Kobelco Crawler Crane Ck1000 2f Crane Operator & Maintenance (S2gh14011ze09)
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OPERATION &
MAINTENANCE
MANUAL
CK1000-II
APPLICABLE : From GH03-02004
BOOK CODE : S2GH14011ZE09 (C) Printed in Japan 2007.05
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TABLE OF CONTENTS
IMPORTANT INFORMATION
1. SAFE OPERATING PRACTICES FOR MOBILE CRANES
2. OPERATION
2.1 TERMINOLOGY OF MACHINE EACH PART.......................................................... 2-1
2.2 LOCATIONS AND TERMS OF OPERATING CONTROLS ..................................... 2-2
2.2.1 OPERATING SWITCHES.................................................................................. 2-6
2.2.2 GAUGE CLUSTER ............................................................................................ 2-14
2.2.3 OPERATING THE AIR CONDITIONER ............................................................ 2-27
2.2.4 AM/FM RADIO (OPTION).................................................................................. 2-29
2.3 CRANE OPERATION............................................................................................... 2-31
2.3.1 ADJUSTING THE OPERATOR'S SEAT............................................................ 2-31
2.3.2 ADJUSTING THE CONTROL LEVER DIRECTION .......................................... 2-31
2.3.3 STARTING AND STOPPING THE ENGINE ..................................................... 2-32
2.3.4 FUNCTION LOCK LEVER................................................................................. 2-36
2.3.5 PROPELLING OPERATION.............................................................................. 2-37
2.3.6 SWINGING OPERATION .................................................................................. 2-39
2.3.7 BOOM RAISING/LOWERING OPERATION ..................................................... 2-41
2.3.8 HOOK RAISING/LOWERING OPERATION...................................................... 2-43
2.4 FREE FALL OPERATION ........................................................................................ 2-46
2.5 CLAMSHELL OPERATION ...................................................................................... 2-49
2.6 HANDLING OF HYDRAULIC TAGLINE (OPTION).................................................. 2-51
3. LOAD SAFETY DEVICE
3.1 ARRANGEMENT OF EQUIPMENTS....................................................................... 3-1
3.2 TYPE AND FUNCTIONS OF EQUIPMENTS........................................................... 3-4
3.3 CONNECTING PROCEDURE OF WIRING ............................................................. 3-9
3.3.1 CRANE ATTACHMENT..................................................................................... 3-9
3.4 FUNCTION OF CONTROLLER/MONITOR ............................................................. 3-14
3.5 OPERATING PROCEDURE OF CONTROLLER..................................................... 3-18
3.5.1 SETTING SCREEN ........................................................................................... 3-19
3.5.2 SETTING OF THE CRANE CONFIGURATION ................................................ 3-24
3.5.3 SELECTION OF MAIN/AUX. LIFTING .............................................................. 3-30
3.5.4 SETTING OF WORKING AREA LIMIT VALUE................................................. 3-31
3.5.5 SETTING OF THE TIME ................................................................................... 3-34
3.6 WARNING ALARM AND AUTOMATIC STOP ......................................................... 3-36
3.6.1 ITEMS OF WARNING ALARM AND AUTOMATIC STOP ................................ 3-36
3.6.2 CONTENTS OF AUTOMATIC STOP ................................................................ 3-37
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TABLE OF CONTENTS
3.6.3 RELEASE OF AUTOMATIC STOP ................................................................... 3-39
3.7 INSPECTION ........................................................................................................... 3-45
3.7.1 INSPECTION BEFORE RAISING THE BOOM AFTER ASSEMBLY OF
ATTACHMENT IS COMPLETED ...................................................................... 3-45
3.7.2 INSPECTION AFTER ERECTING THE ATTACHMENT .................................. 3-48
3.8 CAUTION FOR HANDLING THE LOAD SAFETY DEVICE..................................... 3-49
3.9 INDICATION OF ERRORS AND REMEDY ............................................................. 3-50
3.10 INDICATION OF MESSAGE AND ALARM.............................................................. 3-51
3.11 CONFIRMATION OF FUNCTION FOR LOAD SAFETY DEVICE ........................... 3-52
4. UNLOADING/LOADING THE BASIC MACHINE
4.1 UNLOADING THE BASIC MACHINE FROM THE TRAILER .................................. 4-2
4.2 LOADING THE MACHINE ON A TRAILER ............................................................. 4-2
5. ASSEMBLY/DISASSEMBLY OF BASIC MACHINE
5.1 EXTENDING/RETRACTING THE CRAWLERS ...................................................... 5-2
5.1.1 EXTENDING THE CRAWLERS ........................................................................ 5-2
5.1.2 RETRACTING THE CRAWLER ........................................................................ 5-4
5.2 INSTALLING/REMOVING AXLE EXTENSION ADAPTERS ................................... 5-6
5.2.1 INSTALLING AXLE EXTENSION ADAPTERS ................................................. 5-6
5.2.2 REMOVING AXLE EXTENSION ADAPTERS................................................... 5-7
5.3 ERECTING/LOWERING THE GANTRY .................................................................. 5-8
5.3.1 ERECTING THE GANTRY................................................................................ 5-8
5.3.2 LOWERING THE GANTRY............................................................................... 5-10
5.4 INSTALLATION, REMOVAL OF THE COUNTERWEIGHT
(WHEN USING THE AUXILIARY CRANE) .............................................................. 5-11
5.4.1 INSTALLATION OF THE COUNTERWEIGHT................................................. 5-12
5.4.2 REMOVAL OF THE COUNTERWEIGHT......................................................... 5-16
5.4.3 INSTALLING/REMOVING CARBODY WEIGHTS ............................................ 5-17
5.5 INSTALLATION, REMOVAL OF THE COUNTERWEIGHT
(WHEN USING SELF REMOVAL DEVICE)............................................................. 5-18
5.5.1 SETTING OF LMI .............................................................................................. 5-18
5.5.2 PREPARATIONS FOR OPERATION................................................................ 5-22
5.5.3 INSTALLATION PROCEDURES....................................................................... 5-27
5.5.4 DISASSEMBLY PROCEDURES....................................................................... 5-33
5.5.5 OPERATION OF CYLINDER WHEN SETTING LOW GANTRY POSITION
(FIXATION OF TENSION BAR CONNECTION) (Fig. 5-25) ............................. 5-38
CK1000-II 2
TABLE OF CONTENTS
6. ASSEMBLY/DISASSEMBLY OF CRANE ATTACHMENT
6.1 ASSEMBLING THE ATTACHMENT ........................................................................ 6-3
6.1.1 ARRANGEMENT OF BOOM/JIB/GUY LINE..................................................... 6-3
6.1.2 INSTALLING THE BACKSTOPS....................................................................... 6-10
6.1.3 INSTALLING THE BOOM BASE ....................................................................... 6-11
6.1.4 INSTALLING THE BACKSTOPS TO THE REVOLVING FRAME..................... 6-12
6.1.5 INSTALLING THE UPPER SPREADER ........................................................... 6-12
6.1.6 REEVING THE WIRE ROPE INTO THE UPPER AND LOWER SPREADER .. 6-13
6.1.7 INSTALLING THE BOOM TIP ........................................................................... 6-15
6.1.8 INSTALLATION OF THE BASIC GUY LINE ..................................................... 6-16
6.1.9 MAIN HOIST WIRE ROPE REEVING .............................................................. 6-17
6.1.10 CONNECTING THE INSERT BOOMS.............................................................. 6-19
6.1.11 INSTALLING THE CABLE ROLLERS ............................................................... 6-27
6.1.12 CONNECTING THE BOOM GUY LINES .......................................................... 6-28
6.1.13 CAUTION FOR CANTILEVER .......................................................................... 6-30
6.1.14 ASSEMBLING THE JIB ..................................................................................... 6-30
6.1.15 REEVING OF REAR DRUM WIRE ROPE ....................................................... 6-34
6.1.16 INSTALLING THE AUXILIARY SHEAVE .......................................................... 6-36
6.1.17 REEVING THE REAR DRUM WIRE ROPE TO THE AUXILIARY SHEAVE .... 6-37
6.2 ERECTING THE ATTACHMENT ............................................................................. 6-38
6.2.1 CONFIRMATION BEFORE ERECTING THE ATTACHMENT .......................... 6-38
6.2.2 ERECTING THE ATTACHMENT ...................................................................... 6-39
6.3 LOWERING THE ATTACHMENT ............................................................................ 6-41
6.3.1 LOWERING THE ATTACHMENT ..................................................................... 6-42
6.4 DISASSEMBLING THE ATTACHMENT .................................................................. 6-43
6.4.1 TREATMENT OF OVERHOIST LIMIT SWITCH WIRING ................................. 6-43
6.4.2 WINDING UP THE FRONT DRUM/REAR DRUM WIRE ROPES..................... 6-43
6.4.3 DISASSEMBLING THE JIB ............................................................................... 6-44
6.4.4 REMOVING THE BOOM GUY LINE ................................................................. 6-45
6.4.5 DISASSEMBLING THE BOOM ......................................................................... 6-46
6.4.6 REMOVING THE BOOM BASE ........................................................................ 6-47
6.4.7 REMOVAL OF THE COUNTERWEIGHT.......................................................... 6-48
6.4.8 LOWERING THE GANTRY ............................................................................... 6-48
6.5 CAUTION WHEN TRANSPORTING BOOM............................................................ 6-49
7. WIRE ROPE
7.1 HANDLING OF WIRE ROPE ................................................................................... 7-1
7.1.1 UNREELING METHOD OF WIRE ROPE.......................................................... 7-1
7.1.2 WINDING WIRE ROPE ONTO THE DRUM...................................................... 7-2
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TABLE OF CONTENTS
7.1.3 INSTALLING THE ROPE SOCKET .................................................................. 7-3
7.1.4 SPECIFICATION OF WIRE ROPE ................................................................... 7-3
7.1.5 WIRE ROPE LENGTH ...................................................................................... 7-4
8. MAINTENANCE
8.1 CHECKS .................................................................................................................. 8-6
8.1.1 CHECKS OF THE UPPER ................................................................................ 8-6
8.1.1.1 CHECK OF UPPER DAILY OR EVERY 8HOURS..................................... 8-8
8.1.1.2 CHECK OF UPPER MONTHLY OR EVERY 100 HOURS......................... 8-13
8.1.1.3 CHECK OF UPPER SEMI-ANNUALLY OR EVERY 600 HOURS ............. 8-17
8.1.1.4 CHECK OF UPPER WEEKLY OR EVERY 50 HOURS ............................. 8-18
8.1.2 CHECK OF LOWER.......................................................................................... 8-20
8.1.2.1 CHECK OF LOWER DAILY OR EVERY 8 HOURS ................................... 8-22
8.1.2.2 CHECK OF LOWER MONTHLY OR EVERY 100 HOURS........................ 8-23
8.1.2.3 CHECK OF LOWER QUARTERLY OR EVERY 250 HOURS ................... 8-25
8.1.2.4 CHECK OF LOWER SEMI-ANNUALLY OR EVERY 600 HOURS ............ 8-26
8.1.3 CHECK OF ATTACHMENT .............................................................................. 8-28
8.1.3.1 CHECK OF ATTACHMENT DAILY OR EVERY 8 HOURS........................ 8-30
8.2 OIL/GREASE SUPPLY AND WATER SERVICE ..................................................... 8-36
8.2.1 UPPER LUBRICATION (INCL. WATER SUPPLY) ........................................... 8-40
8.2.2 LOWER LUBRICATION .................................................................................... 8-42
8.2.3 ATTACHMENT LUBRICATION......................................................................... 8-44
8.2.4 GREASE............................................................................................................ 8-46
8.2.5 ENGINE OIL ...................................................................................................... 8-49
8.2.6 FUEL ................................................................................................................. 8-50
8.2.7 COOLANT ......................................................................................................... 8-51
8.2.8 HYDRAULIC OIL ............................................................................................... 8-53
8.2.9 GEAR OIL.......................................................................................................... 8-55
8.3 CLEANING/WASHING/CHANGE OF FILTER ELEMENT AND STRAINER ........... 8-60
8.4 CHECK OF BATTERY ............................................................................................. 8-70
8.5 ARRANGEMENT AND USE OF FUSE.................................................................... 8-73
8.6 OPERATION UNDER UNUSUAL CONDITIONS..................................................... 8-75
8.7 MACHINE STORAGE .............................................................................................. 8-77
8.8 TIGHTENING TORQUE VALUES............................................................................ 8-78
8.9 SECURITY PARTS TO BE REPLACED PERIODICALLY....................................... 8-80
8.10 ADJUSTMENT ......................................................................................................... 8-81
8.10.1 ADJUSTMENT OF FRONT AND REAR DRUM LOCKS .................................. 8-81
8.10.2 ADJUSTMENT OF BOOM DRUM LOCK......................................................... 8-82
8.10.3 ADJUSTMENT OF THIRD DRUM LOCK.......................................................... 8-83
8.10.4 ADJUSTMENT OF CRAWLER SHOES............................................................ 8-84
8.11 CONSUMABLE PARTS LIST................................................................................... 8-85
CK1000-II 4
TABLE OF CONTENTS
9. REFERENCE MATERIALS
9.1 SPECIFICATION ...................................................................................................... 9-1
9.1.1 PERFORMANCE............................................................................................... 9-1
9.1.2 OUTSIDE DIMENSIONS ................................................................................... 9-1
9.2 DIMENSIONS AND WEIGHT OF EACH PARTS..................................................... 9-3
9.2.1 BASE MACHINE............................................................................................... 9-3
9.2.2 COUNTERWEIGHT........................................................................................... 9-4
9.2.3 ATTACHMENT .................................................................................................. 9-5
9.3 STABILITY IN SWINGING AND TRAVELING ......................................................... 9-7
9.4 SYSTEM SCHEMATIC............................................................................................. 9-9
9.4.1 HYDRAULIC SYSTEM SCHEMATIC ................................................................ 9-9
9.4.2 ELECTRICAL WIRING SCHEMATIC ................................................................ 9-10
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TABLE OF CONTENTS
CK1000-II 6
IMPORTANT INFORMATION
IMPORTANT INFORMATION
Thank you for your purchasing KOBELCO crawler crane. Our CK series full-hydraulically operated crawler crane,
is manufactured based on our many years of experience and expertise. This manual describes important informa-
tion about Model CK1000-II.
Before operating the machine, be sure to thoroughly read this manual in order to use the machine safely and effi-
ciently.
Do not operate or maintain this machine until you read this manual and understand the instructions. Improp-
er operation or maintenance of this machine may cause accidents and could result in serious injury or
death.
Always keep this manual in the operators cab.
If it is missing or damaged, place an order to a KOBELCO authorize distributor for a replacement.
If you have any questions, please consult your KOBELCO authorize distributor.
SAFETY INFORMATION
Most accidents, which occur during operation, are due to neglect of precautionary measures and safety rules. Suf-
ficient care should be taken to avoid these accidents.
Erroneous operation, lubrication or maintenance services are very dangerous and may cause injury or death of per-
sonnel.
Thus, precautionary measures, or notes, written in this manual should be read and understood by personnel before
starting each task.
Operation, inspection, and maintenance should be carefully carried out, and safety must be given the first priority.
Messages of safety are indicated with 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:
Indicates an imminently hazardous situation which, if not avoided, will result in death or serious
injury.
Indicates a potentially hazardous situation which, if not avoided, could result in death or serious
injury.
Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate
injury. It may also be used to alert against possible damage to the machine and its components.
Supplementary explanation.
It is very difficult for us to forecast every danger that may occur during operation. However, safety can be ensured
by operating this machine according to methods recommended by KOBELCO. While operating machine, be sure to
perform work with great care, so as to not damage the machine, or let accidents occur.
Please continue studying this manual until proper operation is completely understood.
0-1 CK1000-II
IMPORTANT INFORMATION
MACHINE SERIAL NUMBER
When you order repair parts and when you need repair or service of the machine, always inform us the machine
serial number stamped on the name plate and the total number of hours indicated on the hourmeter which is located
in the gauge.
HOURMETER
MACHINE SERIAL NUMBER
N o. G H 0 3 - 0 0 0 0 0
ENGINE NUMBER
P11C -------------- MODEL CODE MACHINE SERIAL NUMBER
ENTER MACHINE SERIAL NUMBER OF THIS MACHINE
MACHINE MACHINE
CK1000-II GH03- ENGINE No. P11C-
MODEL SERIAL No.
WARRANTY
The terms under which this machine is guaranteed are clearly defined in the accompanying WARRANTY. Trouble
and damage occurred during the terms of guarantee shall be repaired at no cost to the purchaser according to the
warrant description if the trouble or damage is 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
When servicing and repairing the machine, be sure to use genuine parts in order to make the machine performance
display sufficiently. Since the important security parts are prepared to ensure safety and to protect the machine from
an serious accident, be sure to replace them every specified period of time.
CK1000-II 0-2
IMPORTANT INFORMATION
EXPLANATION OF WARNING LABELS
Since the warning labels are installed in the machine and indicated with the three stages in the same way as the
warning description, confirm the positions and contents of all warning labels first. Put them to the practical use to
secure safety when operating, checking and performing maintenance.
HANDLING OF WARNING LABELS
1. When the warning label is damaged or stained, order it to the designated service shop.
2. Do not remove the warning labels.
3. When the surface of the warning label is soiled and difficult to be seen, wipe it cleanly.
0-3 CK1000-II
IMPORTANT INFORMATION
CK1000-II 0-4
IMPORTANT INFORMATION
0-5 CK1000-II
IMPORTANT INFORMATION
CK1000-II 0-6
IMPORTANT INFORMATION
0-7 CK1000-II
IMPORTANT INFORMATION
CK1000-II 0-8
IMPORTANT INFORMATION
0-9 CK1000-II
IMPORTANT INFORMATION
BOOM TOP ONLY
40ft and shorter
CK1000-II 0-10
1. SAFE OPERATING PRACTICES FOR MOBILE CRANES
1. SAFE OPERATING PRACTICES FOR MOBILE CRANES
INTRODUCTION
Because cranes have the ability to lift heavy loads to
great heights, they also have a potential for accidents if
safe operating practices are not followed. This book
will help you prevent accidents that could result in inju-
ry, death, or property damage.
General safe practices for working on machinery must
be followed as well as the safe operating practices rec-
ommended here.
OPERATOR'S RESPONSIBILITY
The operator is the best safety feature in any crane.
Safety must always be the operator's most important
concern. He must refuse to operate when he knows it
is unsafe and consult his supervisor when safety is in
doubt.
He must read and understand the Operator's Manual
and see that the machine is in proper order before op-
erating.
He must understand how to read the rating plate and
know that his machine can safely lift each load before
attempting to lift it.
He must never lift a load without knowing the length of
the boom, the weight of the load, and the load radius or
boom angle.
Never attempt to operate the crane at conditions ex-
ceeding those shown on the rating chart. Such opera-
tion can cause tipping or structural failure of the crane
that can result in damage, injury, or death.
He must be alert, physically fit, and free from the influ-
ences of alcohol, drugs, or medications that might af-
fect his eyesight, hearing, reactions, judgment.
He must see that unnecessary people, equipment, and
material are kept out of the work area. The area around
the machine should be properly barricaded.
When an operator's vision is restricted or when operat-
ing in hazardous places such as near electrical power
lines or around people, a signalman must be used. Be-
cause the operator is not always in the best position to
judge distances and can not see all parts of the jobsite,
a signalman may also be necessary at other times. Op-
erators must understand standard crane signals and
take signals only from designated signalmen.
1-1 CK1000-II
Kobelco Crawler Crane Ck1000 2f Crane Operator & Maintenance (S2gh14011ze09)
Full download: http://manualplace.com/download/kobelco-crawler-crane-ck1000-2f-crane-operator-maintenance-s2gh14011ze
1. SAFE OPERATING PRACTICES FOR MOBILE CRANES
SIGNALMAN'S RESPONSIBILITY
The primary duty of a signalman is to assist the opera-
tor in safe and efficient operation. Operators depend
on designated signalmen to assist them in making
movements without endangering people or property.
Signalmen must have a clear understanding of the
work to be done so that they can safely coordinate each
job with operators and other crew members. Signalmen
must place themselves where they can be clearly seen
and where they can safely observe the entire operation.
Standard crane signals must be used unless other
methods of signaling, such as two way radios or flags
have been agreed upon.
CREW MEMBER'S RESPONSIBILITY
Any unsafe condition or practice must be corrected
or reported to the job supervisor.
Everyone who works around the crane, including
riggers and oilers, must obey all warning signs and
watch out for his own safety and the safety of others.
Crew members setting up machines or handling
loads are expected to know proper machine erec-
tion and rigging procedures.
Watch for hazards during operations and alert the
operator and signalmen of dangers such as power
lines, the unexpected presence of people, other
equipment or unstable ground conditions.
MANAGEMENT'S RESPONSIBILITY
See that operators are trained, competent, physical-
ly fit and, if required, licensed. Good vision is re-
quired, as are good judgment, coordination and
mental ability. Any person who lacks any of these
qualities must not be allowed to operate a crane.
Signalmen must have good vision and sound judg-
ment, know standard crane signals and be able to
give signals clearly. They must have enough expe-
rience to be able to recognize hazards and signal
the operator to avoid them.
Riggers must be trained to determine weights and
distances and to select proper lifting tackle. Rigging
is a complex subject far beyond the scope of this
manual. It is management's responsibility to employ
qualified riggers.
Crew members must be given specific safety re-
sponsibilities and instructed to report any unsafe
conditions to their supervisors.
CK1000-II 1-2
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