Manitowoc Grove YB4411 Manuals

Manuals and User Guides for Manitowoc Grove YB4411. We have 1 Manitowoc Grove YB4411 manual available for free PDF download: Service Manual

Manitowoc Grove YB4411 Service Manual (362 pages)

Brand: Manitowoc | Category: Construction Equipment | Size: 41.4 MB

Table of Contents

3
Section 1 1

11
- Directional Reference
  11
- Identification Plate
  11
- Specifications
  12
- Engine Oil Specifications
  13
- Diesel Fuel
  
  14
- Nomenclature
  
  15
- General Service Information
  
  15
- Cleaning Instructions
  
  16
  - Complete Assemblies
    16
  - Parts with Machined Surfaces
    16
  - Bearings
    16
  - Rough Parts
    16
  - Rubber Parts
    16
  - After Cleaning
    16
  - To Prevent Corrosion
    16
- O-Ring, Seal and Elastic Nut Replacement
  
  16
- Hoses and Tubes
  
  16
  - Installation
    17
- Bearings
  
  17
  - Removal
    17
  - Cleaning
    17
- Hydraulic Pressure Testing
  
  17
- Fatigue of Welded Structures
  
  17
- Loctite
  
  18
  - Application of Medium Strength Loctite
    18
- Fasteners and Torque Values
  
  18
  - Torque Wrenches
    18
  - Torque Values
    19
  - Weld Studs
    22
- O-Ring Face Seal (ORFS) Hydraulic Fittings
  
  22
- Hydraulic Fitting F.F.F.T. Method
  
  24
- (Flats from Finger Tight)
  
  24
- Section 2
  
  27
  - General
    27
    
    Signal Word
    27
    
    Final Word
    30
Section 3 Electric System

31
- Section 3
  31
  - General
    31
    
    Comparing Electrical System to a Hydraulic System
    32
    
    Magnetism
    32
  - Main Electrical System
    33
    
    General
    33
    
    Wire Harnesses
    33
    
    Fuse and Relay Replacement
    33
  - Charging System
    37
    
    Alternator and Voltage Regulator
    37
    
    Battery
    37
    
    Voltmeter
    37
    
    Resistor
    37
    
    Special Precautions
    37
    
    Battery Maintenance and Charging
    37
    
    Battery Replacement
    38
  - Starting Circuit
    38
    
    General Inspections
    38
    
    Starting Circuit Check
    38
  - Instrument and Light Circuits
    39
    
    General
    39
    
    Light Bulbs
    39
    
    Gauges and Indicators
    39
    
    ECM Display Toggle Switch
    39
  - Accessory Circuits
    40
    
    Anti-Double Blocking System
    40
    
    Heater
    40
  - Wire Harnesses
    41
    
    Engine Wire Harness
    41
    
    Transmission Wire Harness
    41
    
    Main Frame Wire Harness
    41
    
    Instrument Panel Wire Harness
    41
    
    Cab Wire Harness
    41
    
    Instrument Panel Wire Harness
    46
    
    Cab Wire Harness
    47
    
    Charging System Troubleshooting
    49
    
    Starting System Troubleshooting
    50
Section 4 Hydraulic System

51
- Section 4
  
  51
- General Description
  
  52
  - General
    52
  - Hydraulic System
    53
- Technical Data
  
  52
  - Hydraulic Pressures
    52
  - Rated Pump Output at 2500 RPM
    52
  - Hydraulic Speeds
    52
- Troubleshooting
  
  53
  - Troubleshooting Aids
    53
  - Troubleshooting Procedures
    53
- Troubleshooting Guides
  
  55
- Hydraulic System
  
  60
  - System Description
    60
  - Description of Operation
    61
  - Hydraulic Swivel
    62
    
    General
    62
    
    Functions
    62
    
    Troubleshooting
    63
- Lift Circuit
  
  63
  - General
    63
    
    Oil Flow
    63
    
    Holding Valve
    64
    
    Lift Cylinder Leakage Check
    64
- Telescope Circuit
  
  66
  - General
    66
  - Oil Flow
    66
  - Holding Valve
    66
  - Port Relief Valve
    66
  - Telescope Cylinder Leakage Test
    67
  - Hydraulic Swivel
    67
- Hoist Circuit
  
  67
  - General
    67
  - Oil Flow
    67
  - Brake Holding Valve
    68
  - Hydraulic Swivel
    68
- Swing Circuit
  
  68
  - General
    68
  - Oil Flow
    68
- Pilot Control System
  
  68
  - Pilot System Relief Valve
    68
- Pressure Setting Procedures
  
  68
  - Checking and Adjusting Hydraulic Pressure Settings
    68
- Anti-Double Block System
  
  71
  - General
    71
  - System Function
    71
- Outriggers Circuits
  
  72
  - General
    72
  - Oil Flow
    72
  - Outrigger Valve
    77
  - Counterbalance Valves
    78
  - Vertical Outrigger Cylinder Leakage Test
    79
- Component Repair
  
  79
  - Hydraulic Pump Repair
    79
  - Main Control Valve
    81
  - Outrigger Control Valve
    84
  - Swing Motor
    86
  - Hoist Motor
    91
  - Hydraulic Swivel
    92
  - Hydraulic Cylinders
    94
- Under Deck Winch
  
  101
Section 5 Maintenance

103
- Maintenance Records
  104
- Preventive Maintenance
  
  105
- Lubricants
  
  108
- Lubrication Points
  
  109
  - Grease Fittings
    111
- Scheduled Maintenance
  
  115
  - Daily (Walk-Around)
    115
  - 50 Hours of Operation/Weekly
    119
  - 100 Hours of Operation
    121
  - 250 Hours of Operation/Monthly
    122
  - 500 Hours of Operation/Three Months
    128
  - 1000 Hours of Operation/Six Months
    131
  - Replace the Hoist Gearbox Lubricant (Braden Model)
    135
  - 2000 Hours of Operation/Yearly
    137
  - Miscellaneous Maintenance
    138
- Carwell® Rust Inhibitor
  
  140
  - Protecting Cranes from Rusting
    140
  - Cleaning Procedures
    140
  - Inspection and Repair
    141
  - Application
    141
  - Areas of Application
    141
Section 6 Engine and Engine Systems

145
- General
  145
- Engine Cooling System
  
  146
  - Coolant Requirements
    146
- Engine Fuel System
  
  147
  - Diesel Engine Fuel System Description
    147
  - Fuel Tank
    147
  - Fuel Level Sender and Gauge
    147
  - Fuel Pump
    147
  - Fuel Filter
    147
  - Fuel Injection Pump
    147
  - Types of Fuel to Use
    148
  - Thermostat
    147
- Engine Electrical System
  
  147
- Engine Air Intake System
  
  148
- Troubleshooting
  
  149
- Engine Exhaust System
  
  149
- Removal and Installation
  
  150
  - Removal
    150
  - Installation
    151
- Engine Pump and Bracket Removal and Installation
  
  152
  - Special Tools
    152
  - Removal
    152
  - Installation
    154
Section 7 Transmission and Torque Converter

157
- Description of Operation
  
  159
  - Torque Converter
    159
  - Transmission
    159
  - Hydraulic Operation
    161
  - Drive Paths
    163
  - Clutch Operation
    166
  - General Troubleshooting
    167
  - Troubleshooting (Electrical)
    167
  - Solenoid Identification
    177
  - Test for Clutch Leakage
    177
- Testing
  
  177
  - Pressure and Flow Tests
    181
  - Transmission Repair
    182
  - Servicing the Torque Converter
    185
  - Servicing the Transmission
    187
  - Transmission Gearbox Repair
    187
  - Output Shaft Removal - Larger Diameter Gear
    204
  - Mainshaft Clutch Repair
    209
  - Layshaft Clutch Repair
    211
  - (PTFE) Piston Ring Seal Installation Procedure
    214
  - Solenoid Valve
    215
Section 8 Axles/Drive Shafts/Wheels and Tires

217
- Front Drive Axle Repair
  
  225
  - Disassembly
    225
  - Removal
    225
- Rear Steering Axle Repair
  
  250
  - Removal
    250
  - Disassembly
    250
  - Inspection
    250
  - Assembly
    253
  - Installation
    253
- Drive Shafts
  
  253
  - Checking for Bearing Wear
    253
  - Removal
    253
  - Disassembly
    254
  - Inspection
    254
  - Assembly
    254
  - Installation
    255
  - Lubrication Procedure
    255
- Wheels and Tires
  
  256
  - Tire Inflation
    256
  - Wheel Nut Torque
    256
Section 9 Brake System

257
- Technical Data
  
  257
- Description
  
  258
  - Service Brake System
    258
  - Parking Brake System
    259
- Maintenance and Adjustments
  
  260
  - Service Brake Bleeding
    260
  - Parking Brake Bleeding
    260
  - Parking Brake Adjustment
    261
  - Accumulator Charging
    261
- Tests
  
  261
  - Brake Piston Seal Leakage Test
    261
- Parking Brake Repair
  
  263
  - Lining Kit Replacement
    263
  - Repair Kit Installation
    264
  - Seal Kit Installation
    266
- Brake Modulating Valve Repair
  
  268
  - Removal
    268
  - Disassembly
    268
  - Assembly
    268
  - Installation
    268
- Troubleshooting
  
  270
  - Service Brakes
    270
  - Parking Brake
    270
Section 11 11

293
- 3-Section Boom Assembly
  293
- Adjustments
  295
- Maintenance
  295
- Boom Repair
  297
- Wire Rope, Sheaves and Hoist Blocks
  
  307
  - Wire Rope Description
    307
  - Wire Rope Safety
    307
  - Inspecting Wire Rope
    308
  - Inspection of Sheaves
    308
  - Wire Rope Lubrication
    308
  - Wire Rope Installation
    309
- Main Hoist
  
  311
  - Theory of Operation
    311
  - Repair
    313
- Main Hoist (Braden Model)
  
  323
  - Description of Hoist
    323
  - Hoist Operation
    324
  - Repair
    326
- Hoist Assembly
  
  328
  - Disassembly
    328
  - Assembly
    331
  - Primary Planet Carrier
    333
  - Motor Support-Brake
    337
  - Brake Cylinder Pressure Test
    341
  - Brake Clutch Service
    341
  - Troubleshooting
    344
- Tulsa Hoist
  
  345
  - Drum Rotation Indicator
    345
  - Programming the Last Layer Indicator
    346
- Bearing, Mast and Related Parts
  
  347
  - General
    347
  - Mast Bearing
    348
  - Mast Bearing Bolts
    348
  - Inspection for Bearing Wear
    349
  - Replacing the Mast Bearing
    349
  - Swing Gearbox and Pinion
    351
  - Swing Gearbox Repair
    352
  - Outriggers
    355
  - Disassembly
    357
  - Installation
    357
  - Outrigger Monitoring System (OMS)
    358
  - (Optional-Standard in North America)
    358

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Manitowoc Grove YB4411 Manuals

Manitowoc Grove YB4411 Service Manual (362 pages)

Table of Contents

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

Related Products

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