Kobelco CK1200 Crawler Crane Operation & Maintenance Manual S2GK23011ZE09 – PDF DOWNLOAD

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Kobelco CK1200 Crawler Crane Operation & Maintenance Manual S2GK23011ZE09 – PDF DOWNLOAD

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Kobelco CK1200 Crawler Crane Operation & Maintenance Manual S2GK23011ZE09 – PDF DOWNLOAD

Language : English
Pages : 376
Downloadable : Yes
File Type : PDF

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Kobelco CK1200 Crawler Crane Operation & Maintenance Manual S2GK23011ZE09 – PDF DOWNLOAD

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 injury, death, or property damage.
• General safe practices for working on machinery must be followed as well as the safe operating
  practices recommended 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 exceeding 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 affect 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 operating in hazardous places such as near
  electrical power lines or around people, a signalman must be used. Because 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. Operators must understand standard crane signals
  and take signals only from designated signalmen.

TABLE OF CONTENTS:

Kobelco CK1200 Crawler Crane Operation & Maintenance Manual S2GK23011ZE09 – PDF DOWNLOAD

COVER...............................................................................  1
TABLE OF CONTENTS...................................................................  3
IMPORTANT INFORMATION...............................................................  9
1. SAFE OPERATING PRACTICES FOR MOBILE CRANES....................................... 19
2. OPERATION........................................................................ 39
	2.1 TERMINOLOGY OF MACHINE EACH PART............................................ 39
	2.2 LOCATIONS AND TERMS OF OPERATING CONTROLS................................... 40
		2.2.1 OPERATING SWITCHES.................................................... 44
		2.2.2 GAUGE CLUSTER CONFIGURATION........................................... 54
		2.2.3 OPERATING THE AIR CONDITIONER......................................... 67
		2.2.4 AM/FM RADIO (OPTION).................................................. 69
	2.3 CRANE OPERATION............................................................. 71
		2.3.1 ADJUSTING THE OPERATOR'S SEAT......................................... 71
		2.3.2 ADJUSTING THE CONTROL LEVER DIRECTION................................. 71
		2.3.3 STARTING AND STOPPING THE ENGINE...................................... 72
		2.3.4 FUNCTION LOCK LEVER................................................... 75
		2.3.5 PROPELLING OPERATION.................................................. 76
		2.3.6 SWINGING OPERATION.................................................... 78
		2.3.7 BOOM RAISING/LOWERING OPERATION....................................... 81
		2.3.8 HOOK RAISING/LOWERING OPERATION....................................... 83
	2.4 FREE FALL OPERATION......................................................... 86
	2.5 HANDLING OF REEVING WINCH (OPTION).......................................... 89
	2.6 HANDLING OF HYDRAULIC TAGLINE (OPTION)...................................... 91
3. LOAD SAFETY DEVICE............................................................... 93
	3.1 ARRANGEMENT OF EQUIPMENTS................................................... 93
	3.2 TYPE AND FUNCTIONS OF EQUIPMENTS............................................ 96
	3.3 CONNECTING PROCEDURE OF WIRING..............................................102
		3.3.1 CRANE ATTACHMENT......................................................102
	3.4 FUNCTION OF CONTROLLER/MONITOR..............................................107
	3.5 OPERATING PROCEDURE FOR CONTROLLER..........................................111
		3.5.1 SETTING SCREEN........................................................112
		3.5.2 SETTING OF THE CRANE CONFIGURATION....................................117
		3.5.3 SELECTING MAIN/AUX LIFTING............................................123
		3.5.4 SETTING OF WORKING AREA LIMIT VALUE...................................124
		3.5.5 SETTING THE TIME......................................................128
	3.6 WARNING ALARMS AND AUTOMATIC STOPS..........................................131
		3.6.1 WARNING ALARMS AND AUTOMATIC STOP INDICATORS..........................131
		3.6.2 CONTENTS FOR AUTOMATIC STOP...........................................132
		3.6.3 RELEASING AUTOMATIC STOP..............................................134
	3.7 INSPECTION..................................................................141
		3.7.1 BEFORE RAISING THE BOOM (UPON COMPLETION OF ATTACHMENT ASSEMBLY)......141
		3.7.2 INSPECTION AFTER ERECTING THE ATTACHMENT..............................144
	3.8 CAUTIONS FOR HANDLING THE LOAD SAFETY DEVICE................................145
	3.9 ERROR MESSAGES AND CORRECTIONS..............................................146
	3.10 TABLE OF ERROR MESSAGES AND ALARMS.........................................147
	3.11 CONFIRMING PROPER FUNCTIONING OF LOAD SAFETY DEVICE........................149
4. ASSEMBLY OF THE MACHINE..........................................................151
	4.1 STABILITY IN SWINGING AND TRAVELING.........................................151
		4.1.1 WITHOUT BOOM BASE.....................................................151
		4.1.2 WITH BOOM BASE........................................................152
	4.2 TRANSLIFTER.................................................................153
		4.2.1 COMPOSITION OF TRANSLIFTER............................................153
		4.2.2 HANDLING TRANSLIFTERS (1) - (4).......................................154
	4.3 UNLOADING BASE MACHINE......................................................157
		4.3.1 ERECTING GANTRY.......................................................158
		4.3.2 SETTING TRANSLIFTERS..................................................160
		4.3.3 UNLOADING BASE MACHINE FROM TRAILER...................................163
	4.4 INSTALLATION OF CRAWLER.....................................................165
		4.4.1 INSTALLATION OF THE FIRST CRAWLER.....................................165
		4.4.2 INSTALLATION OF THE SECOND CRAWLER....................................167
		4.4.3 HOW TO EXTEND AND RETRACT THE CRAWLERS................................169
	4.5 INSTALLATION OF COUNTERWEIGHT...............................................171
		4.5.1 ASSEMBLING COUNTERWEIGHTS.............................................171
		4.5.2 INSTALLATION PROCEDURES...............................................176
	4.6 ASSEMBLING ATTACHMENTS......................................................182
		4.6.1 ASSEMBLY OF BOOM AND FIXED JIB........................................183
		4.6.2 ASSEMBLY OF JIB.......................................................196
		4.6.3 INSTALLATION OF AUXILIARY SHEAVE......................................201
	4.7 REEVING WIRE ROPE FOR CRANE AND AUXILIARY SHEAVE............................202
		4.7.1 REEVING FRONT DRUM WIRE ROPE FOR CRANE................................202
		4.7.2 REEVING REAR DRUM WIRE ROPE TO AUXILIARY SHEAVE.......................204
		4.7.3 REEVING REAR DRUM WIRE ROPE...........................................205
	4.8 ERECTING ATTACHMENT.........................................................207
		4.8.1 CONNECTING SAFETY DEVICE..............................................207
		4.8.2 CHECKING SAFETY DEVICE................................................207
		4.8.3 CONFIRMATION BEFORE ERECTING ATTACHMENT...............................207
		4.8.4 ERECTING ATTACHMENT...................................................208
		4.8.5 CHECK BEFORE STARTING WORK............................................209
5. DISASSEMBLY OF THE MACHINE.......................................................211
	5.1 LOWERING ATTACHMENT.........................................................213
		5.1.1 LOWERING ATTACHMENT...................................................213
	5.2 DISCONNECTING WIRING FOR SAFETY DEVICE......................................214
	5.3 REMOVING BOOM GUY LINE......................................................215
		5.3.1 INSTALLATION OF UPPER SPREADER TO BOOM BASE...........................215
		5.3.2 DISASSEMBLING THE JIB.................................................216
		5.3.3 REMOVAL OF BOOM GUY LINE..............................................217
	5.4 COUNTERWEIGHT REMOVAL.......................................................218
		5.4.1 DISCONNECT BOOM BASE FROM INSERT BOOM.................................218
		5.4.2 PREPARATIONS FOR OPERATION............................................219
		5.4.3 REMOVAL OF COUNTERWEIGHTS.............................................223
	5.5 DISASSEMBLING ATTACHMENT....................................................229
		5.5.1 REMOVING UPPER AND INSERT BOOMS.......................................229
	5.6 CRAWLER REMOVAL.............................................................230
		5.6.1 SETTING TRANSLIFTER (Refer to 4.1)....................................231
		5.6.2 REMOVING CRAWLERS.....................................................231
	5.7 LOADING BASE MACHINE........................................................236
		5.7.1 LOADING BASE MACHINE ON TRAILER.......................................236
		5.7.2 LOWERING BOOM BASE....................................................237
		5.7.3 LOWERING GANTRY.......................................................238
		5.7.4 FOLDING TRANSLIFTER...................................................239
		5.7.5 CAUTION WHEN TRANSPORTING BASE MACHINE................................240
		5.7.6 HANDLING OF TRAVELING KIT.............................................240
6. WIRE ROPE........................................................................241
	6.1 UNREELING WIRE ROPE.........................................................241
		6.1.1 UNREELING WIRE ROPE...................................................241
		6.1.2 WINDING WIRE ROPE ONTO DRUM...........................................242
		6.1.3 INSTALLING THE ROPES..................................................244
		6.1.4 SPECIFICATION OF WIRE ROPE............................................245
		6.1.5 WIRE ROPE LENGTH......................................................246
7. MAINTENANCE......................................................................249
	7.1 INSPECTIONS.................................................................254
		7.1.1 UPPER STRUCTURE PARTS AND DEVICES TO BE INSPECTED.....................254
			7.1.1.1 UPPER STRUCTURE INSPECTIONS-DAILY OR EVERY 8 HOURS..............256
			7.1.1.2 UPPER STRUCTURE INSPECTIONS-MONTHLY OR EVERY 100 HOURS..........261
			7.1.1.3 UPPER STRUCTURE INSPECTIONS-SEMI-ANNUALLY OR EVERY 600 HOURS....265
			7.1.1.4 UPPER STRUCTURE INSPECTIONS-WEEKLY OR EVERY 50 HOURS............266
		7.1.2 LOWER STRUCTURE PARTS AND DEVICE TO BE INSPECTED......................268
			7.1.2.1 LOWER STRUCTURE INSPECTIONS-DAILY OR EVERY 8 HOURS..............269
			7.1.2.2 LOWER STRUCTURE INSPECTIONS-MONTHLY OR EVERY 100 HOURS..........270
			7.1.2.3 LOWER STRUCTURE INSPECTIONS-QUARTERLY OR EVERY 250 HOURS........272
			7.1.2.4 LOWER STRUCTURE INSPECTIONS-SEMI-ANNUALLY OR EVERY 600 HOURS....273
		7.1.3 ATTACHMENT PARTS AND DEVICES TO BE INSPECTED..........................274
			7.1.3.1 ATTACHMENT INSPECTIONS-DAILY OR EVERY 8 HOURS...................276
		7.1.4 REPLACEMENT STANDARDS FOR WIRE ROPE...................................279
	7.2 OIL/GREASE SUPPLY AND WATER SERVICE.........................................282
		7.2.1 UPPER STRUCTURE LUBRICATION (INCLUDING WATER SUPPLY)..................284
		7.2.2 LOWER STRUCTURE LUBRICATION...........................................286
		7.2.3 ATTACHMENT STRUCTURE LUBRICATION......................................288
		7.2.4 GREASE................................................................290
		7.2.5 ENGINE OIL............................................................297
		7.2.6 FUEL..................................................................298
		7.2.7 COOLANT...............................................................299
		7.2.8 HYDRAULIC OIL.........................................................301
		7.2.9 GEAR OIL..............................................................303
	7.3 CLEANING/WASHING/CHANGING FILTER ELEMENT AND STRAINER.......................308
	7.4 BATTERY INSPECTION..........................................................319
	7.5 LOCATION AND USE OF FUSE....................................................322
	7.6 OPERATION UNDER UNUSUAL CONDITIONS..........................................324
	7.7 MACHINE STORAGE.............................................................326
	7.8 TIGHTENING TORQUE VALUES....................................................327
	7.9 SECURITY PARTS TO BE REPLACED PERIODICALLY..................................329
	7.10 ADJUSTMENT.................................................................330
		7.10.1 ADJUSTMENT OF FRONT AND REAR DRUM LOCKS..............................330
		7.10.2 ADJUSTMENT OF BOOM DRUM LOCK.........................................331
		7.10.3 ADJUSTMENT OF THIRD DRUM LOCK........................................332
		7.10.4 CRAWLER SHOES ADJUSTMENT.............................................333
	7.11 CONSUMABLE PARTS LIST......................................................334
8. REFERENCE MATERIALS..............................................................339
	8.1 SPECIFICATION...............................................................339
		8.1.1 PERFORMANCE...........................................................339
		8.1.2 OUTSIDE DIMENSIONS....................................................339
	8.2 DIMENSIONS AND WEIGHT OF EACH PARTS.........................................341
		8.2.1 BASE MACHINE..........................................................341
		8.2.2 COUNTERWEIGHT.........................................................343
		8.2.3 ATTACHMENT............................................................344
	8.3 SYSTEM SCHEMATIC............................................................347
		8.3.1 HYDRAULIC SYSTEM SCHEMATIC............................................347
		8.3.2 ELECTRICAL WIRING SCHEMATIC...........................................349
9. INITIAL ASSEMBLY OF THE MACHINE..................................................361
	9.1 UPPER STRUCTURE (WITH CARBODY) LIFTING PROCEDURES...........................362
		9.1.1 INSTALLATION..........................................................362
	9.2 LOADING/UNLOADING THE MACHINE FROM/ONTO A TRAILER...........................363
		9.2.1 LOADING ONTO A TRAILER................................................363
		9.2.2 UNLOADING FROM A TRAILER..............................................363
	9.3 INSTALLATION OF CRAWLER.....................................................363
	9.4 INSTALLATION OF GANTRY TO REVOLVING FRAME...................................364
	9.5 INSTALLATION OF BOOM BASE...................................................367
		9.5.1 INSTALLATION OF BOOM BASE.............................................367
	9.6 INSTALLATION OF BACKSTOP....................................................369
	9.7 INSTALLING UPPER AND LOWER SPREADER.........................................370

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