Link Belt ABS-78A Crane Service Manual Pdf

1
ABS-78A
MODEL
BOOK No. 406 SERIAL No.
MACHINE SERIAL NUMBER Themachineserialnumberisonth
eserialnumbercapacityplate,orontheCrane Rating
Manual located inside the operator's cab. The
serial number should alwaysbefurnishedwhenorderlng
partsfor the machine or when corresponding with
the distributor or factory concerning the
machine. Providing the serial number is the only
way of ensuring the correct parts and/or
information can be furnished. In the event the
serial number is not readable, a number is
stamped on the upper revolving frame which can be
uaed to identify the machine. On cable crane this
number ia located on the right hand boom foot
mounting lug. On hydraulic craneaand
excavatorsthenumber is stamped just below the
boom hoistcylinder mounting lugs.
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MODEL C- BOOK No. 406 SERIAL No.
MACHINE SERIAL NUMBER Themachineaerial number
isontheaerialnumber capacity plate, orontheCrane
Rating Manual located inaide the operator's cab.
The serial number should alwayabefumishedwhen
ordering partsforthemachine or when corresponding
with the distributor or factory concerning the
machine. Providing the serial number is the only
way of ensuring the correct parta and/or
information can be furnished. In the event the
eerial number is not readable, a numbsr Is
stamped on the upper revolving frame which can N
uaed to identify the machine. On cable crsne this
number is located on the right hand boom foot
mounting lug. On hydraulic cranesandexcavator9the
BUfTibe7 i8stampcdjust below the boom
hoiatcylinder mounting lugs.
4
THIS IS A SAMPLE MANUAL
FOR THE COMPLETE MANUAL
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5
MODEL T -
406
aoox No.
SERIAL No.
MACHINE SERIAL NUMBER Themachineserial number
isontheserial numbercapacityplate, orontheCrane
Rating Manual located inside the operator's cab.
The serial number should alwaysbefumishedwhenorder
ing partsforthemachine or when corresponding with
the distributor or factory concerning the
machine. Providing tfe serial number is the only
way of ensuring the correct parts and/or
information can be furnished. In theevent the
serial number is not readable, a number is
stamped on the upper revolving frame which can be
uaed to identify the machine. On cable crane this
number ia located on the right hand boom foot
mounting lug. On hydraulic craneeandexcavatorsthen
umber isstampedjustbelowtheboomhoistcylinder
mounting lug8.
6
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7
SERVICE MANUAL
gUlC It RE FERE NC E SYST EU
(A) Ls 78 (8) HC 77- y8 ( C) UC 77- 78
OPERATING INSTRUCTIOHS

• Ls 78
• LS 78 PL
• -( C) HC 78

(D) UC 77-78 ( E) Ht 7 7
PROTECTIYE AIHTEHAuCE AND LUBRICATION
(A) LS 78 ( 8) LS 78 PL (c ) Ht 78
(a) uC 77- 78 ( E ) HC 7
LOWER FRA/tE AND CRAVLERS , TO 8 CX CA R RIER
UPPER REYOLYING PRAE VERTICAL SHAFT
ASSEItBLlES HORIZONTAL SHAPT ASSEMBLIES
DRU A BRAKES
CLUTCH ASSEMBLIES
EHGINE, CLUTCH, AND DRIVE CHAIN
SPEED-oMATlC COH TROL SYSTEM
TREHCH HOE ATTACHAENT SHOVEL ATTACHAEHT
(A) ANGLE BOOM ( 8) TUBULAR BOOK
CRAHE BOOk ATTACIJkENT
SPECIFICATIONS AND GEHERAL IHFORAATIOH
673-78 LL
8
SERVICE MANUAL
P R E F A C E
The product ive 1 i fe of any each inc depends
I atge i y on the care ari d cons i de ration
given it . Thi s espeel a11y ho Ids t rue o such
equ1pmen t Bs cranes and ex cav at ors .
Link - Be I t Spee de r mach ines embody the bes
t of eng ineerin g know ie dge , ye ars of expe
rien ce , and con - s t rueti on in accordan ce
ui th th e hi gh st andards oI the Comp any . Th
e pre sen t mach i ne age an d art i ve rs a1 use
of the andomob i le has t aught nos I peop le
to appre ci ate th at sys t einai c , peri odi
cal inspe ct ion and main t enan ce u i 11 be
rep at d u ith a I onge r pe ri od of satisI
acYory se rvi ce .
This ins t met ion book was comp i I ed to exp
1ain the adj ust rien t s ne cess ary- fo r
proper ope rat i on of t he machine . A s tudy of
t h i s book ui 11 acquain t ope rat or or servi
ceman sit h the cons t ructi on of th is
equipaen t and enab 1me hi I o re adi ly di
agnose and reme dy nos t t roub Ie s ah i ch may
ari se . I t i s ad- vi sab1e I o cor rect rrtino
t roub 1e s be Jo re the y de ve lop in to cos t
1 y rRaj o shut - downs .
Ri. gh t hand and ie ft hand part s , as re be
rre d t o in th i s book , ar e 5e te m in ed by
f aci ng boon I row rea r of mach ine . Ope rat
or ' s pos i t i on i s 1ocate d on le ft han d
s i de of mach i ne .
be do no t a tt erp t t o out 1 i n e wh at p art
or pa rt s oI t ft e c ab i t ini gh t be ne ce s
sa ry t o remove_ t o p -to rrn your part i cu
1ar j ob as I hi s ui 11 vary depen di n g upon
th at equipmen t or t oo1s are ava i 1 ab Ie .
Any que st i ons pert ain in g to t he care and
up ke ep of thi S eg ui pmen I vh i ch h ave not
be.n cove re d i n t h i s boot shou ld be di re
ct ed to y our ne are st Lin k - Be 1 t Speede r
di s t rib ut or , or Li nk - Be It Speede r
Cortp an y .
Link - Be I t Spee de r Comp an y rese rves th e
ri gh t t o make al te rat ions or modi I cat i
on s in t hi s equipmen t at any tie , uhi ch in
t he i r op in ion ray i rp rove the pe rfortnan
ce or e ffi ci en cy of the each i ne . The
nanufacture r sha I I not be ob l i ge d t o nak
e such al te rat i ons or nodi fi cati ons t o
mac hines aI ready in servi ce .
9
Operator's ManuaI Sect Jon 2A - Protectîve
f1aJntenance And Lubrlcatlon
Upper, Lower And Attachment Time
The following procedures are im- portant for
proper lubrication of the machine.
Table Read the following instructions before
attempting to operate a new machine.
AUNO T Shut Down Engine Before Fuel4ng Or
Lubricating Machine. To Avoic A FJ re Hazard , Do
Not Smoke 0r Handle Fuel Around An Open F) ame.
To Avold Mach1ne Damage And To Prevent Seri ous I
nj ury, Do Not Lubricate Gears Or Any Assembly
While It Is In Motion.

• Operate at half throttle dur- ing the first 16
  hours (tW0 shifts) of operation. A "Dreak In"
  period under moder- ate loads will assist in pro-
  viding long and trouble-free operation.
• Inspect and adjust all clutches and brakes
  periodically during the "break-in" period. Poor
  lining contact or misadjust- ment will cause
  excessive heat which is detrimental to both
  linings and drums.
• Lubricate all bearings and bushings
  frequently. Lubrica- tion intervals for all
  bearings and bushings may be found in the
  lubrication chart.
• Lubricate open gears at fre- quent intervals. A
  special Molybdenum sulphide base grease has been
  applied at the factory, which because of its
  special qualities protects the tooth surfaces
  during the
• "break-in" period. This grease should not be
  removed, but

• Wipe the grease gun nozzle, and the grease
  fitting before lubricating. This will help keep
  dirt and grit from en- tering the bushing or
  bearing.
• Keep all grease and o i l cans
• and conta1ners c1ean. Ahays replace the l d on
  containers when through to prevent entry of fore
  i gn materi a1 s. II pe off oK can covers before
  using.
• Drain oi1 cases when hot to
• drain off accumulated sludge.
• Watch for signs of incorrect lubrication such as
  failure of clean grease to expel the old
  grease.
• Bleed off hydraulic pressure
• before opening or removing a line or fitting.
• Replace all guards before starting machine.
• Use a clean funnel equipped
• with a strainer for pouring lubricants. Clean an
  area around fill or check plugs before removing
  to prevent entry of foreign material.
• Disengage master clutch be-
• fore working on or lubricating the machine. Shut
  off engine.

allowed to be absorbed by the
norua1 gear lubri can t be ng
used.
(e) Foll or the engine manu fac tur- re's
recommendations for proper engine care. DI
engage the master clutch and shut off the engine
while working on the machine, Replace all guards
before starting the machine.
General Lubrication Information
The machine should be regularly and
systematically lubricated in accordance wi th the
lubri cat Jon charts shown later i n th 1s Secti
on of the manual. A copy of this chart is mounted
on the upper cab in each machine. The time inter-
val shown on the lubrication chart is intended as
a guide only. Under unusual WOFking
conditions, such as working in dry, dusty con-
ditions, in water or mud, around a corrosive
atmosphere, more frequent lubrication will be
neces- sary. In these cases, the oiler must use
his own good sense and work out his own
lubrication schedul e.
Note See specific instructions later in this
Section for lubri- cation check and change_proce-
dures on dll gear compdrtments.
LS78
2A-1
10
O e a o Upon Delivery
s Manuä Section 2A - Continued - Protective
Maintenance And Lubrîcation
Operation Remarks
General Check for any shortages or damages that may have occurred during transit. If any, notify the transportation company involved, immediately. Clean dust, dirt, cinders, and other foreign material from all clutches, gears, and other moving parts. Check all oil compart- ments for the proper weight and level of lubricant. If necessary, change to meet local conditions Lubricate the upper, lower and attachment completely. Check and adjust all clutches, as explained in ection 3B. Check and adjust all drum brakes, as explained in Section 3B. Check and adjust steer brakes as explained in Section 3A.
Engl ne Check fuel, oil and water levels. Start engine and check oil pressure, water temperature, S-o-M pressure, etc.
Master Clutch Before engaging master clutch, inspect the entire machine for any items which may interfere with moving parts.
Controls Become familiar with all controls. Read Section l Operating Instructions, before attempting to operate the machine.
Atta chrient Assemble the desired length of boom on the machine as explained in Section 13. Inspect all wire rope and rope connections. See Section 14 for wire rope inspection procedures. Check all ropes for proper spooling on the drum.
Engine Speed Check engine for proper speed. See reverse shaft speed, Section 14.
Attachment Check all bolts, nuts, rod ends, cotter pins, etc., making sure they are spread and/or securerl. Inspect a1 l rope and connect i ons. Nake sure rope I s spooli ng proper 1y. Check and adjust the boom hoist limiting device, if necessary. See Section 13.
Before Sta rti ng Opera tJ ons
0pera t i on Remarks
Engine theck oi) and water levels, and other items as recommended by the manufacturer.
Clutches Brakes Examine all clutches and brakes. Make sure they are in proper adjustment as explained later in this marual. Examine the linings to make sure they are not oil soaked, or worn to the point that rivets are contacting the drum. See Section 3B,
Speed-o-Matic System Check for correct operat ng pressures (refer to Sec t i on 10 for ore information). Check for external leaks. If any, repair before operating.
Attachment Inspect dll wire rope and wire rope connections. See Section 14 for wire rope inspection procedures. Check all ropes for proper spooling on the drum.
2A-2
11
Operator's Manual Section 2A - Continued -
Protective Maintenance And Lubrication Daily Or
Every 10 Hours
Operation
Remark s
Engine
(1) Provide 10 hour inspection and lubrication as
outlined by the manufacturer.
P.T.O. - Tai n Di sc
(1) Lubricate the throwout bearing. Apply a small
amount of lubricant, before starting, through the
fitting on the tapered part of the housing.
A
Boom Chords and Latti ce L i ve Nas t Gantry

1. Inspect all parts of the attachment, paying
   particular attention to the boom chords and
   lattice. If damaged, the boom may col- lapse. If
   a lattice or diagonal bracing member is damaged,
   replace i t. If bent, straighten i t. Refer to
   General Bu11et i n f174 for repai r i nforma ti
   one If a real n chord i s damaged or bent, even
   a IN ttTe bi I, don I use t. Don t try to
   repai r t. These members are so vital that it is
   not practical to attempt repair. Replace the
   entire boom section.
2. If the live mast or gantry are damaged, repair
   before using.

Battery

1. Check electrolyte level. Fill with distilled
   water if necessary.
2. Keep battery clean at all times. Corroded posts
   or accumulation of grit, electrolyte, etc., on
   top of battery can cause it to become discharged.
3. Don't smoke or use open flame near a
   battery. Battery gas is explosive.
4. These bushIng s should be 1ubri cated at regu1ar
   i nterval s regard- 1es s of the amount of tra
   vet.
5. After lubricating, walk the machine several feet
   to spread lubricant around the bushings.
6. When traveling constantly, lubricate every 4
   hours or oftener.

Lubricate the Following Center Pin Bushing
Traction Shaft Bushings Sprockets Idlers Track
Rollers
Open Gears

1. Maintain a film of clean grease on open gear
   teeth at all times.
2. Stop the engine and disengage the master clutch
   before applying the lubricant.

Track Drive Chains
(J) Lubricate as often as possible with a mixture
of engine oil and kerosene to flush out dirt and
grit, and to lubricate pins and bushings.
ii re Rope
(1 ) Inspect as out1 ined i n Section 14. (I )
Check cool ant level . Check for anti -freeze n
winter.
Radiator
Control Stand Linkage Attachment
(1 ) Use engi ne of 1 on all pins and s1i ding
surfaces.
(1) Lubricate all 10 hour fittings as specified
on the lubrication chart 1ater in thi s sect on.
Traction Shaft Splines
(1) Keep traction shaft splines oiled and clean
to provide smooth jaw clutch operation.
Si de Frarie Bo1ts
(1) Keep tight. See the torque chart in Section
14.
Chain Case

1. Visually check the flow of oil in the chain case
   to assure proper chain lubrication.
2. Check the oi1 level in te chan case.
3. Check for leaks. Repair before operating.

78H Sump Tank S-o-M Sump Tank
(1) Check the oil level. Add oil if
necessary. See Section 10.
LS78
2A-3
12
Operator's ManuaI Section 2A - Cont1nued -
Protective Nalntenance And Lubrication Weekly Or
Every 50 Hours First performall operations listed
under "Every 10 Hours".
Oper at i on Remarks
Engine Lubrlca te the Fol 1ou1ng Conical Roll ers tlutch Arms and Heel 81ocks Control Linkage Drum Brake Controls S-o-N Va1ve Caps Power Take-0ff S1de Hous i ng Bearings (All Hon zontal Shafts ) Reduction Shaft Bearings Redction Shaft Coupling Vertical Shaft Bearings Two Speed Planetary S-o-N FJ1 ter 78H Surip Fi lter Clutches Brakes General - Upper And Attachment Wire Rope Turntable Roller Path RJng Gear Upper Trans . Case Loser Bevel Gear Case Ind. Swï ng Bevel Gear Case Provi de 50 hours inspect i on and lubri cat i on as outl ined by the manufacturer. 1) Consult the lubrication chart later in this section for the proper lubricant to use in each location. Check valve caps for rust and corrosion - clean and lubricate as necessary. Lubricate the clutch pilot bearing through the fitting in the end of the clutch shaft. Lubricate the shaft bearings through the fitting on the housing hub. Lubrcate the cross shft through the two fttings, one at each end of the shaft. Pump in 8 or 10 shots of grease at each lubrication as three bearings are being lubed through one fitting. Wipe up excess grease which otherwise would collect on the clutch linings. Lubricate sufficiently to fill the bearings. Lubricate to prevent coupling seizing on shaft. Stop machine with fitting pointing toward upper engine for ease of lubri- cation. Lubricate sufficiently to fill bearings with grease. Check, and fill i f necessary, uJ th the lubricant speci fi ed later in thi s sect ton. theck for 1eakage. Repai r before operating. Change after the first 50 hours of operation and every 250 hour theeafter See Section 10. Greasy, aged, or worn clutch linings should be replaced. Check linings for proper contact and adjust, if required. Check linings for foreign pa t4cles which may score the drum. Greasy, aged, or worn brake linings should be replaced. Check lining for proper contact and adjust, if required. Check linings for foreign particles which may score the drum. Lubricate all remaining 50 hour points as listed on the lubrication chart. Inspect all wire rope and rope connections See Section 14. Keep path free of excess grease. Use "Tacky" grease as neces- sary during break in only. Maintain a film of grease, as specified in the lubrication specifications, on the gear teeth at all times. Check lubricant level, and add lubricant if necessary. Use only lubricant meeting the specifications listed later in this section. Check for leakage. Ifany, repair before operating.
2A-4
13
Operator's Manual Section 2A - Continued -
Protective Maintenance And Lubrication Month1y
0r Every 250 Hours First perform all operations
listed under "Every 50 Hours".
Operat Jon Remarks Eng i ne
(1) Provide 250 hour maintenance and lubrication
as outlined by the manufacturer. ( T ) Change the
S-o-M filter e1eilient. Clean the housIng in a
sui tabl e so1vent. See Sect ion 10.
2 A
S-o-N FI I ter 78H Sump F11ter
Master Clutch
(1) Check and adjust as necessary.
Boom Hoist Brake

• Visually check band connecting lugs, actuatTng
  linkage, and related pins, and the mounting
  bracket pin hole for any signs of wear or
  cracking.
• Visually check band for any indications of
  bending, inter- ference, or unusual lining wear
  which would indicate excessive wear of the above
  parts.
• Check condition of band adjusting nut and bolt.
  Make sure
• the self locking nut will hold against rotation
  during operation.

Track Drive Chain Track Shoes
(1) Inspect for wear, and adjust if necessary.

1. Check, and adjust if required.
2. If brake bands are worn, replace or reline the
   bands.

Swing Brake
Steer Brakes
Jaw CIutches Si de Frame Reservoi r
( 1 ) Check oJ1 1evel (pi pe1i ners only) .
Every 500 Hours First perform all operations
listed under "Every 250 Hours". Operation Remarks
(1) Remove the band and all related parts for a
detailed, visual inspection. If any parts show
signs of undue wear, cracks, or other distress,
replace them. Reassemble and adjust the brake
mechanism.
Boom Hoist Brake
Every 1000 Hours Or Seasonal First perform all
operations listed under "Every 500 Hours".
Operation Remarks 1000 hours Seasonal
Upper Trans. Case Ind. Swing Bevel Gear Case Lower Bevel Gear Case Drain, flush, and refill with the lubri- cant speciIN ed 1n the s secti on.
Bevel Gears Check bevel gears for proper backlash.
Two Speed Planetary Drain and refill with specified lubricant.
Chai n Case Drain and refill with specified lubricant.
S-o-N System Drain, clean and refill with proper weight of S-o-M oil. Make seasonal weight changes as required.
LS78
2A-5
14
Ope a o s Manual Section 2A - Continued -
Protective Maintenance And Lubricat4on Every 1000
Hours - Continued
0peratJ on Remarks 1000 Hours Seasonal
Engi ne Dri ve Chai n Check for correct alignment, adjustment and normal Wear.
Cotta Transmission Dran, clea and refill. Nae seaona weight changes as necessary,
Turntable Gear Inspect turntable gear and swing pinion for normal wear.
Conical Rollers Inspect rol lers and path for near. Adj us t if necessary.
Jaw C1 utches I ns pect for wear, damage and proper engagement.
Sheaves Inspect for wear and damage.
Eng 1ne See Manufacturer.
78H Sump Tank Drain clean. Refill with proper weight S-o-M oil. Clean strainer.
Each ne Storage Sugges t 1ons Li sted be ton are
a number of Jm- portant points that should be
followed when putting a machine into storage.
Machines stored outside must be thorough l y pro-
tected or seri ous deteri orat on will result.

• heavy grease to prevent rust ing. Cover all
• clutch and brake friction
• surfaces w1th a cove r of waterproof paper or
  plas- tic to protect these sur- faces from rust.
• Set the track shoes on
• p1anks.
• Cover the track drive chains with heavy oil to

i n ref eased pos i II on. (n) Refer to eng i ne
dnd clutch manual for information on s tori ng
power un t. (n) Lock all doors on machine. If in
area where vandalism is possible, cover all
window glass with plywood or metal covers .
( 1 ) Lower boom to ground , and
Note Store machine so it doesn't
s1ack off on boom suspens 1on ,
prevent rust.
provde a paything for chdren.
or remove boom ents rely. Tie down all ropes and
pendants to prevent whi pping i n the w1nd, etc.
(f) Cover the track adjustment Such a unlt can be
an attractive
bolts with heavy oil to muisance" for children to
play oñ.
prevent rust. If they fall off it or get
entangled,
(h) Cover the intake and ex- serious Injury may
result. haust openings on the up- per engine, to
prevent molstu re entering. ( i ) I f an
t1-freeze i s not to be used , compl etel y dra n
the cool i ng sys tern. Lea Ye a1l drai n open
. (j ) Remove the bat te rJes and store them
where they wJ 1 not freeze. Perl odi cal- l y
charge then duri ng the (k ) Cover open spaces
around boorr ho1s t ba i 1 or drums ui th
waterproof p1as tJ c or paper to keep ra Jn from
coming in on machinery parts. (Cover entire up-
per wi th tarp, If avat 1- able ) . ( 1 ) Leave
all control levers in neutral position. Leave
foot brake pedals
(2) Nach ines shou1 d be stored
under cover to reduce the pos-

• s bi 1 ty of rus t and deters -
• I f stored outs de , certai n procedures must be
  fo11owed to protect mach i ne as much as poss b1e
  from the e1event,s
• Clean the un I t horough1 y , renov ng a1 l d1rt
  and other fore i gn materl a1.
• Lubricate entire machine
• as outlined in this sec- tion.

oration.
winter,
(c ) Touch up any spots where
pa nt has been knocked
off to preven t rus t and
deteri or at1on.
(d ) Cover all unpa i nted machines surfaces,
except friction surfaces such as clutch and drum
brake surfaces with a coating of
2A-6
15
0peFa
' ManUal Section 2A - Continued - Protective
Maintenance And Lubrication
WARNING
Note Di sengage ma ster c1u tch before Worki ng
on Mac h1ne. Rep1ace all guard s or panels before
starti'ng machine.
14 2 3 13 5 6 f2 7 52
17
PI PELI NE L01fER
23
26
38
Capacity Chart Location Upper Trans. Case
Ca acit 9.5 Ga1. 35 9L 19.75 Gal. (74.7L ) 7 Ga1.
(26.SL ) 7.5 Ga1. (28. 4L) 3 6al . (1l . 4L) 1. 5
Ga1. (5.7L) 1. s sat. (s.7L ) 18 Gal. (68.lL) 1.5
Qu. (l.4L)
Be1 or 32
bove 32
1 Speed
Upper Trans. Case (2 Speed)
Lower Bevel Gears (P1. Stand. Lower) Lower
Bevel Gears (L.N. And Long Lower) Chan
Case Reverse Beve1 Gear Case Ind. Swing Gear
Case P.L. Side Frame Two Speed P1anetary
2A-7
LS78
16
THIS IS A SAMPLE MANUAL
FOR THE COMPLETE MANUAL
CLICK HERE TO DOWNLOAD