Manitowoc Grove CD3340B Service Manual

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SECTION 1

SECTION 2

SECTION 3

SECTION 4

SECTION 5

SECTION 6

SECTION 7

SECTION 8

SECTION 9

SECTION 10

SECTION 11

SECTION 12

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 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.

Published 05/07/2015 CTRL# 569-00

SERVICE MANUAL

This Manual has been prepared for and is considered part of -

CD3340B/YB4411

Crane Model Number

Crane Serial Number

This Manual is Divided into the following Sections:

INTRODUCTION

SAFETY PRACTICES

ELECTRIC SYSTEM

HYDRAULIC SYSTEM

MAINTENANCE

ENGINE AND ENGINE SYSTEMS

TRANSMISSION AND TORQUE CONVERTER

AXLES/DRIVE SHAFTS/WHEELS AND TIRES

BRAKE SYSTEM

STEERING SYSTEM

STRUCTURAL

SCHEMATICS/WIRING DIAGRAMS

NOTICE

DANGER

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.

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's Manual and Load Chart are in the holder provided on

crane.

Manitowoc is not

Table of Contents

Chapters

Table of Contents

Troubleshooting

Need help?

Do you have a question about the Grove CD3340B and is the answer not in the manual?

Questions and answers

Summary of Contents for Manitowoc Grove CD3340B

Page 1 You are sure that all safety signs, guards, and other safety features are in place and in proper condition. • The Operator’s Manual and Load Chart are in the holder provided on crane. © 2015 Manitowoc Crane Group Published 05/07/2015 CTRL# 569-00...
Page 2 CALIFORNIA PROPOSITION 65 WARNING Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. CALIFORNIA PROPOSITION 65 WARNING Battery posts, terminals, and related accessories contain chemical lead and lead compounds, chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.
Page 3: Table Of Contents
CD3340B/YB4411 TABLE OF CONTENTS SECTION 1 ........Introduction General .
Page 4 TABLE OF CONTENTS CD3340B/YB4411 Charging System ............3-7 Alternator and Voltage Regulator .
Page 5 CD3340B/YB4411 TABLE OF CONTENTS Oil Flow ............4-13 Holding Valve .
Page 6 TABLE OF CONTENTS CD3340B/YB4411 Scheduled Maintenance ..........5-13 Daily (Walk-around) .
Page 7 CD3340B/YB4411 TABLE OF CONTENTS Clutch Operation ........... 7-10 Troubleshooting .
Page 8 TABLE OF CONTENTS CD3340B/YB4411 Description ............9-2 Service Brake System .
Page 9 CD3340B/YB4411 TABLE OF CONTENTS Inspecting Wire Rope ..........11-16 Inspection of Sheaves.
Page 10 TABLE OF CONTENTS CD3340B/YB4411 TOC-viii...
Page 11: Section 1
CD3340B/YB4411 INTRODUCTION SECTION 1 INTRODUCTION SECTION CONTENTS Installation .......1-7 General ........1-1 Bearings .
Page 12: Specifications
INTRODUCTION CD3340B/YB4411 SPECIFICATIONS Table 1-1 Engine Diesel Engine Make and Model.............. Cummins QSB3.3 Tier 4i diesel Type of Aspiration............Turbocharged Horsepower..............100 hp @ 2600 rpm Low Idle Speed..............800 rpm Maximum Engine Speed ..........2860 rpm Boom Construction ..............Telescopic, welded box sections Number of Sections............
Page 13: Engine Oil Specifications
CD3340B/YB4411 INTRODUCTION Wire Rope (Optional Below Deck Winch) Diameter................8 mm (5/16 in) Length ................30.5 m (100 ft) Torque Converter Model................Borg Warner Type................. Hydraulic Transmission Type................. International Transmissions Limited Model................PS-750 Type................. Powershift Travel Speed First ................7.14 km/h (4.6 mph) Second................
Page 14: Diesel Fuel
INTRODUCTION CD3340B/YB4411 FIGURE 1-2 DIESEL FUEL No. 2 diesel fuel with a minimum Cetane number of 40. No. 2 diesel fuel gives the best economy and performance under The Cummins Diesel Engine operates most efficiently with most operating conditions. Fuels with Cetane numbers No.
Page 15: Nomenclature
CD3340B/YB4411 INTRODUCTION NOMENCLATURE 8510 Item Description Item Description Inner Boom (3rd. Section) Recessed Mounted Winch Location (Optional) Intermediate Boom (2nd. Section) Hydraulic Valve Location Main Boom (1st. Section) Right Side - Fuel Tank Location Telescope Cylinder Location Swing Gearbox and Motor Location Mast Lift Cylinder Operator’s Compartment...
Page 16: Cleaning Instructions
INTRODUCTION CD3340B/YB4411 CLEANING INSTRUCTIONS After Cleaning Remove all water or solvent from the parts immediately after Complete Assemblies cleaning. Use compressed air or a clean cloth. Make sure Before removal or disassembly, clean the outside of the the parts are completely dry and clean. DO NOT use component as necessary.
Page 17: Installation
CD3340B/YB4411 INTRODUCTION Installation a0348 Be sure bearings are installed with care during servicing, maintenance and repair. Whenever possible, always install the bearing on the rotating part first. Use proper tools or a press when installing a bearing or bushing. In the absence of the proper tools or press, when installing press fit bearings and bushings, heat the bearing and/or the casing in hot oil to assist in the installation.
Page 18: Loctite
Loctite types are suitable for all applications. Various and nuts being used. types of Loctite are specified throughout the Service Manual. The torque tables are provided by Manitowoc for reference The following types of Loctite brand adhesives are available when performing maintenance.
Page 19: Torque Values
CD3340B/YB4411 INTRODUCTION handle type, with torque limiting devices that can be pre-set • All handles must be parallel to the step wrench during to required values, eliminate dial readings and provide more final tightening. Multiplier reaction bars may be misaligned no more than 30 degrees without causing reliable, less variable readings.
Page 20 INTRODUCTION CD3340B/YB4411 SAE Grade 1 SAE Grade 5 SAE Grade 7 SAE Grade 8 and Grade 2 HHCS HHCS HHCS HHCS Socket Head Socket Head Serrated Capscrew Shoulder Flange Head Screw FIGURE 1-6 Table 1-2: UNC (Coarse) Thread: Torque Values for Zinc-Flake Coated and Untreated Fasteners Bolt Diameter - Inches Torque Values (Pounds-Foot, Maximum/Minimum) SAE Grade...
Page 21 CD3340B/YB4411 INTRODUCTION Table 1-4: Metric Fasteners, Coarse Thread, Zinc-Flake Coating Bolt Diameter - Metric Torque Values (Nm) Class 21.6 42.4 73.1 1195 1608 2072 10.9 12.5 31.5 62.0 1325 1800 2450 3150 12.9 15.0 36.0 75.0 1060 1550 2125 2850 3700 Table 1-5: Metric Fasteners, Coarse Thread, Untreated Bolt Diameter - Metric...
Page 22: Weld Studs
INTRODUCTION CD3340B/YB4411 Table 1-8: UNC (Coarse) Thread: Torque Values for Weld Studs Stainless Steel Fasteners with Oil Lubrication Unless otherwise specified the following grade 2 torque Torque Value values (± 10%) apply. Size lb-in lb-ft Table 1-10: Weld Stud Torque Values #5 (0.125) —...
Page 23 CD3340B/YB4411 INTRODUCTION Place second wrench on nut as near the 3 o’clock Thread Fitting Size Dash Size Torque ft-lbs position as possible. Size Turn nut clockwise to no less than the 4 o’clock position, ORFS 10 1-14 45-50 but no more than the 6 o’clock position. Required ORFS 12 1 3/16-12 65-70...
Page 24: Hydraulic Fitting F.f.f.t. Method (Flats From Finger Tight)
37°Flared Steel Fitting - Tube or Hose to (FLATS FROM FINGER TIGHT) Fitting (Table 1-11) Manitowoc, Inc. recommends that the F.F.F.T. tightening See Hydraulic Fitting F.F.F.T. Method in this section. method described here be used when assembling all hydraulic fittings. This method will minimize the risk of fitting a0028 damage or failure due to under or overtightening.
Page 25: Nonadjustable Straight Thread O-Ring Fitting - Fitting To Port (Table 1-13)
CD3340B/YB4411 INTRODUCTION Hold the fitting in the desired position and tighten the nut a0031 (Figure 1-8 D) following the F.F.F.T. method, see Hydraulic Fitting F.F.F.T. Method starting with step 4. a0030 Table 1-13 FIGURE 1-8 a0032 Nonadjustable Straight Thread O-ring Fitting - Fitting to Port (Table 1-13) Make sure both threads and sealing surfaces are free of burrs, nicks, scratches or any foreign particles.
Page 26 INTRODUCTION CD3340B/YB4411 Published 04/07/2015 Control # 569-00 1-16...
Page 27: Section 2
CD3340B/YB4411 SAFETY PRACTICES SECTION 2 SAFETY PRACTICES SECTION CONTENTS General ........2-1 Final Word .
Page 28 SAFETY PRACTICES CD3340B/YB4411 Table 2-1 Personal Considerations What to Do Check to see that you are suitably clothed. For certain work it may be The wrong clothes or carelessness in Clothing necessary to wear flame or acid dress can cause accidents and injury resistant clothing.
Page 29 CD3340B/YB4411 SAFETY PRACTICES Table 2-3 General Considerations What to Do Use only cleaning fluids and solvents Certain types of fluids cause damage to Solvents that are known to be safe. components and can cause skin irritations. Clean and remove all hazards from the Improves surroundings and daily Housekeeping area.
Page 30: Final Word
SAFETY PRACTICES CD3340B/YB4411 Table 2-4 Operatiional Considerations What to Do Make sure all test equipment is in good condition. Use only specified gauges. Pressure Testing Comply with test procedures specified. Inhibits damage to the system or the equipment and inhibits the possibility of personal injury.
Page 31: Section 3
CD3340B/YB4411 ELECTRIC SYSTEM SECTION 3 ELECTRIC SYSTEM SECTION CONTENTS General ........3-1 Starting Circuit Check .
Page 32: Comparing Electrical System To A Hydraulic System
ELECTRIC SYSTEM CD3340B/YB4411 In series circuit arrangements, the voltage is completely Electrical System Hydraulic System used in the circuit when the current is flowing. In parallel Switches Valves circuit arrangements, the voltage is constant. Wires and Cables Tubes and Hoses When the voltage is constant, resistance controls the rate of current (amps) in the circuit.
Page 33: Main Electrical System
CD3340B/YB4411 ELECTRIC SYSTEM MAIN ELECTRICAL SYSTEM Engine Wire Harness Fuse and Relay Replacement General The fuses and relays are located on fuse blocks under the The electrical system used on this machine is a 12 volt, control panel (Figure 3-1, 3-2 and 3-3) and in the electrical direct current (DC) system with a (-) negative ground.
Page 34 ELECTRIC SYSTEM CD3340B/YB4411 8465-7 8465-8 FIGURE 3-2 Published 04/07/2015 Control # 569-00...
Page 35 CD3340B/YB4411 ELECTRIC SYSTEM 8465-10 8465-9 FIGURE 3-3 Fuse Box 3 8490 FIGURE 3-4 GROVE Published 04/07/2015 Control # 569-00...
Page 36 ELECTRIC SYSTEM CD3340B/YB4411 8465-12 8465-11 FIGURE 3-5 Published 04/07/2015 Control # 569-00...
Page 37: Charging System
CD3340B/YB4411 ELECTRIC SYSTEM CHARGING SYSTEM Special Precautions The purpose of the charging system is to give power for Never cause a short circuit or ground in the output or operation of the lights, instruments, electrical accessories field wires of the alternator. These wires are always hot and controls, and to keep a full charge on the battery.
Page 38: Battery Replacement
ELECTRIC SYSTEM CD3340B/YB4411 When disconnecting the charger, always remove the starting circuit. Use a test lamp or voltmeter to negative ground connection first. Wait perform the checks. approximately one minute after the charger has stopped before disconnecting the chargers positive (+) wire. This procedure will decrease the possibility of explosion of hydrogen gas around the battery.
Page 39: Instrument And Light Circuits
CD3340B/YB4411 ELECTRIC SYSTEM starter relay to the starter solenoid. Repair or replace the Voltmeter Display wiring. If voltage is indicated, the problem is in the starter The voltmeter is connected in parallel with the charging solenoid. circuit. The voltmeter gives an indication of electrical charging system problems that can not be seen with an INSTRUMENT AND LIGHT CIRCUITS ammeter.
Page 40: Accessory Circuits
ELECTRIC SYSTEM CD3340B/YB4411 Table 3-3: Voltage Level Conditions Voltage Measured Engine Speed Condition of Charging System 0-10 volts Stopped or low idle. Battery discharged. Low battery charge. 11-12 volts Above low idle. Problem in charging system. See Troubleshooting - Charging System. Stopped or low idle.
Page 41: Wire Harnesses
CD3340B/YB4411 ELECTRIC SYSTEM WIRE HARNESSES Main Frame Wire Harness The main frame wire harness (Figure 3-9, Figure 3-10, and Engine Wire Harness Figure 3-11) supplies electrical current to operate the The engine wire harnesses (Figure 3-7) supply electrical electrical components attached to the main frame. It also current from the battery to the charging circuit, starting connects to the instrument panel and engine wire harnesses.
Page 42 ELECTRIC SYSTEM CD3340B/YB4411 8468-1 Transmission Wire Harness FIGURE 3-8 Item Description Forward Low Solenoid Main Shaft Solenoid Reverse High Solenoid Gearbox Connector Reverse Low Solenoid Layshaft Solenoid Forward High Solenoid Speed Sensor Pressure Switch 3-12 Published 04/07/2015 Control # 569-00...
Page 43 CD3340B/YB4411 ELECTRIC SYSTEM Continued on Figure 3-10 8468-2 FIGURE 3-9 Main Wire Harness Sheet 1 Item Description Item Description Front Steering Proximity Switch Right Front Headlight Left Front Signal Light Right Front Signal Light Left Front Headlight Transmission Module Left Hand Front OMS Transmission Oil Temperature Switch Outrigger Extend Transmission Oil Cooling Fan Switch...
Page 44 ELECTRIC SYSTEM CD3340B/YB4411 Continued from Continued on Figure 3-9 Figure 3-11 8468-3 FIGURE 3-10 Main Wire Harness Sheet 2 Item Description Item Description Telescope Out To Dash Harness P6 Swing Right Unlock To Dash Harness P1 Boom Up To Dash Harness P2 Hoist Down To Dash Harness P3 Crane Power...
Page 45 CD3340B/YB4411 ELECTRIC SYSTEM Continued from Figure 3-10 FIGURE 3-11 Main Wire Harness Sheet 3 Item Description Item Description Left Rear Outrigger Jack Fuse/Relay Box Left Rear Outrigger Beam Right Rear Turn Signal To Engine Right Rear Work Light To Engine Right Hand Rear OMS Rear Steer Proximity Switch Right Rear Stop/Tail...
Page 46: Instrument Panel Wire Harness
ELECTRIC SYSTEM CD3340B/YB4411 Instrument Panel Wire Harness FIGURE 3-12 8468-5 Item Description Item Description Fuse Box 1 Skylight Wiper 221 Splice Carrier P6 Headlights/Worklights Carrier P1 2WD/4WD Select Switch 46 Splice Steer Select Switch Ignition Switch Transmission Pressure Alarm Parking Brake Flasher Crane Power Shift/Turn Left...
Page 47: Cab Wire Harness
CD3340B/YB4411 ELECTRIC SYSTEM 8468-6 Cab Wire Harness FIGURE 3-13 Item Description Carrier Heater/Air Conditioner RCI A RCI B RCI C Dome Light Strobe i 4300 CPU Seat Switch CE Bridging Key i4300 Cable 60 Carrier GROVE Published 04/07/2015 Control # 569-00 3-17...
Page 48 ELECTRIC SYSTEM CD3340B/YB4411 TROUBLESHOOTING Each circuit in the system has a fuse for protection against overloads. Remember that a burnt fuse is an indication of an Finding a problem in the electrical system is not difficult if you overload or SHORT circuit, not an OPEN circuit. know basic electricity and understand the arrangement of If you did not find the cause of the problem during the visual t h e e l e c t r i c a l s y s t e m .
Page 49: Charging System Troubleshooting
CD3340B/YB4411 ELECTRIC SYSTEM Charging System Troubleshooting Problem Possible Cause Solution Alternator does not Alternator belt loose or Replace and/or tighten to specification. charge broken. Worn brushes or open Replace or repair alternator. brush leads connections. Open circuit, short circuit or Replace alternator.
Page 50: Starting System Troubleshooting
ELECTRIC SYSTEM CD3340B/YB4411 Starting System Troubleshooting Problem Possible Cause Solution Starter motor does not Open circuit, dirty or loose Clean and tighten connections at battery and starter. turn connections. Check wiring and connections between ignition switch and starter solenoid. Bad starter relay. Replace starter relay.
Page 51: Section 4
CD3340B/YB4411 HYDRAULIC SYSTEM SECTION 4 HYDRAULIC SYSTEM NOTE: Schematics are located at the back of this manual. SECTION CONTENTS Technical Data ......4-2 Hydraulic Swivel .
Page 52: Technical Data
HYDRAULIC SYSTEM CD3340B/YB4411 TECHNICAL DATA Hydraulic Pressures: Main System Pressure (Pump Compensator) ..... . 3625 ± 50 psi (24 994± 345 kPa) Pump Margin Pressure .
Page 53: Hydraulic System
CD3340B/YB4411 HYDRAULIC SYSTEM push more oil into the system until the resistance is this section. The main hydraulic system gives hydraulic overcome or the relief valve opens (fixed displacement power to: pumps) or the pump compensator setting is reached The swing motor (variable displacement pumps).
Page 54 HYDRAULIC SYSTEM CD3340B/YB4411 Make a visual inspection. Look for a restriction in the Again, use the schematic. Find which components are in the linkages, low level of hydraulic oil, bent tubes, collapsed circuit or circuits. What component can cause the problem or ballooned hoses, leakage around the hydraulic with these symptoms? Make a list of the possible causes.
Page 55: Troubleshooting Guides
CD3340B/YB4411 HYDRAULIC SYSTEM TROUBLESHOOTING GUIDES General Hydraulic System Troubleshooting Table 4-1 Symptom Possible Cause Remedy With engine at low rpm, operate all control Air in system. functions several times to return the air to atmosphere through the tank breather. Add recommended oil. Low oil supply.
Page 56 HYDRAULIC SYSTEM CD3340B/YB4411 Symptom Possible Cause Remedy Change procedure of operation. Wrong operation (running over the load sense relief pressure setting for long periods). Change filter. See Maintenance, page 5-1. Dirty filters. Overheating of hydraulic oil Use correct oil. Oil too light. Check and add oil.
Page 57: Lift Circuit Troubleshooting
CD3340B/YB4411 HYDRAULIC SYSTEM Lift Circuit Troubleshooting Table 4-2 Symptom Possible Cause Remedy Control valve not actuated. Check hoses to control valve. Also, see “Difficult to Engage Valve Spools”, page 4-6. Not enough oil from pump to operate the See “Loss of Movement During Lift cylinder does not extend or cylinder.
Page 58: Standard Outrigger Circuit Troubleshooting
HYDRAULIC SYSTEM CD3340B/YB4411 Standard Outrigger Circuit Troubleshooting Table 4-4 Symptom Possible Cause Remedy Electrical problem. See Electric System, page 3-1. Dirt or restriction in the dump valve. Clean or replace the dump valve. Dirt in relief valve, keeping the valve off the Clean the relief valve.
Page 59: Independent Outrigger Circuit
CD3340B/YB4411 HYDRAULIC SYSTEM Independent Outrigger Circuit Table 4-5 Symptom Possible Cause Remedy Electrical problem. See Electric System, page 3-1. Dirt in dump valve, keeping the valve off Clean or replace dump valve. No movement, all outriggers the valve seat. Faulty pump section. Overhaul or replace the pump.
Page 60: Swing Circuit Troubleshooting
HYDRAULIC SYSTEM CD3340B/YB4411 Swing Circuit Troubleshooting Table 4-6 Symptom Possible Cause Remedy Damaged or broken motor shaft. Repair or replace the swing motor. Damaged or broken gearbox shaft or gear. Overhaul or replace the gearbox. See Maintenance, page 5-1. Faulty pump. Overhaul or replace the pump.
Page 61: Description Of Operation
CD3340B/YB4411 HYDRAULIC SYSTEM Item Description Housing Piston Shoe Port Plate Drive Shaft Swash Plate Shaft Seal Compensator Control Valve Plate FIGURE 4-1 a0727 signal with load sense pressure plus pump margin or differential pressure. It is this margin or differential pressure Description of Operation that overcomes the compensators (2) and permits flow to bridge (5) and work port A (16) or B (17).
Page 62: Hydraulic Swivel
HYDRAULIC SYSTEM CD3340B/YB4411 a0725 Item Description Item Description Load Sense Shuttle Return Core (To Tank/Outlet) Compensator Bias Spring Spool Work Port A Pump Work Port B Work Port Feeder Core (Bridge) Section Load Sense Line Pump Supply (From Inlet Port) Load Sense &...
Page 63: Troubleshooting
CD3340B/YB4411 HYDRAULIC SYSTEM Port No. 7 Troubleshooting Hydraulic oil under low pressure flows through this port from Leakage between the passages of the hydraulic swivel will the hoist motor drain. cause loss of power or possible wrong operation of one of the circuits.
Page 64: Holding Valve
HYDRAULIC SYSTEM CD3340B/YB4411 Holding Valve The holding valve has three functions: Inhibit cavitation of the cylinder, WARNING Give full control of the lowering of the boom, Do not adjust the holding valve setting. The valve is adjusted by the manufacturer. Hold the load in event of a hydraulic failure.
Page 65 CD3340B/YB4411 HYDRAULIC SYSTEM Swing Telescope Lift Hoist FIGURE 4-4 GROVE Published 04/07/2015 Control # 569-00 4-15...
Page 66: Telescope Circuit
HYDRAULIC SYSTEM CD3340B/YB4411 TELESCOPE CIRCUIT Holding Valve Use the hydraulic schematic in Section 12 along with the The holding valve has three functions: following text to understand how the telescope circuit Inhibit cavitation of the cylinder. functions. Give full control of the lowering of the boom. General Hold the load in event of a hydraulic failure.
Page 67: Telescope Cylinder Leakage Test
CD3340B/YB4411 HYDRAULIC SYSTEM If the pressure readings are correct, stop the engine and Oil Flow remove the pressure gauge. When the valve spool is in the neutral position, both A and B If the pressure readings are incorrect, adjust the ports are closed.
Page 68: Brake Holding Valve
HYDRAULIC SYSTEM CD3340B/YB4411 Brake Holding Valve rotate to the left. Oil from downstream side of the motor returns through the A port and is sent back to the tank The holding valve has three functions: through the return filter. Inhibit cavitation of the motor. PILOT CONTROL SYSTEM Give full control of the lowering of the load.
Page 69 CD3340B/YB4411 HYDRAULIC SYSTEM increases pressure, counterclockwise reduces the With the engine shut off, & pressure check diagnostic pressure. quick disconnect (Parker PD240) with gauge still installed on test nipple @ the G1 port (1, Figure 4-5). Tighten the margin set screw. On the control valve, remove the cap on the load sense Shut off the engine and disconnect the pressure gauge.
Page 70 HYDRAULIC SYSTEM CD3340B/YB4411 Shut off the engine, and disconnect the pressure should cut out at 138 +7/-0 bar (2000 +100/-0 psi) if not gauge. adjust at UP10 piloted unloading valve (2, Figure 4-8); clockwise increases pressure, counterclockwise Set the pressure on the load sense relief valve, refer to Load reduces pressure.
Page 71: Anti-Double Block System
CD3340B/YB4411 HYDRAULIC SYSTEM Supply Pilot Pressure Setting Testing System Pressure With the engine shutdown and the parking brake set, install pressure diagnostic (Parker PD240) with gauge onto pilot test port (3, Figure 4-7) of the control valve. b. Start the engine and actuate the crane power switch and read the pressure indicated on the pressure gauge.
Page 72: Outriggers Circuits
HYDRAULIC SYSTEM CD3340B/YB4411 OUTRIGGERS CIRCUITS control valve, an accumulator charging valve, a dump valve, two four solenoid outrigger valves, four horizontal outrigger General cylinders, and four vertical outrigger cylinders and hydraulic lines. The front outrigger valve consists of a manifold, relief valve, and five solenoid valves.
Page 73 CD3340B/YB4411 HYDRAULIC SYSTEM Oil Flow - Horizontal Outrigger Extend (Right) and Retract (Left) (Standard Outriggers) FIGURE 4-10 a0749 GROVE Published 04/07/2015 Control # 569-00 4-23...
Page 74 HYDRAULIC SYSTEM CD3340B/YB4411 Oil Flow - Vertical Outrigger Extend (Right) and Retract (Left) (Standard Outriggers) FIGURE 4-11 a0750 Published 04/07/2015 Control # 569-00 4-24...
Page 75 CD3340B/YB4411 HYDRAULIC SYSTEM Oil Flow - Horizontal Outrigger Extend (Right) and Retract (Left) (Optional Independently Controlled Outriggers) FIGURE 4-12 a0751 GROVE Published 04/07/2015 Control # 569-00 4-25...
Page 76 HYDRAULIC SYSTEM CD3340B/YB4411 Oil Flow - Vertical Outrigger Extend (Right) and Retract (Left) (Optional Independently Outriggers) FIGURE 4-13 a0752 Published 04/07/2015 Control # 569-00 4-26...
Page 77: Outrigger Valve
CD3340B/YB4411 HYDRAULIC SYSTEM Outrigger Valve Outrigger Valve Ports For easy identification the ports are given in alphabetical Description sequence, starting at the ports nearest the inlet and relief The outrigger valve consists of a manifold, relief valve, and valve. either four or eight solenoid valves, depending upon which Table 4-7 outrigger system is used on the crane.
Page 78: Counterbalance Valves
HYDRAULIC SYSTEM CD3340B/YB4411 Table 4-8 Counterbalance Valves Function The vertical (jack) outrigger cylinders have load-holding Port Sol. Wire (Under High Pressure) (counterbalance) valves installed in the base of the cylinder. The purpose of these valves is to inhibit the cylinder from Left Front Outrigger Up retracting if a hydraulic hose breaks.
Page 79: Vertical Outrigger Cylinder Leakage Test
CD3340B/YB4411 HYDRAULIC SYSTEM When the pressure is high enough to overcome the spring in the counterbalance valve plus the pressure in the cylinder base end, the counterbalance valve opens and the cylinder retracts. If the cylinder starts to retract too rapidly, for example, because of heavy load on the cylinder, pilot pressure from the rod end of the cylinder decreases and the load-holding valve closes.
Page 80 HYDRAULIC SYSTEM CD3340B/YB4411 it is filtered through a 10 micron (absolute) or less Adjust the pump to deliver system pressures. Follow the filter. instruction under “Adjusting Hydraulic Pressure Settings,”. The pump will fill with hydraulic oil when the tank is filled. The air in the pump will work itself back to tank.
Page 81: Main Control Valve
CD3340B/YB4411 HYDRAULIC SYSTEM Main Control Valve Disassembly Complete Valve Assembly General Place the valve assembly on the work bench and The main control valve is designed with very close remove all hydraulic fittings. tolerances between the spools and the valve bores. Dirt, chips or sludge can cause these surfaces and seals to wear Position the valve with the load sense section (8, and result in internal leakage, sticking spools or both.
Page 82 HYDRAULIC SYSTEM CD3340B/YB4411 Item Description Inlet/Outlet Section Working Section Shut-off Plug (5) Working Section Working Section Port Relief Valve Working Section Load Sense Section Studs (2) Nut (4) Stud Nut (2) Load Sense Relief Valve Anti-Void Valve Relief Valve Mid-Inlet Section O-ring (8) O-ring (4) Backup Ring (4)
Page 83 CD3340B/YB4411 HYDRAULIC SYSTEM Slowly loosen spool end shoulder screw (30). The screw Place the first spool valve section (2) (Swing), O-ring is under pressure from spring (21), be sure to hold the side up over the studs onto inlet section (1). Place O-ring spring seats (31) and spring (21) when removing screw (24) in position on the face of the valve section.
Page 84: Outrigger Control Valve
HYDRAULIC SYSTEM CD3340B/YB4411 should be smooth and free of nicks, scratches or grooves. If operating difficulties indicate that the pilot poppet is leaking Examine O-rings and backup washers for any damage and or sticking, remove internal parts of the pilot section, and replace if necessary.
Page 85 CD3340B/YB4411 HYDRAULIC SYSTEM Standard Outriggers - Remove the side panel to gain If the complete valve assembly must be removed, tag all access to the valve area (Figure 4-20). hydraulic lines for correct assembly. Clean the valve and connecting lines. Disconnect the hydraulic lines from the Independent Outriggers - Access to the valves can be valve ports.
Page 86: Swing Motor
HYDRAULIC SYSTEM CD3340B/YB4411 Installation ports then use a wire brush to remove foreign material and debris from around the external joints If complete valve assembly is being installed, put the of the motor. Check the shaft and key slot, remove valve assembly in position and secure it with four all nicks, burrs or sharp edges that might damage capscrews, washers and nuts.
Page 87 CD3340B/YB4411 HYDRAULIC SYSTEM Item Description Screw (4) Exclusion Seal Mounting Flange Backup Ring* Shaft Pressure Seal * Seal* Bearing Race Thrust Needle Bearing Output Shaft Housing O-ring Plug Seal (3)* Drive Shaft Spacer Plate Gerotor Set End Cap Seal Washer (7)* Screw (7) * Included In Seal Kit FIGURE 4-24...
Page 88 HYDRAULIC SYSTEM CD3340B/YB4411 Inspection/Cleaning Check all mating surfaces. Replace any parts with scratches or burrs that could cause leakage or damage. Clean all metal parts in a suitable solvent. Blow dry with air. Do not wipe parts with a cloth or paper towels, because lint or other matter could get into the hydraulic system and cause damage.
Page 89 CD3340B/YB4411 HYDRAULIC SYSTEM Output Shaft Needle Thrust Bearing Shaft Pressure Seal Seal Driver Lubricate these Areas Bearing Race Exclusion Seal Seal Tube FIGURE 4-29 a0768 Install needle thrust bearing (8), then bearing race (7) on shaft (9). Pull shaft partially out of housing. Push all Mounting three parts in housing (10) together (See Figure 4-29).
Page 90 HYDRAULIC SYSTEM CD3340B/YB4411 NOTE: To aid installation of seals, apply a light coat of clean petroleum jelly to seals. Do not stretch the Place Tip of seals before installing them in a groove. Applicator at Top of Threaded Portion 13. Pour approximately 1 ounce (35 mm) of clean hydraulic oil in the output shaft cavity.
Page 91: Hoist Motor
CD3340B/YB4411 HYDRAULIC SYSTEM hydraulic lines from the hoist motor. Put caps and plugs on the hoses and ports to keep dirt out. Loosen remove capscrews lockwashers securing the motor to the hoist. Remove the hoist motor and gasket. Discard the gasket. Remove the adapter flanges, spacer block and line mount body (Figure 4-35) from the pump.
Page 92: Hydraulic Swivel
HYDRAULIC SYSTEM CD3340B/YB4411 Hydraulic Swivel Inspection Wash the housing and shaft in a suitable solvent. Check the Removal housing for damage. If there is scoring or deep grooves, the NOTE: The area around the swivel and the swivel must be housing must be replaced.
Page 93 CD3340B/YB4411 HYDRAULIC SYSTEM Item Description Flat Head Screw (3) Flange O-ring* Thrust Washer* Swivel Housing Seal (2)* Swivel Stem Seal (8)* O-ring (8)* * Included in Seal Kit FIGURE 4-36 a0962 GROVE Published 04/07/2015 Control # 569-00 4-43...
Page 94: Hydraulic Cylinders
HYDRAULIC SYSTEM CD3340B/YB4411 NOTE: Do not stretch the seal too far. The seal will not Installation return to its original shape. If the seal diameter is Put the hydraulic swivel in place on the machine. Fasten too large, damage to the seal will occur when the the hydraulic swivel to the brackets in the mast using spool is installed into the housing.
Page 95 CD3340B/YB4411 HYDRAULIC SYSTEM Put the ports of the cylinder down to drain the oil from Assembly the cylinder. Install new rings, rod wiper and seals on the head gland. Fasten the base of the cylinder in a vise with soft jaws. See cylinder illustrations for location and correct Place a support under the rod so the cylinder is level.
Page 96 HYDRAULIC SYSTEM CD3340B/YB4411 pressure for a minimum of 10 seconds. Visually check Installation for internal and external leakage. No internal or external Install the cylinder on the machine using the correct leakage is permitted. mounting hardware. Fully extend the cylinder rod. Keep the rod port open. Connect the hydraulic lines.
Page 97 CD3340B/YB4411 HYDRAULIC SYSTEM Use Loctite 243 and Tighten to a Torque of 1200 lb-ft (1632 Nm) Item Description3 Item Description3 Cylinder Tube Wear Ring (2)* Wear Ring (2) Gland Seal* Seal* Loader* Wiper* Piston Cylinder Rod O-ring* Bushing (4) O-ring* Back-Up Ring* * Include In Seal Kit FIGURE 4-38...
Page 98 HYDRAULIC SYSTEM CD3340B/YB4411 Item Description Cylinder Tube Tighten to a Torque of Piston Nut 1200 lb-ft (1632 Nm) Wear Ring (2)* Seal* Loader* Piston O-ring* Spacer O-ring* Back-Up Ring* Wear Ring* Gland Seal* Wiper* Cylinder Rod * Include In Seal Kit FIGURE 4-39 a0754 Published 04/07/2015 Control # 569-00...
Page 99 CD3340B/YB4411 HYDRAULIC SYSTEM Item Description Cylinder Tube Piston Nut Wear Ring (2)* O-ring* Tighten to a Torque of 100 Seal* lb-ft (759 Nm) Piston O-ring* O-ring* Back-Up Ring* Gland Seal* Wiper* Cylinder Rod * Include In Seal Kit FIGURE 4-40 a0756 GROVE Published 04/07/2015 Control # 569-00...
Page 100 HYDRAULIC SYSTEM CD3340B/YB4411 Item Description Cylinder Tube Piston Nut Piston Wiper* O-ring* Seal* O-ring Tighten to a Torque of 100 O-ring lb-ft (759 Nm) Back-Up Ring Gland Seal* Wiper* Cylinder Rod * Include In Seal Kit FIGURE 4-41 a0757 Published 04/07/2015 Control # 569-00 4-50...
Page 101: Under Deck Winch
CD3340B/YB4411 HYDRAULIC SYSTEM UNDER DECK WINCH activated three position directional control valve to provide directional control and a two-position control valve to supply The under deck winch is connected to the front outrigger oil flow. control manifold. Hydraulic oil flows through an electrically GROVE Published 04/07/2015 Control # 569-00 4-51...
Page 102 HYDRAULIC SYSTEM CD3340B/YB4411 Published 04/07/2015 Control # 569-00 4-52...
Page 103 LUBRICANTS AND CAPACITIES ENVIRONMENTAL PROTECTION It is not the policy of Manitowoc, Inc. to publish lists of Dispose of waste properly! Improperly disposing of waste approved lubricants or to guarantee lubricant performance. can threaten the environment.
Page 104: Maintenance Records
MAINTENANCE CD3340B/YB4411 completely with the distributor or manufacturer of the Maintenance Records lubricant. Dated records must be kept for inspection of critical In various paragraphs of this manual, statements may be components such as, brakes, crane hooks, wire ropes, found, “Use (lubricant brand name) or equivalent.” This hydraulic cylinders and relief valve pressure settings.
Page 105: After First 50 Hours Of Operation (New Cranes)
CD3340B/YB4411 MAINTENANCE Chart 1. Recommended Planetary Gear Oil After First 50 Hours of Operation (New Cranes) Table 5-2 Engine Change the engine oil and filter Transmission Change the transmission oil filter Swing Gearbox Check and tighten mounting bolts Hoist Gearbox Check and tighten mounting bolts Swing Gear Pinion and Swing Gear Lubricate...
Page 106 MAINTENANCE CD3340B/YB4411 INTERVAL Daily SERVICE/CHECK See Page 1000 2000 Before Hours Hours Hours Hours Hours Hours Operation Inspect Reeving, Clamps and 5-13 Connections Inspect The Lifting Hook 5-13 Inspect Safety Devices 5-13 Check Controls Operation 5-13 Check Engine Crankcase Oil Level 5-14 Check Transmission Oil Level 5-14...
Page 107 CD3340B/YB4411 MAINTENANCE INTERVAL Daily SERVICE/CHECK See Page 1000 2000 Before Hours Hours Hours Hours Hours Hours Operation Add Grease to Swing Gearbox 5-27 Replace Fuel Filter Elements (Diesel) 5-27 Replace In-Line Fuel Filter 5-27 Inspect the Parking Brake Pads 5-26 Inspect Tires for Damage 5-26 Check SCA level in cooling system...
Page 108: Lubricants
MAINTENANCE CD3340B/YB4411 LUBRICANTS Lube Symbol Description Specification EP-MPG EP-MPG- Multipurpose Grease A6-829-003477 AFC- Anti-freeze/coolant A6-829-101130 HYDO Hydraulic Oil A6-829-006444 HTF- Hydraulic Transmission Fluid 80057784 EO-15w-40 EO-15w-40- Engine Oil A6-829-104182 Anti-Seize Compound A6-829-003689 EP-OGL Open Gear Lube Ceplattyn 300 Spray A6-829-102971 EPGL-5 EPGL-5- Gear Lubricant A6-829-003479...
Page 109: Lubrication Points
CD3340B/YB4411 MAINTENANCE LUBRICATION POINTS 8504 FIGURE 5-1 Location Name Capacity Symbol Instruction Front Drive/steer Axle Differential 2.1 Gal (8 Liters) HYDO Planetary Hub Gears 0.21 Gal (0.8 Liters) HYDO Kingpin Bearings EP-MPG Steer Cylinder Bearing EP-MPG Universal Joints EP-MPG Brake Caliper EP-MPG GROVE Published 04/07/2015 Control # 569-00...
Page 110 MAINTENANCE CD3340B/YB4411 Location Name Capacity Symbol Instruction Rear Steer Axle Hub Bearings EP-MPG Kingpin Bearings EP-MPG Steer Linkage Bearing EP-MPG Steering Cylinder EP-MPG Engine & Trans. Engine Crankcase 5.8-7.4 Qts (5.5-7.0 L) EO-15W-40 See Note 4 Engine Coolant 3.7 Gal (13.9 Liters) See Notes 2 &...
Page 111: Grease Fittings
10. Engine coolant capacity listed is the combined capacity for coolant in the engine and radiator. 5. The hydraulic oil shall meet or exceed manitowoc cleanliness spec. 6829014631. Grease Fittings Apply grease to the following fittings after every 50 hours of operation. Use a Lithium Base, E.P. No. 2 bearing grease or equivalent.
Page 112 MAINTENANCE CD3340B/YB4411 p0498 Mast Bearing Two Fittings Located on Inside Lube Points Surface of Bearing Ring Boom FIGURE 5-2 FIGURE 5-5 p0305 Head Lube Both Sides p0470 a0611 Boom Pivot FIGURE 5-3 p0306 Lube Points Both Sides p0469 Extend Chain Roller Lube Points FIGURE 5-6 a0612 Retract Chain Roller Lube Points...
Page 113 CD3340B/YB4411 MAINTENANCE p0307 Both Sides Steering Cylinder Pivot Lube FIGURE 5-10 p0309 Points - Base End (Rear Axle) Lift Cylinder Lube Points FIGURE 5-7 p0308 Steering Link Pivot Lube Points Both Sides (Rear Axle) Both Sides Steering Knuckle Lube Points p0310 FIGURE 5-11 FIGURE 5-8...
Page 114 MAINTENANCE CD3340B/YB4411 p0312 FIGURE 5-13 Drive Shaft Lube Points Boom Extension Head FIGURE 5-16 Sheave Lube Point p0315 p0313 FIGURE 5-14 Parking Brake Lube Point Boom Extension Deflector FIGURE 5-17 Sheave Lube Point p0316 Drop Block FIGURE 5-15 p0447 Published 04/07/2015 Control # 569-00 5-12...
Page 115: Scheduled Maintenance
CD3340B/YB4411 MAINTENANCE SCHEDULED MAINTENANCE Do not operate the crane if any of the above is found. Only after correcting the problem should the crane be put back in Daily (Walk-around) service. Inspect the Lifting Hook NOTE: You must read and understand the warnings and basic safety rules, found in Section 1, Introduction of this manual, before performing any operation or maintenance procedures.
Page 116 MAINTENANCE CD3340B/YB4411 Check the Transmission Oil Level W0015 Check the oil when the oil is cold. Level the crane, engage the parking brake and shut off the engine. Open and support the engine compartment cover. Remove the transmission dipstick (Figure 5-20) and check the oil level.
Page 117 CD3340B/YB4411 MAINTENANCE Level the crane, engage the parking brake and shut off the engine. W0017 Look through the grate behind the engine, coolant should be visible in the sight gauge (Figure 5-22). If level is low, add only a 50-50 mixture of glycol antifreeze and water, do not add only water as this could cause rust to form in the radiator and engine.
Page 118 MAINTENANCE CD3340B/YB4411 Check the Air Cleaner Restriction Indicator Inspecting the Element Don’t be fooled by the appearance of the element, it The air cleaner is equipped with a filter restriction indicator should look dirty. (Figure 5-25). The air cleaner element needs replacing if the indicator’s colored piston has popped out and is visible when Check the element for uneven dirt patterns.
Page 119: 50 Hours Of Operation/Weekly
CD3340B/YB4411 MAINTENANCE 50 Hours of Operation/Weekly • It makes possible the discovery and correction of faults in equipment or operation that can cause costly NOTE: You must read and understand the warnings and accelerated rope wear. basic safety rules, found in Section 1 of this Inspection manual, before performing any operation or maintenance procedures.
Page 120 MAINTENANCE CD3340B/YB4411 Apply bronze anti-seize, or equivalent, to the inner boom retract the booms to distribute the lubricant along the surface in front of and behind the slide block. Only use a slide path. small amount of lubricant for best results. Extend and a0590 Reduction from Normal Evidence of Heat Damage...
Page 121: 100 Hours Of Operation
CD3340B/YB4411 MAINTENANCE The boom retract chain is lubricated through the access holes in the boom. Align the holes to expose sections of the boom chain. Each section must be lubricated as directed below. NOTE: Use a good grade of spray chain lubricant. If none is available, use preheated oil (15°...
Page 122: 250 Hours Of Operation/Monthly
MAINTENANCE CD3340B/YB4411 Any cracking on V-belts is not acceptable. Replace any a0158 V-belt that has cracking. See Figure 5-32 Cracked Plates (Fatigue) a0589 Replace Belt FIGURE 5-33 b. Distortion or spreading of an outside link plate, evidenced by increasing clearance between overlapping link plates, or between the inner link plates and the roller.
Page 123 CD3340B/YB4411 MAINTENANCE a0161 Turned Pin FIGURE 5-36 Inspect the Boom Chain Tension The boom chains should be checked for the correct tension Pry Nut Away From Bulkhead Plate to ensure proper retraction of the boom sections. FIGURE 5-38 p0322 Lower Retract Chain Inspect Hydraulic Hoses To check for correct tension on the lower retract chain loosen t h e j a m n u t o n t h e r e t r a c t c h a i n a d j u s t i n g s c r e w...
Page 124 MAINTENANCE CD3340B/YB4411 Open the battery compartment cover (Figure 5-42). a0591 a0299 FIGURE 5-42 FIGURE 5-40 Tighten all battery mounting hardware to keep the Clean Battery and Cables battery securely in place. Disconnect the battery cables. w0019 Sprinkle the top of the battery with baking soda. Apply water to wash the baking soda from battery.
Page 125 CD3340B/YB4411 MAINTENANCE 100°F) will help the oil penetrate into the wire rope. Use Replace the Crankcase Oil and Filter a brush or cloth to apply the oil. Change the engine oil more frequently if operating under NOTE: Be sure the lubricant enters the strands of the wire difficult conditions, for example in high or low temperatures, rope for proper lubrication.
Page 126 MAINTENANCE CD3340B/YB4411 Swing Gearbox Mounting Bolts p0323 Torque the 1/2” gearbox mounting bolts (4) seeTorque Values page 1-9. Refer to Figure 5-46 for bolt locations. p0324 FIGURE 5-45 Four Bolts Four Bolts FIGURE 5-46 Published 04/07/2015 Control # 569-00 5-24...
Page 127 CD3340B/YB4411 MAINTENANCE Mast Mounting Bolts p0325 Because of the cyclic loading on the mast bolts, it is important that these bolts be checked at regular intervals. Make a record of any loose bolts. If any bolt does not hold to correct torque after the second check, remove and replace the bolt.
Page 128: 500 Hours Of Operation/Three Months
MAINTENANCE CD3340B/YB4411 p0326 p0328 FIGURE 5-51 Both Sides FIGURE 5-49 Mast Mounting Bolts 500 Hours Of Operation/Three Months Front Axle Mounting Bolts NOTE: You must read and understand the warnings and NOTE: It is necessary to climb under the crane to check basic safety rules, found in Section 2 of this the axle mounting bolts.
Page 129 CD3340B/YB4411 MAINTENANCE Replacing Fuel Filter See the engine operator’s manual furnished with the crane and follow the replacement procedures. NOTE: If the filter is not filled with fuel prior to installation, the engine will not start due to air in the fuel system.
Page 130 MAINTENANCE CD3340B/YB4411 Apply Lithium Base, E.P. No. 2 bearing grease to the fitting. Fill gear box until grease exits the check plug p0459 hole. Install the check plug. Check the Axle Housing Lubricant Level It is necessary to climb under the crane to check the axle housing lubricant level.
Page 131: 1000 Hours Of Operation/Six Months
CD3340B/YB4411 MAINTENANCE p0321 p0321 Breather Check Plug FIGURE 5-59 FIGURE 5-60 Location Remove the check plug (Figure 5-58). Check the lubricant level, which should be level with the bottom of the check plug hole. DANGER Failure to use the proper type and viscosity of planetary gear oil may contribute to intermittent brake clutch slippage which could result in property damage, severe DANGER...
Page 132 MAINTENANCE CD3340B/YB4411 Place suitable container under strainer Clean the strainer in a suitable solvent. (Figure 5-61). Remove the strainer and gasket and drain Install the cleaned strainer and a new gasket. Tighten the oil into the container. Discard the gasket. the strainer mounting bolts to a torque of 7.4 lb-ft (10 Nm).
Page 133 CD3340B/YB4411 MAINTENANCE Place a container under the differential drain plug p0319 (Figure 5-64). Remove the drain plug and drain the fluid into the container. Install the drain plug. P0334 Axel Housing FIGURE 5-66 Check/Fill Plugs Fill the differential and brake housings with appropriate oil through both check fill plugs.
Page 134 MAINTENANCE CD3340B/YB4411 Remove the fill/check plug (Figure 5-70). p0459 Place a suitable container under the drain plug. p0320 Fill/Check Plug Breather FIGURE 5-70 Using a ratchet wrench with an extension and a 3/8” hex Fill Position FIGURE 5-68 wrench attached, remove the drain plug. Allow the fluid to drain into the container.
Page 135: Replace The Hoist Gearbox Lubricant (Braden Model)
CD3340B/YB4411 MAINTENANCE Place a suitable container under the brake drain plug (Figure 5-72). Clean around the drain plug and then remove the plug and allow the fluid to drain into the container. p0337 FIGURE 5-73 Brake Drain Plug FIGURE 5-72 Install a 1”...
Page 136 MAINTENANCE CD3340B/YB4411 Level the crane, engage the parking brake, shut off the engine and remove the ignition key. Place a suitable container under the hydraulic pump, DANGER located in front of the engine. Failure to use the proper type and viscosity of planetary Loosen the suction hose clamp at the hydraulic pump.
Page 137: 2000 Hours Of Operation/Yearly
CD3340B/YB4411 MAINTENANCE 16. Fill the hydraulic tank with Mobil #424 hydraulic oil to the bottom of fill stainer or to sight gauge. w0022 17. After the tank is filled, start the engine and operate each function until all the cylinders and lines are filled. 18.
Page 138: Miscellaneous Maintenance
MAINTENANCE CD3340B/YB4411 Replace the Engine Coolant • Provide ventilation and wear safety glasses. • Never check battery charge by placing a metal w0020 object across the posts. The sparks could explode battery gases and cause injury or death. Use a voltmeter or hydrometer. w0019 Open and prop in place the engine compartment cover.
Page 139 CD3340B/YB4411 MAINTENANCE Replacing the Battery Fuel System NOTE: The fluid in electric storage batteries contains w0015 sulfuric acid, which is a POISON and can cause SEVERE CHEMICAL BURNS. Avoid all contact of fluid with eyes, skin or clothing. Use proper protective gear when handling batteries.
Page 140: Carwell® Rust Inhibitor
While the surfaces of the crane that are easily seen have the biggest impact on the appearance of the crane, particular Manitowoc Crane Group's cranes are manufactured to high attention should be given to the undercarriage of the crane to quality standards, including the type of paint finish minimize the harmful effects of corrosion.
Page 141: Inspection And Repair
• Cover all bare metal with a primer that is compatible with the original paint finish and allow to dry thoroughly. Please contact Manitowoc Crane Care should you have any questions. • Prepare the surface prior to applying the finish coat of paint.
Page 142 MAINTENANCE CD3340B/YB4411 unpainted fasteners and hardware, valves, slew ring • All hardware, clips, pins, hose connections not painted fasteners and all bare metal surfaces. will have treatment applied. • Boom applications areas are; pivot pins, hose end and fittings, jib pins and shafts, all bare metal surfaces, headache ball pins/ hook block pins and fasteners.
Page 143 CD3340B/YB4411 MAINTENANCE Item Description Turntable Bearing Fasteners Item Description O/R Pins, Clips Hoist Tension Spring Hook block Tiedown Cable Hoist Hose Connections O/R Hose Connections Pivot Shaft Entire underside of unit Wire Rope Powertrain Hardware inside compartment Hose Connections inside turntable Boom Extension Pins, Clips - Option All Hardware, Clips, Pins, Hose Connections not painted O/R Pins, Clips...
Page 144 MAINTENANCE CD3340B/YB4411 Published 04/07/2015 Control # 569-00 5-42...
Page 145: General
CD3340B/YB4411 ENGINE AND ENGINE SYSTEMS SECTION 6 ENGINE AND ENGINE SYSTEMS SECTION CONTENTS General ........6-1 Fuel Pump .
Page 146: Engine Cooling System
ENGINE AND ENGINE SYSTEMS CD3340B/YB4411 Do not use “break-in” lubricating oils in new or rebuilt ENGINE COOLING SYSTEM engines. Only use lubricating oils specified for normal engine The engine cooling system consists of the coolant passages operation. in the engine, a thermostat, water pump, hoses and radiator. Oil Viscosity Recommendations The engine is cooled by the circulation of coolant through the The use of a multigrade lubricating oil improves oil...
Page 147: Thermostat
CD3340B/YB4411 ENGINE AND ENGINE SYSTEMS gasket. These holes are orifices and their size is critical. Do not enlarge the size of the orifices. To do 8465-4 so will disturb the coolant flow and will not solve any overheating problem. If you use water without a corrosion inhibitor for even a short period, the cup plugs will rust through, allowing coolant leakage.
Page 148: Types Of Fuel To Use
ENGINE AND ENGINE SYSTEMS CD3340B/YB4411 Types of Fuel to Use A0321 Fuel represents the major portion of the crane’s operating costs. Therefore, it is important to use it efficiently. Don’t let cost tempt you to use an inferior diesel fuel. The savings is a false economy when you consider the damage poor fuel can do to your crane’s engine.
Page 149: Engine Exhaust System
CD3340B/YB4411 ENGINE AND ENGINE SYSTEMS Replace the air filter at the regular maintenance intervals. Exhaust system components get very hot and can cause Make sure all clamps on the intake tube and filter are tight. If severe burns. dust or foreign materials enter the engine, permanent The exhaust system is installed under the frame to minimize damage can be caused to the engine.
Page 150: Removal And Installation
ENGINE AND ENGINE SYSTEMS CD3340B/YB4411 Problem Probable Cause Action Engine overload. Reduce the load. Intake air restriction. Service air cleaner. Clogged fuel filters. Replace fuel filters. Lack of power. Overheated engine. See Engine Operators Manual. Check for plugged radiator/oil cooler fins. Below normal engine temperature.
Page 151: Installation
CD3340B/YB4411 ENGINE AND ENGINE SYSTEMS 15. If equipped, remove the optional cold start kit from the NOTE: Have a fire extinguisher handy and know how to bracket inside the chassis frame. use it before performing the next step. 16. Disconnect the engine ground cable from the engine or Connect the fuel lines to the engine.
Page 152: Engine Pump And Bracket Removal And Installation
ENGINE AND ENGINE SYSTEMS CD3340B/YB4411 ENGINE PUMP AND BRACKET REMOVAL Set the machine on a level, firm surface. AND INSTALLATION Extend and lower each outrigger. Place a block under each outrigger pad to raise the machine for easy access NOTE: In the following section the illustration and photos to the pump and brackets.
Page 153 CD3340B/YB4411 ENGINE AND ENGINE SYSTEMS 8472-1 Item Description Primary Hydraulic Pump Drive Coupling Pump Mount Plate Coupling Sleeve Engine Coupling Hub Pump Coupling Hub Hex Head Capscrew (6) Pump Support Bracket Socket Head Capscrew (4) Spacer (2) Item Description Flat Washer Flat Washer (6) Socket Head Capscrew (2) Socket Head Capscrew (2)
Page 154: Installation
ENGINE AND ENGINE SYSTEMS CD3340B/YB4411 12. Attach a hook and chain to the engine and overhead 20. Remove six capscrews (17) and drive coupling (2). crane as shown in Figure 6-5. Between the chain and Installation overhead crane, attach a come-along. NOTE: The following figures show the engine mounted in p1432...
Page 155 CD3340B/YB4411 ENGINE AND ENGINE SYSTEMS the engine block on both sides (Figure 6-8). Do not Test fit the pump coupling hub (6, Figure 6-4) onto the tighten the bolts. pump shaft. It should slide on by hand. Then, insert the pump coupling hub (6) into coupling sleeve (4).
Page 156 ENGINE AND ENGINE SYSTEMS CD3340B/YB4411 12. Install pump (1, Figure 6-4) as shown. Apply Loctite® p1419 243 to the threads of capscrews (21, Figure 6-4). Attach the pump with capscrews (21), lockwashers (22), and flat washers (23). Tighten the capscrews to a torque of 87 Nm (64 lb-ft).
Page 157 CD3340B/YB4411 TRANSMISSION AND TORQUE CONVERTER SECTION 7 TRANSMISSION AND TORQUE CONVERTER SECTION CONTENTS Technical Data ......7-1 Solenoid Identification .
Page 158 TRANSMISSION AND TORQUE CONVERTER CD3340B/YB4411 Converter Pressures (in neutral): PSI......Bar Converter IN at 122°F (50°C) 1000 rpm 40-60......2.8-4.1 2000 rpm. 70-90.......4.8-6.2 Converter OUT at 122°F (50°C) PSI......Bar 1000 rpm 27-33......1.9-2.3 2000 rpm 33-39.......2.3 - 2.7 Converter Inlet Relief Valve Pressure (Max.) 95......6.5 Lubrication Pressures (in neutral) PSI......Bar...
Page 159: Description Of Operation
CD3340B/YB4411 TRANSMISSION AND TORQUE CONVERTER DESCRIPTION OF OPERATION leakage in the seals and gaskets of the torque converter. Do not continue operation if the Torque Converter temperature increases above 82° - 88°C (180° - 190°F). A warning light on the cab instrument panel The torque converter (Figure 7-1) is the hydraulic link will illuminate when the temperature rises above a between the engine and the drive train.
Page 160 TRANSMISSION AND TORQUE CONVERTER CD3340B/YB4411 A0799 Item Description Torque Converter Input Clutch Assembly Forward Clutch Assembly Main Shaft Assembly Layshaft Assembly 4 WD Clutch Assembly (Not used) 3-Position Solenoid Valve (Reverse Travel) Input Shaft Parking Brake Disc Spined Output Shaft 3-Position Solenoid Valve (Forward Travel) 3- Position Solenoid Valve (Mainshaft/ Layshaft Pump...
Page 161: Hydraulic Operation
CD3340B/YB4411 TRANSMISSION AND TORQUE CONVERTER Hydraulic Operation Excess oil from the maintenance valve flows through the casing to the torque converter. Oil enters the converter When the Powershift Transmission is operated, multi-disc between the converter hub and stator support, and leaves clutch packs are pressurized and engaged.
Page 162 TRANSMISSION AND TORQUE CONVERTER CD3340B/YB4411 A0784 Two-Wheel Drive Transmission Hydraulic Circuits Item Description Torque Converter Reverse Low Ratio Clutch Layshaft Drive Clutch 3-Position Solenoid Valve (Reverse) Input Shaft 3-Position Solenoid Valve (Mainshaft/Layshaft) Pump Pressure Maintenance Valve Adapter Block Relief Valve Oil Cooler Pipe Cluster Restrictor Orifices...
Page 163: Drive Paths
CD3340B/YB4411 TRANSMISSION AND TORQUE CONVERTER Drive Paths The drive paths and engaged clutches for the four forward and four reverse drive speeds are shown on the following pages. Clutch Identification Solenoid Identification (Figure 7-4) (Figure 7-4) Item Description Item Description Reverse Low Ratio Clutch Reverse Low Solenoid Reverse High Ratio Clutch...
Page 164 TRANSMISSION AND TORQUE CONVERTER CD3340B/YB4411 Drive Paths - Forward 3rd Gear Forward 1st Gear Forward Clutches Engaged Clutches Engaged C1 - Forward Low Ratio C1 - Forward Low Ratio D - Mainshaft Solenoids Active E - Layshaft Solenoids Active L1 - Forward Low Ratio M2 - Mainshaft L1 - Forward Low Ratio M1 - Layshaft...
Page 165 CD3340B/YB4411 TRANSMISSION AND TORQUE CONVERTER Drive Paths - Reverse 3rd Gear Reverse 1st Gear Reverse Clutches Engaged B1 - Reverse Low Ratio Clutches Engaged D - Mainshaft B1 - Reverse Low Ratio Solenoids Active E - Layshaft G1 - Reverse Low Ratio Solenoids Active M2 - Mainshaft G1 - Reverse Low Ratio...
Page 166: Clutch Operation
TRANSMISSION AND TORQUE CONVERTER CD3340B/YB4411 Clutch Operation clutch is vented back to tank through the solenoid valve spool. The transmission’s reverse high and reverse low clutch NOTE: The forward high and forward low clutch assembly assemblies (Figure 7-5) are operated by the double solenoid operates the same way.
Page 167: General Troubleshooting
CD3340B/YB4411 TRANSMISSION AND TORQUE CONVERTER TROUBLESHOOTING General Troubleshooting Problem Possible Cause Remedy Poor engine condition. Check and repair engine if necessary. Low oil level. Add oil to transmission. Worn pump. Check, repair or replace the pump. Torque converter damaged. Check and replace the torque converter. Low mainline pressure.
Page 168 TRANSMISSION AND TORQUE CONVERTER CD3340B/YB4411 Problem Possible Cause Remedy Low oil level. Add oil to transmission. Low Pump Flow Blocked suction strainer. Clean suction strainer. Worn pump. Repair or replace the pump. High Converter Out Oil cooler/lines blockage. Clean cooler, remove blockage. Pressure Low mainline pressure.
Page 169 CD3340B/YB4411 TRANSMISSION AND TORQUE CONVERTER Problem Possible Cause Remedy Low oil level. Add oil to transmission. High oil level. Drain oil to correct level. Pinched or kinked hoses in Repair or replace hoses. cooler system. Low converter out pressure Repair or replace the converter relief valve. and flow rate.
Page 170 TRANSMISSION AND TORQUE CONVERTER CD3340B/YB4411 Troubleshooting (Electrical) Table 7-1 Solenoid Valve Energizing Sequence System Operation Gear Direction Valves Each powershift transmission is provided with electrical First Forward FL and LS safety locks which inhibit inadvertent operation of the machine while in an unsafe condition. Second Forward FH and LS...
Page 171 CD3340B/YB4411 TRANSMISSION AND TORQUE CONVERTER A0796 FIGURE 7-8 GROVE Published 04/07/2015 Control # 569-00 7-15...
Page 172 TRANSMISSION AND TORQUE CONVERTER CD3340B/YB4411 Electrical Troubleshooting Chart Problem Possible Cause Remedy Blown ECU fuse. Check ECU fuse (also check fuse to shift lever.) No drive at engine start up. ECU connector loose. Check that connector is mating correctly with ECU.
Page 173 CD3340B/YB4411 TRANSMISSION AND TORQUE CONVERTER Finding Electrical Problems The correct operation can be confirmed as follows: Chock the wheels. It is possible to carry out a large portion of the ECU diagnostics with basic workshop tools, such as a test lamp Disable the machine neutral start protection to prevent and/or voltmeter.
Page 174 TRANSMISSION AND TORQUE CONVERTER CD3340B/YB4411 Checking for (+ V) Supply to Solenoids Checking the Instrument Panel Harness Chock all four tires, or lower all outriggers. NOTE: The following checks should be carried out with the parking brake DISENGAGED. Disable the machine neutral start protection to prevent the engine from starting.
Page 175 CD3340B/YB4411 TRANSMISSION AND TORQUE CONVERTER Table 7-2 Instrument Panel Wire Harness Check See Notes Below Key for the table: Full battery charge No voltage measured with key On N.C. Pin not connected Forward Gears Reverse Gears Pin No. Function Jumps to 10 N.C.
Page 176 TRANSMISSION AND TORQUE CONVERTER CD3340B/YB4411 Checking Parking Brake Switch passes the front of the sensor, the meter should be registering 12 VDC. If it does not register 12 VDC, The correct operation of the parking brake can be checked replace the speed sensor. using either of the following tests: While the sensor is removed, check the sensor for Check continuity between pin 8 and ground (pin 11 or...
Page 177: Testing
CD3340B/YB4411 TRANSMISSION AND TORQUE CONVERTER The speed sensor is inoperable (Check speed sensor Table 5-3 and installation. Solenoid Description Shift control switch contact or wiring problems. Item Solenoid Description Reverse Low Erratic / Sticking Gears Reverse High It is possible that a mechanical issue is the cause of this problem.
Page 178 TRANSMISSION AND TORQUE CONVERTER CD3340B/YB4411 are working normally (1 and 3 gear selection show normal operating pressures). So it can be assumed that the forward high clutch is leaking. We can now confirm the forward reverse clutch is leaking by completing an Individual Clutch Leakage Test.
Page 179 CD3340B/YB4411 TRANSMISSION AND TORQUE CONVERTER Item Description 1901976 1901978 1901977 1901979 Test Points Item Description Item Description Mainline Pressure Reverse low ratio clutch pressure Converter inlet/converter relief valve pressure Lubrication Pressure Converter outlet pressure Cooler flow (flowmeter in line from cooler to transmission) Mainshaft clutch pressure Forward high ratio clutch pressure Layshaft clutch pressure...
Page 180 TRANSMISSION AND TORQUE CONVERTER CD3340B/YB4411 Individual Clutch Leakage Test greater than 0.7 bar (10 psi), service the reverse high clutch. In the following procedures the reverse clutch is tested, If after interchanging the gauges, the readings are therefore, in Step 2 a pressure gauge is connected to the different than in step 4, have the gauges calibrated reverse high clutch test point.
Page 181: Pressure And Flow Tests
CD3340B/YB4411 TRANSMISSION AND TORQUE CONVERTER In the example shown, the engine speed is abnormally high Stop the engine, remove the filter F and filter head when 2 gear forward is selected indicating a slipping clutch. adapter from the transmission. Install a special test adapter X onto the threaded spigot.
Page 182: Transmission Repair
TRANSMISSION AND TORQUE CONVERTER CD3340B/YB4411 Converter In Pressure a0249 See Figure 7-13. Connect a 0-20 bar (0-300 psi) pressure gauge to test point B. Install a load valve P into the converter out line. NOTE: Make sure the load valve is in the OPEN position (the adjusting knob screwed fully out) before P/N 1001834 starting the following pressure test.
Page 183 CD3340B/YB4411 TRANSMISSION AND TORQUE CONVERTER a1386 Item Description 1902712 Seal 1902713 Stake Nut 1902714 Setting Tool Kit 1902715 Torque Wrench 1902737 Space Kit (Includes Spacers Listed Below Item Description Item Description 1902716 Spacer - 12.75 MM 1902729 Spacer - 13.40 MM 1902717 Spacer - 12.80 MM 1902730 Spacer - 13.45 MM 1902718 Spacer - 12.85 MM...
Page 184 TRANSMISSION AND TORQUE CONVERTER CD3340B/YB4411 End Play Checking Kit - P/N 1902739 (Includes Items 2 - 13) Base Plate and Bolts Yoke Mainshaft Adapter Pillar (20.75 mm) Pillar (45.75 mm) Setting Body (54 mm) Setting Body (64 mm) Setting Tool (12 mm) 10.
Page 185: Servicing The Torque Converter
CD3340B/YB4411 TRANSMISSION AND TORQUE CONVERTER Servicing the Torque Converter recommended that the transmission be mounted in a service fixture. Removal The torque converter assembly (4) is fastened to the Remove complete power unit. See Sections 6 and 6A. engine flywheel (11) through a drive plate (7). Remove the six drive plate mounting screws (6) to remove the Fasten engine to an engine stand.
Page 186 TRANSMISSION AND TORQUE CONVERTER CD3340B/YB4411 Installing with Alignment Tool Locate the torque converter and drive plate assembly on the flywheel. Install three bolts to attach the drive plate to Ensure that the flywheel face, drive plate and hardware are the flywheel. Check the converter run-out as shown in B clean and free from burrs or other surface imperfections.
Page 187: Servicing The Transmission
CD3340B/YB4411 TRANSMISSION AND TORQUE CONVERTER each time to align the bolts with the access hole. Removal Re-install access plate. Remove complete power unit. See Engine and Engine Installing without Alignment Tool (Optional) Systems, page 6-1. If the torque converter alignment tool (A) is not available, the Fasten engine to an engine stand.
Page 188 TRANSMISSION AND TORQUE CONVERTER CD3340B/YB4411 WARNING Certain seals and gaskets may contain fluoroelastomeric materials such as Viton, Fluorel and Technoflon. Fluoroelastomeric materials subject to high temperatures can produce highly corrosive hydrofluoric acid. THIS ACID CAN SEVERELY BURN. N e w f l u o r o e l a s t o m e r i c c o m p o n e n t s a t a m b i e n t temperature require no special safety precautions.
Page 189 CD3340B/YB4411 TRANSMISSION AND TORQUE CONVERTER FIGURE 7-28 A0805 FIGURE 7-29 A0806 10. Unscrew four bolts (14, Figure 7-29) and remove the transmission pump assembly (15). GROVE Published 04/07/2015 Control # 569-00 7-33...
Page 190 TRANSMISSION AND TORQUE CONVERTER CD3340B/YB4411 FIGURE 7-30 a0800 7-34 Published 04/07/2015 Control # 569-00...
Page 191 CD3340B/YB4411 TRANSMISSION AND TORQUE CONVERTER Component Identification for Figure 7-30 Figure 7-30 shows all the components which are referred to in the disassembly/assembly procedures. Item numbers correspond with numbers in the instructions and the following illustrations. Item Description Item Description Bolt Case Mounting Bolts Oil Strainer...
Page 192 TRANSMISSION AND TORQUE CONVERTER CD3340B/YB4411 disc back and forth slightly to dislodge the internal components. 22. Remove and discard three O-rings (33, Figure 7-33). CAUTION 23. Tilt and lift out layshaft assembly (T). The transmission weighs approximately 220kg (484 lb) dry.
Page 193 CD3340B/YB4411 TRANSMISSION AND TORQUE CONVERTER 27. Unscrew eleven bolts (35, Figure 7-34) and remove flywheel housing (36). It may be necessary to tap the housing with a soft hammer to release the flywheel from dowels (37). 28. Mark the position of the brake disc (38, Figure 7-35) on the spline output shaft (41).
Page 194 TRANSMISSION AND TORQUE CONVERTER CD3340B/YB4411 Lightly oil output shaft inner bearing (45, Figure 7-38) d. Install special tool pillar C so that the fork end and cup and install to output shaft 41. engages in special tool nut B, tighten bolt D. NOTE: The transmission should be rebuilt with a solid spacer 44, which is the preferred option.
Page 195 CD3340B/YB4411 TRANSMISSION AND TORQUE CONVERTER Remove nut B and sleeve A, Figure 7-41. Install a new seal 42 (apply grease between the lips before installation). Assemble the parking brake flange (38) (the flange may be a tight fit). NOTE: Do not excessively hammer on the flange during assembly because damage to the shaft bearings could occur.
Page 196 TRANSMISSION AND TORQUE CONVERTER CD3340B/YB4411 pillar 12. Tighten the bolt ensuring that the slot in the pillar faces the input shaft. Mount the base plate onto the transmission casing. b. Select adapter tool 13 and screw into the tapped hole in the input shaft. Locate yoke 3 and wrench 11 into the adapter tool 13 and pillar 12.
Page 197 CD3340B/YB4411 TRANSMISSION AND TORQUE CONVERTER FIGURE 7-46 a0817 FIGURE 7-47 a2345 10. Measure the end play of the forward shaft using the end play checking kit (See Figure 7-21). 11. If the end play checking kit is not available, use the following procedure: NOTE: Numbers in Figure 7-47 correspond with numbers...
Page 198 TRANSMISSION AND TORQUE CONVERTER CD3340B/YB4411 d. Calculate the required thickness of shims to give the on at this point, the spacer will be difficult to correct end play, which should be 0.03 - 0.08 mm remove. New O-rings are installed after the correct (0.001 - 0.003 in).
Page 199 CD3340B/YB4411 TRANSMISSION AND TORQUE CONVERTER NOTE: Do not apply an excessive amount of Loctite 574 NOTE: Numbers in Figure 7-52 correspond with numbers around the O-rings. Too much can dislodge the in Figure 7-24. O-rings. 18. Apply Loctite 574 to the front case mating face. Prior to installing the rear case, ensure that all bearings have been coated with a Lithium Base, E.P.
Page 200 TRANSMISSION AND TORQUE CONVERTER CD3340B/YB4411 NOTE: Access to the layshaft end face is gained through 26. Measure the end play of the main shaft using the end the 4WD bolt hole X, as shown in Figure 7-53. play checking kit (see Figure 7-21) Calculate the required thickness of shims to give NOTE: Numbers in Figure 7-55 correspond with numbers...
Page 201 CD3340B/YB4411 TRANSMISSION AND TORQUE CONVERTER NOTE: To rotate the main shaft, use air and adapter tool P/ N 1902746 (see Figure 7-19) d. Add or subtract shims (34, Figure 7-58) to correct the end play. (The end play should be set as near as possible to the minimum tolerance.) The shims must only be fitted between the bearing outer race and spacer (50).
Page 202 TRANSMISSION AND TORQUE CONVERTER CD3340B/YB4411 the spigot on the plug. Using a new seal washer, install the plug and tighten. a0829 FIGURE 7-60 a0828 FIGURE 7-59 31. Before installing the solenoid adapter block to the casing, be sure that the M8 oilway plug (A, Figure 7-61) NOTE: On some gearboxes, locating dowels in the bell is installed.
Page 203 CD3340B/YB4411 TRANSMISSION AND TORQUE CONVERTER a0831 FIGURE 7-64 FIGURE 7-62 38. Install the drain plug (4) with a new sealing washer. a0807 Tighten to a torque of 203 Nm (150 lb-ft). 33. Install new O-rings (13, Figure 7-63) into each valve 39.
Page 204: Output Shaft Removal - Larger Diameter Gear
TRANSMISSION AND TORQUE CONVERTER CD3340B/YB4411 Connect removed hydraulic lines, electrical Output Shaft Removal - Larger Diameter harnesses, cables, etc. Fill the transmission with Gear recommended fluid. See Maintenance, page 5-1. In the event of output gear (A, Figure 7-67) hitting the Installing a Collapsible Spacer transmission housing (at position B) when removing output shaft (1), proceed as follows:...
Page 205 CD3340B/YB4411 TRANSMISSION AND TORQUE CONVERTER Installation of 75 Micron Strainer c o n t a m i n a t e d o i l b e i n g p u m p e d i n t o t h e transmission.
Page 206 TRANSMISSION AND TORQUE CONVERTER CD3340B/YB4411 a0834 Item Description Item Description Piston Ring Seal Counter plates (12) Bearing Disc spring Gear Retaining ring (2) Needle thrust bearing Spring retaining plate (2) Thrust washer Spring (2) Hub assembly Oil baffle (2) Needle roller bearing Piston (2) Thrust washer (2) O-ring (2)
Page 207 CD3340B/YB4411 TRANSMISSION AND TORQUE CONVERTER Disassembly Remove the clutch end bearing (2) and gear (3), using a collet tool and press. The following instructions are for repair of both the input and Remove the needle roller thrust bearing (4) and thrust forward clutch assemblies.
Page 208 TRANSMISSION AND TORQUE CONVERTER CD3340B/YB4411 14. Remove and discard piston and shaft O-rings (20 and Using a dial test indicator as shown in Figure 7-73, 21). measure the end play of the pressure end plate. End play should be 1.90 to 2.50 mm (0.075 - 0.098 in). 15.
Page 209: Mainshaft Clutch Repair
CD3340B/YB4411 TRANSMISSION AND TORQUE CONVERTER Mainshaft Clutch Repair a0838 Item Description D e s c r i p t i o n Description Piston ring seal (2) Retaining rings Taper roller bearing Spring retaining plate Bearing Spring Retaining ring Oil baffle End plate Piston Shim...
Page 210 TRANSMISSION AND TORQUE CONVERTER CD3340B/YB4411 Disassembly Assembly Carefully remove piston ring seals (1, Figure 7-74). Visually inspect the friction and counter plates: NOTE: If the piston ring seals are excessively worn, then • Counter plates - light scoring/polishing is permissible, check for burrs or damage on the shaft grooves.
Page 211: Layshaft Clutch Repair
CD3340B/YB4411 TRANSMISSION AND TORQUE CONVERTER Layshaft Clutch Repair Component Identification for Figure 7-77 a0841 FIGURE 7-77 Item Description Item Description Piston Rings (2) Needle Thrust Washer Taper Roller Bearing Thrust Bearing Spacer Needle Roller Bearing (2) Taper Roller Bearing Thin Thrust Washer Piston Housing Needle Thrust Washer Spring Retainer Plate...
Page 212 TRANSMISSION AND TORQUE CONVERTER CD3340B/YB4411 Carefully remove piston rings (1). Remove retaining ring (11). NOTE: If the piston ring seals are excessively worn, then Remove the gear and splined hub (12) together with check for burrs or damage on the shaft grooves. If thrust washer (13), needle thrust bearing (14) and thin necessary, remove the burrs with a fine grade thrust washer (15).
Page 213 CD3340B/YB4411 TRANSMISSION AND TORQUE CONVERTER Assembly To adjust the end play, there is a choice between a 6.0 mm (0.23 in) or a 6.5 mm (0.25 in) pressure end plate (20) with Visually inspect the friction and counter plates: either a shim (21) or extra counter plate (23) between retaining ring (19) and pressure end plate (20).
Page 214: (Ptfe) Piston Ring Seal Installation Procedure
TRANSMISSION AND TORQUE CONVERTER CD3340B/YB4411 15. Prior to installing the clutch assembly, align teeth of (PTFE) Piston Ring Seal Installation clutch plates using a thin rod (screw driver). Procedure Wedge the plates together by inserting two blunt tools Wind the PTFE piston ring around your finger, as shown (small round screwdrivers A, Figure 7-80) through the in Figure 7-81, so that the seal forms a coil.
Page 215: Solenoid Valve
CD3340B/YB4411 TRANSMISSION AND TORQUE CONVERTER Solenoid Valve Disassembly/Assembly The numerical sequence shown in Figure 7-83 is intended as a guide for disassembly. For assembly the sequence should be reversed. For clarity, only one solenoid has been numbered in the disassembly sequence. FIGURE 7-83 a0314 GROVE...
Page 216 TRANSMISSION AND TORQUE CONVERTER CD3340B/YB4411 7-60 Published 04/07/2015 Control # 569-00...
Page 217 CD3340B/YB4411 AXLES/DRIVE SHAFTS/WHEELS AND TIRES SECTION 8 AXLES/DRIVE SHAFTS/WHEELS AND TIRES SECTION CONTENTS Description ....... 8-1 Rear Steering Axle Repair .
Page 218 AXLES/DRIVE SHAFTS/WHEELS AND TIRES CD3340B/YB4411 FIGURE 8-1 A0723 A0855 FIGURE 8-2 Number of brake counterdiscs (each side)..Two TECHNICAL DATA Nominal brake disc thickness.....4.83 mm (0.19 in) Nominal brake counterdisc thickness..5.0-10.8 mm (0.197 - Front Steering Drive Axle 0.425 in) Type.............3-piece spiral Maximum brake disc wear....0.15 mm (0.006 in) bevel input with epicyclic hub reduction and inboard braking Nominal brake piston stroke....1 mm (0.039 in)
Page 219 CD3340B/YB4411 AXLES/DRIVE SHAFTS/WHEELS AND TIRES Toe-in..............0° TOE-IN/STEERING ANGLE ALIGNMENT Steering Angle.............35° Front Steering Axle Bevel gear reduction..........1.55:1 Toe-in Check and Adjustment Hub reduction.............6.00:1 Total Reduction..........10.66:1 Bevel gear set backlash......0.15 - 0.20 mm WARNING (0.006 - 0.008 in) A raised and badly supported machine can fall on you Pinion bearings (measured D=34.8 mm without seal)..P = causing severe injury or death.
Page 220 AXLES/DRIVE SHAFTS/WHEELS AND TIRES CD3340B/YB4411 If toe-in is incorrect, loosen the jam nuts (Figure 8-4) Checking with Axle Removed from Machine securing the guide rods to the cylinder rod. Place two equal (one-meter) long linear bars on the wheel sides of the hubs and lock them in place with two nuts on the wheel stud bolt (Figure 8-6) FIGURE 8-4 P0663...
Page 221 CD3340B/YB4411 AXLES/DRIVE SHAFTS/WHEELS AND TIRES If tow-in is incorrect, loosen the jam nuts (Figure 8-9) Use the same bars assembled for the toe-in adjustment, securing the guide rods to the cylinder rod. page 8-5. Steer the axle to maximum steering position. Hold a long bar against the steering cylinder mounting brackets on the axle (Figure 8-11), so that the two bars form an acute angle.
Page 222 AXLES/DRIVE SHAFTS/WHEELS AND TIRES CD3340B/YB4411 Loosen the lock nut on the steering angle screw Checking / Adjusting Toe-in (Figure 8-13). Checking with Axle on Machine Place the wheels in the straight forward position. Take measurements from the tire to the crane frame at the four positions A, B, C and D indicated in Figure 8-3.
Page 223 CD3340B/YB4411 AXLES/DRIVE SHAFTS/WHEELS AND TIRES Checking with Axle Removed from Machine Both dimensions must be the same. If incorrect, use steps 3 through 8 under Checking with Align the wheel hubs in straight forward position. Axle on Machine, page 8-6 to adjust the measurements. Measure the distance between the hubs on both sides of the axle (Figure 8-15).
Page 224 AXLES/DRIVE SHAFTS/WHEELS AND TIRES CD3340B/YB4411 FRONT DRIVE AXLE PROBLEMS AND DIAGNOSIS Table 8-1 PROBLEM CAUSE RECOMMENDED REPAIR Excessive play between pinion Adjust. and bevel gear Worn pinion and bevel gear. Replace Worn pinion bearings Replace Pinion bearing loose Adjust. Excessive axle pinion play Adjust preload only.
Page 225: Front Drive Axle Repair
CD3340B/YB4411 AXLES/DRIVE SHAFTS/WHEELS AND TIRES FRONT DRIVE AXLE REPAIR WARNING A raised and badly supported machine can fall on you causing severe injury or death. Position the machine on a firm, level surface before raising one end. Ensure that the other end is securely chocked.
Page 226 AXLES/DRIVE SHAFTS/WHEELS AND TIRES CD3340B/YB4411 Driver for wheel hub oil seal Driver for piston P/N 1901767 P/N 1901770 FIGURE 8-23 FIGURE 8-20 A0685 A0680 Driver for differential bearing cone Wrench for pinion lock nut P/N 1901771 P/N 1901768 FIGURE 8-21 FIGURE 8-24 A0684 A0679...
Page 227 CD3340B/YB4411 AXLES/DRIVE SHAFTS/WHEELS AND TIRES Pinion shaft lock wrench Driver for bushing P/N 1901773 P/N 1901776 FIGURE 8-26 FIGURE 8-29 A0687 A0682 Driver for Bearing Driver for bushing P/N 1901774 P/N 1901777 FIGURE 8-30 A0686 A0689 FIGURE 8-27 False differential for distance measure False Pinion with false pinion FIGURE 8-31...
Page 228 AXLES/DRIVE SHAFTS/WHEELS AND TIRES CD3340B/YB4411 Washer O-Ring Flange Driver for pinion oil seal P/N 1901779 FIGURE 8-32 Retaining Ring A0692 FIGURE 8-35 A0694 Steering Cylinder Removal Loosen the hex nut (Figure 8-36) on one of cylinder tie rod ends until none of the threads on the tie rod end are exposed.
Page 229 CD3340B/YB4411 AXLES/DRIVE SHAFTS/WHEELS AND TIRES Wheel Hub Disassembly Position the hub with the drain plug to the top of hub (Figure 8-37). Loosen the drain plug slightly to remove any pressure that may have built-up in the hub. FIGURE 8-39 P0589 Should any of the planetary gears need replacement perform the following:...
Page 230 AXLES/DRIVE SHAFTS/WHEELS AND TIRES CD3340B/YB4411 Remove all of the rollers (Figure 8-42) and check their condition. If any gear pin shaft is damaged, replace the entire planetary carrier assembly. FIGURE 8-44 P0594 FIGURE 8-42 P0592 Unscrew and remove the nine fastening screws NOTE: Before disassembling the splined sleeve, it is (Figure 8-45) from the hub-lock ring gear.
Page 231 CD3340B/YB4411 AXLES/DRIVE SHAFTS/WHEELS AND TIRES 10. Remove the hub-lock ring gear together with the during removal. Remove bearing cups (B) from both epicyclic ring gear (Figure 8-47). sides of the hub using a driver and hammer. Remove the bearing cone from the swivel housing end, using a suitable puller.
Page 232 AXLES/DRIVE SHAFTS/WHEELS AND TIRES CD3340B/YB4411 FIGURE 8-56 P0605 FIGURE 8-53 P0602 20. Using a suitable puller, remove the bushings from the 17. Remove the Belleville washers and shim from the upper king pins (Figure 8-57). and lower side of the axle beam (Figure 8-54). FIGURE 8-57 FIGURE 8-54 A0696...
Page 233 CD3340B/YB4411 AXLES/DRIVE SHAFTS/WHEELS AND TIRES Put alignment marks on the axle beam and on the Remove the axle beam (Figure 8-62). When removing differential supporting flanges (Figure 8-59) to identify the axle beam be careful that the brake discs do not fall from the brake flange.
Page 234 AXLES/DRIVE SHAFTS/WHEELS AND TIRES CD3340B/YB4411 If necessary, use compressed air through the bleed screw port to eject the piston. The piston may eject with force, be sure no part of your body or other persons are CAUTION in the way of the ejecting piston. This procedure frees the differential housing, which could fall if not properly supported causing possible personal injury.
Page 235 CD3340B/YB4411 AXLES/DRIVE SHAFTS/WHEELS AND TIRES FIGURE 8-69 P0615 FIGURE 8-72 P0618 13. Using a hammer and driver, remove the bearing cup Disassemble the components (Figure 8-73). Check for from the brake flange (Figure 8-70). proper operation and for any damage or wear to the components.
Page 236 AXLES/DRIVE SHAFTS/WHEELS AND TIRES CD3340B/YB4411 FIGURE 8-75 P0619 FIGURE 8-78 P0622 Remove the ring nut (Figure 8-76) with SPECIAL TOOLS P/N 1901768. Using a suitable puller, remove the bearing cone from the bevel pinion (Figure 8-79). Remove the adjusting shim under the bearing and check for wear and damage. FIGURE 8-76 P0620 P0623...
Page 237 CD3340B/YB4411 AXLES/DRIVE SHAFTS/WHEELS AND TIRES Assembly Check the correct positioning of the right and left brake flanges, using the reference marks on them and the Pinion Assembly center housing (Figure 8-83). Place the center housing on a work bench. Using Assemble the two brake flanges and secure them with SPECIAL TOOL P/N 1901782, press the taper roller their mounting screws (screw in at least two screws,...
Page 238 AXLES/DRIVE SHAFTS/WHEELS AND TIRES CD3340B/YB4411 Measure the distance measurements described below Table 8-2. using a depth gauge through the hole in the false pinion S = SHIM RANGE (Figure 8-85). Thick X = (conical distance to be measured) 2.5 2.6 2.7 2.8 2.9 3.0 3.1 3.2 3.3 3.4 (MM) A = (measured value) B = (known value - 100 mm)
Page 239 CD3340B/YB4411 AXLES/DRIVE SHAFTS/WHEELS AND TIRES FIGURE 8-89 P0630 P0632 FIGURE 8-91 11. Assemble onto the pinion shaft a new ring nut washer Differential Assembly and ring nut retainer. Install the bearing cones of the new taper roller bearings Screw the ring nut in, using SPECIAL TOOLS P/N on the differential housing halves (Figure 8-92).
Page 240 AXLES/DRIVE SHAFTS/WHEELS AND TIRES CD3340B/YB4411 Position the ring bevel gear on the assembled differential housing (Figure 8-94). Apply Loctite 270 on the threads of screws. Install the screws and tighten to a torque of 95 Nm (70 lb-ft). P0636 FIGURE 8-96 Install the piston into the brake flange and position SPECIAL TOOL P/N 1901779 or a flat disc on the piston (Figure 8-97).
Page 241 CD3340B/YB4411 AXLES/DRIVE SHAFTS/WHEELS AND TIRES Install a new O-ring (Figure 8-99) in the oil pipe hole on Install the upper screw and lower stud bolt to fasten the the center housing. Lubricate the O-ring before brake flange to the center housing (Figure 8-101). Tighten the upper bolt to a torque of 80 Nm (59 lb-ft).
Page 242 AXLES/DRIVE SHAFTS/WHEELS AND TIRES CD3340B/YB4411 11. Install SPECIAL TOOL P/N 1901769 to the end of the 13. Measure the total pre-loading (T) of the bearing (pinion- pinion shaft (Figure 8-103). Using a dial indicator bevel gear system), using a dynamometer whose cord is mounted so that the feeler is in contact with the bracket wound on the pinion spline end (Figure 8-105).
Page 243 CD3340B/YB4411 AXLES/DRIVE SHAFTS/WHEELS AND TIRES 14. To test the tooth contact of the pinion with the bevel gear, 17. Excessive contact at the tooth base - X contact. paint the teeth of the bevel gear with red lead paint (Figure 8-109) (Figure 8-106).
Page 244 AXLES/DRIVE SHAFTS/WHEELS AND TIRES CD3340B/YB4411 Axle Beam and Brake Assembly Install a new O-ring into the axle beam housing. Install the axle beam on the brake flange (Figure 8-114). Be Inspect the friction disc and counterdiscs for signs of careful to align the mounting holes. burning.
Page 245 CD3340B/YB4411 AXLES/DRIVE SHAFTS/WHEELS AND TIRES P0646 FIGURE 8-116 FIGURE 8-118 P0644 Grease the inside of the kingpin cavities of the swivel Lubricate the bushing and lips of the ring seal. Install the housing. U-joint inside the axle beam (Figure 8-117). Place a shim under the Belleville washer and install this NOTE: Be careful not to damage the ring seal.
Page 246 AXLES/DRIVE SHAFTS/WHEELS AND TIRES CD3340B/YB4411 Secure the swivel housing with a rope and hoist (Figure 8-121). NOTE: Be sure the swivel housing is securely fastened before lifting it in place. Possible personal injury could result from a falling swivel housing. Lubricate the lips of the ring seal.
Page 247 CD3340B/YB4411 AXLES/DRIVE SHAFTS/WHEELS AND TIRES Install the wheel carrier assembly on the wheel hub using the two projecting bushings as dowel pins A0719 FIGURE 8-128 12. Install the rings and shim onto the axle shaft and lock FIGURE 8-126 P0652 with the retaining ring (Figure 8-129).
Page 248 AXLES/DRIVE SHAFTS/WHEELS AND TIRES CD3340B/YB4411 Place the planetary carrier on a workbench. Flange Assembly Install the epicyclic planetary gears onto the planetary Install seal ring (A, Figure 8-133) in the center housing pins (Figure 8-131). Then install the rollers inside the with SPECIAL TOOL P/N 1901779 and a hammer.
Page 249 CD3340B/YB4411 AXLES/DRIVE SHAFTS/WHEELS AND TIRES Loosen the jam nut on the guide rod and adjust the Toe-in Adjustment guide so that the ball joint can be inserted into the swivel See page 8-3 for toe-in adjustment procedures housing (Figure 8-135). Steering Angle Adjustment See page 8-5 for steering angle adjustment.
Page 250: Rear Steering Axle Repair
AXLES/DRIVE SHAFTS/WHEELS AND TIRES CD3340B/YB4411 Bleed the brakes. See Brake System, page 9-1. Pull hub (24) from spindle (9 or 10). Lower the wheels to the ground. Remove the inner bearing cone (15) from the hub. 10. Bleed the steering lines, see Steering System, page 10- Remove outer oil seal retainer (14) and felt seal (13).
Page 251 CD3340B/YB4411 AXLES/DRIVE SHAFTS/WHEELS AND TIRES A0673 Item Description Item Description Item Description Item Description Cotter Pin (6) Oil Seal Retainer (2) Hex Nut (12) Tap Screw Socket Assembly (4) Seal (2) Axle Hub (2) Self-Locking Nut (8) Steering Cylinder (2) Oil Seal Retainer (2) Wheel Stud (12) Capscrew (8)
Page 252 AXLES/DRIVE SHAFTS/WHEELS AND TIRES CD3340B/YB4411 FIGURE 8-139 A0674 8-36 Published 04/07/2015 Control # 569-00...
Page 253: Assembly
CD3340B/YB4411 AXLES/DRIVE SHAFTS/WHEELS AND TIRES Assembly Install the assembled hub on the spindle of the steering knuckle. Install washer (22) and slotted nut (21). Rotate the hub while tightening the slotted nut (21) snug WARNING until tight to displace grease. Then, back off nut until the Crushing Hazard! hub rotates free, usually 1/4-1/2 turn and install cotter pin (19).
Page 254: Disassembly
AXLES/DRIVE SHAFTS/WHEELS AND TIRES CD3340B/YB4411 Disassembly Disassemble journal cross (2, Figure 8-140) from the drive shaft using the procedure in step 2. After the snap Place a flange yoke (1, Figure 8-140) in a vice. Using rings are removed, use a hammer and soft drift, with a pliers, remove the two snap rings from the bearing caps flat face slightly smaller than the diameter of the bearing, in the flange yoke.
Page 255: Installation
CD3340B/YB4411 AXLES/DRIVE SHAFTS/WHEELS AND TIRES Repeat steps 1 through 3 and install a flange yoke (1) to Apply a Lithium Base, E.P. No. 2 bearing grease to the each end of the drive shaft. three grease fittings on the drive shaft. One fitting on each journal cross and one on the slip yoke.
Page 256: Wheels And Tires
AXLES/DRIVE SHAFTS/WHEELS AND TIRES CD3340B/YB4411 WHEELS AND TIRES Wheel Nut Torque Tightening order of the studs is shown in Figure 8-143. Check the tightness of the lug nuts after every 50 hours of operation. WARNING Proper wheel nut torque for both axles is 306 Nm (225 lb-ft). Flying Objects Hazard! Never try to disassemble the wheel until all air is released from the tire.
Page 257: Technical Data
CD3340B/YB4411 BRAKE SYSTEM SECTION 9 BRAKE SYSTEM SECTION CONTENTS Technical Data ......9-1 Parking Brake Repair .
Page 258: Description
BRAKE SYSTEM CD3340B/YB4411 Table 9-4 warning switch, an accumulator, a needle valve, a brake PRIORITY FLOW CONTROL VALVE modulating valve, a brake light switch and the front axle service brakes. Priority Flow Set At 12. 3 L/min (3.25 gpm) Description of Operation Control Pressure 758 kPa (110 psi) Hydraulic Pump...
Page 259: Parking Brake System
CD3340B/YB4411 BRAKE SYSTEM charging. This does not noticeably affect the operation of Brake Light Switch these components. Full system pressure is available to the The brake light switch illuminates the brake lights when the downstream components at all times, providing oil delivery brake modulating valve builds system pressure to 552 kPa and pressure from the pump and relief valve are not (80 psi).
Page 260: Maintenance And Adjustments
BRAKE SYSTEM CD3340B/YB4411 (Figure 9-4) and place the other end in a suitable container. FIGURE 9-3 P0314 Parking Brake Solenoid Valve The parking brake solenoid valve is activated by the parking brake switch in the operator’s instrument panel. It is a A0873 FIGURE 9-4 normally-closed solenoid valve.
Page 261: Parking Brake Adjustment
CD3340B/YB4411 BRAKE SYSTEM Tighten the jam nut while holding the adjusting screw with a wrench. Remove the feeler gauge. Engage the parking brake. Then, release the parking brake and recheck that the brake moves freely on the guide/slide pin. FIGURE 9-5 P0828 Parking Brake Adjustment FIGURE 9-6...
Page 262 BRAKE SYSTEM CD3340B/YB4411 With the engine shutoff and the parking brake engaged, b. Install the hand pump fitted with a 0 to 6890 kPa (0 close the accumulator needle valve (Figure 9-7) to shut to 1000 psi) pressure gauge to port (B, Figure 9-8). off hydraulic pressure to the service brakes.
Page 263: Parking Brake Repair
CD3340B/YB4411 BRAKE SYSTEM Reconnect all brake lines and bleed the brake system as Loosen lock nut (8, Figure 9-10) and back off adjusting recommended on page 9-4. bolt (7). Remove the bolts and nuts used to fasten the brake SERVICE BRAKE REPAIR mounting bracket assembly to the crane.
Page 264: Repair Kit Installation
BRAKE SYSTEM CD3340B/YB4411 A0779 FIGURE 9-10 Item Description Item Description Item Description Capscrew (4) O-Ring Lining Lockwasher (4) Backup Ring Housing Cover Piston Screw (2) Seal O-Ring Seal (2) Belleville Springs (5) Backup Ring Grease Zerk Washer O-Ring (2) Bleeder Screw Adjusting Bolt Piston Mounting Bracket Assembly...
Page 265 CD3340B/YB4411 BRAKE SYSTEM WARNING Before repairing the parking brake, make sure that the machine is on level ground. Place chocks on both sides of th e f ou r ti r e s . R em ov e t he ig ni t io n k e y. If th es e precautions are not adhered to, the crane could run you over while performing the repair.
Page 266: Seal Kit Installation
BRAKE SYSTEM CD3340B/YB4411 20. Install new lining (20) on piston (19) using new flat head 31. Install the parking brake assembly onto the frame of the screws (21). Tighten screws to a torque of 3.4-4.5 Nm crane. (30-40 lb-in). Install new O-rings (18) on piston (19) and 32.
Page 267 CD3340B/YB4411 BRAKE SYSTEM Remove the bolts and nuts used to fasten the brake 17. Install new O-rings (18) on lining and piston assembly mounting bracket to the crane. Remove the parking (22) and insert the assembly into housing (26) bore. brake assembly.
Page 268: Brake Modulating Valve Repair
BRAKE SYSTEM CD3340B/YB4411 BRAKE MODULATING VALVE REPAIR NOTE: Be careful not to damage the spool or housing bore as they are a matched set and not sold separately. Removal Assembly A seal kit is available for repair of the valve. It consists of the items indicated with a black dot in Figure 9-13.
Page 269 CD3340B/YB4411 BRAKE SYSTEM FIGURE 9-13 A0780 Item Description Item Description Boot O-Ring Piston Assembly Spring Spring Spool Spring Housing Spring Screw Shim Retainer Assembly Seal End Plug GROVE Published 04/07/2015 Control # 569-00 9-13...
Page 270: Troubleshooting
BRAKE SYSTEM CD3340B/YB4411 TROUBLESHOOTING Service Brakes Table 9-5 PROBLEM POSSILBE CAUSE REMEDY Warning light on instrument Loss of brake pressure Any cause under NO BRAKES. panel illuminates Fault brake modulating valve Repair or replace. Faulty priority flow control valve. Replace. Loss of fluid from broken line, Check all circuit lines, hoses, and fittings.
Page 271 CD3340B/YB4411 STEERING SYSTEM SECTION 10 STEERING SYSTEM SECTION CONTENTS Technical Data ......9-1 Parking Brake Repair .
Page 272 STEERING SYSTEM CD3340B/YB4411 8519 FIGURE 10-1 Published 04/07/2015 Control # 569-00 10-2...
Page 273 CD3340B/YB4411 STEERING SYSTEM Two-wheel Steering the four-wheel steering mode solenoids 749 and 752 are actuated. Oil passes through the porting of the valve block During two-wheel steering, the front wheels steer in the and out port A to the rear axle steering cylinder. Oil is same direction that the steering wheel turns.
Page 274 STEERING SYSTEM CD3340B/YB4411 TROUBLESHOOTING Table 10-1 Symptom Probable Cause Action Worn or malfunctioning pump. Repair or replace pump. Priority valve not opening correctly. Check for sticky spool. Repair or replace. Check load sense line for leaks or poor connection. Malfunctioning relief valve. Replace the priority valve.
Page 275 CD3340B/YB4411 STEERING SYSTEM Symptom Probable Cause Action Insufficient oil level. Check for leaks and fill tank. Leaks in relevant hoses or component Check hoses and connections for connections. leaks. Air in the hydraulic system. Bleed system - bleed the load sense line.
Page 276 STEERING SYSTEM CD3340B/YB4411 Symptom Probable Cause Action Air in system due to low level of Correct condition and add fluid. hydraulic oil, cavitating pump, leaky Bleed system and load sense line. fitting, pinched hose, etc. Erratic steering Loose steering cylinder piston. Repair or replace cylinder.
Page 277 CD3340B/YB4411 STEERING SYSTEM STEERING PROXIMITY SWITCHES The system is used to select one of the three steering modes. When the selector switch in the cab is placed in General either two-wheel steer, four-wheel steer or crab steer, that particular mode of steering is used to steer the crane. The The purpose of the steering proximity switches in the system, however, will not activate unless the front and rear steering system is to prevent the changing of steering modes...
Page 278 STEERING SYSTEM CD3340B/YB4411 FIGURE 10-4 P0760 Published 04/07/2015 Control # 569-00 10-8...
Page 279 CD3340B/YB4411 STEERING SYSTEM Sensor Operation and Spacing Checks If the sensor is working properly, check the spacing between the sensor and sensor bracket. Adjust if Checking Alignment and Operation necessary. Both sensors must be working and spaced properly for the If the sensor is malfunctioning, replace it and adjust the steering mode selection to function properly.
Page 280 STEERING SYSTEM CD3340B/YB4411 STEERING ORBITROL Orbitrol Repair Special Tools Description A spring installation tool, is required to assemble the orbitrol. General This tool is available under part number 1900476. The steering orbitrol (Figure 10-8) provides directional Removal control and metering of oil for precise steering control. In the neutral or balance position, when the steering wheel is not Remove the outside cover plate (Figure 10-7) in front of turned, the IN port (P) is connected to the OUT port (T) and...
Page 281 CD3340B/YB4411 STEERING SYSTEM P0671 FIGURE 10-8 GROVE Published 04/07/2015 Control # 569-00 10-11...
Page 282 STEERING SYSTEM CD3340B/YB4411 Remove the four bolts which fasten the steering column NOTE: Although not all illustrations show the unit in a vice, and orbitrol to the mounting bracket. Be sure to hold the we recommend that you keep the unit in a vice steering orbitrol in position while the last bolt is being d u r i n g d i s a s s e m b l y.
Page 283 CD3340B/YB4411 STEERING SYSTEM with your thumbs just far enough to free gland bushing (3) from the housing. Remove gland bushing (3). Remove quad seal (5) from gland bushing (3). Use a thin bladed screwdriver to pry dust seal (1) from gland bushing (3).
Page 284 STEERING SYSTEM CD3340B/YB4411 Install set screw (25) and tighten to a torque of 11.3 Nm (100 lb-in). To prevent interference, make sure the top of the set screw is slightly below the housing mounting surface. Lubricate the spool (12) and sleeve (9). Install spool (12) and sleeve (9) carefully so that the spring slots (Figure 10-15) line up at the same end.
Page 285 CD3340B/YB4411 STEERING SYSTEM 10. Insert pin (11, Figure 10-9) through the spool and sleeve assembly until the pin becomes flush at both sides of the Screwdriver sleeve. Dust Seal 11. Lubricate the spool and sleeve assembly and position the assembly so that the splined end of the spool enters Retaining Ring the meter end of housing (8, Figure 10-9).
Page 286 STEERING SYSTEM CD3340B/YB4411 between the slotted end of the drive to the splined end of 22. With seal side of the gerotor toward spacer plate (14), the drive when marking. align star valleys (Figure 3-24, Ref. A) on drive (Ref. B). Note the parallel relationship of reference lines A, B, C and D.
Page 287 CD3340B/YB4411 STEERING SYSTEM REAR STEERING CYLINDER Raise and support the machine to gain access to the steering cylinders. Technical Data With the engine not running, turn the steering wheel in both directions to release any pressure in the hydraulic Cylinder Bore........57 mm (2.25 in) lines to the steering cylinders.
Page 288 STEERING SYSTEM CD3340B/YB4411 Item Description Cylinder Tube Piston Nut Piston Piston Ring O-Ring Piston Seal O-Ring Cylinder Head Tighten Nut to a O-Ring Torque 10 lb-ft (136 Back-Up Ring Rod Seal Wiper Seal Cylinder Rod a0670 FIGURE 10-23 Remove nut (2) from the from cylinder rod (13). end cap and cylinder are thoroughly cleaned using a wire brush to remove grease, hydraulic oil and Loctite.
Page 289 CD3340B/YB4411 STEERING SYSTEM Assembly Wipe the cylinder rod clean. Then move the cylinder through four complete strokes at 5510 kPa (800 psi), but Install rod seal (11, Figure 10-23) in the bore of the do not permit the cylinder to hit bottom on each stroke. cylinder head.
Page 290 STEERING SYSTEM CD3340B/YB4411 Start the engine and operate the cylinder(s) through Place a tag on hoses for identification and correct several complete cycles to remove air from the system. assembly. Be prepared to collect the hydraulic oil as you Operate the cylinders slowly and do not let them hit remove steering lines.
Page 291 CD3340B/YB4411 STEERING SYSTEM On the other end of the cylinder, repeat steps 4 and 5. Install the cylinder head onto the cylinder rod, being careful not to damage any of the seals in the cylinder Remove three cap screws (17) fastening the cylinder to head.
Page 292 STEERING SYSTEM CD3340B/YB4411 Published 04/07/2015 Control # 569-00 10-22...
Page 293: 3-Section Boom Assembly
CD3340B/YB4411 STRUCTURAL SECTION 11 STRUCTURAL SECTION CONTENTS Booms ........11-1 Planet Carrier Service .
Page 294 STRUCTURAL CD3340B/YB4411 Item Description Item Description Item Description Item Description 3rd Boom Section 23. Top Extend Chain End 43. Bottom Slide Pad (2) 66. Pivoting Boom Head 2nd Boom Section 24. Extend Rod 44. Lockwasher (4) 67. Shim 1st Boom Section 25.
Page 295: Maintenance
CD3340B/YB4411 STRUCTURAL Maintenance P/N 1005522 = 1.02 mm (0.04 in) P/N 1005475 = 1.78 mm (0.07 in) Boom Slide Pads See Maintenance, page 5-1 for lubrication intervals and To install the shims: instructions. Extend the boom sections until the side slide pads are Boom Chains visible (Figure 11-2) See Maintenance, page 5-1 for lubrication and inspection...
Page 296 STRUCTURAL CD3340B/YB4411 FIGURE 11-2 a0607 NOTE: Use the following procedure to check if the chain is Adjusting Nut and Scribe Line too tight after adjusting: Remove the inspection Jam Nut Location c o ve r f r o m o n t o p o f t h e 1 s t b o om se c t io n (Figure 11-4).
Page 297: Boom Repair
CD3340B/YB4411 STRUCTURAL 3rd Boom Section 2nd Boom Section Bottomed Against 2nd Bottomed Against 1st Boom Section Boom Section FIGURE 11-6 P0829 Boom Repair FIGURE 11-4 P0680 When the boom has extended slightly, remove the pipe Removal wrench and fully retract the booms. Check that the 3rd Lower the boom to lowest position.
Page 298 STRUCTURAL CD3340B/YB4411 10. Remove the boom mounting pin and remove the boom capscrew (7) and lockwasher (8). Remove pin (6) and assembly. Place boom on supports capable of handling the pivoting boom head (66). the weight of the boom. At the front end of the second boom assembly remove 11.
Page 299 CD3340B/YB4411 STRUCTURAL 13. Attach an overhead crane and sling to the telescope cylinder as shown in Figure 11-9. Raise the 3rd boom assembly far enough to remove two capscrew (14) and lockwashers (13). Remove rear slide pad (12). FIGURE 11-9 P0670 GROVE Published 04/07/2015 Control # 569-00...
Page 300 STRUCTURAL CD3340B/YB4411 Item Description Washer Cotter Pin Castle Nut Counterbalance Valve Telescope Cylinder Chain Sheave Bearing (2) Nylatron Spacer (2) Lockwasher (4) Capscrew Extend Chain Roller Bracket Grease Filling (2) Chain Roller Pin Retaining Ring (2) End Guide Bracket Cylinder End Slide Pad Lockwasher (2) Capscrew (2) Capscrew (4)
Page 301 CD3340B/YB4411 STRUCTURAL 14. See previous WARNING. Secure the 2nd boom section NOTE: Coat the threads of all fasteners with an anti-seize from pulling off the supports. Pull 3rd boom assembly compound, except where use of Loctite 243 is indicated. out far enough to attach a sling and overhead crane. Pull the 3rd boom section about half way out.
Page 302 STRUCTURAL CD3340B/YB4411 Lock the pin in place with two set screws (72). If boom slide pads (19) were removed, install new pads using two capscrews (18). Coat the threads of capscrew If grease fittings (74) were removed, install them into the (18) with Loctite 243 before installation.
Page 303 CD3340B/YB4411 STRUCTURAL the 3rd section upper slide pads will slide, with anti-seize compound. FIGURE 11-12 FIGURE 11-11 p0671 p0669 Using the sling and overhead hoist, raise the 3rd boom Using an overhead crane and sling, align the 3rd boom section enough to install rear slide pad (12). Install the section with the end of the 2nd boom section.
Page 304 STRUCTURAL CD3340B/YB4411 Coat the internal slide areas on the 1st boom section with an anti-seize compound. Position retract roller assembly (37) in the 1st boom section. See Figure 11-16. FIGURE 11-14 90673 12. At the rear of the boom (Figure 11-15), check for proper height adjustment.
Page 305 CD3340B/YB4411 STRUCTURAL Slide the 2nd boom assembly into the 1st boom 10. Check that the threaded end of the telescope cylinder assembly far enough that the telescope cylinder hoses aligns with and can be installed in the mounting hole in the boom section (Figure 11-20).
Page 306 STRUCTURAL CD3340B/YB4411 22. At the front of the second boom section (Figure 11-22), 2rd Boom Section Bottomed 3rd Boom Section Bottomed install brass wear pads (40) between the 2nd and 3rd Against 1st Boom Section Against 2nd Boom Section boom sections. Wear Pad (Units prior to S/N 100710-99) P/N 1004468 = 11.18 mm (0.44 in) Wear Pads (Units with S/N 100710-99 and After...
Page 307: Wire Rope, Sheaves And Hoist Blocks
NEVER use the wire rope where the load applied to it is One cannot determine the grade of wire rope by its feel or greater than the working load determined by Manitowoc appearance. To be sure you are using the proper rope, Cranes, Inc.
Page 308: Inspecting Wire Rope
STRUCTURAL CD3340B/YB4411 • In the U.S.A., regular INSPECTIONS of the wire rope Contact with electrical wires and resulting arcing will and keeping of PERMANENT RECORDS SIGNED BY damage a wire rope. A QUALIFIED PERSON ARE REQUIRED BY OSHA Inspecting Wire Rope FOR ALMOST EVERY WIRE ROPE APPLICATION.
Page 309: Wire Rope Installation
CD3340B/YB4411 STRUCTURAL FIGURE 11-24 A0349 Wire Rope Installation Anchoring Wire Rope Take the free end of the wire rope and insert it through the small opening on the anchor pocket. Loop the wire rope and push the free end about 3/4 of the way through the pocket. Install the wedge, then pull the slack out of the wire rope.
Page 310 STRUCTURAL CD3340B/YB4411 X = A minimum of 6 rope diameters, but not less than 152 mm (6 in). FIGURE 11-26 FIGURE 11-27 a2275 a0069 Installation of Socket and Wedge Installation of a New Wire Rope Always connect the socket so that the load is pulled on the The wire rope is given a natural bend or winding from the same line as the socket (See Figure 11-27).
Page 311: Main Hoist
CD3340B/YB4411 STRUCTURAL the drum. Loose windings will increase wear on the wire MAIN HOIST rope and cause bad performance. Theory of Operation The main hoist design is composed of high speed, low torque gerotor motor, driving through a multiple disc brake, and a pair of planet gear sets to the cable drum.
Page 312 STRUCTURAL CD3340B/YB4411 Brake Valve Hoist Disc Brake Cable Drum Planet Gear Sets Hoist Gerotor Motor FIGURE 11-30 a0472 FIGURE 11-31 A0957 Published 04/07/2015 Control # 569-00 11-20...
Page 313: Repair
CD3340B/YB4411 STRUCTURAL FIGURE 11-32 A0958 Item Description Plug Breather Output Shaft Seal (2) Bearing (2) Snap Ring Mounting Bracket Thrust Washer (2) Input Sun Gear Cable Drum Bearing Carrier O-ring Plug Capscrew (8) Thimble Output Sun Gear O-ring Capscrew (20) Support Rod (2) Side Plate (2) Base...
Page 314 STRUCTURAL CD3340B/YB4411 the extra two tapped holes (Figure 11-34) and tighten Install three 1/4 inch eyebolts (Figure 11-36) into the them evenly until the brake housing has come loose three planet pins in the input planet set (22, from the mounting bracket. See Brake Section for repair Figure 11-33).
Page 315 CD3340B/YB4411 STRUCTURAL Check the snap ring (6, Figure 11-33) on output shaft (3) to ensure it is in its groove and not bent over (Figure 11-39). Replace if necessary. P0191 FIGURE 11-37 P0196 FIGURE 11-39 Reference mark for proper assembly and remove the drum from the mounting bracket.
Page 316 STRUCTURAL CD3340B/YB4411 Install a new seal (4), O-ring (12) into the bearing carrier Brake Vent Plug (11). Install bearing (5) into the bearing carrier (Figure 11-41). Grease the O-ring on the bearing carrier (Figure 11-42) and install the bearing carrier into the drum.
Page 317 CD3340B/YB4411 STRUCTURAL Each spring should be 30.5 mm (1.200 in) long with no force on them. Remove the piston (10, Figure 11-46) by installing two pieces of 3/8 NC all-thread (Figure 11-48) in the bottom of two spring pockets. Using jam nuts, screw the all- thread pieces in evenly until the piston is clear of the housing.
Page 318 STRUCTURAL CD3340B/YB4411 Item Description Item Description Brake Housing Bushing and Breather Kit Capscrew (8) Capscrew (4) Bushing Plug Seal Brake Spring (12) Spacer Snap Ring (2) Friction Disc (7) Snap Ring (2) Stator Plate (8) Brake Driver Seal (2) Race (2) Piston Bushing (2) O-ring...
Page 319 CD3340B/YB4411 STRUCTURAL FIGURE 11-49 P0202 If one or both of the square seals (8, Figure 11-46) remain in the bore of the brake housing (1), remove them. Grasp the brake driver/clutch assembly (items 17 through 23, Figure 11-46) and remove it from the brake housing.
Page 320 STRUCTURAL CD3340B/YB4411 FIGURE 11-52 P0205 P0208 FIGURE 11-55 10. Carefully disassemble the brake driver/clutch assembly (17-23, Figure 11-46) noting the direction of lockup on the clutch. The clutch assembly must be assembled with the arrow pointing in the proper direction for the hoist to operate properly.
Page 321 CD3340B/YB4411 STRUCTURAL out Install the other seal with grooves facing in (Figure 11-59). FIGURE 11-57 P0211 After installing plates and discs, set piston in place and FIGURE 11-59 P0212 check the brake stack-up to make sure that the d i m e n s i o n s a r e w i t h i n t h e t o l e r a n c e s h o w n i n Install the piston into the brake housing and gently tap it Figure 11-58.
Page 322 STRUCTURAL CD3340B/YB4411 Install the cover onto the brake housing and draw it down evenly, alternating between opposite capscrews. Make sure that the cover is properly aligned with brake housing to orient the motor as it should be. Check the brake release with a portable pump. Full release should be obtained at 1034 kPa (350 psi), plus or minus 138 kPa (20 psi).
Page 323: Main Hoist (Braden Model)
CD3340B/YB4411 STRUCTURAL Remove the planet gears (2), thrust washers (7) and bearings (6) from the carrier (1). See Figure 11-65. Inspect the pins, bearings and gear bores for evidence of wear and replace if necessary. On the output planet sets, note that two bearings (10) with a spacer (13) between them are used.
Page 324: Hoist Operation
STRUCTURAL CD3340B/YB4411 the brake cylinder. The other end of the drum rotates on a clutch. When driven by the sun gear, the primary planet ball bearing on the support bolted to the base. The ring gear gears walk around the ring gear in the drum and drive the for both planetary sets is machined into the drum’s inside planetary carrier.
Page 325 CD3340B/YB4411 STRUCTURAL a2206 FIGURE 11-68 a2207 FIGURE 11-70 The static brake system has thee operating components When the control valve is placed in the lowering position, the (see Figure 11-67): spring loaded, pilot operated spool valve remains closed (Figure 11-69) until sufficient pilot pressure is applied to the Spring applied, multiple friction disc static brake end of the spool valve to shift it against spring pressure;...
Page 326: Repair
STRUCTURAL CD3340B/YB4411 reverse input causes the sprag cams to instantly roll forward and firmly lock the shaft to the fully engaged friction brake (Figure 11-72). When the hoist is powered in reverse, to lower the load, the motor cannot rotate until sufficient pilot pressure is present to open the brake valve.
Page 327 CD3340B/YB4411 STRUCTURAL FIGURE 11-73 P2289 GROVE Published 04/07/2015 Control # 569-00 11-35...
Page 328: Hoist Assembly
STRUCTURAL CD3340B/YB4411 Legend for Figure 11-73 1. Sight Gauge 26. Lockwasher (2) 51. Spring Spacer 2. Relief Valve 27. Capscrew (2) 52. O-Ring 3. Capscrew (22) 28. Thrust Washer (6) 53. BAckup Ring 4. Lockwasher (36) 29. Planet Gear (3) 54.
Page 329 CD3340B/YB4411 STRUCTURAL thoroughly clean the outside surfaces. To drain the oil, remove the hydraulic hoses that connect the brake valve install a short piece of 1 inch threaded pipe in the larger and manifold to the brake cylinder (Figure 11-76). threads of the drain hole (Figure 11-84).
Page 330 STRUCTURAL CD3340B/YB4411 surfaces. Refer to “Motor Support-Brake Cylinder Service,” page 11-45 for additional information. Using two heel type pry bars (Figure 11-80) placed between the primary planet carrier and the drum closure, pry upward to remove the drum closure. Remove and discard the O-ring from the outside of the drum closure.
Page 331: Assembly
CD3340B/YB4411 STRUCTURAL 14. Remove the output planet carrier (Figure 11-84) from the drum. Refer to “Planet Carrier Service” on page 11-43, for additional information. FIGURE 11-82 a2219 13. Remove the output sun gear and thrust washer (Figure 11-83) from the output planet carrier. a2221 FIGURE 11-84 15.
Page 332 STRUCTURAL CD3340B/YB4411 Place hoist base on side with bearing support end up NOTICE! (Figure 11-85). Make certain the snap ring is installed on the bearing support. This snap ring will keep the output planet carrier correctly positioned in the hoist. Gear train damage may occur if this snap ring is omitted.
Page 333: Primary Planet Carrier
CD3340B/YB4411 STRUCTURAL Install the output planet carrier (Figure 11-89) into the drum while meshing the planet gears with the ring gear and the planet housing with the bearing support. FIGURE 11-91 a2228 11. Lubricate the O-ring and drum opening with petroleum jelly or gear oil and install the drum closure a2226 FIGURE 11-89...
Page 334 STRUCTURAL CD3340B/YB4411 rope in. An easy way to check the rotation is to hold the 14. If the brake discs are misaligned: preventing the outer race in one hand, and rotate the inner race. installation of the clutch, then with a hand pump, apply 750-1000 psi to the brake release port.
Page 335 CD3340B/YB4411 STRUCTURAL FIGURE 11-96 FIGURE 11-98 a2233 a2235 20. After the hoist assembly is complete, check all capscrews and fittings to make certain they have been tightened correctly. 21. Refill the hoist with the recommended oil listed in Section 5, and install the oil level plug. Planet Carrier Service Output Planet Carrier Disassembly...
Page 336 STRUCTURAL CD3340B/YB4411 Use a punch (Figure 11-100) to drive the roll pins from Assembly the planet shafts. Do not reuse the roll pins. Place the output planet carrier on workbench with spline coupling side down. Install output thrust plate in center of carrier (Figure 11-102).
Page 337: Motor Support-Brake
CD3340B/YB4411 STRUCTURAL Primary Planet Carrier To service the primary planet carrier, the steps are the same as for the output carrier except there is only one bearing for each gear and no bearing spacer. Motor Support-Brake Cylinder Service IMPORTANT! Some of the illustrations show spined brake discs. This brake uses a lobed steel brake separator and motor support as shown in Figure 11-106.
Page 338 STRUCTURAL CD3340B/YB4411 Check oil seal and bearing surfaces on the brake cylinder for damage and wear (Figure 11-111). FIGURE 11-108 a2245 Remove brake springs (Figure 11-109) and the spring spacer. FIGURE 11-111 a2248 Place friction plate disc on a flat surface and check for distortion with a straight edge.
Page 339 CD3340B/YB4411 STRUCTURAL IMPORTANT! It is good practice to pre-lubricate the discs in a light motor oil prior to assembly. a2250 FIGURE 11-113 a2254 FIGURE 11-115 NOTICE! Install the brake spacer on top of the last steel brake disc Failure to replace brake springs as a set may result in (Figure 11-115).
Page 340 STRUCTURAL CD3340B/YB4411 a2256 a2259 FIGURE 11-117 FIGURE 11-119 Lubricate the brake piston seal and motor support Install the pressure plate into the brake cylinder followed sealing surface with petroleum jelly or hydraulic oil. by the piston backup ring (Figure 11-120). The close Insert a new piston seal to the motor support with the lip fitting piston backup ring may be depressed slightly to seal down (Figure 11-118).
Page 341: Brake Cylinder Pressure Test
CD3340B/YB4411 STRUCTURAL Release the pressure on the cylinder, and then remove the brake clutch assembly. The brake cylinder assembly is now complete and ready to install in the hoist Brake Clutch Service Disassembly Remove the snap ring and sprag bushing retainer from one end only (Figure 11-123).
Page 342 STRUCTURAL CD3340B/YB4411 Press a sprag bushing into the outer race, using a suitable press. A flat plate of approximately the same diameter as the bushing flange outside diameter should be placed between the press and bushing. This will protect the bushing from damage. Be certain the bushing flange is against the shoulder in the outer race (Figure 11-127).
Page 343 CD3340B/YB4411 STRUCTURAL a2271 FIGURE 11-131 a2268 FIGURE 11-129 Figure 11-132 shows a completed clutch assembly. Slide the inner race through the bushings and sprag clutch. The race will have to be rotated in the freewheeling direction to start it through the sprag clutch.
Page 344: Troubleshooting
STRUCTURAL CD3340B/YB4411 Troubleshooting TROUBLE PROBABLE CAUSE REMEDY 1.The friction brake may not be A -The hoist will not lower the load or releasing as a result of a defective 1.Check brake cylinder seal as follows: not lower the load smoothly. brake cylinder seal.
Page 345: Tulsa Hoist
CD3340B/YB4411 STRUCTURAL TROUBLE PROBABLE CAUSE REMEDY C - Hoist “chatters” while raising rated 1. Hydraulic oil flow to motor may be 1. Hydraulic pump not operating load. too low. efficiently. 2. Hoist control being operated too 2. Conduct operator training as quickly.
Page 346: Programming The Last Layer Indicator
STRUCTURAL CD3340B/YB4411 Insert the DRI into the drum. Rotate the DRI (1, Run the hoist to the third wrap. Figure 11-134) so that the DRI shaft (2) engages the Remove the programming screw (1, Figure 11-136) on drive inside the drum. the DRI.
Page 347: Bearing, Mast And Related Parts
CD3340B/YB4411 STRUCTURAL BEARING, MAST AND RELATED PARTS General The mast is fastened to the main frame of the crane through a bearing. The outer race of the bearing is fastened to the mast and the inner race of the bearing is fastened to the frame.
Page 348: Mast Bearing
STRUCTURAL CD3340B/YB4411 Mast Bearing Mast Bearing Bolts The mast bearing is a ball thrust bearing. The inner race Very high stress is put on the mast bolts during crane rotates inside the outer race on a row of steel balls. operation.
Page 349: Inspection For Bearing Wear
CD3340B/YB4411 STRUCTURAL Inspection for Bearing Wear Set the dial indicator to zero. Raise the boom to its full upright position and record the Because of conservative design parameters, static loading amount of movement on the dial indicator. and slow intermittent rotation, there are very few mast bearings that ever see their full design use.
Page 350 STRUCTURAL CD3340B/YB4411 Item Description Lockwasher (15) Capscrew (2) Item Description Pin Assembly (2) Eccentric Ring Rope Deflector Roller Mast Bearing Capscrew (4) Capscrew (24) Structural Washer (28) Lift Cylinder Main Hoist Assembly Counterbalance Valve Counterweight Capscrew (2) Mast Pin Assembly Flat Washer (2) Capscrew (3) Lock Washer (4)
Page 351: Swing Gearbox And Pinion
CD3340B/YB4411 STRUCTURAL Installation Adjustments Using a suitable solvent, clean the holes in the bearing Checking Backlash plate on the main frame. Remove the residue with Remove the front cover to expose the swing pinion and compressed air. Clean all dirt from the bearing plate. ring gear.
Page 352: Swing Gearbox Repair
STRUCTURAL CD3340B/YB4411 Slightly loosen the four capscrews securing the swing Disassembly gearbox (Figure 11-144). Remove the hydraulic motor. With a spanner wrench, turn the eccentric ring until the Clean the outside of the gearbox before disassembly. pinion tooth comes in contact with ring gear tooth (zero backlash).
Page 353 CD3340B/YB4411 STRUCTURAL Assembly Install pinion gear shaft (3) into housing (4). Be sure to seat oil seal (2) into the housing, being careful not to If removed, press new bearing cups into housing (18) damage it. and end caps (20 and 22) Pack the other bearing cone (15) with grease and install Coat a new oil seal (7) with grease and install it onto over pinion gear shaft (3) into housing (4).
Page 354 STRUCTURAL CD3340B/YB4411 Item Description Item Description Item Description Bearing Cup (2) Key (2) Oil Seal Oil Seal Bearing Cone (2) Shim (2) Pinion Shaft Set Screw Shim (2) Housing Bearing Cone (2) Capscrew (4) Cover SH Capscrew Pipe Plug (3) Oil Seal End Cap Breather...
Page 355: Outriggers
CD3340B/YB4411 STRUCTURAL 10. Apply Loctite 243 to the threads of pinion gear shaft (3). fitting located on the housing. Fill gearbox until grease Install thrust washer (13), washer (23) and lock nut (27). flows from the setscrew hole. 11. Tighten lock nut (27) to 68 Nm (50 lb-ft), then loosen the Installation nut and tighten again to a torque of 27.2 - 40.8 Nm (20 - Install an eyebolt with 1/2 NF threads into the tapped...
Page 356 STRUCTURAL CD3340B/YB4411 Item Description Lock Nut (4) Flat Washer (4) Capscrew (4) Bracket (2) Horizontal Outrigger Cylinder Outrigger Beam Inner Box Assembly Snap Ring (4) Snap Ring (2) Vertical Outrigger Cylinder Counterbalance Cartridge FIGURE 11-146 a0851 Published 04/07/2015 Control # 569-00 11-64...
Page 357: Disassembly
CD3340B/YB4411 STRUCTURAL Disconnect the two hydraulic hoses for the vertical Assembly outrigger cylinder from the bulkhead fittings attached to Completely clean outrigger beam (6, Figure 11-146) and the outside of the frame (Figure 11-147). Let the outrigger inner box (7). Use steam or suitable solvent. hydraulic oil drain into a suitable container.
Page 358: Outrigger Monitoring System (Oms)
STRUCTURAL CD3340B/YB4411 Outrigger Monitoring System (OMS) (Optional—Standard in North America) The Outrigger Monitoring System (OMS) proximity switches (if equipped) are mounted outside the outrigger housing tubes. The proximity switches identify whether an outrigger beam is at the fully extended position or at any position less than fully extended.
Page 359 CD3340B/YB4411 SCHEMATICS/WIRING DIAGRAMS SECTION 12 SCHEMATICS/WIRING DIAGRAMS For your convenience, the latest version of schematics available at the time of printing are placed in this section. GROVE 12-1...
Page 360 SCHEMATICS/WIRING DIAGRAMS CD3340B/YB4411 THIS PAGE BLANK 12-2...
Page 361 CD3340B/YB4411 SERVICE MANUAL ALPHABETICAL INDEX Accessory Circuits ........... . . 3-10 Anti-double Block System .
Page 362 SERVICE MANUAL CD3340B/YB4411 O-Ring Face Seal (ORFS) Hydraulic Fittings ....... . 1-12 O-ring, Seal and Elastic Nut Replacement .

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Grove yb4411

Manitowoc Grove CD3340B Service Manual

Table of Contents

Section 1 1

Diesel Fuel

Nomenclature

General Service Information

Cleaning Instructions

O-Ring, Seal and Elastic Nut Replacement

Hoses and Tubes

Bearings

Hydraulic Pressure Testing

Fatigue of Welded Structures

Loctite

Fasteners and Torque Values

O-Ring Face Seal (ORFS) Hydraulic Fittings

Hydraulic Fitting F.F.F.T. Method

(Flats from Finger Tight)

Section 2

Section 3 Electric System

Section 4 Hydraulic System

Section 4

General Description

Technical Data

Troubleshooting

Troubleshooting Guides

Hydraulic System

Lift Circuit

Telescope Circuit

Hoist Circuit

Swing Circuit

Pilot Control System

Pressure Setting Procedures

Anti-Double Block System

Outriggers Circuits

Component Repair

Under Deck Winch

Section 5 Maintenance

Preventive Maintenance

Lubricants

Lubrication Points

Scheduled Maintenance

Carwell® Rust Inhibitor

Section 6 Engine and Engine Systems

Engine Cooling System

Engine Fuel System

Engine Electrical System

Engine Air Intake System

Troubleshooting

Engine Exhaust System

Removal and Installation

Engine Pump and Bracket Removal and Installation

Section 7 Transmission and Torque Converter

Description of Operation

Testing

Section 8 Axles/Drive Shafts/Wheels and Tires

Front Drive Axle Repair

Rear Steering Axle Repair

Drive Shafts

Wheels and Tires

Section 9 Brake System

Technical Data

Description

Maintenance and Adjustments

Tests

Parking Brake Repair

Brake Modulating Valve Repair

Troubleshooting

Section 11 11

Wire Rope, Sheaves and Hoist Blocks

Main Hoist

Main Hoist (Braden Model)

Hoist Assembly

Tulsa Hoist

Bearing, Mast and Related Parts

Quick Links

Chapters

Troubleshooting

Need help?

Questions and answers

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