Link Belt 108 HYLAB 5 Crane Service Manual

1
108 HYLAB 5 SERVICE MANUAL CONTENTS
WET0081 -102 07 01R0
SECTION 0 General How To Use This Manual, General
Service Instructions, And Safety Procedures . . .
. . . . . SM00 - 000 - 001.00 Equipment Layout .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . ES00 - 03 - 0077.0R0S SECTION
1 Upper Mechanism Power Transmission System . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
ES01 -01 - 0081.0R0S Front And Rear Drum Shaft
Maintenance Chart . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . ES01 - 10
- 2052.0R0S Front And Rear Drum Shaft Disassembly
And Reassembly . . . . . . . . . . . . . . . . .
. . . . . . . . . ES01 - 10 - 6070.0R0S Boom
Hoist Drum Structure And Outline . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . ES01 - 15 - 0064.0R1S Boom
Hoist Drum Disassembly And Reassembly . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . ES01 - 15 - 6067.0R0S Clutch Structure And
Outline . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . ES01 -17 - 0060.0R0S Clutch
Maintenance Chart . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . ES01 - 17 -
2073.0R0S Clutch Troubleshooting . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . .
ES01 -17 - 4023.0R0S Clutch Disassembly And
Reassembly . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. ES01 - 17 - 6051.1R0S Turntable Bearing
Maintenance Chart . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . ES01 - 30 - 2030.6R0S Turntable Bearing
Disassembly And Reassembly . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . .
ES01 - 30 - 6055.0R0S
Drum Indicator Troubleshooting . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . SECTION 2 Lower
Mechanism Lower General Explanation . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . Tread
Drive Sprocket Maintenance Chart . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . Tread Drive Sprocket
Disassembly And Reassembly . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . Take -
Up Idler Maintenance Chart . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . Take - Up Idler
Inspection And Adjustment . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . .
ES01 -50 - 4001.1R0S
ES02 - 01 - 0052.0R0S ES02 -05 - 2056.0R1S ES02
-05 - 6046.0R1S ES02 - 07 - 2060.0R1S ES02 - 07 -
5047.0R1S
Take - Up Idler Disassembly And Reassembly . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . ES02 - 07 - 6054.0R1S Carrier
Roller Maintenance Chart . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . ES02 - 08 -
2059.0R0S Carrier Roller Disassembly And
Reassembly . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . ES02 - 08
- 6034.0R0S Track Roller Maintenance Chart . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . ES02
-09 - 2049.0R0G Track Roller Disassembly And
Reassembly . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . ES02 -
09 - 6035.0R0S
ES02 -10 - 2056.0R0S ES02 - 10 - 5053.0R0S ES02 -
10 - 6060.0R0S
Track Shoe Maintenance Chart . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . Track Shoe
Inspection And Adjustment . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . Track Shoe Disassembly And Reassembly
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . SECTION 3 Control
System
Front And Rear Drum Brake Control Maintenance
Chart . . . . . . . . . . . . . . . . . . . . . .
. . . . . . ES03 - 05 - 2077.0R0S Front And Rear
Drum Brakes Control Disassembly And Reassembly .
. . . . . . . . . . . . . . . . ES03 - 05 -
6078.0R0S SECTION 4 Hydraulic System
Hydraulic Circuit Outline . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . ES04 -01 -
0090.0R0S
Hydraulic Circuit Pressure Adjustment . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . SECTION 5 Hydraulic
Unit Variable Delivery Pump Outline And Structure
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . Variable Delivery Pump
Maintenance Chart . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . .
. Variable Delivery Pump Troubleshooting . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . Gear Pump Disassembly
And Reassembly . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . .
Accumulator Structure . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . Accumulator
Inspection . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . Accumulator Disassembly
And Reassembly . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . Motor
Structure And Outline . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . Motor Maintenance
Chart . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . .
ES04 - 01 - 5088.0R0S
ES05 -02 - 0071.0R0S ES05 -02 - 2050.0R1S ES05
-02 - 4009.0R1S ES05 -03 - 6051.0R1S ES05 - 05 -
0035.1R1S ES05 -05 - 5032.1R1S ES05 - 05 -
6046.1R1S ES05 - 09 - 0043.0R1S ES05 - 09 -
2025.0R0S
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0207
Book 1086
2
108 HYLAB 5 SERVICE MANUAL CONTENTS
WET0081 -102 0701R0
ES05 -09 - 4025.0R0S ES05 - 09 - 6025.0R1S
Motor Troubleshooting . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . Motor
Disassembly And Reassembly . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . .
Travel Motor Structure And Outline . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . ES05 - 13 -
0054.0R0S Travel Motor Maintenance Chart . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . ES05 - 13
- 2048.0R0S Travel Motor Disassembly And
Reassembly . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . ES05 - 13
- 6026.0R0S Rotating Joint Disassembly And
Reassembly . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . ES05 -14 -
6029.2R3S Remote Control Valve Structure And
Operation . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . ES05 - 17 -
0035.0R0S Remote Control Valve Troubleshooting .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . ES05 -17 -
4028.0R0S Clutch Cylinder Disassembly And
Reassembly (1 - Cylinder Type) . . . . . . . . .
. . . . . . . . . . . ES05 - 18 - 6073.0R1S
Automatic Brake Cylinder Disassembly And
Reassembly . . . . . . . . . . . . . . . . . . .
. . . . . . . . . ES05 - 19 - 6032.1R0S Retract
Cylinder Disassembly And Reassembly . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . ES05 - 23 - 6039.0R0S Line Filter
Inspection . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . ES05 -30 -
5061.1R1S Line Filter Disassembly And Reassembly
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . ES05 - 30 -
6061.1R1S Return Filter Inspection . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
ES05 - 32 - 5011.0R0S Return Filter Disassembly
And Reassembly . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . ES05
- 32 - 6011.1R0S 8 -Way Rotating Joint Inspection
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . .
ES05 -34 - 5012.0R1S 8 -Way Rotating Joint
Disassembly And Reassembly . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . ES05 - 34
- 6012.0R1S Control Valve (2 - Series) Structure
And Working . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . ES05 -36 -
0033.0R1S Control Valve (1 - Series) Structure
And Working . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . ES05 -36 -
0034.0R0S 4 -Series Control Valve Structure And
Operation . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . ES05 -38 -
0047.0R0S Check Block Structure And Outline . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . ES05 - 49 -
0019.0R0S Take - Up Cylinder Disassembly And
Reassembly . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . ES05 - 57 -
6053.0R0S Counterweight Cylinder Disassembly And
Reassembly . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . ES05 - 59 - 6054.0R1S SECTION
6 Gantry
Crane Gantry Maintenance Chart . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . Gantry Disassembly
And Reassembly . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . SECTION 7 Crane Attachment Boom Foot
Maintenance Chart . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . SECTION 13 Electrical
System Electrical Diagram . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . .
. Electrical System Standardization . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . Storage Battery
Servicing And Installation . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . SECTION 14 Tightening Torque Table
ES06 - 01 - 2065.0R1S ES06 - 01 - 6037.0R1S
ES07 - 08 - 2063.0R0S
ES13 -01 - 0075.0R0S ES13 -01 - 9033.0R1S ES13
-04 -5004.0R0S
Bolt Tightening Torques . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . ES14 - 02 -
0004.0R1S
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0207
Book 1086
3
Equipment Layout
ES00-03-0072.0R0S
1 Components ?n Operator?s Cab
Front Drum Brake Pedal
Sun Visor
Swing Lever
Front Drum Lever Rear Drum Lever Boom Hoist Drum
Lever
Side Frame Control Lever
Throttle Lock Knob
Gate Lock Lever
Engine Key L.H. Travel Lever
Fan
R.H. Travel Lever
Rear Drum Brake Pedal Throttle Pedal Third Drum
Lever Swing Lock Lever
CB00-001
0504
4
Equipment Layout
ES00-03-0072.0R0S
2 General Equipment Of Upper Machinery
Hydraulic Reservoir Tank Line Filter
Rear Drum Clutch Brake Variable Pump/Gear
Pump Engine Air Cleaner
Counterweight Control Valve Boom Hoist Drum Rear
Drum Motor
Accumulator Return Filter
Radiator
Front Drum
Fuel Tank
Boom Hoist Drum Motor Solenoid Valve Check Block
Swing Motor
4-Series Control Valve
Front Drum Motor Swing Control Valve
CB00-002
0504
5
Equipment Layout
ES00-03-0072.0R0S
3 Lower Travel Machinery
Rotating Joint Track Shoe Turntable Bearing
Travel Motor
Lower Frame
Side Frame Retract Cylinder
Carrier Roller
Drive Sprocket
Travel Reduction Gear Case
Retract Mechanism
Front Idler
Track Roller Side Frame
CB00-003
0504
6
THIS IS A SAMPLE MANUAL
FOR THE COMPLETE MANUAL
CLICK HERE TO DOWNLOAD
7
Power Transmission System
ES01-01-0081.0R0S
Power from the engine is 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.
Counterweight Control Valve
Hydraulic Oil Reservoir Tank
Oil Cooler
Engine
VP
FP FP VP
CTWT CYL
I
BR CL Fourth Drum
Boom Hoist Drum
CL BR
CL BR
Front Drum
Rear Drum
FM
LBCE Supply
BV
CV
FM
BR
Third Drum
CV
A
E
FM FM
Swing/Retract Control Valve
B
F
FM
C
G
Operator's Cab
BR
CV
CV
D
H
CV
3rd/4th Drum
Return Filter
Control Valve
VP
Variable-Capacity Pump
Swing
BR
FP
Fixed-Capacity Pump
FM
VM Variable-Capacity Motor
Turntable Bearing
FM Fixed-Capacity Motor
Brake Valve
BV
Rotating Joint
CV Counterbalance Valve
To L.H. Travel Device
Clutch
CL
BR Brake CYL Cylinder
Retract CYL
A R.H. Travel B Boom Hoist C Rear Drum
1-Speed
D Front Drum 2-Speed E L.H. Travel F
Third/Fourth Drum G Rear Drum 2-Speed H Front
Drum 1-Speed I Control Device
BV
VM
R.H. Travel Device
CB01-001
1/1
0504
8
(No Transcript)
9
Front And Rear Drum Shaft Maintenance Chart
ES01-10-2052.0R0S
Unit inches (mm)
Item Part name Number Of Teeth 1 Allowable Backlash Treatment
1 Spur gear 6 8.0" (205.5) .08" (2.0) Replacement
2 Spur gear 3 3.7" (95.02) .08" (2.0) Replacement
1 Allowable Displacement Over A Given Number Of
Teeth.
2
1
ECD1-177S
1/1
0002
10
(No Transcript)
11
Front And Rear Drum Shaft Disassembly And
Reassembly
ES01-10-6069.0R0S
4
Rear Drum
32
Front Drum
14
16
ECD1-2S
3
15
16 17
19
38 18 2 20 12 26 22 28
Brake Band
10 12
8
9 30 13
5
23
1
24 25 37 36 34 35
27
31 11 33
21 7
29
6
ECD1-178S
CBD0158Z-E
1 Motor 11 Bearing Holder 22 Bolt 33 Bolt
2 Pinion 12 Ball Bearing 23 Plug 34 Hose
3 Plug 13 Ball Bearing 24 End Plate 35 Drain Cap
4 Gear Case 14 Oil Filler Cap 25 Bolt 36 Cover
5 Rotating Joint 15 Drain Plug 26 Spacer 37 Bolt
6 Gear 16 Check Cover 27 Oil Seal 38 Sponge Packing
7 Roller Bearing 17 Bolt 28 Seal Collar
8 Drum Shaft 18 Spacer 29 Bolt
9 Clutch Assembly 19 Bolt 30 Spacer
10 Hoist Drum 20 Snap Ring 31 Bearing Nut, Washer
21 Seal Retainer 32 Drum Indicator Assembly
1/17
0504
12
Front And Rear Drum Shaft Disassembly And
Reassembly
ES01-10-6069.0R0S
Disassembly Disassembly Procedure 1
3
4
2
Counterweight removal
Attachment removal
Front and rear drum wire rope removal
Gantry folding
Upper Machinery
5
6
Brake cover removal
Brake band removal
9
8
7
10
Drums and gear case assemblies removal
Drum indicator assembly removal
Hydraulic pipe removal
Gantry removal

1. Hydraulic Pipe Pressure Release
2. Drum Motor Connection Pipe Removal
3. Rotating Joint Removal

11
Gear case oil drain
13
14
Drum motor removal
Drum shaft assembly removal
12
Drum Motor oil drain
17
16
15
Bearing holder removal
Clutch assembly removal
Drum shaft removal

• Work Preparation
• Main body support
• Park the machine on level and stable ground.
• Extend the side frames.
• For side frame extension, refer to the opera-
  tor's manual.

CAUT?ON Take The Surrounding ?nto Consideration?
Select A Place Where Safe Operation ?s Possible
And Take Precautions Against Dangers.
Particularly Avoid Slopes.
WARN?NG Since The Component Parts Related To This
Procedure Are Heavy? Handle Them Carefully Or
Accidents May Result. Use A Hoist To Handle Them
Efficiently. Check That The Hoist Capacity ?s
Sufficient.
0504
13
Front And Rear Drum Shaft Disassembly And
Reassembly
ES01-10-6069.0R0S
1 Counterweight Removal 1) To remove the
counterweight with the gantry in the high
position, refer to the operator's manual.
Counterweight
CB01-002
2 Gantry Folding 1) To position the gantry from
high to low, refer to the operator's manual.
Pin Lock Pin
3 Attachment Removal 1) To remove the attachment
from the upper section, refer to the operator's
manual.
CB01-003
4 Front and Rear Drum Wire Rope Removal
CAUTION Avoid Injury To Yourself. Replace Or
Rearrange Rope Carefully To Avoid An Accident.
Rope Wrapped Around Sheaves May Become
Twisted. When Released, The Rope Can Spin As The
Dead End Pins Or Sockets Are Removed.
1) Pull out wire ropes from the front and rear
drums, and wind them with the winder.
CAUTION Properly Release The Hoist Drum Brake
During Removal Of Wire Rope Or Rope May Become
Kinked Or Twisted, Resulting In Excessive
Deformation, Shortening Wire Rope Life.
Winder Types
2) Remove the drum wedge, and remove the wire
rope from the hoist drum.
0504
14
Front And Rear Drum Shaft Disassembly And
Reassembly
ES01-10-6069.0R0S

• 5 Brake Cover Removal
• Open the upper cover of the brake cover.
• Loosen the locknut and remove the adjusting nut.
  The hanging bolt and spring cannot be separated
  from the band.
• Remove the bolt and brake cover.

• 6 Brake Band Removal
• 1) For brake band removal, refer to "front and
  rear drum brake control disassembly and re-
  assembly" ES03-05-60 in this manual.
• Hydraulic Pipe Removal
• Hydraulic pipe pressure release

WARNING All Trapped Hydraulic Pressure Must Be
Exhausted From The System Before Re- moving Any
Line Or Component. A Sudden Release Of Hot Oil
Could Cause Burns Or Other Serious Injury.
1) Operate the control lever back and forth sev-
eral times to release any hydraulic pressure
trapped in the lines. Note Even if pressure is
completely released, oil remains. Before
disconnecting a pipe or valve, position a
container to collect the oil.

• 7.2 Drum motor connection pipe removal
• Remove all pipes connected to the motor. (Ex-
  cept hoses 34)
• Attach blank plugs, blank flanges, caps, etc. to
  the pipe ports of the motor and the ports of the
  removed pipes to prevent oil from flowing out
  and foreign materials from entering.
• Note Place the removed pipes where disas- sembly
  and reassembly are not hindered. La- bel pipes,
  hoses, fittings, and other parts to prevent
  errors during reassembly.

0504
15
Front And Rear Drum Shaft Disassembly And
Reassembly
ES01-10-6069.0R0S

• 7.3 Rotating joint removal
• Loosen hose ferrule (a) and disconnecty hose
• (b) from adapter (c).
• Note To prevent oil from contacting the lin-
  ings, cover with a cloth before disconnecting
  hose (b).
• Note To prevent entry of foreign materials, cap
  or plug the opening of the disconnected hose.
• Note Contamination in the hydraulic equip- ment
  causes excessive parts wear.
• Loosen rotating joint (d) and remove it as an
  assembly with adapter (c).
• Remove the hose (b) and piping connected to the
  hose (b), if necessary.
• Disassemble the rotating joint.
• (Refer to ES05-14-60 in this manual.)

8 Gantry Removal 1) For gantry removal, refer to
"gantry disassem- bly and reassembly"
ES06-01-60 in this manual.
Bracket
Electromagnetic Switch
9 Drum Indicator Assembly Removal

1. Remove bolt, and remove bracket as an as- sembly
   with electromagnetic switch.
2. Disassemble removed bracket, and put it where
   reassembly is not hindered.
3. Remove spacer.
4. Remove bolt and slit plate.

Slit Plate
ECD1-8S
0504