Grove TMS9000-2 User manual

Service Manual
Grove TMS9000-2

SERVICE MANUAL
This Manual has been prepared for and is considered part of -
TMS9000-2
Crane Model Number
NOTICE
The crane serial number is the only method your distributor or the
factory has of providing you with correct parts and service informa-
tion.
The crane serial number is identified on the builder’s decal
attached to the operator’s cab. Always furnish crane serial
number when ordering parts or communicating service problems
with your distributor or the factory.
An untrained operator subjects himself and others to death or
serious injury. Do not operate this crane unless:
• You are trained in the safe operation of this crane. Manitowoc is not
responsible for qualifying personnel.
• You read, understand, and follow the safety and operating
recommendations contained in the crane manufacturer’s manuals and
load charts, your employer’s work rules, and applicable government
regulations.
• You are sure that all safety signs, guards, and other safety features are
in place and in proper condition.
• The Operator Manual and Load Chart are in the holder provided on the
crane.
DANGER
!
©2019 Grove U.S. L.L.C.
Published 02-28-2019 Control # 649-01

The original language of this publication is English.
WARNING
California Proposition 65
Breathing diesel engine exhaust exposes you to
chemicals known to the State of California to cause
cancer and birth defects or other reproductive harm.
• Always start and operate the engine in a well-
ventilated area.
• If in an enclosed area, vent the exhaust to the
outside.
• Do not modify or tamper with the exhaust system.
• Do not idle the engine except as necessary.
For more information go to www.P65warnings.ca.gov/
diesel.
Battery posts, terminals, and related accessories contain
chemical lead and lead compounds, chemicals known to
the State of California to cause cancer, birth defects, and
other reproductive harm. Wash hands after handling.
California Spark Arrestor
Operation of this equipment may create sparks that can
start fires around dry vegetation. A spark arrestor may be
required. The owner/operator should contact local fire
agencies for laws or regulations relating to fire prevention
requirements.

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TMS9000-2 SERVICE MANUAL TABLE OF CONTENTS
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TABLE OF CONTENTS
SECTION 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Instructions
Using the Service Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Safety Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Safety Alert Symbol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Signal Words. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Manitowoc CraneCare Service instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Definitions of stated directions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Breaking in a New Crane. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
Handling Substances which are Harmful to the Environment . . . . . . . . . . . . . . . . . . . . . 1-4
What do environmentally harmful substances include? . . . . . . . . . . . . . . . . . . . . . . 1-4
Overview of the Operating and Display Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Axle Weight Distribution Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Boom Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Overview of the Components that are Easily Damaged when Cleaning . . . . . . . . . . . . . 1-8
On Truck Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Fasteners and Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Torque Wrenches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Weld Studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
SECTION 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic System
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Draining and Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Removing Air from the Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Parts Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Supply Pressure and Return Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Hydraulic Reservoir and Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Pump Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Return Hydraulic Filter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Element Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Element Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Hydraulic Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Carrier Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Outrigger Selector-A/C Manifold Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Outrigger Control Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Pilot Operated Check Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
Internal Leak Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
Superstructure Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26

TABLE OF CONTENTS TMS9000-2 SERVICE MANUAL
1-2
Turntable Hydraulic Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
Main Directional Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
Access Manifold Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28
Hydraulic system of the superstructure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28
Checking for Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28
Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
Steer Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31
Outrigger Extension Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34
Outrigger Jack Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37
Center Front Jack Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41
Lift Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45
Counterweight Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48
Telescope Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48
Pressure Setting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49
Objective . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49
Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49
Valve Pressure Setting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49
Service Tool Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-50
A. Procedure for checking/setting the piston pumps cut-off & differential
pressures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51
Procedure for checking/setting the pilot supply pressure . . . . . . . . . . . . . . . . . . . 2-52
C. Procedure for checking/setting the main directional control valve, load sense,
lift and telescope pressures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53
D. Procedure for checking/setting cab tilt raise and lower pressures . . . . . . . . . . 2-58
E. Procedure for checking/setting counterweight (CWT) raise and
lower pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58
F. Procedure for checking/setting swing pressure. . . . . . . . . . . . . . . . . . . . . . . . . 2-59
G. Procedure for checking/setting outrigger pressure . . . . . . . . . . . . . . . . . . . . . . 2-59
H.Procedure for checking/setting Air Conditioning pressure . . . . . . . . . . . . . . . . . 2-60
I. Procedure for checking/setting the center front stabilizer pressure.. . . . . . . . . . 2-61
J. Procedure for checking/setting the front steer pressure. . . . . . . . . . . . . . . . . . . 2-62
K. Procedure for adjusting electronic controllers (meter-in dead band
and/or max function speeds) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-63
SECTION 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical System
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
General Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Tools for Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Troubleshooting Engine Starting Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

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TMS9000-2 SERVICE MANUAL TABLE OF CONTENTS
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Troubleshooting Engine Charging Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Troubleshooting Slip Ring-Caused Electrical Problems . . . . . . . . . . . . . . . . . . . . . . 3-9
Connector Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Troubleshooting Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Troubleshooting Gauges and Meters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Troubleshooting Alarms, Indicators, and Emergency Components . . . . . . . . . . . . 3-11
Troubleshooting the CCS System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
ODM error code viewer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Troubleshooting Crane Components and Accessories. . . . . . . . . . . . . . . . . . . . . . 3-12
Alternator Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Starter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Battery Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Relay Panel Component Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Instrument Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Rocker Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
All Other Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Windshield Wiper Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Windshield Washer Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Remote Controller (Optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Receiver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Battery Charger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Remote Controller Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Jump Starting the Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
SECTION 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Superstructure
Description of maintenance work on the superstructure . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Hoist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Boom Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Boom Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Functional Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Boom Nose Sheaves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Boom Nose Sheaves Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Boom Nose Sheaves Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Boom Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Boom Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Telescope Section 5 Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Telescope Section 4 Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Telescope Section 3 Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Telescope Section 2 Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Telescope Section 1 Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31
Telescope Base Section Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37
Pinning Boom Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38
Mechanical Locking Head Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38
Proximity Switch Descriptions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39
Hydraulic Actuator Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40
Precision Length Sensor Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41
Control System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42
mechanical emergency unlocking and locking of the telescopic sections . . . . . . . . . . . 4-42
Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43
New York House Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44
Bleeding the Telescoping Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44
Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44
Bleeding Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44

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1-4
Telescoping status. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-45
Telescope Slide Pad Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-46
Check the locking system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-46
Hoist ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-46
Checking the Position of Sheaves and Rope Drums. . . . . . . . . . . . . . . . . . . . . . . 4-46
Wire Rope Inspection/Replacement (All Wire Rope) . . . . . . . . . . . . . . . . . . . . . . . . . . 4-48
Rated Capacity Limiter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-53
Maintenance of the Slip Ring Assembly of the Cable Drum . . . . . . . . . . . . . . . . . 4-53
Lubricating the Swing Angle Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-55
Superstructure Air Conditioning System (Additional Equipment) . . . . . . . . . . . . . . . . . 4-56
Checking Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-56
Other Maintenance Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-56
Checking for Correct Operation of the Auxiliary Heater (Additional Equipment) . . 4-56
Lubricating the Piston Rod of the Lifting Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . 4-56
SECTION 5. . . . . . . . . . . . . . . . . . . . . . . . . .Superstructure Maintenance
Superstructure maintenance overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Maintenance Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Maintenance plans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Maintenance plan D: Daily/Before Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Maintenance plan W: Weekly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Maintenance Plan M 1: Monthly/
After 100 Operating Hours/Approximately 2,000 km (1240 mi). . . . . . . . . . . . . . 5-5
Maintenance Plan M 3: Every 3 Months/After 300 Operating Hours/
5 000 - 6 000 km (3,100 - 3,730 mi) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Maintenance Plan M 6: Every 6 Months/After 500 Operating Hours/
10 000 - 12 500 km (6,210 - 7,770 mi) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Maintenance Plan M 12: Every 12 Months/After 1,000 Operating Hours/
20 000 - 25 000 km (12,430 - 15,530 mi) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Maintenance and Inspection Plan Y 2:
Every 24 Months/After 100 000 - 125 000 km (62,150 - 77,800 mi) . . . . . . . . . . 5-9
Maintenance and Inspection Plan Y 3:
Every 36 Months/After 3,000 Operating Hours.. . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Maintenance and Inspection Plan Y 5:
Every 60 Months/After 5,000 Operating Hours . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Maintenance and Inspection Plan Y 6:
Every 72 Months/After 6,000 Operating Hours . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Periodic inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Load hook inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Measures required for hoist monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Theoretical service life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Proportion of the theoretical service life used . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Table example to determine the remaining theoretical service
life on hoist no. 1 (main hoist) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
SECTION 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Swing System
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Swing Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Swing Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Swing Box Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Swing Motor Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Swing gear brake function check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

Grove 1-5
TMS9000-2 SERVICE MANUAL TABLE OF CONTENTS
T
O
C
Swing Brake Assembly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Swing Gearbox Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Swing Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Swivels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Hydraulic Swivel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Electrical Swivel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Swing Lock Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
360° Swing Lock Control (Positive Lock Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
SECTION 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Train
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Engine Drive Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Engine Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Functional Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Engine Control System Switches and Indicator Lights . . . . . . . . . . . . . . . . . . . . . . . 7-6
Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-6
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Air Intake System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Exhaust System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
Exhaust System Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
Slip Joint Exhaust Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
Aftertreatment Diesel Exhaust Fluid (DEF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
DEF Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
DEF Dosing Unit Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
Water Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
Component Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
Radiator Assembly Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
Drive Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-23
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
Drive Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
Clutch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25
Theory Of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27

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Clutch Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-33
General Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34
Gearshift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34
Manual Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35
Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-39
Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-40
Transmission Shift Air System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-40
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-40
Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-40
Pump/PTO Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41
Pump/PTO Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41
SECTION 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Carrier
Front Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Axle Alignment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Steering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
Steering Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14
Steering Gearbox. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
Steer Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16
Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17
Rear Axle and Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17
Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17
Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21
Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21
Mounting the Wheels on the Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21
Air System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22
Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22
Braking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24

Grove 1-7
TMS9000-2 SERVICE MANUAL TABLE OF CONTENTS
T
O
C
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-25
Air System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-36
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-36
Air Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-36
Normal Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-36
Vehicle Parking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-36
Anti-lock Braking Systems (ABS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-36
Automatic Traction Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-37
Emergency Braking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-37
Non-Asbestos Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-37
Front Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-37
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-37
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-38
Automatic Slack Adjuster. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-43
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-43
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-43
Rear Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-52
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-52
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-52
Rear Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-55
Anti-Lock Brake System (ABS)/Automatic Traction Control (ATC) . . . . . . . . . . . . . . . . 8-57
ABS System Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-57
ATC System Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-59
ABS Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-60
Troubleshooting Diagnostic Trouble Codes: Traction Control Valves . . . . . . . . . . 8-69
Power Supply Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-71
Troubleshooting Diagnostic Trouble Codes: J1939 Serial Communications . . . . . 8-72
Miscellaneous Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-74
Troubleshooting Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-75
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-78
Tests, Repair and Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-78
Component Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-81
Outriggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-84
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-84
Theory Of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-84
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-84
Extension Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-92
Outrigger Jack Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-92
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-92
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-92
Center Front Jack Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-93
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-93
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-93
Functional Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-94
Outrigger Monitoring System (Optional—Standard in North America) . . . . . . . . . . . . . 8-96
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-96
OMS String Potentiometers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-96
SECTION 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubrication
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Environmental Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Cummins Oil Registration List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Arctic Conditions Below -18° C (0° F). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Standard Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3

TABLE OF CONTENTS TMS9000-2 SERVICE MANUAL
1-8
Cold Weather Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
Arctic Lubricants and Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
Drivetrain Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
Clutch Release Bearing Grease Interval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11
Steering Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13
Axle Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13
Outrigger Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16
Miscellaneous Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-17
Turntable & Cab Tilt Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-18
Hoist Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-21
Turntable Central Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-22
Boom Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-23
Monthly Lubrication Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-26
Carwell® Rust Inhibitor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-27
Protecting Cranes From Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-27
Cleaning Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-27
Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-28
Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-28
Areas of Application. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-28

Grove Published 02-28-2019, Control # 649-01 1-1
TMS9000-2 SERVICE MANUAL GENERAL INSTRUCTIONS
SECTION 1
GENERAL INSTRUCTIONS
SECTION CONTENTS
Using the Service Manual . . . . . . . . . . . . . . . . . . . 1-1
Safety Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Safety Alert Symbol . . . . . . . . . . . . . . . . . . . . . . . 1-1
Signal Words . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Manitowoc CraneCare Service instructions. . . . . 1-2
Definitions of stated directions . . . . . . . . . . . . . . . 1-2
Breaking in a New Crane . . . . . . . . . . . . . . . . . . . . 1-3
Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Handling Substances which are Harmful to the
Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
What do environmentally harmful substances
include? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Overview of the Operating and Display Elements 1-5
Axle Weight Distribution Table . . . . . . . . . . . . . . . 1-5
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Boom Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Overview of the Components that are Easily
Damaged when Cleaning . . . . . . . . . . . . . . . . . . . . 1-8
On Truck Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Fasteners and Torque Values . . . . . . . . . . . . . . . . 1-8
Torque Wrenches . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Weld Studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
USING THE SERVICE MANUAL
This manual is not designed to replace proper training and
instruction!
Truck crane maintenance personnel are required to have
relevant specialized knowledge of proper safety procedures!
Read this section carefully before beginning maintenance
work.
SAFETY MESSAGES
General
The importance of safe operation and maintenance cannot
be overemphasized. Carelessness or neglect on the part of
operators, job supervisors and planners, rigging personnel,
and job site workers can result in their death or injury and
costly damage to the crane and property.
To alert personnel to hazardous operating practices and
maintenance procedures, safety messages are used
throughout the manual. Each safety message contains a
safety alert symbol and a signal word to identify the hazard’s
degree of seriousness.
Safety Alert Symbol
Signal Words
This safety alert symbol means ATTENTION!
Become alert - your safety is involved! Obey all safety
messages that follow this symbol to avoid possible death
or injury.
DANGER
Identifies hazards that will result in death or serious injury
if the message is ignored.
WARNING
Identifies hazards that could result in death or serious
injury if the message is ignored.

GENERAL INSTRUCTIONS TMS9000-2 SERVICE MANUAL
1-2 Published 02-28-2019, Control # 649-01
NOTE: Highlights operation or maintenance procedures.
MANITOWOC CRANECARE SERVICE
INSTRUCTIONS
This Service Manual is intended for maintenance personnel.
The maintenance manual does not contain information on
repair work. Repair work may only be carried out by qualified
repair personnel (e.g. the local authorized distributor or
Manitowoc Crane Care).
Repair work also requires:
-appropriate workshop equipment,
-special tools and
-replacement parts authorized by Manitowoc Crane
Care.
It is your responsibility to maintain and service the truck
crane regularly in order to lengthen its service life and keep it
in good working order.
Please note that Manitowoc Crane Care can only uphold the
warranty provided for the truck crane if the following
conditions are met:
-proper use,
-prescribed care and maintenance,
-professional repair work / overhauling.
Failures can be caused by improper maintenance such as:
-lack of oil, grease or antifreeze,
-dirt,
-rope damage,
-damaged compressed air and hydraulic systems,
-hose damage or loose screw connections,
-malfunctioning or mis-adjusted brakes,
-worn or damaged tires or wheel rims,
-exceeded maintenance intervals.
For your safety and the safety of others, avoid these errors
by carrying out maintenance work carefully within the
specified intervals. Do not put off maintenance work that is
due. Notify either your local Grove Crane distributor or your
qualified repair personnel immediately should repair work
become necessary. This work may only be carried out by
trained, qualified personnel.
A few general maintenance instructions:
•Clean the parts of the truck crane that are to be serviced,
particularly the area around oil filler, inspection, and
drain openings and lubricating nipples.
•When changing the oil, let the oil run out at operating
temperature.
•Ensure that only oils and lubricants specified in the
Lubrication Section are used.
•Replace all filters within the specified period if cleaning
is not explicitly permitted.
•Replace all seals before assembly. Clean the sealing
surfaces.
•Only tighten loose screw connections on hydraulic
systems when the system is depressurized.
•Keep brake and clutch linings free of grease.
•Replace hydraulic hoses immediately once damage or
evidence of moisture becomes visible.
•When handling hydraulic oil, cleanliness is imperative.
Even new hydraulic oil must be filtered.
•Check fastening and retaining elements (screws, nuts,
lock washers) before re-using them and replace them if
necessary.
Tightening torques may be found in Torque Values, page 1-
9.
Our training center at our plant in Shady Grove,
Pennsylvania offers specialized training programs. Your
local Grove Crane distributor can provide you with any
information you may need in this regard.
Ensure compliance with all applicable regulations regarding
operation of the crane on public roads.
DEFINITIONS OF STATED DIRECTIONS
Some of the terms which are used to describe the location of
components are defined in this section.
On the carrier, the driver's cab is always at the front. The
terms rear, right and left are used in relation to the definition
of the term “front” on the carrier.
On the superstructure, front is the direction facing forward
when seated in the operators cab. The terms rear, right and
left are used in relation to the definition of the term “front” on
the superstructure.
CAUTION
Identifies hazards that could result in minor or moderate
injury if the message is ignored.
CAUTION
Without the safety alert symbol, identifies hazards that
could result in property damage if the message is ignored.

Grove Published 02-28-2019, Control # 649-01 1-3
TMS9000-2 SERVICE MANUAL GENERAL INSTRUCTIONS
BREAKING IN A NEW CRANE
Special running-in instructions must be observed for
individual components (hoist, gearbox, etc.)
-after initial start-up or
-after part replacement or
-after a general inspection
Special run-in instructions must be observed, i.e. additional
maintenance work must be carried out on the carrier and the
superstructure in certain intervals:
1) Operating hours is the amount of time the engine has run.
2) 1 oh corresponds to approximately 40 kilometers (24.8
miles) driven.
Please note the instructions concerning run-in times / run-in
regulations / oil change intervals in the enclosed operating
manual of the engine manufacturer and in the crane diesel
engine maintenance booklet.
1) after 1000 operating hours, after 12 months at the latest.
SAFETY RULES
When carrying out maintenance work, it is imperative that
you observe safe work practices.
The following instructions are general safety rules for
maintenance personnel:
•Familiarize yourself with the truck crane and its
operation.
Read the operating instructions carefully and request
guidance from crane operator.
•Do not carry out maintenance work unless you are
authorized to do so.
•Use personal protective equipment when performing
maintenance (e.g., safety shoes, gloves, safety glasses,
hard hats, fall protection, etc.)
•Observe all safety and warning signs on the truck crane.
•Observe all safety instructions contained in this
maintenance manual.
•Familiarize yourself with the conditions under which the
superstructure may be slewed and the boom may be
extended into horizontal position.
•Do not carry out maintenance work unless the truck
crane is standing on flat, stable ground and is prevented
from rolling.
Operating
hours
(oh)1,2)
Travelled
km (miles) Additional maintenance work on the CARRIER
after 50 (31.0) Tighten wheel nuts. Refer to Wheels and Tires, page 8-17.
after 150 (93.2) Tighten wheel nuts. Refer to Wheels and Tires, page 8-17.
after 50 Tighten hose clamps on all coolant hoses.
during the
first 100 Check the hydraulic oil filters weekly. Refer to Lubrication Section
Operating
hours (oh)
Travelled
km Additional maintenance work on the SUPERSTRUCTURE
during the
first 100 Check the hydraulic oil filters weekly.
after 100 Check tightness of retaining bolts; tightening torque.
after 200 Carry out first oil change on hoist gears (auxiliary hoist optional).
after 200 Carry out first oil change in slewing gear transmission.
after10001) Carry out second oil change on hoist gears (auxiliary hoist optional).

GENERAL INSTRUCTIONS TMS9000-2 SERVICE MANUAL
1-4 Published 02-28-2019, Control # 649-01
•Keep all handles, steps, landings and ladders free of
dirt, grease, snow and ice.
•Use the proper access aids and working platforms when
carrying out overhead work. Use personal fall protection
when working at height.
•Walk only on those machine parts which are equipped
with appropriate steps and railings. During rigging and
maintenance work use ladders and/or other equipment
to assist in reaching locations at height where other
means of access are not provided, (e.g. when lubricating
telescopic slide faces).
•Perform maintenance work only after the truck crane
has been shut down. Always ensure that the truck crane
is protected from unauthorized operation before
beginning maintenance work. Remove the key and put
up warning signs.
If, as an exception, the truck crane needs to be put into
operation for certain types of maintenance work, great
care must be taken where there are moving parts
(superstructure, outrigger, drive shafts, swiveling
connections, motors, tiltable crane cabs, superstructure
lock). There is a risk of injury!
•Ensure that all hydraulic components are returned to
their initial positions (e.g. the boom) or locked (e.g. the
outrigger).
Escaping hydraulic fluid or compressed air can cause
severe injury. Remember that hydraulic and
compressed air systems of the truck crane are
pressurized even when the crane is not in operation.
Only tighten loose screw connections when the system
is in depressurized condition. Always depressurize the
hydraulic and compressed air systems before opening
them.
•Do not allow hot materials to escape unchecked. Risk of
scalding!
•Observe the applicable safety regulations when working
with inflammable fluids.
•Observe the applicable safety regulations when working
with process materials.
•Disconnect the earthing terminal and switch off all
electrical consumers before removing any batteries.
•Keep the corroding effect of battery acid in mind.
•Note the fire alarm and fire fighting facilities on the site.
•Return the truck crane to proper working order once
maintenance work is completed. Inform the crane
operator accordingly.
HANDLING SUBSTANCES WHICH ARE
HARMFUL TO THE ENVIRONMENT
What do environmentally harmful
substances include?
When you carry out maintenance work on the truck crane
you will occasionally work with substances which are
considered to be harmful to the environment according to the
current national and local regulations.
This includes, amongst others, oil, fuel, grease, used oil and
fuel filters as well as cloths which have come into contact
with these environmentally harmful substances.
•When handling these substances observe the current
national and regional regulations as well as the
instructions in this chapter.
Use suitable equipment
Substances harmful to the environment can be corrosive.
Therefore only use containers, hoses, pumps, funnels etc.
which are resistant to the respective substance.
Filling and draining
•When filling and draining, make absolutely sure that no
substances harmful to the environment seep into the
earth, escape into the sewage system or pollute natural
waters.
•Collect draining oil in a suitable container.
•Always use a drain hose when draining, a funnel or a
filling pump and hose suitable for the respective
substance when filling.
Collect and store separately
Substances which are environmentally harmful should
always be collected separately from other waste.
•Also collect the environmentally harmful substances
divided according to solid materials (e.g. filter elements)
and liquids. Disposal costs will be reduced if you collect
liquids separately according to certain categories.
•Ask your local environmental protection authority about
the different categories for the substances.
•Only store environmentally harmful substances in
approved containers and in locations which meet the
regulations according to the current national and
regional regulations.
Disposal
•Ask your local environmental protection authority about
the prescribed disposal possibilities.

Grove Published 02-28-2019, Control # 649-01 1-5
TMS9000-2 SERVICE MANUAL GENERAL INSTRUCTIONS
•Only have collected environmentally harmful substances
disposed of by disposal companies which are approved
by the national or regional authority responsible.
OVERVIEW OF THE OPERATING AND
DISPLAY ELEMENTS
NOTE: Refer to the Operator Manual for the operating and
display elements.
AXLE WEIGHT DISTRIBUTION TABLE
Description
C G T o C L
R e a r B o g i e
cm (in)
W e i g h t
kg (lb)
F r o n t A x l e
kg (lb)
R e a r A x l e
kg (lb)
Maximum Axle Loads Allowed 23224 (51200) 27216 (60000)
Maximum Tire & Wheel Loads Allowed 23224 (51200) 27216 (60000)
Standard Carrier Assy (8x4x4) 300.23 (118.20) 19100 (42108) 10198 (22483) 8902 (19626)
Superstructure Assy with both hoists,
cables, lower lift cyl pin -15.57 (-6.13) 5932 (13077) -164 (-362) 6096 (13439)
Boom Assy w/pivot pins 454.36 (178.88) 10590 (23347) 8557 (18865) 2033 (4482)
Lift Cylinder 347.90 (136.97) 1005 (2216) 622 (1371) 383 (845)
Complete Basic Machine: Standard Carrier
Ass'y, 6-Section Boom, Cummins EPA2017
Engine, 445/65R22.5 Goodyear Front
Tires, 315/80R22.5 Goodyear Rear Tires,
Full Fuel and Hydraulic Oil, cable on both
hoists
294.97 (116.13) 36627 (80748) 19212 (42356) 17414 (38391)
Boom Extensions
10 - 17 m (34.5 - 57.6 ft) Bi-fold Manual
Boom Extension 572.90 (225.55) 1529 (3370) 1557 (3433) 29 (-63)
34.5-57.6 ft Bi-fold Hydraulic Boom
Extension 585.88 (230.66) 1604 (3535) 1671 (3683) -67 (-148)
Boom Extension Carrier Brackets - Manual 460.15 (181.16) 190 (419) 156 (343) 35 (76)
Hydraulic Integrated Heavy-Duty 10 - 17 m
(34.5 - 57.6 ft) Bi-fold Boom Extension 595.86 (234.59) 1715 (3780) 1817 (4006) 103 (-226)
Manual Integrated Heavy-Duty 34.5 - 57.6
Bi-fold Boom Extension 584.23 (230.01) 1640 (3615) 1704 (3756) -64 (-141)
Boom Extension Carrier Brackets -
Integrated Heavy Duty 458.50 (180.51) 200 (441) 163 (360) 37 (81)
Hose Reel for Hydraulic Boom Extension 849.10 (334.29) 201 (443) 304 (669) 103 (-226)
Aux Boom Nose 1014.10 (399.25) 86 (190) 155 (342) -69 (-152)
Counterweights
3000 lb counterweight tray (pin on with
pins) on S/S -246.05 (-96.87) 1369 (3019) -599 (-1321) 1969 (4340)
10000 lb counterweight (non pin on) on S/S -246.05 (-96.87) 4536 (10000) -1985 -4376) 6521 (14376)
2 x 5000 lb counterweight (pin on with pins)
on S/S -246.05 (-96.87) 4553 (10038) -1992 (-4392) 6545 (14430)
3000 lb counterweight (pin on with pins) on
S/S -246.05 (-96.87) 1369 (3019) -599 (-1321) 1969 (4340)
2000 lb counterweight (pin on) on S/S -246.05 (-96.87) 907 (2000) -397 (-875) 1304 (2875)

GENERAL INSTRUCTIONS TMS9000-2 SERVICE MANUAL
1-6 Published 02-28-2019, Control # 649-01
3000 lb counterweight (pin on with pins) on
carrier deck 474.35 (189.75) 1369 (3019) 1174 (2588) 196 (431)
3000 lb counterweight (pin on with pins) on
carrier deck 474.35 (189.75) 1369 (3019) 1174 (2588) 196 (431)
2000 lb counterweight (pin on) on carrier
deck 474.35 (189.75) 907 (2000) 778 (1714) 130 (286)
3000 lb counterweight (tray) on carrier deck 474.35 (189.75) 1361 (3000) 1166 (2571) 195 (429)
5000 lb counterweight (pin on with pins) on
carrier deck 474.35 (189.75) 2277 (5019) 1951 (4302) 325 (717)
10000 lb counterweight (non pin on) on
carrier deck 474.35 (189.75) 4536 (10000) 3888 (8571) 648 (1429)
Rigging Equipment
12.1 ton (11 t) Overhaul Ball (Swivel) in
stowage tray 830.58 (327.00) 294 (648) 435 (958) -140 (-309)
12.1 ton (11 t) Overhaul Ball (Swivel) - tied
to front bumper 942.34 (371.00) 294 (648) 493 (1086) -199 (-438)
28.7 ton (26 t) Hookblock (1 sheave) - tied
to front bumper 955.04 (376.00) 323 (712) 549 (1210) -225 (-497)
49.6 ton (45 t) Hookblock (3 sheave) - tied
to front bumper 955.04 (376.00) 450 (992) 764 (1685) -314 (-693)
66.1 ton (60 t) Hookblock (5 sheave) - tied
to front bumper 955.04 (376.00) 565 (1245) 959 (2114) -394 (-869)
100 ton (91 t) Hookblock (5 sheave) - tied
to front bumper 955.04 (376.00) 658 (1451) 1118 (2464) -460 (-1013)
Rigging 170.18 (67.00) 45 (100) 14 (30) 32 (70)
Cribbing (in rear troughs) -35.56 (-14.00) 181 (400) -11 (-25) 193 (425)
Optional Equipment
Automated Transmission -562.31 (221.38) 34 (75) -34 (75) 0 (0)
Driver 762.00 (300.00) 91 (200) 123 (271) -32 (-71)
Rear Frame Counterweight Mount -236.22 (-93.00) 100 (220) -42 (-92) 142 (312)
Tag axle mounting 220.98 (-87.00) 176 (387) 69 (-152) 245 (539)
Trailing Boom - Carrier Components -83.82 (-33.00) 33 (73) -5 (-11) 38 (84)
Trailing Boom - Boom Brackets (use with
trailing boom w/dolly option) 822.40 (323.78) 87 (192) 127 (281) -40 (-89)
Substitutions and Removals
SUB: Main Hoist Only (replace aux hoist
and cable with IPO cwt) -271.91 (-107.05) -376 (-830) 166 (365) -508 (-1119)
REM: Main Hoist Cable (738' of 3/4” Bridon
Dyform 34LR) -176.91 (-69.65) -483 (-1065) 152 (335) -635 (-1400)
REM: Aux Hoist Cable (738' of 3/4” Bridon
Dyform 34LR) -271.91 (-107.05) -342 (-754) 166 (365) -508 (-1119)
SUB: Main Hoist Cable (257 m K-100 ™
Rope) -176.91 (-69.65) -401 (-884) 126 (278) -527 (-1162)
SUB: Aux Hoist Cable (184 m K-100 ™
Rope) -271.91 (-107.05) -286 (-631) 138 (305) -425 (-936)
SUB: Steel Outrigger Floats 163.07 (64.20) -86.24 (-190.12) -25 (-55) -61 (-135)
SUB: Manual Transmission 00
ADD: Tag Axle (-127.60) (3400) (-1960) (5360)
ADD: Tag Axle down force (-132.60) (-13800) (8266) (-22066)
Description
C G T o C L
R e a r B o g i e
cm (in)
W e i g h t
kg (lb)
F r o n t A x l e
kg (lb)
R e a r A x l e
kg (lb)

Grove Published 02-28-2019, Control # 649-01 1-7
TMS9000-2 SERVICE MANUAL GENERAL INSTRUCTIONS
CLEANING
The paint on the truck crane will continue to harden for the
first three months.
•During this period the truck crane may only be cleaned
with cold water.
•Do not use high-pressure or steam-jet cleaning
equipment during this period.
•Avoid water temperatures over 60°C (140°F), even after
the first three months.
•Do not use corrosive cleaning agents that might corrode
the paint.
•Never hold the spray nozzle of your cleaning unit at a
right angle to the surface you are cleaning and ensure
that you are standing at a sufficient distance away from
the surface you are cleaning.
Boom Cleaning
The operator should ensure that each of the telescoping
boom sections are clean during operation. Any dirt that is on
the painted boom sections can get stuck in the wear pads,
and this will lead to scoring of the paint. Eventually, the
telescoping of a section with damaged paint will become
more difficult to complete as the paint damage becomes
more severe. Each of the telescoping boom sections should
be cleaned with a nonabrasive, solvent free cleaning agent
at least once a month or as required. If the sections are
pressure washed, caution should be used to not damage the
paint.
•Never point the nozzle at electrical equipment, relay and
control boxes, suction and venting filters or control
elements and lubricated surfaces.
NOTE: The components specified in section Overview of
the Components that are Easily Damaged when
Cleaning, page 1-8 are to be cleaned with
particular care.
•After cleaning with a high-pressure device or a steam jet
device, activate an intermediate lubrication at the
centralized lubrication system. Lubricate all remaining
lubrication points with a grease gun.
CAUTION
High Pressure Water Jet Hazard!
When working with high-pressure and steam jet cleaners,
the water jet will be deflected by crane parts and could
spray into your face and eyes at great speed and high
pressure.
Always wear a face guard when cleaning the truck crane
with high-pressure and steam-jet cleaning equipment.

GENERAL INSTRUCTIONS TMS9000-2 SERVICE MANUAL
1-8 Published 02-28-2019, Control # 649-01
OVERVIEW OF THE COMPONENTS THAT
ARE EASILY DAMAGED WHEN CLEANING
On Truck Crane
FASTENERS AND TORQUE VALUES
Use bolts of the correct length. A bolt which is too long may
bottom before the head is tight against the part it is to hold. If
a bolt is too short, there may not be enough threads engaged
to hold the part securely. Threads can be damaged. Inspect
them and replace fasteners, as necessary.
Torque values should correspond to the type bolts, studs,
and nuts being used.
The torque tables are provided by Manitowoc for reference
when performing maintenance.
Use of proper torque values is extremely important. Improper
torquing can seriously affect performance and reliability.
Identification of fastener grade is always necessary. When
marked as a high strength bolt (grade 5, 8, etc.), the
mechanic must be aware that he/she is working with a highly
stressed component and the fastener should be torqued
accordingly.
NOTE: Some special applications require variation from
standard torque values. Reference should always
be made to component overhaul procedures for
recommendations.
Special attention should be given to the existence of
lubricant, plating, or other factors that might require variation
from standard torque values.
The use of lubricants on zinc-flake coated parts shall be
prohibited since this will change the required torque value.
When maximum recommended torque values have been
exceeded, the fastener should be replaced.
Previously installed bolts and nuts of Grade 8 or Class 10.9
and higher may not be reused.
1Air Ride Suspension 4 Telescope slide faces
2RCL connecting box 5 RCL length and angle measuring unit
3Lifting limit switch 6 Angle sensor control box
2
3
45
1
1
6