Link Belt ABS-48A Crane Service Manual

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Service Manua?
SMOOOOOOOO.OO
0519
How To Use This Manua?? Genera? Service
?nstructions? And Safety Procedures The fo??owing
information is provided to he?p guide the user of
this manua?. An exp?anation of how this manua? is
organized? as we?? as genera? information and
safety considerations which shou?d be
understood when performing any service or
maintenance procedure? is given. This information
is genera? in nature and shou?d supp?ement any of
the specific procedures in this manua? a?ong with
a constant awareness of safety and common
sense. How To Use This Manua? This Service
Manua? is a co??ection of written procedures
which are used to service and maintain a specific
crane mode?. The index? which is ca??ed
a ?Keysheet?? is used to organize the procedures
within this manua? and serve as a Tab?e Of
Contents as we??. Each procedure? in this manua??
is written so that it can stand a?one and
typica??y covers on?y one procedure. Procedures
are given a numerica? designation? or ?SM Code?
Number? (Examp?e SM01005034.00) which is
unique to that procedure and that procedure on?y.
The fo??owing is a ?isting of the genera? area
definitions which are designated by the first
digits in the SM Code Number sequence Genera?
Area Descriptions SM01 Rubber Tire Lower SM02
Craw?er Lower SM03 Upper Revo?ving Frame ?
Machinery SM04 Vertica? Shafts SM05
Horizonta? Shafts SM06 Upper Engine SM07
Hydrau?ic Power Supp?y SM08 Ang?e Boom SM09
Tubu?ar Boom SM10 Tag?ine Winder SM11
Fair?eader SM12 Shove? Attachment SM13 Trench
Hoe? Logger ? Scrapper Attachment ? Prop
Hand?er SM14 Cab ? House Assemb?y SM15
Rotascope Attachment (Discontinued) SM16 Wire
Rope Requirements SM17 Hydrau?ic Boom And
Attachments SM18 Specia? Attachments SM19
Diese? Pi?e Hammer (Discontinued) SM20 Tower?
C?imbing Assemb?y? Trave?ing Base ? Gantry
(Discontinued) SM21 Log Skidder
(Discontinued) SM22 Hydrau?ic Hammer
(Discontinued) The procedures in this manua? are
co??ated by SM Code Number sequence. Use the
Keysheet in the front of this manua?? the genera?
area descriptions shown previous?y? and the SM
Code tit?e shown on the
Keysheet to find the specific procedure required
to service the crane. Throughout this manua??
reference is made to the ?eft? right? front? and
rear? pertaining to directions and ?ocations.
These reference directions are re?ative to
the operator? sitting in the operator?s seat?
with the upper direct?y over the front of the
carrier? un?ess otherwise stated. (Craw?er
mounted cranes upper over the front of the crane
with trave? motors to the rear.) Danger? warning?
and caution captions as we?? as specia? notes are
used throughout this manua? and on the crane to
emphasize important and critica? instructions.
?f any instruction? caution? warning? or danger
?abe?s? deca?s? or p?ates become ?ost? damaged?
or unreadab?e? they must be rep?aced. Information
contained on such ?abe?s? deca?s? and p?ates is
important and fai?ure to fo??ow the information
they contain cou?d resu?t in an accident.
Rep?acement ?abe?s? deca?s? and p?ates can be
ordered through a danger? warning? and caution
captions and notes are defined as fo??ows
DANGER
An operating procedure? practice? etc. which? if not correct?y fo??owed? may resu?t in severe persona? injury? dismemberment? or ?oss of ?ife.

WARN?NG
An operating procedure? practice? etc. which? if not correct?y fo??owed? may resu?t in persona? injury.

CAUT?ON
An operating procedure? practice? etc. which? if not correct?y fo??owed? may resu?t in damage to? or destruction of? equipment or property.
NOTES Note An operating procedure step?
condition? etc. which is essentia? in order for
the process to be comp?eted proper?y.
This symbo? may appear in manua?s or on a ?abe?
on the crane to a?ert personne? that
additiona? instructions are inc?uded in the crane
Operator?s Manua?. 1 of 6
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SMOOOOOOOO.OO
Service Manual
0519
DANGER
Keep clear of moving parts to prevent serious
bodily injury.
Figure 1 Keep hands and tools clear of moving
parts.
Figure 3 Pinch Point Label
Diesel exhaust fumes can be harmful. Start and
operate engine in a well ventilated area. If it
is necessary to operate in an enclosed area, vent
the exhaust to the outside. Properly maintain
the exhaust system to its original design.

• First aid supplies and a fire extinguisher should
  be on the job site to assist in an unexpected
  situation. The location of these items should be
  known to all as well as access to a telephone
  for emergencies.
• Work in a clean,
• sible. Choosing the correct work site can make a
  big difference on how well the job goes.

Figure 2 Diesel Exhaust Fumes.
5. Use caution around flammable materials. Be
aware of all the materials in the work area which
are
Service Safety And Set Up Guidelines The
following is a list of safety and set up
als post signs if necessary. 6. Release all
trapped pressure in air and hydraulic
nent. Shutdown the crane, exhaust all pressure
considerations which may apply to any service or
maintenance procedure. Review the entire list
and understand the type of things you must
consider to perform a safe service procedure and
then apply these guidelines to each specific
service or maintenance procedure.
draulic control levers back ing the crane. 7. Do
not disconnect any hydraulic line from a crane
ing a line could release the trapped pressure,
DANGER

• ment to the ground or on to its rest before
  servicing the crane.
• Do not work on a crane which is in motion. Fans,
  belts, gear trains, etc. can catch an
  unexpecting
• person and quickly dismember them.
• Do not climb on the attachment or other hard to
  reach areas. If the steps and/or ladders which
  are

Do not operate the crane unless you are
qualified. Unauthorized operation by
untrained personnel could result in an
accident. Crane operation is to be performed by a
certified operator only.

• Service Safety
• Read and understand the service or maintenance
  procedure to be performed before beginning work.
• By reading the procedure ahead of time, you can
  be sure to have the replacement parts and tools
  on hand that are required to complete the job.
• Wear protective gear to prevent injury hard hat,
  safety glasses, gloves, steel toed shoes, etc.

ing, use a step ladder or other approved
device. 10. Pinch points exists between the upper
and lower frames. Death or dismemberment may
result from personnel caught in these points.
Learn where these pinch points are and stay clear
of the rotating upper frame.
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THIS IS A SAMPLE MANUAL
FOR THE COMPLETE MANUAL
CLICK HERE TO DOWNLOAD
6
Service Manual
SMOOOOOOOO.OO
0519
Right
Figure 5 Allow engine to cool before removing
the radiator cap.
Figure 4 Use a guard when inflating tires.

• If the crane is equipped with outriggers, it may
  be safer as well as an advantage to raise and
  level the crane on outriggers to provide easier
  access to areas underneath. Do not work under a
  crane that is improperly supported.
• Shutdown the engine(s) per the instructions given
  in the Operators Manual.
• Post a sign in the operators cab to alert others
  that the crane is being serviced.
• Engines, transmissions, hydraulic systems, etc.
• atures can reach levels which may cause serious
  burns. Allow the crane to cool before attempting
  to service it.

• equate ventilation when
• ing toxic solvents, welding, or any other
  operation which contaminates the fresh air
  supply.
• Post a sign in the operators cab to alert others
  that the crane is under service. Starting the
  crane while it is being serviced could severely
  injure someone.
• erated prematurely. Imagine starting the
  engine(s) before the oil is replaced.
• Secure access panels, doors, and machinery
  hoods when in the open position to ensure they
  do
• ruption. propriate lifting
• tempt to lift an object without knowing its
  weight.
• Get help if necessary.
• flating tires. W
• plode from the assembly causing serious injury.
  Use a safety rim cage, clip on air chuck, and
  stand aside when inflating or deflating tires.
• Crane Set Up And Disassembly
• Properly
• tors Manual. Park
• vides the most comfortable working conditions.
  However, do not park the crane where it will be
  an obstruction or an intrusion to traffic,
  coworkers, or to the public. Keep in mind that a
  major service procedure, or a repair part which
  requires a long lead time,
• tended period of time.
• Keep in mind the mess which is sometimes caused
  by a crane under repair. Oil or other fluid
  leaks should be contained or prevented. Consider
  your
• responsibility of maintaining a safe clean work
  area and a healthy environment for all.

WARNING
Engine coolant is hot. Failure to allow
engine(s) to sufficiently cool before draining
coolant could result in severe burns or other
personal injury. Allow the engine(s) and
radiator(s) to cool before draining coolant from
the radiator(s).
7. Pressure is generated inside the engines
cooling system due to the heat transfer process
from the engine(s) to the radiator(s). Do not
attempt to open or drain the radiator(s) until
it/they has/have had sufficient time to cool.
Disconnecting hoses before the engine(s) and
radiator(s) has/have cooled is even more
dangerous. Wait gine(s) and radiator(s) have
cooled and then drain the radiator(s) before
disconnecting any hoses. Properly store or
dispose of used coolant.
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0519

• Hydraulic systems, while operating, are under
  high pressure. Even after the crane is shutdown
  these pressures can remain trapped in the
  hydraulic lines and system components. Some
  hydraulic systems utilize an air pressurized
  reservoir which maintains pressure on the system
  after the crane is shutdown. It is critical
  that all residual pressure,
• nent. Use the following techniques to exhaust
  trapped hydraulic pressure from the system
• Lower the attachment to the boom rest, onto
• blocking, or onto the ground and shutdown the
  engine(s).
• voir(s), if equipped, to bleed the air system
  pressure.
• Relieve any residual or precharge pressure by
  pushing the button on the pressure relief valve,
• wise, loosen the filler cap 1/4 turn.
• Turn the ignition switch to the ON POSITION, but
  DO NOT START THE ENGINE.
• Operate the steering control(s) back and forth
  repeatedly until steering becomes hard. (On
• cranes equipped with emergency steering
• system, it will take several rotations of
  steering wheel before steering becomes hard.)
• Work the crane control levers and outrigger
• switches, if equipped, back and forth several
  times.
• Turn ignition switch to the OFF POSITION.
• When pressure is fully relieved, close the drain
  valves on the air system reservoir(s), if

Wrong
Figure 6 Do not use an open flame near the
battery.
WARNING
Solvents and cleaning solutions can be
hazardous. Serious personal injury may
result from misuse of these products. Read and
follow all the manufacturer?s
recommendations concerning solvents and cleaning
solutions.

• Thoroughly clean the area of the crane which is
  to
• ter the hydraulic, air, lubricating system, etc.
  and cause immediate and/or long term problems.
• tamination problems but it also makes working on
  the crane easier and sometimes problems are more
  recognizable.
• Before
• cedure, take a moment to observe critical
  features
• of the assembly which may greatly simplify the
  installation or assembly process. Label
  electrical, hydraulic, air, or other connections.
  Index mark pump, motor, and valve sections.
  Lightly spray paint or count the threads of
  adjustment screws. Simple steps such as these can
  minimize the effort needed to put the crane back
  in service.

WARNING
Air lines may contain high pressure. Opening
lines and fittings before relieving air pressure
may result in serious injury. Shutdown the
engine(s) and drain the air system
reservoir(s) before opening any line or fitting.
WARNING
11. Air system circuits, like hydraulic circuits,
contain high pressures also. Although the threat
of a hot working fluid does not exist, highly
pressurized lines and components can possibly
?fly off if lines are disconnected bef lieved.
Hydraulic oil is under pressure and may be hot. A
sudden release of hot oil could cause severe
burns and/or other serious injury. Shutdown
the engine(s) and exhaust all trapped
hydraulic pressure from the system before
removing any line or component.
ing on the crane.
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Service Manual
SMOOOOOOOO.OO
0519

• Do not position the ground connection where seals
  or bearing, as in transmissions or valves, will
  be between it and the welded parts.
• Remove any flammable materials from the area.
• Use the appropriate setting on the welder for the
  size of the welding operation. Do not use more
  than 200 Volts continuously.
• Cleaning And Inspection

WARNING

• Use care not to cause sparks at the battery
  terminals while disconnecting or connecting the
  battery. Battery gasses are volatile and could
  be ignited by a spark or flame causing the
  battery to explode. Keep the area around the
  battery well ventilated and disconnect the
  negative side of the battery first, with the
  ignition switch ?OFF?, to minimize hazard.
• Battery posts, terminals, and accessories contain
  lead and compounds. Eating or smoking with lead
  residue on hands may cause lead poisoning. Wash
  hands after handling lead products.
• When working on electrical circuits, disconnect
  the battery to minimize shock, burn, spark, or
  other hazard. When disconnecting the battery,
  confirm
• connect the negative side of the battery first to
  minimize the potential for sparks at the battery.
  Battery gases which are exposed to such sparks,
• necting the battery, confirm that the ignition
  switch is in the OFF position and install the
  positive cable(s), first and the negative
  connection(s) last.
• It is a good practice when disassembling
  hydraulic components to lay the parts out in the
  order that they were disassembled. Keeping the
  parts in this
• tion will aid in the assembly process.
• Welding
• connect any electronic equipment (such as rated
  capacity limiters and engine computers) to
  prevent damage to them. Use the battery
  disconnect switch(es), if equipped.
• Be aware of systems adjacent to areas being
  welded. Residual heat from the welding process
  could cause damage to other components. Heat
  may also vaporize materials which may become
  toxic or volatile.
• Remove paint from areas to be welded to prevent
  toxic fumes.
• The grounding connection should be within 3 feet
  (1 m) of the welded parts.
• Connect the ground to the lower, if welding on
  the lower, or to
• trical current through the turntable bearing
  could

WARNING
Solvents and cleaning solutions can be
hazardous. Serious personal injury may
result from misuse of these products. Read and
follow all the manufacturer?s
recommendations concerning solvents and cleaning
solutions.
related lead

• All components should be thoroughly cleaned with
• fully inspected for damage, wear and corrosion.
• All Loctite
• moved from threads of hardware and parts that are
  going to be reused.
• All soft parts, such as seals, gaskets, back up
• Replacement of
• ly a good preventive maintenance measure. Even
  though a bearing or bushing seems to be intact
  and is functioning properly, its life span is
  limited. Replacing a simple bearing or bushing
  while the opportunity is at
• ponent failure later.
• sonnel for directions whether to repair or
  replace any major component.
• Crane Assembly
• Loosely assemble parts to ensure all parts are in
  place and fasteners started before beginning
  torquing procedure. Always use a cross torquing
  sequence to ensure even and uniform installation.

WARNING
Lubricants, sealants, joint and thread locking
compounds, etc. can be hazardous. Serious
personal injury may result from misuse of these
products. Read and follow all manufacturer?s
recommendations concerning these products.
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• Unless otherwise stated, torque all fasteners per
  the instructions given in SM Code Area 18000.
• When installing hydraulic hoses, lines, and
  fittings, use two wrenches to ensure the hoses
  and lines
• are not twisted. One wrench must be on the male
  fitting, the other wrench on the female fitting.
• Unless otherwise stated, torque all hydraulic
  fittings per the instructions given in SM Code
  Area 07018.
• Check all fluid levels before returning the crane
  to
• service hydraulic reservoir oil level,
  transmission

Wrong
quired. See Operators Manual and/or engine(s)
manufacturers manual(s) for correct type of
fluids and procedures. 6. Always replace guards,
grilles, and other types of protective shields.
Also, be sure that any systems which were
disconnected such as load indicating
etc. are functioning properly before returning
the crane to service. 7. Start the appropriate
engine and let it idle for five minutes. Inspect
the connections on the hydraulic, air,
transmission, etc. lines for leaks. Repair if
needed.
Figure 7 Proper disposal is important.
tions are operating normally before returning the
crane to service. 9. After crane is assembled,
refer to the Operators Manual for any periodic
type of adjustments which may have been affected
by the service procedure. ers, etc.
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SM3-1-1.0
Service Manual
Area 3 - Ugper Revolve ng Frame
3 Clips 4" Apart (All four connections.) Sl.ou l d be tai ce the d i ameter of the shat .
3 Clips 4" Apart (All four connections.) Sl.ou l d be tai ce the d i ameter of the shat .
3 Clips 4" Apart (All four connections.) Sl.ou l d be tai ce the d i ameter of the shat .
Fig. S11ng Assemb1y Bom Foot Pins (3) Gantry Headshatt (S) Wire Rope Clips (3 Per Connec- Sl i ng As senb1y (4) fire Rope ThinbJ e ti on , 4" Apart) (A) 189" (B) 2.31 Ft. (To tenter 0f Grav i ty) (C ) 123 Note Center o gravity will vary due to welghts of optional eq pment. Sling lengths are starting point only. They may have to be agjusted to make machine hang perfectly level. Fig. S11ng Assemb1y Bom Foot Pins (3) Gantry Headshatt (S) Wire Rope Clips (3 Per Connec- Sl i ng As senb1y (4) fire Rope ThinbJ e ti on , 4" Apart) (A) 189" (B) 2.31 Ft. (To tenter 0f Grav i ty) (C ) 123 Note Center o gravity will vary due to welghts of optional eq pment. Sling lengths are starting point only. They may have to be agjusted to make machine hang perfectly level. Fig. S11ng Assemb1y Bom Foot Pins (3) Gantry Headshatt (S) Wire Rope Clips (3 Per Connec- Sl i ng As senb1y (4) fire Rope ThinbJ e ti on , 4" Apart) (A) 189" (B) 2.31 Ft. (To tenter 0f Grav i ty) (C ) 123 Note Center o gravity will vary due to welghts of optional eq pment. Sling lengths are starting point only. They may have to be agjusted to make machine hang perfectly level. Fig. S11ng Assemb1y Bom Foot Pins (3) Gantry Headshatt (S) Wire Rope Clips (3 Per Connec- Sl i ng As senb1y (4) fire Rope ThinbJ e ti on , 4" Apart) (A) 189" (B) 2.31 Ft. (To tenter 0f Grav i ty) (C ) 123 Note Center o gravity will vary due to welghts of optional eq pment. Sling lengths are starting point only. They may have to be agjusted to make machine hang perfectly level.
Genera1
equl pnents capaci ty chart and make (1 ) Remove
di rt , shavt ngs , excess sure i I can do the
job before pro- of 1 from the threads .
The basic upper weighs approximate- needing.

• Thoroughly degrease threads
• Eli th ( 16N119 ) octi te" safe ty So1vent
  . A11ow so1 vent to dry .
• App1y "locqui c" pri ver N (16P IN 8) to caps
  crew heads . A1 for
• 3 to S minutes to dry.
• Apply amount of "1oc ti te" pi pe sea1ant (
  16A845) neces sary to cover thread engagement.
• I ns tall capscreu and nut .

1y 9,400 1bs . v\ thout ca tea1ks or counterwe
igh t. Add1t1 on of opt i on- Prepare tJ on For
Install ng The at equ1pment w111 1ncrease thi
s Upper khen a 48A mach1ne 1s
shh pped from the factory, unmount-
weight. The fo11oxi ng are approx- mate weights
of optional equip- sent F.D. Loueri ng
Clutch..... 150 lbs. R.D. Lowering Clutch.....170
lbs. Ca tea1ks ...............1, 2G0 bs. An upper
u1th all Of these options cout d eel gh as much
as 11, 000 1bs . L1ft1ng equipment must be
prov1d- ed that can safely lift the upper. Th1s
equi prent must be in good cond1t1on, proper 1y
adjusted and reeved, before atter sting to 11ft
the upper. Refer to such 11fting
ed, the machined surface on the upper , where i t
counts aga nst the bearing 1s covered Ltd th
pre- serYative to prevent rusting. The exterior
of the beari ng s a1so coated. Th1s preserve t1
ve riust
be removed before mounting the
0n TC . ABS , or API machines , a
upper. Thorough1y reoove a11 pre- oounti ng ba se
i s shi pped w1 th the
servat1 ve uJ th an approved comer- frachJne
. Thi s ba se mus t be a ttach-
cial solvent. ed to a pedestal, barge, ship deck,
before the upper can be mounted.
khen lnstal l ing capscreus and nuts , Proper
construe t1 on of and connec - the capscreus must
be "locti ted II on of the mount1ng base to the
as fo11ozs supports ng structure shall be the
HC48A
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11
Service Manua I Area 3 - Upper Revo1vlng Frame -
Continued
respons 1b111ty of the owner. Load values and
react1on 1oca t1 ons are available for such
construction. These can be obta i ned froi FfJC
Corporati on, Crane Excavator D1- v i s on. The
serv1ces of a qua1i - fi ed engl neer should be
used in the des gn and cons truc ti on of
the supporting structure.

• to F1g . 1 f0I" Iflore infoma- t1on. See secti on
  T4 in op- erators manual for informa- tf on of ui
  re rope c1i ps.
• Drop four mountt ng capsc rexs through the
  mountl ng holes In
• the upper to use as a11gnment tool s .
• Pick the upper slightly off
• the ground . Check to make sure it hangs
  level. If not, set 1t back down and adjust the st
  1ngs .

• capscreus .
• After fi na tf ghteni ng , allow the loctite
  to cure for ap- proximately six hours before
  operating machine.
• Assemble live mast, backstops, counterweight,
  catwalks and attachment on the machlne. Re- fer
  to operators manual for assembly instructions.

• Installing The Upper The follow- i ng procedure
  covers mounting the upper on a truck ca rri er or
  riount- i ng ba se
• lf installing on a truck, park on level ground.
  Apply parking brakes, and block the wheels.
• Attach s1lng s to upper ( See
• F\ g. 1 ) . Connec t one eg to each boom foot
  pin, and one 3eg to the extended gantry
  headshaft. (Where the boom backs tops noun t)
  . Ins ta11 keeper pJ ns or cotter pi ns i n the
  boon foot pins to prevent their orki ng out.
• Secure the rear s i ngs to the headsha ft wJ th
  ti e ui re to
• pr even t the s1 Jngs cal ng off the sha ft .
• The s1i ng mus t have four 1egs, and be s trong
  enough to 11ft the upper. If us ing u1re
• rope , use a Sri nion 5/8" di a- me ter rope wi
  th a ml nimum breaklng strength of 20 tons. FMC
  type N rope is recommended. Use new rope straight
  off the reel for making up the sling. Never use
  used, scrapped, or damaged rope for a sling as
• an accident may occur. Refer

oper Storage If the upper is to
be stored for a long period of
time before mounting, or wlll set
Pick the upper and swing it into place over the
turntable bearing. Stay out from under the upper
idle for long periods of time af- ter mounting,
follow storage pro- cedures in operators manuals.
In adds II on , fu y ubr i ca te the ma-
chine at least every 60 days,
arefu11y over the upper i nto while in storage.
Then start the
place. Engage the capscrews machine and rotate
all shafts and
wlth the holes in the bearing. the turntable
bearing to distri-
bute the grease and help prevent rust. This is
especially important on machines working around
salt water where rust and corrosion foms fa s
ter then usua . In add J - tion, coat all
unpainted metal uJ th preserva t1 ve . Store
nachi nes under cover if at all possible.
Set the upper in place on the bearing . 8a1ntaln
a stral n on the s1i ngs to keep the up- per from
ti 1tJ ng . (e) Ins ta 1 at) ( 16 tota ) cap-
screws . Start a nut on each capscreu.
Note All capscrews must be l oc-
ti ted" as exp1a i ned ear1 er i n Before putt
ng a stored uni t to
the s sects on. Two lengths of cap_ xork ,
thoroughl y Ins pect i t for
screw are used. The ones to the rust,
deterioration, damage, etc.
rear of the upper are 1onger.
Repa r any damage before operating the macho ne.
(f) F1na1 t1 ghten each capscrew
to 350 ft . -lbs torque . Tigh- Preparation For
Undecking The Ma-
ten capscrews by starting at chine Refer to
operators manua1 the centerline of the machlne,
and perform the following steps
and working outward, alterna- tely tightening a
capscrew to the left, then to the right of the
centerline. Repeat this procedure on the rear

• Rwove j i b or t1 p exten s1on from machine.
  Remove boom from mach1ne.
• Remove catwalks from the mach-
• ine if so equlpped.

F1 g. 2 F1 g. 2 F1 g. 2 F1 g. 2 F1 g. 2 F1 g. 2 F1 g. 2
Turntab Ie Bear1ng Assecib1 y
( 1) Shlms (4) Lower Frame (6) Ball s
( 2) Capscrevs (5) Turntable Bearing (7) Capscreus
(3) Upper Frame

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SM3-1-1.0
Service Manual Area 3 - Upper Revbl vlng Frame -
Cont1nued

• Rmove all counterweight from the nachl ne.
• Lower 11ve mast unt11 t 1s hori zonta1. Block
  securel y under the 1ve ria st. Rmove boon hot s
  t rope.
• Remove 11ve cast froo the ma- ch1ne.
• Remove boom backs tops from the machine.
• 0n mach1nes equi pped v1th hyd-
• raulJc outr1ggers , move ro- tat1ng j oint hous
  ing. See
• SB .Area -48.
• gn4eck10g The ftachlne
• I f carr1er mounted, park na- chs ne on fi m ,
  1eve1 surface . Apply wergenc/ brakes and block
  whee1 s .
• Attach st i ngs to upper (See F tg. ) . Connec
  t one leg to each boon foot p1n, and one 1eg to
  the extended gantry headshaft. (there the box
  backs tops count) . lnstal 1 keeper pi ns 1n the
  boom foot
• p1ns to prevent their work ng out.
• Secure the rear s1ings to the headshaft wi th t1e
  wire to prevent s i ngs com1ng off the shaft.
• Connect hook block from the 11ft1ng equi pnent to
  stings . Hoi st aga i nst sl1ng to provi de
  see tensi on 1n the st 1ng.
• Reeove the haunting capscrevs .
• xote pscrews are ins ta11ed a t the factory uJ
  th "1octi te" olpe sea lant. Heati ng the
  Jocknuts twtoh ch 1 Joosen the "J oc- t te",
  makl ng 1ocknut s easier to remove. Use a heat
  ng p. AppT_y

ported. Be careful not to da- mage S-o-8 tubing
or control J images under the rrachi ne
. Turntabl e Beari ngRepl accent See SN3-1-8. 0.
hest to the 1ocknu t only. Hea t to a
eax1fflUfB tetnpera ture of 350 . e h tlng
may rum the bearing. Use a "terp11-sti ck" or
other eeans to check. khet_j eplac1ng bear1ng
or y/hen eachfne 1s undecked, use new cap-
a d ocknuts upon reassem- ldy pA rmiJxy be dama
durlng removal and 0f reused.

• could cause an accldent.
• L1ft the upper off of the car- r1er or mount1ng
  base. Stay out frofn under the upper.
• Set the upper on b1ocklng , or
• on a trall er 1f beIng trans-

IJC48A
3 of 3
13
THIS IS A SAMPLE MANUAL
FOR THE COMPLETE MANUAL
CLICK HERE TO DOWNLOAD
14
SM3-18.0
Service Manual Area 3 - Upper RevoTvlng Frame

• Remove And Rep1ace Turntab1e Bear- 1yg
• (a Undeck machine. Refer to SM 3-1-1.0.
• Renove rotatl ng jot nt from ria- chine 1f
  app1icab1e.
• Tack weld a steel plate over the hole in the
  carri er frame in center of the bearlng .
• Take ueasurwents to accurate- 1y 1ocate the
  center of the
• bearing. Mark this spot on the p1a te for later
  use when a1ignlng the new beari ng .
• Cut o1d beari ng Iron carri er
• ui th arc/a r cuttlng equi prient . Be carefu1 to
  cut we1d wi th-
• out gouge ng the truck frame plate.
• After the o1d bear Ing s remov-
• ed , grlnd the frane p1ate smooth before nountlng
  the new bearfng.
• The beari ng mountl n pl ate on the weld flange
  of the bearing aust be free of o11 ,
• grease, rust , ml 11, sea1e . etc .
• in the weld zone.
• Renove any surface condition that will keep the
  bearing flange Iron fi tting near1y flat on the
  bearing mounting plate.
• (i ) Set the new bearing Tn place.
• Align beari ng by measur ng from center a s 1oca
  ted i n step (d). There 1s a letter "S" s tapped
  on the bear Ing race. Thi s 1etter Pius t be
  toward the front of the car- rler, and on the
  carr 1er cen- ter 11ne .
• keld ng Equi prrent
• Use standard equl pment , helmet, g1oves , etc
  . ho spec a1 equt jxrent or too1s requi red
  except .010 fee1er gauge.

• note the gap under the beari ng . If there are
• hi gh spots on the mounting pl ate whi ch can be
  eas 1y ground off, do so. If
• not , tack the beari ng down a s lollozs
• Us i ng an E7018, 5/32" dJ a. rod , riake tack
  ue1ds 1 long at points where con- tact i s
  riade . Space the tack eel ds evenly to pre-
  vent bear 1ng tJ pplng dur- 1ng shirrm ng .
  (Four Tacks Maximum).
• Use ei ther flat shins (29
• B381 ) or tapered shims
• (12B238) . The f1a t ones
• are preferred because they can be stacked up ,
  and do not have a tendency to pry up on the bean
  ng . Do not dry ve shams Into place.
• To shim , use the thi ckest shim, stack of shims
  , or paired wedge shi ms xhJ ch wi 11 fi t the
  gap u1thout prylng up the beari ng . Gaps less
  than .010" need not be shined . Pl ace shins
  under the bearing f1ange so i t i s supported at
  Tea s t eve ry 3" about the beard ng c i
  rcurrference.
• Us ing an E7018, 5/32" di ameter
• rod , make 16 tack welds two Inches long as shown
  In vlew
• f/ote the tack eel d Iequence l and 2 i ns i de
  front and rea r ,
• 3 and 4 outsi de front and rear , etc.
• Lsing an E7028, 5/32 diameter
• rod (D. C . A . C . 260 - 300
• amperes, 22-25 volts), weld each layer as shown
  in view D, inside and out. Use the weld sequence
  as shown in view B. held approximately 22 per
  rod.
• Using an E7028, 3/16 diameter rod, weld the
  fourth pass on the inside only as shoWn in view
  C.
• Chip off slag. Thorougiy
• clean and then paint a1 1 welds to prevent
  rusting.

HC48A
1 of 2
15
Service ManuaI
Area 3 - Upper Revolving Frane - Continued
SH I HS
D
TACK UE LD SEQUENCE
IST . 2fJD , 3RD PASS \ELD SEQUENC E
4TH PASS I NS I DE
A
B
Fig . 1 ke1dlng Procedure
2 ot 2
StYt3-1-8.0
16
SM3 31.0
Service Manua I
Area 3 - Upper Revolv Jng Frate
H272A

• Fijure 1
• Coun terueJ ght As senb1y
• Capscrew
• Capscrew

1. Revolving Frame
2. Counterweight

Counterweight Assembly

• under with the capscrew.
• (d) T1ghten each capscrew to the torque listed
  earlier on this page.
• Coynterve1gh Rpmoya
• Attach a chain or wire rope sling to the ctwt.
  lake sure that the sling is strong enough to lift
  the ctwt.
• Connect to the sling with a helper crane.
• Take a strain against the
• slin9 to support the ctwt.
• Remove the four capscrews shi ch hold the ctvt.
  on the machi ne.
• S1ng the ctwt. out from under
• the riach ine.

The counterweight is attached to the rear of the
upper frame by four capscrews. The larger (l-
J/2" capscrews) a t the rear are tightened to
1,360 ft-lbs. torque. The smaller (l) capscrews
at the front are tightened to 390 ft.- lbs.
torque. The capscrews should be checked
occasionally for proper torque. If the capscrews
work loose, it may cause damage to the revolving
frame or the mounting bolts.

• Counterve1qht I ns tall ati oq-
• Attach a cha i n or u1re rope s1i ng to the
  ctt. Nake sure that the st ng , and helper
  crane are strong enough to 11ft the c ty/t. C
  txt . welghts are as fo1loss
• HC48. . . . . . . ... 5, 000 1bs .
• HC48A (u/GH Engine......

• . . . ..8,700 lbs.
• (3) HC48A (P/Continenta0 engine........9,200 lbs.
• Lift the counterweight and swing into place
  under the rear of the revolving frame.
• Slide the mounting capscrews through the ctwt.
  and revol- vlng frame. Have someone
• start the nuts on the capscrewz
• Dont stand under the ctWt. Stand to one side and
  reach

1 Of 1
48 Series