Description
Link Belt Crane 238 Hylab 5 Service Manual
Link Belt Crane 238 Hylab 5 Index:
SECTION 0 General
How To Use This Manual, General Service Instructions, And Safety Procedures . . . . . . . . SM00—000—001.00
Equipment Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES00—03—0074.0R0S
SECTION 1 Upper Mechanism
Power Transmission System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES01—01—0083.0R0S
Front And Rear Drum Shaft Structure And Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES01—10—0050.0R0S
Front And Rear Drum Shaft Maintenance Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES01—10—2050.0R0S
Front And Rear Drum Shaft Disassembly And Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . ES01—10—6050.0R0S
Boom Hoist Drum Shaft Structure And Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES01—15—0050.0R0S
Boom Hoist Drum Shaft Maintenance Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES01—15—2051.0R0S
Boom Hoist Drum Shaft Disassembly And Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES01—15—6050.0R0S
Clutch Structure And Outline (1—Cylinder Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES01—17—0055.0R1S
Clutch Maintenance Chart (1—Cylinder Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES01—17—2077.0R0S
Clutch Troubleshooting (1—Cylinder Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES01—17—4023.0R0S
Clutch Disassembly And Reassembly (1—Cylinder Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES01—17—6040.2R0S
Swing Mechanism Maintenance Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES01—29—2053.0R0S
Turntable Bearing Maintenance Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES01—30—2030.3R0S
Turntable Bearing Inspection And Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES01—30—5051.0R0S
Drum Indicator Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES01—50—4001.1R0S
SECTION 3 Control System
Front And Rear Drum Brake Control Maintenance Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES03—05—2070.0R0S
Front And Rear Drum Brakes Control Inspection And Adjustment . . . . . . . . . . . . . . . . . . . . ES03—05—5067.1R0S
Front And Rear Drum Brakes Control Disassembly And Reassembly . . . . . . . . . . . . . . . . . ES03—05—6071.1R0S
Front, Rear And Boom Hoist Drum Lock Pawl Control Maintenance Chart . . . . . . . . . . . . . ES03—10—2050.1R0S
SECTION 4 Hydraulic System
Hydraulic Circuit Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES04—01—0087.0R0S
Hydraulic Circuit Pressure Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES04—01—5080.0R0S
SECTION 5 Hydraulic Unit
Hydraulic Unit Equipment Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES05—01—0019.0R0S
Variable Pump Structure And Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES05—02—0068.0R0S
Variable Delivery Pump Maintenance Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES05—02—2052.0R0S
Variable Delivery Pump Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES05—02—4009.0R0G
Variable Delivery Pump Disassembly And Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES05—02—6041.0R0S
Gear Pump Disassembly And Reassembly (2—Series Type) . . . . . . . . . . . . . . . . . . . . . . . . . ES05—03—6054.0R0S
Accumulator Structure And Working . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES05—05—0035.1R0S
Accumulator Inspection And Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES05—05—5032.1R0S
Accumulator Disassembly And Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES05—05—6046.1R0S
Front And Rear Winch Motor
Motor Structure And Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES05—09—0044.1R0S
Motor Maintenance Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES05—09—2025.0R0S
Motor Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES05—09—4011.0R0S
Motor Disassembly And Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES05—09—6034.1R0S
Boom Hoist Motor
Motor Structure And Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES05—09—0023.0R0S
Motor Maintenance Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES05—11—2025.0R0S
Motor Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES05—11—4002.0R0S
Motor Disassembly And Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES05—09—6023.0R0S
Travel Motor
Travel Motor Structure And Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES05—13—0053.0R0S
Rotating Joint Disassembly And Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES05—14—6029.2R2S
Brake Booster Structure And Working . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES05—16—0016.0R1S
Brake Booster Disassembly And Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES05—16—6005.0R1S
Remote Control Valve Structure And Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES05—17—0032.0R0S
Remote Control Valve Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES05—17—4028.0R0S
Clutch Cylinder Disassembly And Reassembly (1—Cylinder Type) . . . . . . . . . . . . . . . . . . . . ES05—18—6050.1R0S
Automatic Brake Cylinder Disassembly And Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES05—19—6032.1R0S
Hydraulic Cylinder Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES05—23—4001.1R0S
Counterweight Cylinder Disassembly And Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES05—26—6003.0R0S
Boom Foot Pin Cylinder Disassembly And Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES05—27—6052.0R0S
Line Filter Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES05—30—5061.1R0S
Line Filter Disassembly And Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES05—30—6061.1R0S
Return Filter Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES05—32—5011.0R0S
Return Filter Disassembly And Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES05—32—6011.0R0S
Rotating Center Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES05—34—0004.0R0S
Swing Control Valve Structure And Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES05—35—0055.0R0S
4—Series Control Valve Structure And Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES05—38—0043.0R0S
Check Block Structure And Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES05—49—0019.0R0S
SECTION 13 Electrical System
Electrical Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES13—01—0073.0R0S
Electrical System Standardization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES13—01—9033.0R1S
Storage Battery Servicing And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES13—04—5004.0R0S
SECTION 14 Tightening Torque Table
Bolt Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES14—02—0004.0R0S
SERVICE MANUAL 0311 KEYSHEET
Book 1109 1 of 2
238 HYLAB 5 Series — Master Keysheet (Crawler, Third Drum, & Boom)
(N2 Prefix On Crane Serial Number)
AREA 00 GENERAL INFORMATION
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SM00—000—000.00 How To Use This Manual, General Service Instructions, And Safety Procedures
AREA 02 CRAWLER LOWER
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SM02—001—002.00 Track, R & I
SM02—003—030.00 Track Drive And Sprocket, R & I
SM02—003—031.00 Track Drive Planetary, Brake, & Motor, Recondition
SM02—004—012.00 Take—Up Roller, R & I
SM02—004—013.00 Take—Up Roller, Recondition
SM02—004—014.00 Sealed Take—Up Roller, Recondition
SM02—004—015.00 Sealed Take—Up Roller, R & I
SM02—005—014.00 Track Roller, R & I
SM02—005—015.00 Sealed Track Roller, Recondition
SM02—007—004.00 Track Adjustment Cylinder, Recondition
SM02—007—005.00 Track Adjustment Hand Pump, Recondition
SM02—010—022.00 Hydraulic System Cleaning
SM02—010—029.00 Hydraulic Components, R & I
SM02—011—017.00 Travel Motor, R & I
SM02—014—001.00 Jack Cylinder, R & I
SM02—014—002.00 Jack Cylinder, Recondition
SM02—014—003.00 Jack Cylinder Control Valve, R & I
SM02—014—004.00 Control Valve, Recondition (Jack Cylinder)
SM02—014—005.00 Jack Cylinder Lock Valve, R & I
SM02—014—006.00 Jack Cylinder Lock Valve, Recondition
AREA 05 HORIZONTAL SHAFTS
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SM05—005—016.00 Winch, Recondition (L & S)
SM05—005—030.00 Third Drum Winch, R & I (L & S)
SM05—005—032.00 Third Drum Winch, R & I (NAHI/Dinamic w/o Free Spooling)
SM05—005—033.00 Winch, Recondition (NAHI/Dinamic)
SM05—005—034.00 Third Drum Winch, R & I (NAHI/Dinamic w/Free Spooling)
AREA 07 HYDRAULIC POWER SUPPLY
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SM07—000—000.00 Hydraulic Schematic Diagram Symbol Legend
SM07—003—006.00 Solenoid Valves, General Recondition (Third Drum Controls)
SM07—006—066.00 Hydraulic Motor, Recondition (L & S Third Drum Winch)
SM07—006—119.00 3rd Drum Winch Motor, R & I (L & S)
SM07—006—122.00 3rd Drum Winch Motor, R & I (NAHI/Dinamic)
SM07—006—125.00 3rd Drum Winch Motor, R & I w/Free Spooling (NAHI/Dinamic)
SM07—018—001.00 Hydraulic System Tube Fittings
AREA 09 TUBULAR BOOM, FLY, & JIB
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SM09—001—002.00 Repairing Damaged Tubular Booms, Flys, & Jibs
AREA 18 SPECIAL ATTACHMENTS
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SM18—000—001.00 Capscrew Torques
SM18—000—002.00 Gear, Shaft, Bearing, & Housing Inspection
SM18—000—003.00 Crane System Schematics