Link Belt 308 HYLAB 5 Crane Service Manual by Heavy Equipment Manual

FrontAndRearDrumBrakeControlDisassemblyAndReassemblyES03---05---6074.1R0S

FourthDrumBrakeControlMaintenanceChartES03---07---2035.1R0S

FourthDrumBrakeControlDisassemblyAndReassemblyES03---07---6002.1R0S ..........................

FrontAndRearDrumPawlLockMaintenanceChartES03---10---2069.0R0S

BoomHoistDrumPawlLockMaintenanceChartES03---12---2064.0R0S

FourthDrumPawlLockMaintenanceChartES03---14---2002.0R0S

SECTION4HydraulicSystem

HydraulicCircuit ES04---01---0081.0R0S

HydraulicCircuitPressureAdjustmentES04---01---5082.0R0S

308HYLAB5SERVICEMANUALCONTENTS 0501R0 1of2 0205 Book1038 SECTION0General HowToUseThisManual,GeneralServiceInstructions,AndSafetyProceduresSM00---000---001.00 ........ EquipmentLayoutES00---03---0068.0R0S SECTION1UpperMechanism SystemDiagramOfHydraulicControlES01---01---0069.0R0S FrontAndRearDrumShaftStructureAndOutlineES01---10---0073.0R0S FrontAndRearDrumDisassemblyAndReassemblyES01---10---6067.0R0S FourthDrumShaftStructureAndOutlineES01---12---0040.0R0S .......................................... BoomHoistDrumOutlineAndStructureES01---15---0072.0R0S .......................................... ClutchStructureAndOutlineForFrontAndRearDrumES01---17---0056.0R1S ClutchStructureAndOutlineForFourthES01---17---0057.0R0S ClutchMaintenanceChartForFrontAndRearDrumES01---17---2075.1R0S ClutchMaintenanceChartForFourthDrumES01---17---2079.0R0S ClutchTroubleshootingES01---17---4048.1R0S ClutchDisassemblyAndReassemblyForFrontAndRearDrumES01---17---6052.0R2S TurntableBearingMaintenanceChartES01---30---2032.0R0S PowerDivider(GearBox)StructureAndOilInspectionES01---40---0003.0R0S DrumMaintenanceChartES01---42---2076.0R0S DrumIndicatorTroubleshooting(MechanicalType)ES01---50---4001.1R0S ................................. SECTION2LowerMechanism LowerGeneralExplanationES02---01---0058.0R0S TreadDriveSprocketMaintenanceChartES02---05---2060.0R0S Take---UpIdlerMaintenanceChartES02---07---2064.0R0S Take---UpIdlerInspectionAndOilReplacementES02---07---5052.0R0S Take---UpIdlerDisassemblyAndReassemblyES02---07---6059.0R0S CarrierRollerMaintenanceChartES02---08---2058.0R0S TrackRollerMaintenanceChartES02---09---2056.0R0S TrackShoeMaintenanceChartES02---10---2053.0R2S TrackShoeInspectionAndAdjustmentES02---10---5058.0R0S TrackShoeDisassemblyAndReassemblyES02---10---6058.0R0S ........................................ TreadMemberAndGuideShoeMaintenanceChartES02---12---2052.0R0S ................................ TravelReductionGearCaseStructureAndOilInspectionES02---21---5056.0R0S ........................... RetractEquipmentMaintenanceChartES02---26---2007.0R0S SECTION3ControlSystem FrontAndRearDrumBrakeControlMaintenanceChartES03---05---2073.1R0S

SECTION5HydraulicUnit

HydraulicUnitEquipmentLayoutES05---01---0015.0R0S .................................................

VariableDeliveryPumpOutlineAndStructure(ForHammer)ES05---02---0062.0R0S

VariableDeliveryPumpOutlineAndStructure(P1,P2,P3)ES05---02---0063.0R0S

VariableDeliveryPumpMaintenanceChart(P1,P2,P3,Hammer)ES05---02---2054.0R0S

VariableDeliveryPumpTroubleshooting(P1,P2,P3,Hammer)ES05---02---4010.0R0S

VariableDeliveryPumpDisassemblyAndReassembly(P1,P2,P3,Hammer)ES05---02---6038.0R0S ...........

GearPump(SingleType---P6)ES05---03---0010.0R0S ...................................................

GearPumpTroubleshooting(Singleand2---SeriesType)ES05---03---4051.0R0S

GearPumpDisassemblyAndReassembly(2---SeriesType)ES05---03---6055.0R0S

AccumulatorStructureES05---05---0035.1R1S

AccumulatorInspectionES05---05---5032.1R1S .........................................................

AccumulatorDisassemblyAndReassemblyES05---05---6046.1R1S .......................................

AxialPistonMotorOutlineAndStructure(Front,Rear,4thDrum)ES05---09---0046.0R0S ......................

AxialPistonMotorMaintenanceChart(Front,Rear,4thDrum)ES05---09---2028.0R0S

AxialPistonMotorTroubleshooting(Front,Rear,4thDrum)ES05---09---4027.0R0S

AxialPistonDisassemblyAndReassembly(Front,Rear,4thDrum)ES05---09---6041.0R0S

RotatingJointDisassemblyAndReassemblyES05---14---6029.2R4S ......................................

ClutchCylinderDisassemblyAndReassemblyForFrontAndRearDrumES05---18---6075.0R0S .............

ClutchCylinderDisassemblyAndReassemblyForFourthDrumES05---18---6076.0R0S

HydraulicCylinderTroubleshootingES05---23---4001.1R0S

SideFrameRetractCylinderDisassemblyAndReassemblyES05---23---6035.0R0S

HydraulicCylinderTroubleshootingES05---23---4001.1R0S ...............................................

GantryCylinderDisassemblyAndReassemblyES05---24---6001.0R0S ....................................

LineFilterStructureAndInspectionES05---30---0004.0R0S ...............................................

ReturnFilter(ForHammer)ES05---32---0001.0R0S

ReturnFilter ES05---32---0002.0R1S

8---WayRotatingJointDisassemblyAndReassemblyES05---34---6014.0R1S

Take---UpCylinderDisassemblyAndReassemblyES05---57---6048.0R0S ..................................

SECTION6Gantry

GantryMaintenanceChartES06---01---2067.0R1S

SECTION7CraneAttachment

BoomFootMaintenanceChartES07---08---2061.0R1S

SECTION13ElectricalSystem

ElectricCircuitDiagramES13---01---0068.0R0S

ElectricalSystemStandardizationES13---01---9033.0R0S

StorageBatteryServicingAndInstallationES13---04---5004.0R0S

ElectricalEquipmentLayout,WiringAndWireHarnessES13---10---0007.0R0S .............................

SECTION14TighteningTorqueTable

BoltTighteningTorquesES14---02---0004.0R0S .........................................................

308HYLAB5SERVICEMANUALCONTENTS 0501R0

2of20205Book1038



 

4  



  Gantry (Mast) # Catwalk Operator's Cab      Gantry Cylinder Main Hook Bottom Boom Bridle Boom Raising/Lowering Wire Rope Backstop Counterweight Bail Top Boom Pendant Rope Main Hoisting Wire Rope

R.H. Travel Levers

L.H. Travel Levers Air Conditioner

2/4 ES00-03-0068.0R0S

0410   Fan Grip Throttle Swing Control Lever Engine Key Sun Visor

Equipment Layout

Rear Drum Lever

Drum

Gate

Boom Hoist Drum Lever Rear Drum Brake

4th Drum Brake Pedal Front Drum Brake Pedal Throttle

Swing

Front Drum Lever

4th

Control Lever

lock Leve

Pedal

Lock Control Lever

Equipment Layout

3 Lower Machinery

3/4 0410 ES00-03-0068.0R0S



 Track Shoe Pontoon Retract Mechanism Take-Up Idler Lower Frame Travel Motor (Travel Reduction Gears) Track Roller Side Frame Carrier Roller Guide Shoe Drive Sproket # : Indicates options. Fuel Tank Aux. Hoist Drum Brake Oil Cooler Aux. Hoist Motor Hydraulic Oil Reservoir Pump Drive Gear Case Main Hoist Motor Radiator Reservoir Tank Radiator Battery Main Hoist Drum Brake Turntable Bearing Swing Motor And Reduction Gear Return Filter Drum Lock Drum Brake Pedal Fuse Boom Hoist Motor Clutch # 4th Drum Hydraulic Motor Drum Lock Drum Lock # Oil Cooler For Hammer # 4th Drum Brake # Hydraulic Oil Reservoir For Hammer 

•••

System Diagram Of Hydraulic Control

Power from the engine is separated by the power divider (pump splitter) to drive hydraulic pumps. The rotating energy of engine power is also converted into fluid energy (the flow of high pressure hydraulic oil) which is directed by the control valves, through hydraulic lines, to various actuators.

0410 1/2

ES01-01-0069.0R0S

Spotter Spotter Control Valve Brake Master Cylinder Front 4th Rear 4th Or 3 rd Boom Hoist Front Rear Boom Hoist 3 rd Front Swing L.H.Travel R.H.Travel 4th Remote Control Valve L.H.Travel R.H.Travel Boom Hoist Rear Line Filter Accumulator Accumulator Accumulator Accumulator Tank Solenoid Valve Boom Hoist Brake Rear Brake Pump Control Swing Brake Hyd. Hammer Control Valve Hyd. Hammer Solenoid Valve Block Front Clutch Solenoid Valve Solenoid Valve Block Rear Clutch Front Brake 4th Clutch 4th Brake Gantry Cylinder Gantry Counterweight Cylinder CTWT Fix Pin Cylinder Counterweight Return Filter Quick Draw Fan Motor Oil Cooler Suction Filter Sump Tank P10 P3 P4 P5 P6 P1 P2 P7 P8 WinchRemoteContol Cylinder Return Filter Nephron Filter Sump Tank For Hyd. Hammer Engine Controler Rotating Joint Turntable Bearing RV Lower Control Valve Lower Hydraulic Source Or Spotter Coupling For Flashing Circuit CV BC Brake FM Brake Pinion Pinion Brake FM RE RE VM RE RV CV VM RE FM RE RV CV VM RE Boom Hoist 4th Front Rear BC CC BC CC CC L.H.Travel R.H.Travel Retract Cylinder Take-Up Cylinder Front Jack-Up Cylinder Rear Jack-Up Cylinder Retract Cylinder RV L.H.Retract R.H.Retract Rear Jack-Up Front Jack-Up Rear Jack-Up Front Jack-Up BC:Brake Cylinder CC:Clutch Cylinder CV:Counter-Balancing Valve RE:Reduction Gears RV:Relief Valve FM:Fixed-Capacity Motor VM:Variable-Capacity Motor FP:Fixed-Capacity Pump VP:Variable-Capacity Pump RV RV RV RV RV RV FP VP FP VP FP P9 FP VPVP FP VP FM To 3rd Drum RV RV Clamp Manifold RV CV Cylinder Solenoid Valve Block 3rd Or Control Valve Control Valve Control Valve Control Valve Control By Hydraulic Control By Electric } RV RV RV Solenoid Valve Return Filter Return Filter Hammer ECE1-288S RV RV RV

   

  

    



                                     

   

   





 





      

    











                  



 

             



 POWER INSPECTION USUAL FREE FALL IMPOSSIBILITY INSPECTION MODE POSSIBILITY Free Fall Possibility/Impossibility Switch

Controller Front Drum Control Lever Rear Drum Control Lever Rear Drum Brake Pedal Drum Brake Mode/Lever Lock Switch Front Drum Brake Pedal OPERATION STOP FREE RELEASE FRONTREAR BOOM HOIST 3RD 4TH EXTEND RETRACT GANTRY CYLINDER LOWER JACK CYL OFF ON WORKING MODE 3RD HIGH SPEED CRANE CLAM OFF ON 3RD/4TH SELECT 3RD 4TH ECE1-289S

Safety

Check the oil level in the planetary after every 250 hours of operation. The oil, in a new or rebuilt planetary, should be changed after the initial 200 hours of operation. Thereafter, change the oil with each 1000 hours of operation or seasonally, whichever occurs first.

1. Park the crane on a firm level surface.

2. Position the oil fill plug at the top and upper directly over the front or rear of the crawler, engage the travel swing lock, and shutdown the engine.

3. Thoroughly clean the exterior surface of the planetary around the check and fill plugs to prevent contamination from entering the unit.

4. Remove the check and fill plugs.

5. Add oil until it begins to flow from the check plug hole.

Note: For proper oils, refer to the operator's manual.

6. Clean and install the check and fill plugs.

1. Park the crane on a firm level surface.

2. Cycle the winch for several minutes, without a load to agitate and warm the oil within the planetary.

3. Position the oil fill plug at the top and upper directly over the front or rear of the crawler, engage the travel swing lock and shutdown the engine.

4. Thoroughly clean the exterior surface of the planetary around the check, fill, and drain plugs to prevent contamination from entering the unit.

5. Remove the check, fill, and drain plugs and allow the oil to drain into a suitable container.

6. After the oil has thoroughly drained, clean and install the drain plug.

7. Fill the unit with oil through the fill hole, until it begins to flow from the check plug hole.

Note: For proper oils, refer to the operator's manual.

8. Clean and install the check and fill plugs. Properly dispose of the used oil.

4/4 ES01-10-0073.0R0S

Drum

0410  

Front And Rear

Shaft Structure And Outline





 1 2 3

1. Fill Plug 2. Check Plug



3. Drain Plug





 

2)Remove the wire rope of front and rear drum.

3)Remove the covers.

(1)Removethebrake coveroffrontandreardrum.

(2) Remove the motor cover of the right-hand house.

(3) Remove the interior cover of the left-hand house.

4)Remove the boom backstop from the winch plate.

Disconnect the connector of the boom backstop limit.

               

RIGGING MODE Rigging Mode Key Switch NORMAL DISABLEO.R. SWITCHES ENABLEO.R. SWITCHES OVER RIDE LMI OVERRIDESWITCH MASTERCONTROL ECE1-247S

Short Circuit Connector Connector ECE1-251S ECE1-292S ECE1-293S Winch Plate Boom Backstop

Front And Rear Drum Disassembly And Reassembly

5)Remove the gantry.

(1)Lower the gantry in the low position.

Carryoutaccording to the separate operator's manual.

(2)Put the bridle on the gantry.

After disconnecting the bridle from the pendantrope,putthebridle onthegantryaswinding the boom hoist wire rope and fasten it with the wires.

(3)Fasten the upper backstay and middle backstay to the gantry with the wires.

(4)Remove the gantry.

Remove the gantry after pulling out the pin 1, 2 and 3.

Remove electric wiring of the load detector.

Let out the boom hoist wire rope as required.

6)Lock the clutch spring.

(1)Start the engine and place the gate lock lever in "Operation" side.

(2)Switch the brake into the free mode.

The clutch spring is compressed by the cylinder.

(3)Installsixspacers totherodofthe clutch spring part and lock with the nut. Part number of the spacer : CDC0166 Nut : M20

7)Remove the brake band.

Refer to "Front And Rear Drum Band Brake Adjustment" in the operator's manual.

8)Shutdown the engine and place the gate lock lever in "Stop" side.

2/16 ES01-10-6067.0R0S

0410 Bridle Winch Plate Gantry Upper Backstay Middle Backstay Pin 3 Pin 1 Pin 2 ECE1-252S Wire

Spacer Spring Cylinder Rod Nut ECE1-253S

Front And Rear Drum Disassembly And Reassembly

9)Disconnect all hydraulic hoses and electric wirings from the winch and the winch plate.

  Hydraulic

Install the cap on the hydraulic hose removed so that the foreign materials do not come in.

10)Remove the winch plate assembly.

(1)Loosen the winch plate adjusting bolts. (4 places)

(2)Screw the adjusting bolt of the lock plate and loosen the lock plate. (4 places)

(3)Remove the pins. (4 places)

(4)Hoist the winch plate assembly and put on the blocking.

Install the lifting attachment on the rear hole of the left-hand winch plate and sling with installing the shackle directly on the right-hand.

Adjust the sling rope length so that the winch plate assembly does not incline.

Use the sling rope with a sufficient strength. Mass : 5450 kg (12015 lb)

Part number of lifting attachment for the winch plates : JACDD215

High strength shackle

Use the shackle with the allowable load of 6 t (13228 lb) or more.

Shackle installing hole diameter : 41.5 mm (1.63 in)

Winch Plate Assembly

Winch Plate

Adjusting Bolt

Lock Plate

Adjusting Bolt

High Strength

Shackle

High Strength

3/16 0410

ES01-10-6067.0R0S

Pin Pin

350mm (13.8 in) ECE1-254S

Shackle Lifting Attachnent Blocking



Hoisting, Lowering Line Pilot Line Servo Line Drain Line Clutch Line Electric Wirings Backstop Limit Drum Rotation Indicator Motor Regulator

Hoses