Kobelco CK1600 and CKE1350 Crawler Crane Workshop Service Repair Manual PDF - MKOBCK1600.zip

Full OPERATION & MAINTENANCE guide, including the Parts Manual, for the KOBELCO CK1600 and CKE1350 Crawler Cranes.

KOBELCO CK1600, CKE1350 Electrical Circuit Chart.pdf

S2GN00003ZE10 - KOBELCO CK1600 Crawler Crane OPERATION & MAINTENANCE MANUAL.pdf

S2GN10002ZE08 - KOBELCO CK1600 (LUFFING) Crawler Crane OPERATION & MAINTENANCE MANUAL.pdf

S3GN12003ZO01 - KOBELCO CK1600 Crawler Crane Parts Manual.pdf

S5GN00003ZE08 - KOBELCO CK1600, CKE1350 Crawler Crane OPERATION & MAINTENANCE MANUAL.pdf

PRODUCT DETAILS:

Total Pages: 2,322 pages

File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)

Language: English

TABLE OF CONTENTS

KOBELCO CK1600, CKE1350 Electrical Circuit Chart....1

S2GN00003ZE10 - KOBELCO CK1600 Crawler Crane OPERATION & MAINTENANCE MANUAL....33

COVER....33

TABLE OF CONTENTS....35

IMPORTANT INFORMATION....41

1. SAFE OPERATING PRACTICES FOR MOBILE CRANES....49

2. OPERATION....69

2.1 TERMINOLOGY OF MACHINE EACH PART....69

2.2 LOCATIONS AND TERMS OF OPERATING CONTROLS....70

2.2.1 OPERATING SWITCHES....74

2.2.2 GAUGE CLUSTER CONFIGURATION....84

2.2.3 OPERATING THE AIR CONDITIONER....98

2.2.4 AM/FM RADIO (OPTION)....100

2.3 CRANE OPERATION....102

2.3.1 ADJUSTING THE OPERATOR'S SEAT....102

2.3.2 ADJUSTING THE CONTROL LEVER DIRECTION....102

2.3.3 STARTING AND STOPPING THE ENGINE....103

2.3.4 FUNCTION LOCK LEVER....106

2.3.5 PROPELLING OPERATION....107

2.3.6 SWINGING OPERATION....109

2.3.7 BOOM RAISING/LOWERING OPERATION....112

2.3.8 HOOK RAISING/LOWERING OPERATION....114

2.4 FREE FALL OPERATION....117

2.5 HANDLING OF REEVING WINCH (OPTION)....120

3. LOAD SAFETY DEVICE....123

3.1 ARRANGEMENT OF EQUIPMENTS....123

3.2 TYPE AND FUNCTIONS OF EQUIPMENTS....126

3.3 CONNECTING PROCEDURE OF WIRING....132

3.3.1 CRANE ATTACHMENT....132

3.4 FUNCTION OF CONTROLLER/MONITOR....137

3.5 OPERATING PROCEDURE OF CONTROLLER....141

3.5.1 SETTING SCREEN....142

3.5.2 SETTING OF THE CRANE CONFIGURATION....147

3.5.3 SELECTION OF MAIN/AUX. LIFTING....152

3.5.4 SETTING OF WORKING AREA LIMIT VALUE....153

3.5.5 SETTING OF THE TIME....157

3.6 WARNING ALARM AND AUTOMATIC STOP....159

3.6.1 ITEMS OF WARNING ALARM AND AUTOMATIC STOP....159

3.6.2 CONTENTS OF AUTOMATIC STOP....160

3.6.3 RELEASE OF AUTOMATIC STOP....162

3.7 INSPECTION....168

3.7.1 INSPECTION BEFORE RAISING THE BOOM AFTER ASSEMBLY OF ATTACHMENT IS COMPLETED....168

3.7.2 INSPECTION AFTER ERECTING THE ATTACHMENT....171

3.8 CAUTION FOR HANDLING THE LOAD SAFETY DEVICE....172

3.9 INDICATION OF ERRORS AND REMEDY....173

3.10 INDICATION OF MESSAGE AND ALARM....174

3.11 CONFIRMATION OF FUNCTION FOR LOAD SAFETY DEVICE....176

4. ASSEMBLY OF THE MACHINE....177

4.1 STABILITY IN SWINGING AND TRAVELING....177

4.1.1 WITHOUT BOOM BASE....177

4.1.2 WITH BOOM BASE....179

4.2 TRANSLIFTER....180

4.2.1 COMPOSITION OF TRANSLIFTER....180

4.2.2 HANDLING TRANSLIFTERS (1) - (4)....181

4.3 UNLOADING BASE MACHINE....184

4.3.1 ERECTING GANTRY....185

4.3.2 SETTING TRANSLIFTERS....187

4.3.3 UNLOADING BASE MACHINE FROM TRAILER....191

4.4 INSTALLATION OF THE CARBODY WEIGHT (OPTION)....193

4.5 INSTALLATION OF CRAWLER....195

4.5.1 INSTALLATION OF THE FIRST CRAWLER....195

4.5.2 INSTALLATION OF THE SECOND CRAWLER....200

4.6 INSTALLATION OF THE COUNTERWEIGHT....202

4.6.1 ASSEMBLING THE COUNTERWEIGHTS....202

4.6.2 REMOVING THE HOOK BLOCK FROM THE BASE BOOM....206

4.6.3 SETTING THE COUNTER-WEIGHT LINK....206

4.6.4 INSTALLATION OF COUNTERWEIGHTS TO MACHINE....207

4.7 ASSEMBLING ATTACHMENTS....212

4.7.1 ASSEMBLY OF BOOM AND FIXED JIB....212

4.7.2 ASSEMBLY OF THE JIB....227

4.7.3 INSTALLATION OF THE AUXILIARY SHEAVE....232

4.8 REEVING THE WIRE ROPE FOR CRANE AND AUXILIARY SHEAVE....233

4.8.1 REEVING THE FRONT DRUM WIRE ROPE FOR CRANE....233

4.8.2 REEVING THE REAR DRUM WIRE ROPE TO THE AUXILIARY SHEAVE....235

4.8.3 REEVING OF REAR DRUM WIRE ROPE....236

4.9 ERECTING THE ATTACHMENT....238

4.9.1 CONNECTING THE SAFETY DEVICE....238

4.9.2 CHECK THE SAFETY DEVICE....238

4.9.3 CONFIRMATION BEFORE ERECTING THE ATTACHMENT....238

4.9.4 ERECTING THE ATTACHMENT....239

4.9.5 CHECK BEFORE STARTING THE WORK....239

5. ASSEMBLY/DISASSEMBLY OF DISASSEMBLY OF THE MACHINE....241

5.1 LOWERING THE ATTACHMENT....243

5.1.1 LOWERING THE ATTACHMENT....243

5.2 DISCONNECTING THE WIRING FOR SAFETY DEVICE....244

5.3 REMOVING THE BOOM GUY LINE....245

5.3.1 INSTALLATION OF THE UPPER SPREADER TO THE BOOM BASE....245

5.3.2 REMOVE THE BOOM GUY LINE....245

5.4 REMOVING THE COUNTERWEIGHT....246

5.4.1 DISCONNECT THE BOOM BASE FROM THE INSERT BOOM....246

5.4.2 REMOVE THE COUNTER-WEIGHTS FROM THE MACHINE....246

5.4.3 INSTALLATION OF THE HOOK BLOCK TO THE BOOM BASE....251

5.4.4 DISASSEMBLY OF THE COUNTERWEIGHT....251

5.5 DISASSEMBLING THE ATTACHMENT....253

5.5.1 REMOVING UPPER AND INSERT BOOMS....253

5.6 REMOVAL OF THE CRAWLERS....254

5.6.1 SETTING THE TRANSLIFTER (Refer to 4.3.2)....254

5.6.2 REMOVAL OF THE CRAWLERS....255

5.7 REMOVAL OF THE CARBODY WEIGHTS....261

5.8 LOADING THE BASE MACHINE....262

5.8.1 LOADING THE BASE MACHINE ON THE TRAILER....262

5.8.2 LOWERING THE BOOM BASE....264

5.8.3 LOWERING THE GANTRY....265

5.8.4 FOLDING THE TRANSLIFTER....266

5.8.5 CAUTION WHEN TRANSPORTING THE BASE MACHINE....267

5.8.6 HANDLING OF TRAVELING KIT (OPTION)....268

6. WIRE ROPE....269

6.1 HANDLING OF WIRE ROPE....269

6.1.1 UNREELING METHOD OF WIRE ROPE....269

6.1.2 WINDING WIRE ROPE ONTO THE DRUM....270

6.1.3 INSTALLING THE ROPE SOCKET....272

6.1.4 SPECIFICATION OF WIRE ROPE....272

6.1.5 WIRE ROPE LENGTH....273

7. MAINTENANCE....275

7.1 CHECKS....280

7.1.1 CHECKS OF THE UPPER....281

7.1.1.1 UPPER STRUCTURE INSPECTIONS-DAILY OR EVERY 8 HOURS....282

7.1.1.2 UPPER STRUCTURE INSPECTIONS-MONTHLY OR EVERY 100 HOURS....287

7.1.1.3 CHECK OF UPPER SEMI-ANNUALLY OR EVERY 600 HOURS....291

7.1.1.4 CHECK OF UPPER WEEKLY OR EVERY 50 HOURS....292

7.1.2 CHECK OF LOWER....294

7.1.2.1 CHECK OF LOWER DAILY OR EVERY 8 HOURS....296

7.1.2.2 CHECK OF LOWER MONTHLY OR EVERY 100 HOURS....297

7.1.2.3 CHECK OF LOWER QUARTERLY EVERY 3 MONTHS OR EVERY 250 HOURS....299

7.1.2.4 CHECK OF LOWER SEMI-ANNUALLY OR EVERY 600 HOURS....299

7.1.3 CHECK OF ATTACHMENT....300

7.1.3.1 CHECK OF ATTACHMENT DAILY OR EVERY 5 HOURS....302

7.2 OIL/GREASE SUPPLY AND WATER SERVICE....309

7.2.1 UPPER LUBRICATION (INCL. WATER SUPPLY)....312

7.2.2 LOWER LUBRICATION....314

7.2.3 ATTACHMENT LUBRICATION....316

7.2.4 GREASE....318

7.2.5 ENGINE OIL....324

7.2.6 FUEL....325

7.2.7 COOLANT....326

7.2.8 HYDRAULIC OIL....328

7.2.9 GEAR OIL....330

7.3 CLEANING/WASHING/CHANGING FILTER ELEMENT AND STRAINER....336

7.4 BATTERY INSPECTION....347

7.5 LOCATION AND USE OF FUSE....350

7.6 OPERATION UNDER UNUSUAL CONDITIONS....352

7.7 MACHINE STORAGE....354

7.8 TIGHTENING TORQUE VALUES....355

7.9 SECURITY PARTS TO BE REPLACED PERIODICALLY....357

7.10 ADJUSTMENT....358

7.10.1 ADJUSTMENT OF FRONT AND REAR DRUM LOCKS....358

7.10.2 ADJUSTMENT OF BOOM DRUM LOCK....359

7.10.3 ADJUSTMENT OF THIRD DRUM LOCK....360

7.10.4 CRAWLER SHOES ADJUSTMENT....361

7.11 CONSUMABLE PARTS LIST....362

8. REFERENCE MATERIALS....367

8.1 SPECIFICATION....367

8.1.1 PERFORMANCE....367

8.1.2 OUTSIDE DIMENSIONS....367

8.2 DIMENSIONS AND WEIGHT OF EACH PARTS....369

8.2.1 BASE MACHINE....369

8.2.2 COUNTERWEIGHT....371

8.2.3 ATTACHMENT....372

8.3 SYSTEM SCHEMATIC....375

8.3.1 HYDRAULIC SCHEMATIC....375

8.3.2 ELECTRIC SYSTEM SCHEMATIC....378

9. INITIAL ASSEMBLY OF THE MACHINE....393

9.1 UPPER STRUCTURE (WITH CARBODY) LIFTING PROCEDURES....394

9.1.1 INSTALLATION....394

9.2 LOADING/UNLOADING OF THE MACHINE FROM/ONTO A TRAILER....395

9.2.1 LOADING ONTO A TRAILER....395

9.2.2 UNLOADING FROM A TRAILER....395

9.3 INSTALLATION OF THE CARBODY WEIGHT (OPTION)....399

9.4 INSTALLATION OF THE CRAWLER....400

9.4.1 INSTALLATION OF THE FIRST CRAWLER....400

9.4.2 INSTALLATION OF THE SECOND CRAWLER....404

9.5 INSTALLATION OF THE GANTRY TO THE SWING FRAME....405

9.6 INSTALLATION OF THE BOOM BASE....409

9.6.1 INSTALLATION OF THE BOOM BASE....409

9.7 INSTALLATION OF THE BACKSTOP....410

9.8 INSTALLING THE UPPER AND LOWER SPREADER....411

S2GN10002ZE08 - KOBELCO CK1600 (LUFFING) Crawler Crane OPERATION & MAINTENANCE MANUAL....419

COVER....419

TABLE OF CONTENTS....421

IMPORTANT INFORMATION....427

1. SAFE OPERATING PRACTICES FOR MOBILE CRANES....437

2. OPERATION....457

2.1 TERMINOLOGY OF MACHINE EACH PART....457

2.1.1 LUFFING UPPER BOOM ATTACHMENT....457

2.1.2 LUFFING JIB ATTACHMENT....458

2.2 LOCATIONS AND TERMS OF OPERATING CONTROLS....459

2.2.1 OPERATING SWITCHES....463

2.2.2 GAUGE CLUSTER CONFIGURATION....473

2.2.3 OPERATING THE AIR CONDITIONER....487

2.2.4 AM/FM RADIO (OPTION)....489

2.3 CRANE OPERATION....491

2.3.1 ADJUSTING THE OPERATOR'S SEAT....491

2.3.2 ADJUSTING THE CONTROL LEVER DIRECTION....491

2.3.3 STARTING AND STOPPING THE ENGINE....492

2.3.4 FUNCTION LOCK LEVER....495

2.3.5 PROPELLING OPERATION....496

2.3.6 SWINGING OPERATION....498

2.3.7 BOOM RAISING/LOWERING OPERATION....501

2.3.8 HOOK RAISING/LOWERING OPERATION....503

2.4 LUFFING JIB OPERATION....506

2.4.1 JIB RAISING/LOWERING OPERATION....507

2.4.2 HOOK HOIST DRUM CONTROL....509

2.5 FREE FALL OPERATION....510

2.6 HANDLING OF REEVING WINCH (OPTION)....513

3. LOAD SAFETY DEVICE....515

3.1 ARRANGEMENT OF EQUIPMENTS....515

3.2 TYPE AND FUNCTIONS OF EQUIPMENTS....519

3.3 CONNECTING PROCEDURE OF WIRING....527

3.3.1 CRANE ATTACHMENT....527

3.3.2 LUFFING ATTACHMENT....531

3.4 FUNCTION OF CONTROLLER/MONITOR....536

3.5 OPERATING PROCEDURE OF CONTROLLER....540

3.5.1 SETTING SCREEN....541

3.5.2 SETTING OF THE CRANE CONFIGURATION....546

3.5.3 SELECTION OF MAIN/JIB/AUX. LIFTING....551

3.5.4 SETTING OF WORKING AREA LIMIT VALUE....552

3.5.5 SETTING OF THE TIME....556

3.6 WARNING ALARM AND AUTOMATIC STOP....558

3.6.1 ITEMS OF WARNING ALARM AND AUTOMATIC STOP....558

3.6.2 CONTENTS OF AUTOMATIC STOP....560

3.6.3 RELEASE OF AUTOMATIC STOP....564

3.7 INSPECTION....570

3.7.1 INSPECTION BEFORE RAISING THE BOOM AFTER ASSEMBLY OF ATTACHMENT IS COMPLETED....570

3.7.2 INSPECTION AFTER ERECTING THE ATTACHMENT....576

3.8 CAUTION FOR HANDLING THE LOAD SAFETY DEVICE....577

3.9 INDICATION OF ERRORS AND REMEDY....578

3.10 INDICATION OF MESSAGE AND ALARM....579

3.11 CONFIRMATION OF FUNCTION FOR LOAD SAFETY DEVICE....581

4. ASSEMBLY OF THE MACHINE....583

4.1 STABILITY IN SWINGING AND TRAVELING....583

4.1.1 WITHOUT BOOM BASE....583

4.1.2 WITH BOOM BASE....585

4.2 TRANSLIFTER....586

4.2.1 COMPOSITION OF TRANSLIFTER....586

4.2.2 HANDLING TRANSLIFTERS (1) - (4)....587

4.3 UNLOADING BASE MACHINE....590

4.3.1 ERECTING GANTRY....591

4.3.2 SETTING TRANSLIFTERS....593

4.3.3 UNLOADING BASE MACHINE FROM TRAILER....597

4.4 INSTALLATION OF THE CARBODY WEIGHT (OPTION)....599

4.5 INSTALLATION OF CRAWLER....601

4.5.1 INSTALLATION OF THE FIRST CRAWLER....601

4.5.2 INSTALLATION OF THE SECOND CRAWLER....605

4.6 INSTALLATION OF THE COUNTERWEIGHT....607

4.6.1 ASSEMBLING THE COUNTERWEIGHTS....607

4.6.2 REMOVING THE HOOK BLOCK FROM THE BASE BOOM....611

4.6.3 SETTING THE COUNTER-WEIGHT LINK....611

4.6.4 INSTALLATION OF COUNTERWEIGHTS TO MACHINE....612

4.7 ASSEMBLING CRANE WITH LUFFING BOOM TIP ATTACHMENTS....617

4.7.1 ASSEMBLY OF BOOM/GUY LINE....617

4.7.2 ASSEMBLING OF BOOM/GUY LINE (Using an assisting crane)....623

4.7.3 ASSEMBLING OF BOOM/GUY LINE (Self-erection with boom base on the base machine)....631

4.7.4 INSTALLATION OF AUXILIARY SHEAVE....636

4.7.5 REEVING FRONT DRUM WIRE ROPE FOR CRANE....637

4.7.6 REEVING REAR DRUM WIRE ROPE TO AUXILIARY SHEAVE....639

4.8 ASSEMBLING THE LUFFING ATTACHMENTS....640

4.8.1 ARRANGEMENT OF BOOM/JIB/GUY LINE....640

4.8.2 ASSEMBLING OF BOOM/JIB/GUY LINE (Using an assisting crane)....645

4.8.3 ASSEMBLING OF BOOM/JIB/GUY LINE (Self-election with boom base on the base machine)....659

4.8.4 REEVING FRONT DRUM WIRE ROPE FOR CRANE....673

4.9 ERECTING ATTACHMENT....676

4.9.1 CONNECTING SAFETY DEVICE....676

4.9.2 CHECKING SAFETY DEVICE....676

4.9.3 CONFIRMATION BEFORE ERECTING ATTACHMENT....676

4.9.4 ERECTING THE CRANE ATTACHMENT....677

4.9.5 CHECK BEFORE STARTING WORK....678

4.9.6 ERECTING THE LUFFING ATTACHMENT....679

4.9.7 CHECK BEFORE STARTING THE WORK....683

5. DISASSEMBLY OF THE MACHINE....685

5.1 LOWERING THE ATTACHMENT....687

5.1.1 LOWERING THE ATTACHMENT....687

5.2 LOWERING THE LUFFING ATTACHMENT....688

5.2.1 LOWERING THE ATTACHMENT....689

5.3 WINDING UP THE FRONT DRUM/REAR DRUM WIRE ROPES....692

5.4 DISCONNECTING THE WIRING FOR SAFETY DEVICE....692

5.5 WINDING UP THE JIB DRUM WIRE ROPE....693

5.6 REMOVING BOOM GUY LINE....693

5.6.1 INSTALLATION OF UPPER SPREADER TO BOOM BASE....693

5.6.2 DISCONNECT BOOM BASE FROM INSERT BOOM....693

5.7 COUNTERWEIGHT REMOVAL....695

5.7.1 REMOVAL OF COUNTERWEIGHTS....695

5.7.2 INSTALLATION OF THE HOOK BLOCK TO THE BOOM BASE....700

5.7.3 DISASSEMBLY OF THE COUNTERWEIGHT....700

5.8 DISASSEMBLING CRANE WITH LUFFING BOOM TIP ATTACHMENT....702

5.8.1 REMOVING THE AUXILIARY SHEAVE....702

5.8.2 REMOVAL OF BOOM GUY LINE....702

5.8.3 REMOVING UPPER AND INSERT BOOMS....703

5.9 DISASSEMBLY OF LUFFING ATTACHMENT....704

5.9.1 DISASSEMBLING THE LUFFING JIB....704