TMS800E OPERATOR’S MANUALOPERATING CONTROLS AND PROCEDURES

engine speed when it is being pushed by a heavy crane. When the engine exceeds the rated governed RPM while descending a grade or downshifting at the high end of the operating range, engine overspeed can result in serious damage. On downhill operation, use the vehicle brakes and gears in combination to keep crane speed under control and the engine below rated governed RPM.

The transmission has 11 forward speeds and three reverse speeds. It has a five speed front section and a three speed auxiliary section. The auxiliary section contains low and high range ratios, plus three deep reduction gears. The three lowest (LL1, LO, LL2) gear sets are used for road speed control and are not intended to be used as progressive shifts. The other four ratios are used twice, once in low range and once in high range.

As with any transmission gearing, shifting depends on proper synchronization. Adhere to the following:

• Never try to force the gear lever.

• During regular shifts, when moving the gear lever into the next gear position for engagement, the lever should be held lightly against the gear to be engaged.

• If gears are synchronized, engagement will be made immediately.

• If not synchronized, the flat gear teeth will rotate against each other until synchronization is reached.

• Do not jerk the shift lever into the next gear position or try to force gear engagement.

• If gears are out of synchronization, no amount of force is going to make the engagement before synchronization.

All shifts are made with one lever and a range control switch which is used only once during an upshift sequence, and only once during a downshift sequence.

In the following instructions, it is assumed that the driver is familiar with motor trucks and tractors, and that he can coordinate the necessary movements of the shift lever and clutch pedal to make progressive and selective gear engagements in either direction, up or down.

Crane Transmission Initial Start-Up

Caution

Before moving the crane, make sure you understand the shift pattern configuration (see Figure3-12), or see the decal in the cab.

1. Ensure the shift lever is in neutral and the parking brake is set.

2. Start the engine.

3. Allow air pressure to build up.

4. Apply the service brakes.

5. Ensure the range control switch is down in the low position.

6. If the crane is to be started in deep reduction (LL2 or LL1), move the deep reduction switch forward to IN (Figure3-13).

7. Depress the clutch pedal to the floor.

8. Move the shift lever to the desired initial gear.

9. Release the parking brakes.

10. Slowly release the clutch pedal and depress the foot throttle pedal.

Upshifting

Caution

Never move the deep reduction switch or the range control switch with the shift lever in neutral while the crane is moving.

1. To make a deep reduction switch shift from LL2 to 1st, proceed as follows.

a. Just before making the upshift, move the deep reduction switch rearward to OUT while maintaining foot throttle position.

b. Immediately release the foot throttle pedal, depress the clutch pedal once to break torque, release the pedal to engage the clutch, allow the engine to decelerate until the shift is complete. Continue driving or upshifting. The transmission shifts from LL2 to 1st when synchronous is reached.

2. To shift in low range, proceed as follows.

a. Move the shift lever, double clutching, to the next desired gear position in low range (1st to 2nd to 3rd to 4th).

3. To shift from low (4th) to high (5th) range, proceed as follows.

a. When in the last gear position for low range and ready for the next upshift, pull the range control switch up to high and move the shift lever, double clutching, to the next higher gear position. As the shift lever passes through neutral, the transmission will automatically shift from low to high range.

Caution

Never move the shift lever to the low speed gear position after high range preselection, or anytime the transmission is in high range.

Published 09-14-2012, Control # 132-07 a. Move the shift lever, double clutching, to the next desired gear position in high range (5th to 6th to 7th to 8th).

4. To shift in high range, proceed as follows.

Downshifting

These ratios are not progressively shifted.

These ratios are progressively shifted.

Do not change range while moving in reverse

Caution

Never move the deep reduction switch or range control switch with the shift lever in neutral while crane is moving.

1. To shift in high range, proceed as follows.

a. Move the shift lever, double clutching, to the next desired gear position in high range (8th to 7th to 6th to 5th).

2. To shift from high (5th) to low (4th) range, proceed as follows.

a. When in the 5th gear position for high range and ready for the next downshift, push the range control switch down to low range and move the shift lever, double clutching, to the next lower gear position. As the shift lever passes through neutral, the transmission will automatically shift from high range to low range.

3. To shift in low range, proceed as follows.

a. Move the shift lever, double clutching, to the next desired gear position (4th to 3rd to 2nd to 1st).

4. To make a deep reduction switch shift from low range (1st) to low-low range (LL2), proceed as follows.

a. Just before making the downshift, move the deep reduction switch forward to IN while maintaining foot throttle position.

b. Immediately release the foot throttle pedal, depress the clutch pedal once to brake torque, release the pedal to engage the clutch, and depress the foot throttle pedal. The transmission shifts from 1st to LL2 when synchronous speed is reached.

Shifting To Reverse

Caution

Never make a range shift or deep reduction shift while moving in reverse.

1. With the transmission in neutral, determine which reverse range is to be used. Move the range control switch up for high reverse or down for low reverse.

2. Move the shift lever to the reverse position.

Published 09-14-2012, Control # 132-07