Kobelco CK1000-II Crawler Crane Operation & Maintenance Manual S2GH10001ZE01 – PDF DOWNLOAD

OPERATION & MAINTENANCE MANUAL

CKIO00-11

APPLICABLE : GH02-01001 BOOKCODE: S2GH10001ZE01

(c) Printed in Japan2002.09

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IMPORTANT INFORMATION Thank you for your purchasing KOBELCO crawler crane. Our CKseries full-hydraulically

operated crawler crane is

manufacturedbased on our long years of experience and expertise. This manualdescribes the important information about Model CK1000-II. Before operating the machine, be sure to thoroughly read this manualto use the machinesafely and efficiently.

WARNING Do not operate or maintain this machineuntil you read this manualand understandthe instructions.

Improper operation or maintenance of this machinemay cause accidents and could result in serious injury or death.

Always keep this manualin the operators cab.

If it is missing or damaged,place an order to a KOBELCO distributor

for a replacement.

If you have any questions, please consult your KOBELCO distributor.

¯ SAFETY INFORMATION Mostaccidents, whichoccur during operation, are due to neglect of precautionary measuresand safety rules.

Sufficient care should be taken to avoid these accidents.

Erroneousoperation, lubrication or maintenanceservices are very dangerousand maycause injury or death of personnel.

Thus, precautionary measures, or notes, written in this manualshould be read and understoodby personnel before starting each task.

Operation, inspection, and maintenanceshould be carefully carried out, and safety must be given the first priority.

Messagesof safety are indicated with ,i~ marks. The safety information contained in this manual is intended only general safety information.

Messages of safety appear in this manual and on the machine. All messages of safety are identified

by the words

"DANGER", "WARNING"and "CAUTION".

These words mean the following:

I ~i~ DANGER i[ ............. Indicates an imminentlyhazardoussituation which, if not avoided, will result in death

i

[

or serious injury.

~

WARNING

[ ~’k

CAUTION

I

[ ............. Indicates a potentially hazardoussituation which, if not avoided, could result in death or serious injury.

I

[ ............. Indicates a potentially hazardous situation which, if not avoided, mayresult in minor or moderate injury. It mayalso be used to alert against possible damageto the machine and its components.

I

NOTE

J............. Supplementary explanation.

It is very difficult for us to forecast every danger that mayoccur during operation. However,safety can be ensured by operating this machine according to methods recommendedby KOBELCO. Whileoperating machine,be sure to performwork with great care, so as to not damagethe machine,or let accidents occur.

Please continue studying this manualuntil proper operation is completely understood.

¯ MACHINE SERIAL NUMBER .

Whenyou order repair parts and whenyou needrepair or service of the machine,always inform us the machineserial number stamped on the name plate andthe total number of hours indicated on the hourmeterwhichis locatedin the gauge.

J

¯[ ; \

HOtPRMETER ENGINE NUMBER

44 MACHINE SERIAL NUMBER

MODEL CODE 6D24......

MACHINE SERIALNLrN[BER

I

¯ ENTERMACHINESERIAL NUMBEROF THIS MACHINE CK 1000-II MACHINEMoDEL

¯

GH02SERIALMACHINENo,

6D24ENGINENo.

WARRANTY

The terms under which this machine is guaranteed are clearly defined in the accompanying WARRANTY. Trouble and damageoccurred during the terms of guarantee shall be repaired at no cost to the purchaser according to the warrant description if the trouble or damageis recognized to be our responsibility.

However,if you use the machine contrary to the instructions of this manual, the WARRANTY does not cover any damage to the machine.

¯ REPAIR PARTS Whenservicing and repairing the machine, be sure to use genuine parts in order to makethe machineperformancedisplay sufficiently.

Since the important security parts are prepared to ensure safety and to protect the machinefrom an serious accident, be sure to replace themevery ’specified period of time.

¯ EXPLANATION OF WARNING LABELS Since the warning labels are installed in the machineand indicated with the three stages in the same wayas the-warning description, confirm the positions and contents of all warninglabels first.

Put them to the practical use to secure safety whenoperating, checking and performing maintenance.

¯

HANDLING OF WARNING LABELS

(1) Whenthe warning label is damagedor stained, order it to the designated service shop.

(2) Donot removethe warning labels.

(3) Whenthe surface of the warninglabel is soiled and difficult to be seen, wipe it cleanly.

NEVER

FORGET

GANTRY

CONNECTION

TQ

ENGAGE PrN$

TO AYOIGFAt, LING GF §OGNS,GANTRY CONNECTqON PINS MUST8~ ENGAGED I:4ENGANTRYIS AT HIGN POSt~’IGN, ALSO. LOWER PARTSOF TI~N$1ONGAR$ WUSTBE CONN|CTED ro REVOLVING FRAME Oil COUNT~RIEIGItT 1lINEN GANTRY IS AT LOWPGSITION. ,..,o,.., ~

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ing

~arts; J)lororolsp

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out from 3veln~

area.

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-I AVOID EXPLOSION WHEN HANDLING ACCUMULATOR

] DETAI L B (ACCUMULATOR)

THIS CASE IS CHARGED WIT~ ~IGH PRESSURE NITROGEN GAS. NEVER ArTEMP TO WELO, GAS-CUT, PUT ON FIRE, NOR DISASSEMBLE THE CASE TO AVOID EXPLOSION.

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TO 1042P

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A

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Stea=of hotcoolant cancause injury or blindness, Hewer loosenor ouenradialor rapwhencoolant is hotand gader sressurso

RotatinoDartscan cause persona~ injury.

KeepawayfromPanand belt mhenengineis running.

Stabenuine be#ors servicino. vmt*rJt*ot~

DETAIL

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to

ooen is

radiator

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NEVER FORGET TO ENGAGE GANTRY CONNECTION PiNS re AVOIU FALLINGOF aooMn, GANTRT C0NNECfIONPINS wusr =e UNGAGEU IWEN GANTRY in AT NIG# P0n~rto~ ALSO, LOWEAPARTSOF rENSION8AR$ Ngsr Be CONNECTED TO flUvukVINC FRAME OR COUMTERWEIGNT 1HENGAnrRv is AT LOWPU$ITIO~ *~ll**~,

when

sto#=ed.

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STAYAWAYFROMMACHINE IF CLOSETOPOWERLINES. MACHINE. LOADANDGROUNO MAY BECOME ELECTRIFIED ANDDEADLY. GG20TOII28Pl

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caD:

)]-Cover radiator mithclolbrag. )) "Loosencapslowly to relieve

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It "CooFlownenoine comuletell,,

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HYDRAULIC TANK CAUTLON FOR HIGH

TEMPERATURE

AS ENGINES ANO MUFFLERS MAY BE HEATED TO HIGH TEMPERATURES. DO NOT DIRECTLYTOUCH THEiW BY HAND.

HIGH TEMPERATURE DO NOT TOUCH w,t,lrJlo4gPq

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SECTION

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TENSION

BAR

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CONNECTIONS

WitHOUTCOUNrEIIW£1GNT WI~H CC~UNT~RWEIGHT

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/ Stay out from crane swine area.

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PREVENT6ATTEAYEXPLOSION -Bttteries lives gft hvdrole| olses Ih|t ¢|n ~xplodt amd ¢iuse ler|on|l i~i~t~, ¯ Keel $1atks, oee~ Illl~J |nd ¢i~lretl~ a~a~ Irom ~atleries. ¯ KeepRelilli¢ Itli¢l~s awlT Irom I|Itetle|° -Klee ill vem~il~lio¢ ¢lJ~ lil~tl~ |ecvte~ Heve~ Check CNitl~ ~y pla¢in! i~tll arlicl¢~ |cross ~lttefr termin|~s,

AVOIDA¢10 CORNS ¯ Electrglyle is |n acid s~d camcsest i|i,r~ gf dlindleis il il con(sets ~ki~ Or ires. ’wear eve irale¢lioa Sad eralectivG ¢lolhit$ =de| I|Adlin| |I IlttiKIll |alltrie~ ¯ 11 eltcttoIple ccallct$ skin at eves. llusb alle¢led it,ll immedialel~,ilk ¢leaa v|lef tl~ |l~k |edic|l allemtion iBmedi~lelT, ~NtOrelOI~PI

FUEL TANK uSE DIESEL FUEL ONLY

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FUEL

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TANK

DETAI L H

CRANE WORK SHOULD BE EXERCISEO ONrNEUTRAL BRAKE MOOEJ. OPERATIONS ONrFREEFALL MOOEJ MAY DUE

CAUSE PALLING TO OPERATIONAL

OF LOADS ERROR. Fp2orol iI 4~I#i

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Oo ~ot travel ~n~ or ooerz~e viOrale Wor~ .ith the .in~01 assembly oeened to aYoid ~m~ie to the Canoax and/or [he ~i~dow s~Poorrs F~IIUt~ to o~$erve thls orec~[zon m~ resul~ in a sef=o~s ,n;urY

~h~n ooon~no ~1~o~ ~$5~bly, the ~r~ h~fl~5 tG r~5~raifl Failure to heed this Caution COUld tesul[ i~ damage {0 ~he ~aonOOx and the~n~ur~. *in(10w a ser,ous

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ar~g lead ,,~oro,z~,,

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0I] NOTLIFT WITHCRAWLERSRETRACTE0 £~FE~O ClAmberS TOPIOPER PO~Irl0NI~EN LI~IING. FAILUnE TO00 SO.AV CAUS£ tIppING OVER 0U~IO LACXOPSrAOILIrT.

~E~,D BE~IBRE OPERAT~IBt~ OP~RAT~I~NANUAL~HOUL00ER~A0 ~o UNOEISr0OO |E~ORE{~PERATION. OAI~Y ~A~N~EN^NCE$~OUL~ ~LW~$ ~U!~!!!0rIN IAI;NGPLAT~ HU~IF~ (]~[RV~0

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INSIDE

ill L,

HI WHENLOCKfNG rUE BRAKE PEOAL. STEP ON /HE PEOAL FULLY TO LOCK THE PAWL AT THE BOTTOM NOTCH.

LIMIT FOR 9O0M CONNECTING LENGTH WHEN 8OQW 15 SUPPQRTEO iM CANhLEVER SidLE. ANDMTE~PTtNG TOI~C~EASE BO0~LENGIN. GANTRf #UST9E ~EP[IN XIG~GANTRY. 5TRICTLf FOLLOI RE~TXlCTEO LENGIa AS $HO~.

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--~=fLEEp.~! ± P__o N L YI

~THIN

40FT/

THIS MACHINI~ ¢ONTNNSALLOYANO HEATTREATED STEE~.S. DO NOTWELD OR APPLYHEATWITHOUT~HECKI NG WITH YOURAUTHORIZEDDEALER. UNAUTHORIZED MO~FI~ON~, MAy WEAKEN THE MACHINE.

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STAY AWAY FROM MACHINE IF CLOSETO ~O~ERLINES. MACHINE,LOADAND GROUNOMAY BECOMEELECfRIEIEO AND DEADLY.

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vIEW

DO NOT ~ PEOPLE W1TH 1~IS CRANE FAILURETO DO SO MAYCAUSEu,.~=r~i SERIOUSINJUR~

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CAUTION

~ORKIf46 FOSITII$H OISASSEIdOLING S1"OnI~~SIPIOII <O<X;l+OISA$$~ISLIP~ GF FIN "A" /ASSB48L.ING ) *,~,~

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DANGER

IJ UNOER 800M l’O AYOIOSERIOUS IHdURY CAUSEB

BY FALLINGOF BOC~ DOMOTENTER UNGER BOOM WN(LE Ol 5ASSD/BLI NG/ ASS~4BLI,~OF ~0N.

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TABLE OF CONTENTS 1. SAFEOPERATING PRACTICES FORMOBILE CRANES ........................................................................

Introduction ............................................................................................................................................

I- 1

Operator’s Responsibility .......................................................................................................................

I- l

Signalman’s Responsibility ....................................................................................................................

1- 2

Responsibilities of AllCrew Members ..................................................................................................

1- 2

Management Responsibility ...................................................................................................................

1- 2

Planning theJob.....................................................................................................................................

1- 3

Operator’s Check List.............................................................................................................................

1- 4

Operating Precautions ............................................................................................................................

1- 4

Measures forRadio Transmitters ...........................................................................................................

Measure forLighting ..............................................................................................................................

I - 16 1-16

Measure forEarthquake .........................................................................................................................

1-16

Influence of Wind ...................................................................................................................................

Caution of Wind .....................................................................................................................................

1 - 17

Method of Wind Velocity Measurement ................................................................................................

1 - 18

2. OPERATION ................................................................................................................................................... of Machine EachPart.......................................................................................................

2.1 Terminology 2.2

2.3

I- 1

Locationsand Termsof OperatingControls .............

1-18

2° I 2- 1

i ............................................................................ 2- 2

2.2.1

Handling ofEach Switch ...........................................................................................................

2- 7

2.2.2 2.2,3

Gauge Cluster ............................................................................................................................

Handling theAirConditioner ....................................................................................................

2-15 2-26

Crane Operation .....................................................................................................................................

2-28

2.3.1 2.3.2

Adjusting theOperator’s Seat....................................................................................................

Adjusting theControl Lever Direction ......................................................................................

2-28

2.3.3

Starting andStopping theEngine ..............................................................................................

2.3.4 2.3.5

Function Lock Lever ..................................................................................................................

Propelling Operation ..................................................................................................................

2.3.6

Swinging Operation ...................................................................................................................

2.3.7

. ................................................................. 2-37 Boom Raising/Lowering Operation.........................

Hook Raising/Lowering Operation ............................................................................................

2-38

2.3.8

2-28 2-29 2-33 2-33 2-35

2.4

FreeFallOperation .................................................................................................................................

2-40

2.5

Clamshell?

Operation ...............................................................................................................................

2.6

Handling of Hydraulic Tagline(Optional) .............................................................................................

2-42 2-44

. ................................................. 3- 1 3, LOAD SAFETY DEVICE .............................................................................

3.1 Arrangement of Equipments ..................................................................................................................

3- 1 3.2

TypeandFunctions of Equipments ........................................................................................................

3- 4

3.3

Connecting Procedure of Wiring ............................................................................................................

3- 9

3.3,1 Crane Attachment ......................................................................................................................

3- 9

3.4Function of Controller/Monitor ..............................................................................................................

3-13

3.5

Operating Procedure of Controller .........................................................................................................

3-17

3.5.1

Setting Screen ............................................................................................................................

3-18

3.5.2

Setting of theCraneConfiguration ............................................................................................

3-23

3.5.3 Selection of Main/Aux Lifting...................................................................................................

3.5.4- Settingof Working AreaLimitValue.......................................................................................

3-29 3-29

3.5.5Settingof theTime ....................................................................................................................

3.6

3.7

Warning Alarm andAutomatic Stop.....................................................................................................

3-31 .3-33

3.6.1

Itemsof Warning Alarm andAutomatic Stop...........................................................................

3-33

3.6.2

Contents of Automatic Stop.......................................................................................................

3-34

3.6.3

Release of Automatic Stop........................................................................................................

3-35

Inspection ...............................................................................................................................................

3-39

3.7.1 Inspection Before Raising the BoomAfter Assemblyof Attachmentis Completed................

3-39

3.7.2Inspection AfterErectingtheAttachment .................................................................................

3-42

3.8

Caution for Handling theLoadSafetyDevice .......................................................................................

3-42

3.9

Indication of ErrorsandRemedy ...........................................................................................................

3-43

3.10 Indication of Message andAlarm .......................................................................................................... of Function for LoadSafetyDevice ................................................................................

3.11 Confirmation

3-44 3-45

4. UNLOADING/LOADING THEBASIC MACHINE ......................................................................................

4.1Unloading the BasicMachine From the Trailer.....................................................................................

4- l

4.2 Swing Loading the Machine ona Trailer...............................................................................................

4- 2

5. ASSEMBLY~DISASSEMBLY OFBASIC MACHINE .................................................................................

5.1 Extending/Retracting theCrawlers ........................................................................................................

5- 1

5.1.IExtending theCrawlers ..............................................................................................................

5- 2 5- 4

5.1.2Retracting theCrawler ...............................................................................................................

5.2

4- 2

5- 2

Installing/Removing AxleExtension Adapters ....................................................................................

5.2.1InstallingAxleExtension Adapters ...........................................................................................

5- 5

5.2.2Removing AxleExtension Adapters ..........................................................................................

Erecting/Lowering theGantry ................................................................................................................

5- 6 5- 7

5.3.1Erecting theGantry ....................................................................................................................

5- 7

5.3.2Lowering theGantry ..................................................................................................................

5.4 Installation, Removalof the Counterweight (WhenUsingthe Auxiliary Crane)..................................

5- 8 5- 9

5.3

5.4.1 5.4.2

Installation of theCounterweight ..............................................................................................

Removal of theCounterweight ..................................................................................................

5- 9

Installing/Removing Carbody Weights .....................................................................................

Installation, Removalof the Counterweight (WhenUsingSelf RemovalDevice)................................

5-13

5.5.1 Preparations for Operation ..........................................................................................................

5.5.2 Installation Procedures ................................................................................................................

5-14 5-18

5.5.3

5-25

5.4.3 5.5

5- 5

Disassembly Procedures .............................................................................................................

5-12 5-14

5.5.4 Operation of Cylinder WhenSetting LowGantry Position (Fixation of Tension BarConnection) ........................................................................................

6.

5-29

ASSEMBLY/DISASSEMBLY OF CRANE ATTACHMENT 6.1

Assembling theAttachment ...................................................................................................................

6- 3

6.1.1

Arrangement of Boom/Jib/Guy Line.........................................................................................

6- 3

6.1.2

Installing theBackstops .............................................................................................................

6-10

6.1.3

Installing theBoom Base...........................................................................................................

6-11

6.1.4

Installingthe Backstops to the Revolving Frame ......................................................................

6-12

6.1.5

Installing theUpper Spreader ....................................................................................................

6-12

6.1.6

Reeving the WireRopeinto the UpperandLowerSpreader....................................................

6-13

6.1.7

Installing theBoom Tip.............................................................................................................

6-14

6.1.8

Installationof the BasicGuyLine.............................

. ............................................................... 6-15

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