Lube Amount - Until grease extrudes
8 Steer Connecting Rods
Application - 4 grease fittings
9 Front Aluminum Wheel Pilots
9. Front Aluminum Wheel Pilots
10 Front Axle Hubs
Lube Type - ASC
11 Front Axle Tie Rod Ends
12 Front Axle King Pins Lube Interval - When wheels are removed for service.

13 Front Axle Brake Slack Adjusters Lube Amount - Generously coat the wheel pilot or hub
pads with Anti-Seize (ASC) compound. Do not apply
14 Front Axle Brake Camshafts Anti-Seize compound to the face of the wheel of the hub.
15 Spring Eye Bushings Application - Brush on
16 Rear Aluminum Wheel Pilots
10. Front Axle Hubs
17 Front Rear Axle Differential
Lube Type - GL-5
18 Rear Rear Axle Differential
Lube Interval - Check fluid level and fill every 250 hours
19 Rear Axle Brake Slack Adjusters

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TM500E-2 SERVICE MANUAL LUBRICATION

15. Spring Eye Bushings

Lube Type - BAS
CAUTION
Use of non-semi-synthetic lubricant may damage Lube Interval - 40,225 km (25,000 mi) or 1 year;
components and/or invalidate published lubrication whichever interval occurs first
intervals.
Application - Disassemble spring eye bushings. Clean
and lubricate bushings. Install bushings. Refer to
NOTE: Any lubricant used in the field for either top-off or Service Manual Section 8 - Undercarriage in the service
refill of the axles must be an “Extended Drain manual.
Lubricant” as approved by ArvinMeritor. These
lubricants are listed in ArvinMeritor Technical 16. Rear Aluminum Wheel Pilots
Bulletin TP-9539 available at
Lube Type - ASC
www.arvinmeritor.com or by contacting Manitowoc
CraneCARE. Lube Interval - When wheels are removed for service.
Lube Amount - Lube Amount - Generously coat the wheel pilot or hub
pads with Anti-Seize (ASC) compound. Do not apply
Application - Fill to the oil level mark on the housing with
Anti-Seize compound to the face of the wheel of the hub.
the fill plug and the oil level mark horizontal.
Application - Brush on - 8 Places
NOTE: Refer to (Figure 5-2) for proper checking of lube
levels. 17. Front Rear Axle Differential
11. Front Axle Tie Rod Ends Lube Type - GL-5
Lube Type - EP-MPG Lube Interval -
Lube Interval - 1000 hours • Drain and fill every 250 hours

Lube Amount - Until grease extrudes • Check and fill every 80,450 km (50,000 mi) or 2
years; whichever interval occurs first.
Application - 2 grease fittings
• Change filter when changing gear oil
12. Front Axle King Pins
• Clean magnetic drain plug
Lube Type - EP-MPG
NOTE: Any lubricant used in the field for either top-off or
Lube Interval - 1000 hours refill of the axles must be an “Extended Drain
Lubricant” as approved by ArvinMeritor. These
Lube Amount - Until grease extrudes
lubricants are listed in ArvinMeritor Technical
Application - 4 grease fittings Bulletin TP-9539 available at
www.arvinmeritor.com or by contacting Manitowoc
13. Front Axle Brake Slack Adjusters
CraneCARE.
Lube Type - EP-MPG
NOTE: Engine shall be running during lubrication to
Lube Interval - 1000 hours ensure equal distribution of grease.
Lube Amount - Until grease extrudes Lube Amount - Capacity -
Application - 2 grease fittings Application - Check level using filler plug located on axle
bowl.
14. Front Axle Brake Camshafts
Lube Type - EP-MPG
CAUTION
Lube Interval - 1000 hours
Use of non-semi-synthetic lubricant may damage
Lube Amount - Until grease extrudes components and/or invalidate published lubrication
Application - 2 grease fittings
intervals.
9
NOTE: Lube level (Figure 9-2) close enough to the hole to
be seen or touched is not sufficient. It must be level
with the hole.

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LUBRICATION TM500E-2 SERVICE MANUAL

When checking lube level, also check and clean NOTE: Lube level (Figure 9-2) close enough to the hole to
housing breathers. be seen or touched is not sufficient. It must be level
with the hole.
When checking lube level, also check and clean
housing breathers.
19. Rear Axle Brake Slack Adjusters
Lube Type - EP-MPG
Correct Lube Interval - 1000 hours
Incorrect
Lube Amount - Until grease extrudes
Application - 4 grease fittings
6626
___ Correct: Lube level at 20. Rear Axle Brake Camshafts.
bottom of filler hole. Lube Type - EP-MPG
- - - Incorrect: Lube level below
filler hole. FIGURE 9-2 Lube Interval - 1000 hours
NOTE: Figure 9-1 and instructions pertains to the Lube Amount - Until grease extrudes
Differentials and the Planetary Hubs and Wheel Application - 4 grease fittings
Bearings.
21. Outrigger Beams
18. Rear Rear Axle Differential
Lube Type - EP-MPG
Lube Type - GL-5
Lube Interval - 50 hours or 1 week; whichever interval
Lube Interval - occurs first
• Drain and fill every 250 hours
Lube Amount - Brush on bottom of outrigger boxes.
• Check and fill every 80,450 km (50,000 mi) or 2
Application - Brush on; 8 places; extend beams fully and
years; whichever interval occurs first.
coat the bottom plate.
• Change filter when changing gear oil
22. Jack Cylinder Barrels
• Clean magnetic drain plug
Lube Type - EP-MPG
NOTE: Any lubricant used in the field for either top-off or
refill of the axles must be an “Extended Drain Lube Interval - 50 hours or 1 week; whichever interval
Lubricant” as approved by ArvinMeritor. These occurs first
lubricants are listed in ArvinMeritor Technical Lube Amount - Fully extend outriggers and brush
Bulletin TP-9539 available at lubricant onto cylinder barrels.
www.arvinmeritor.com or by contacting Manitowoc
CraneCARE. Application - Brush lubricant on I.D. of jack cylinder
support tube and rear bands before installing jack
NOTE: Engine shall be running during lubrication to cylinder - 4 places
ensure equal distribution of grease.
23. Jack Cylinder Support Tubes
Lube Amount - Capacity -
Lube Type - EP-MPG
Application - Check level using filler plug located on axle
bowl. Lube Interval - 50 hours or 1 week
Lube Amount - Brush lubricant on ID of jack cylinder
support tubes and wear bands before installing jack
CAUTION cylinders.
Use of non-semi-synthetic lubricant may damage
components and/or invalidate published lubrication Application - Brush on; 4 places.
intervals.

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TM500E-2 SERVICE MANUAL LUBRICATION

SUPERSTRUCTURE LUBRICATION 27. Upper Lift Cylinder Pivot Pin

24. Turntable Gearbox Lube Type - EP-MPG

Lube Type - GL-5 Lube Interval - 500 hours or every 3 months; whichever
interval occurs first
Lube Amount - Until grease extrudes
CAUTION
When checking the swing gearbox oil level, remove Application - 2 grease fitting
dipstick and wipe clean. Insert dipstick into the level check 28. Lower Lift Cylinder Pivot Pin
sleeve until the cap is flush with the end of the sleeve. Do
not screw the cap onto the sleeve to check the oil. Lube Type - EP-MPG
Lube Interval - 500 hours or 3 months; whichever
Lube Interval - interval occurs first
• Check and fill every 50 hours. Lube Amount - Until grease extrudes
• Drain and fill after first 250 hours Application - 2 grease fittings
• Drain and fill every 500 hours or 12 months
29. Main Hoist
thereafter; whichever interval occurs first.
Lube Type - AGMA EP-4
Lube Amount - 4.0 liters (4.25 quarts)
Application - Remove dipstick and observe level. If no Lube Interval - Check and fill every 1000 hours or
dipstick is available, fill to top of case. Fill to top of case. 12 months; whichever interval occurs first. Drain and fill
annually.
25. Turntable Gear and Drive Pinion
Lube Amount - Capacity - 5.2 liters (5.5 quarts)
Lube Type - EP-OGL
Application - Fill until level with the check plug opening.
Lube Interval - 500 hours or 6 months; whichever
interval occurs first 30. Auxiliary Hoist (Optional)

Lube Amount - Coat all teeth Lube Type - AGMA EP-4

Application - Spray on Lube Interval - Check and fill every 1000 hours or
12 months; whichever interval occurs first. Drain and fill
26. Turntable Bearing annually.
Lube Type - EP-MPG Lube Amount - Capacity - 5.2 liters (5.5 quarts)
Lube Interval - 500 hours or 6 months; whichever Application - Fill until level with the check plug opening.
interval occurs first
31. Engine Crankcase
Lube Amount - Until grease extrudes the whole
circumference of the bearing. Lube Type - EO - 15W40

Application - 2 grease fittings - Rotate the turntable 90° Lube Interval -

and apply grease to fittings. Continue rotating 90° and • Drain and fill every 250 hours
grease the fittings until the whole bearing is greased.
• Check and fill every 10 hours or daily; whichever
interval occurs first.
• Change filter every 250 hours
Lube Amount - Capacity - 6.1 liters (6.5 quarts)
Application - Fill to full mark on dipstick.

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LUBRICATION TM500E-2 SERVICE MANUAL

35
34
33

6955-1

29
30 6955-2
Opposite Side

28

32

27
31
34

25
26 7017-2
24

Superstructure
FIGURE 9-3

32. Engine Cooling System

Item Description Lube Type - AFC
24 Turntable Gearbox Lube Interval -
25 Turntable Gear and Drive Pinion • Check coolant level every 10 hours or daily;
26 Turntable Bearing whichever occurs first.

27 Upper Lift Cylinder Pivot Pins • Drain and fill per engine service manual.

28 Lower Lift Cylinder Pivot Pins Lube Amount - Capacity - 17.3 liters (18 quarts)

29 Main Hoist
30 Auxiliary Hoist CAUTION
31 Engine Crankcase Improper filling of the engine coolant system can result in
engine damage.
32 Engine Cooling System
33 Hydraulic Tank Application -

34 Hydraulic Filter a. Open petcock in upper radiator tube to vent air

during initial fill.
35 Fuel Tank

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TM500E-2 SERVICE MANUAL LUBRICATION

Fill slowly. Flows exceeding 12 l/min (3 gpm) can 37. Hook Block Sheaves
give a false level. When coolant squirts out, close
Lube Type - EP-MPG
petcock, then fill radiator to bottom of filler neck with
mixture of 50% AFC and 50% water. Lube Interval - 250 hours or 3 months; whichever
Run engine through two (2) thermal cycles. interval occurs first

Wait 1 minute and recheck coolant level and refill as Lube Amount - Until grease extrudes
required. Application - 1 grease fitting per sheave
33. Hydraulic Reservoir - 3 fittings total - (35 ton)
Lube Type - HYDO - 4 fittings total - (35 ton)
Lube Interval - 38. Telescope Cylinder Wear Pads
• Check fluid level every 10 hours or daily, using sight Lube Type - EP-MPG
gauge on side of tank, with boom retracted and in
boom rest and all outrigger cylinders retracted. Lube Interval - 125 hours or 3 months; whichever
interval occurs first
• Drain and refill as necessary.
Lube Amount - Thoroughly coat all areas the wear pads
NOTE: After 2000 hours or 2 years of service, an oil move on.
sample should be taken and laboratory analyzed. If
it continues to meet a minimum cleanliness level of Application - Brush on: 2 places; extend boom for entry
ISO 19/17/14, the service interval can be increased through access holes.
to 3000 hours or 3 years.
39. Side Wear Pads
Lube Amount - 436.4 liters (96 gal.) (tank only), to FULL
Lube Type - EP-MPG
mark on sight gauge.
Lube Interval - 250 hours or 3 months
Application - Fill through breather/fill cap on top of tank.
When tank is drained, clean the magnetic pipe plug. Lube Amount - Thoroughly coat all areas the wear pads
move on.
Replace breather every 500 hours or 6 months;
whichever interval occurs first. Application -Brush on: 12 places; extend boom for entry
through access holes.
34. Hydraulic Filter
40. Boom Section Upper Wear Pads
Replace the hydraulic filter element when the restriction
indicator gauge on the filter head is in the red Lube Type - EP-MPG
35. Fuel Tank Lube Interval - 50 hours or 1 week; whichever interval
occurs first
Lube Interval - Check fluid level and fill daily
Lube Amount - Thoroughly coat all areas the wear pad
Lube Amount - 136.3 liters (30 gallons)
moves on.

BOOM, BOOM EXTENSION, AND BOOM Application - By brush: 6 places; extend boom for entry
through access holes.
ACCESSORIES LUBRICATION
41. Boom Section Lower Wear Pads
36. Headache Ball Swivel Top (Not Shown)
Lube Type - EP-MPG
Lube Type - EP-MPG
Lube Interval - 50 hours or 1 week; whichever interval
Lube Interval - 250 hours or 3 months; whichever
occurs first
interval occurs first
Lube Amount - Thoroughly coat all areas the wear pad
Lube Amount - Until grease extrudes
moves on.
Application - 2 grease fitting
Application - By brush; 3 places; extend boom for entry
9
through access holes.

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LUBRICATION TM500E-2 SERVICE MANUAL

40 42 47
46 46 38 42 39
45
44
49

41
50
43 46
41
48

51 37

Boom, Boom Extension, and Boom Accessories Lubrication Diagram

FIGURE 9-4

42. Extend Cable Sheaves

Item Description Lube Type - EP-MPG
31 Headache Ball Swivel Top Lube Interval - 250 hours or 3 months; whichever
32 Hook Block Sheaves interval occurs first

33 Telescope Cylinder Wear Pads Lube Amount - Until grease extrudes

34 Side Wear Pads Application - 3 grease fitting; extend boom for entry
through access holes.
35 Boom Section Upper Wear Pads
43. Retract Cable Sheaves
36 Boom Section Lower Wear Pads
37 Extend Cable Sheaves Lube Type - EP-MPG

38 Retract Cable Sheaves Lube Interval - 250 hours or 3 months; whichever

interval occurs first
39 Boom Pivot Shaft
Lube Amount - Until grease extrudes
40 Boom Extension Sheave
Application - 4 grease fittings; extend boom for entry
41 Boom Extension Roller
through access holes.
42 Upper Boom Nose Sheave
44. Boom Pivot Shaft
43 Lower Boom Nose Sheave
Lube Type - EP-MPG
44 Auxiliary Boom Nose Sheave
Lube Interval - 250 hours or 3 months; whichever
45 Boom Extension Mast Sheave interval occurs first
46 Hook Block Swivel Bearing Lube Amount - Until grease extrudes
Application - 2 grease fittings, one on each side

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TM500E-2 SERVICE MANUAL LUBRICATION

45. Boom Extension Sheave 49. Auxiliary Boom Nose Sheave

Lube Type - EP-MPG Lube Type - EP-MPG
Lube Interval - 250 hours or 3 months; whichever Lube Interval - 250 hours or 3 months; whichever
interval occurs first interval occurs first
Lube Amount - Until grease extrudes Lube Amount - Until grease extrudes
Application - 1 grease fitting Application - 1 grease fitting
46. Boom Extension Roller 50. Boom Extension Mast Sheave
Lube Type - EP-MPG Lube Type - EP-MPG
Lube Interval - 250 hours or 3 months; whichever Lube Interval - 500 hours or 12 months; whichever
interval occurs first interval occurs first
Lube Amount - Until grease extrudes Lube Amount - Until grease extrudes
Application - 4 grease fitting 51. Hook Block Swivel Bearing
47. Upper Boom Nose Sheave Lube Type - EP-MPG
Lube Type - EP-MPG Lube Interval - 250 hours or 3 months; whichever
interval occurs first
Lube Interval - 250 hours or 3 months; whichever
interval occurs first Lube Amount - Until grease extrudes
Lube Amount - Until grease extrudes Application - 1 grease fitting
Application - 1 grease fitting per sheave See Section 7 - Power Train in the Service Manual for
instructions on exhaust brake lubrication.
48. Lower Boom Nose Sheave
Lube Type - EP-MPG WIRE ROPE LUBRICATION
Lube Interval - 250 hours or 3 months; whichever Wire rope is lubricated during manufacturing so that the
interval occurs first strands, and individual wires in strands, may move as the
Lube Amount - Until grease extrudes rope moves and bends. A wire rope cannot be lubricated
sufficiently during manufacture to last its entire life.
Application - 1 grease fitting per sheave Therefore, new lubricant must be added periodically
throughout the life of a rope to replace factory lubricant which
is used or lost. For more detailed information concerning the
lubrication and inspection of wire rope, refer to WIRE ROPE
in Section 1- INTRODUCTION in the Service Manual.

PRELIMINARY Published 10-05-2007, Control # 151-00 9-11