Kobelco CK1600 CKE1350 Crawler Crane Shop Manual S5GN00003ZE08 – PDF DOWNLOAD

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Kobelco CK1600 CKE1350 Crawler Crane Shop Manual S5GN00003ZE08 – PDF DOWNLOAD

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Kobelco CK1600 CKE1350 Crawler Crane Shop Manual S5GN00003ZE08 – PDF DOWNLOAD

Language : English
Pages : 584
Downloadable : Yes
File Type : PDF

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Kobelco CK1600 CKE1350 Crawler Crane Shop Manual S5GN00003ZE08 – PDF DOWNLOAD

SAFETY:
PRECAUTIONS FOR INSPECTION AND MAINTENANCE:
1. Service and maintenance must be performed only by authorized personnel who are qualified in
compliance with a relevant law or regulation.
2. Regular maintenance or inspection should be quickly performed after shutting down the machine
and ensuring safety to personnel and equipment.
Post an “INSPECTION IN PROGRESS. DO NOT START.” warning sign on a readily visible location.

GENERAL SAFETY PRECAUTIONS:
1. Wear safety shoes, helmets and clothing suitable for the job. Also use protective goggles,
mask, gloves, etc., as required.
2. To ensure safe and correct maintenance, carefully study this SHOP MANUAL and get fully
familiar with the in- structions in it.
3. Place the machine in a safe place. Always maintain safe clearance around the machine.
4. Before starting crane operation, hold a safety meeting. Also, make agreement on standardized
hand signals.
5. When inspecting or handling the battery or oil, do not use exposed flame nearby. To avoid fire
accident, only use explosion-proof lighting equipment.
6. Start an inspection or maintenance work only after shutting down the engine.
7. Certain machine components remain hot immediately after the engine is shut down. Do not touch
them.
8. Before removing the radiator cap, wait until the coolant water gets sufficiently cool. Next,
carefully loosen the cap and release radiator pressure, and them remove the cap.
9. Before inspecting or maintaining an electrical system on the machine, power off the machine
by, for example, disconnecting the battery cables.
10. When working at a high lift area, always wear a safety belt.
11. When leaving the operator’s cab for an inspection or maintenance work, post an “INSPECTION IN
PROGRESS. DO NOT START.” warning sign on a readily visible location. Also, lock the cab for
security.
12. Before starting a cleaning or lubrication work on the machine, always shut down the engine.
13. While adjusting tire pressure, be absolutely careful about rupture of a tire, flying of wheel
part.
14. Use genuine KOBELCO replacement parts and oils only.
15. Always keep the oil containers clean. Protect them against ingress of dust or moisture. Also,
fill clean, fresh oils only.
16. Once a maintenance work is complete, clean the machine.
Protect grease nipples, breathers, and oil level gages against ingress of dust.
17. Always keep the subjects of regular inspection clean to allow problems such as oil leakage,
crack, looseness, etc., to be readily detected.
18. During car washing, do not allow high pressure steam to be directly applied to electrical
components and con- nectors.
19. After removing O-rings, oil seals, gaskets, etc., clean the mounting seats. Then, install
fresh O-rings, oil seals, gaskets, etc. Also, remember to thinly apply oil to the seal faces of
these parts before installation.
20. Before disconnecting pressurized piping, release the inside pressure.

TABLE OF CONTENTS:

Kobelco CK1600 CKE1350 Crawler Crane Shop Manual S5GN00003ZE08 – PDF DOWNLOAD

COVER
................................................................................................................................................  1
TABLE OF CONTENTS.....................................................................................................................................  3
SAFETY................................................................................................................................................ 11
1. SPECIFICATION...................................................................................................................................... 23
	1.1 CKE1350 SPECIFICATION......................................................................................................................... 25
		1.1.1 PERFORMANCE............................................................................................................................. 25
		1.1.2 PERFORMANCE OF LUFFING JIB.............................................................................................................. 25
		1.1.3 OUTSIDE DIMENSIONS...................................................................................................................... 26
		1.1.4 DIMENSIONS AND WEIGHT OF EACH PARTS..................................................................................................... 31
		1.1.5 CKE1350 STABILITY IN SWINGING AND TRAVELING............................................................................................. 40
	1.2 CK1600 SPECIFICATION.......................................................................................................................... 43
		1.2.1 PERFORMANCE............................................................................................................................. 43
		1.2.2 PERFORMANCE OF LUFFING JIB.............................................................................................................. 43
		1.2.3 OUTSIDE DIMENSIONS...................................................................................................................... 44
	1.3 DIMENSIONS AND WEIGHT OF EACH PARTS........................................................................................................... 49
		1.3.1 BASE MACHINE............................................................................................................................ 49
		1.3.2 COUNTERWEIGHT........................................................................................................................... 51
		1.3.3 ATTACHMENT.............................................................................................................................. 52
		1.3.4 STABILITY IN SWINGING AND TRAVELING..................................................................................................... 55
2. MAINTENANCE STANDARDSTEST PROCEDURES............................................................................................................... 59
	2.1 MAINTENANCE STANDARD.......................................................................................................................... 61
		2.1.1 PIN, BUSHING, SPRING, LINING AND SHEAVE................................................................................................. 61
		2.1.2 PROPEL DEVICE........................................................................................................................... 68
		2.1.3 PROPEL BRAKE PLATE...................................................................................................................... 76
	2.2 PERFORMANCE STANDARD AND TEST PROCEDURE....................................................................................................... 77
		2.2.1 OPERATING SPEED......................................................................................................................... 77
		2.2.2 POINT AND METHOD OF MEASURING PRESSURE.................................................................................................. 78
		2.2.3 SLEWING RING............................................................................................................................ 83
3. GENERAL WORK STANDARD.............................................................................................................................. 85
	3.1 TIGHTENING TORQUE OF CAPSCREWS AND NUTS....................................................................................................... 87
		3.1.1 METRIC COARSE THREADS................................................................................................................... 87
		3.1.2 METRIC FINE THREADS..................................................................................................................... 87
		3.1.3 COARSE THREDS UNC....................................................................................................................... 88
		3.1.4 FINE THREADS UNF........................................................................................................................ 88
		3.1.5 TIGHTENING TORQUE OF HYDRAULIC FITTINGS................................................................................................. 89
	3.2 STANDARD PARTS................................................................................................................................ 91
		3.2.1 BOLT.................................................................................................................................... 91
		3.2.2 O-RING.................................................................................................................................. 92
		3.2.3 BACK-UP RING............................................................................................................................ 93
		3.2.4 BITE FITTING............................................................................................................................ 94
	3.3 CONVERSION TABLE.............................................................................................................................. 96
		3.3.1 UNIT CONVERSION......................................................................................................................... 96
		3.3.2 MILLIMETER : INCH CONVERSION TABLE...................................................................................................... 97
		3.3.3 METER-FOOT CONVERSION TABLE............................................................................................................. 99
		3.3.4 GRADIENT CONVERSION TABLE...............................................................................................................100
	3.4 TABLE OF UNIT WEIGHT..........................................................................................................................101
4. POWER TRAIN........................................................................................................................................103
	4.1 INTRODUCTION..................................................................................................................................105
	4.2 ENGINE........................................................................................................................................107
		4.2.1 INTRODUCTION............................................................................................................................107
		4.2.2 REMOVAL.................................................................................................................................107
		4.2.3 REPAIR AND MAINTENANCE..................................................................................................................108
		4.2.4 RE-INSTALLATION.........................................................................................................................109
	4.3 PUMP DRIVE ASSEMBLY...........................................................................................................................112
		4.3.1 INTRODUCTION............................................................................................................................112
		4.3.2 REMOVAL.................................................................................................................................112
		4.3.3 DISASSEMBLING THE POWER DIVIDER.........................................................................................................114
		4.3.4 CHECK AND REPAIR OF THE POWER DIVIDER...................................................................................................115
		4.3.5 ASSEMBLING THE POWER DIVIDER............................................................................................................116
		4.3.6 RE-INSTALLATION.........................................................................................................................117
5. HYDRAULIC SYSTEM...................................................................................................................................123
	5.1 LOCATION OF MAIN HYDRAULIC COMPONENTS.........................................................................................................125
	5.2 HYDRAULIC CIRCUITS AND COMPONENTS.............................................................................................................126
		5.2.1 HYDRAULIC CIRCUIT.......................................................................................................................126
		5.2.2 COMPONENT SPECIFICATIONS................................................................................................................130
		5.2.3 LOCATION OF HYDRAULIC COMPONENTS........................................................................................................134
	5.3 HYDRAULIC SYSTEM..............................................................................................................................145
		5.3.1 PREFACE.................................................................................................................................145
		5.3.2 OUTLINE.................................................................................................................................145
		5.3.3 OIL FLOW FROM No.1 and No. 2 PUMPS......................................................................................................146
		5.3.4 OIL FLOW FROM No.3 AND No.4 PUMPS.......................................................................................................148
		5.3.5 OIL FLOW FROM No.5 PUMP (CONTROL PUMP)..................................................................................................150
		5.3.6 OIL FLOW FROM No.6 PUMP (FOR AUXILIARY ACTUATOR CIRCUIT)................................................................................153
	5.4 VALVES........................................................................................................................................156
6. HOIST SYSTEM.......................................................................................................................................163
	6.1 APPARATUS AND LOCATION OF COMPONENTS..........................................................................................................165
	6.2 CONSTRUCTION AND FUNCTION.....................................................................................................................166
		6.2.1 HYDRAULIC SCHEMATIC.....................................................................................................................166
		6.2.2 LIFTING A LOAD..........................................................................................................................168
		6.2.3 HOLDING A RAISED LOAD...................................................................................................................170
		6.2.4 LOWERING A LOAD (POWERED LOWERING)......................................................................................................172
		6.2.5 FREE FALL OPERATION.....................................................................................................................174
		6.2.6 FREE FALL ACCELERATION..................................................................................................................178
	6.3 DRUM LOCK.....................................................................................................................................180
		6.3.1 ASEEMBLY DRAWING........................................................................................................................180
		6.3.2 ADJUSTMENT OF DRUM LOCK.................................................................................................................181
	6.4 WINCH ASSEMBLY................................................................................................................................182
		6.4.1 WINCH INSTAL............................................................................................................................182
		6.4.2 WINCH ASSEMBLY / REDUCTION UNIT WITHOUT FREE FALL (STD.)................................................................................183
		6.4.3 WINCH ASSEMBLY WITH FREE FALL (OPT.)....................................................................................................185
	6.5 BRAKE PEDAL...................................................................................................................................186
		6.5.1 ASSEMBLY DRAWING........................................................................................................................186
		6.5.2 ADJUSTING THE BRAKE PEDAL...............................................................................................................188
	6.6 BLEEDING AIR FROM BRAKE CIRCUIT...............................................................................................................189
7. BOOM HOIST SYSTEM..................................................................................................................................191
	7.1 APPARATUS AND LOCATION OF COMPONENTS..........................................................................................................193
	7.2 CONSTRUCTION AND FUNCTION.....................................................................................................................195
		7.2.1 HYDRAULIC SCHEMATIC.....................................................................................................................195
		7.2.2 RAISING THE BOOM........................................................................................................................196
		7.2.3 NEUTRAL(MAINTAINING THE BOOM POSITION)..................................................................................................198
		7.2.4 LOWERING THE BOOM.......................................................................................................................200
	7.3 BOOM DRUM LOCK................................................................................................................................202
		7.3.1 ASSEMBLY DRAWING........................................................................................................................202
		7.3.2 ADJUSTING THE BOOM DRUM LOCK............................................................................................................203
	7.4 DRUM AND REDUCTION UNIT.......................................................................................................................204
		7.4.1 BOOM WINCH ASSEMBLY.....................................................................................................................204
		7.4.2 BOOM DRUM AND REDUCTION UNIT ASSEMBLY...................................................................................................206
8. SWING SYSTEM.......................................................................................................................................209
	8.1 APPARATUS AND LOCATION OF COMPONENTS..........................................................................................................211
	8.2 CONSTRUCTION AND FUNCTION.....................................................................................................................212
		8.2.1 HYDRAULIC SCHEMATIC.....................................................................................................................212
		8.2.2 SWING...................................................................................................................................214
		8.2.3 STOPPING................................................................................................................................217
	8.3 SWING REDUCTION UNIT..........................................................................................................................220
	8.4 SWING BEARING.................................................................................................................................222
	8.5 SWING LOCK....................................................................................................................................224
9. PROPEL SYSTEM......................................................................................................................................225
	9.1 LOCATION OF THE MAJOR COMPONENTS..............................................................................................................227
	9.2 CONSTRUCTION AND FUNCTION.....................................................................................................................228
		9.2.1 HYDRAULIC SCHEMATIC.....................................................................................................................228
		9.2.2 PROPELLING (RIGHT SIDE FORWARD).........................................................................................................230
		9.2.3 STOPPING................................................................................................................................232
	9.3 PROPEL REDUCTION UNIT.........................................................................................................................234
		9.3.1 MOTOR AND REDUCTION UNIT................................................................................................................236
	9.4 ADJUSTMENT....................................................................................................................................238
10. ELECTRIC SYSTEM...................................................................................................................................239
	10.1 ELECTRICAL WIRING SCHEMATIC..................................................................................................................241
	10.2 CONNECTOR LIST...............................................................................................................................252
	10.3 ARRANGEMENT OF ELECTRICAL PART...............................................................................................................304
		10.3.1 ELECTRICAL PART OF CAB.................................................................................................................304
		10.3.2 ELECTRICAL PART OF RIGHT DECK..........................................................................................................308
		10.3.3 ELECTRICAL PART OF FLOOR PLATE & LEFT SIDE STAND PANEL.................................................................................316
		10.3.4 ELECTRICAL PART OF REVOLVING FRAME.....................................................................................................321
		10.3.5 ELECTRICAL PART OF LEFT DECK...........................................................................................................324
		10.3.6 ELECTRICAL PART OF LEFT GUARD..........................................................................................................331
		10.3.7 HARNESS PART NUMBER LIST (ALL MODELS)..................................................................................................332
	10.4 ELECTRICAL PART..............................................................................................................................334
		10.4.1 LOCATION AND USE OF FUSE...............................................................................................................334
		10.4.2 FUSE BOX (GG73E00004F1)................................................................................................................336
		10.4.3 WIPER CONTROL UNIT (2480U306)..........................................................................................................338
		10.4.4 SWING FLASHER UNIT (2480U306)..........................................................................................................339
		10.4.5 PRESSURE SWITCH (CONTROL PRESSURE CUT & FREE FALL) (GG52S00006P1)......................................................................340
		10.4.6 PRESSURE SENSOR........................................................................................................................341
		10.4.7 RELAY BOX (GG24E00024F1)...............................................................................................................343
		10.4.8 LEFT SIDE STAND PANEL..................................................................................................................348
	10.5 TROUBLESHOOTING OF EXHAUST GAS THIRD REGULATION ENGINE.......................................................................................352
		10.5.1 FAILURE DIAGNOSIS FUNCTION.............................................................................................................352
		10.5.2 HOW TO CHECK THE FAILURE CONTENTS......................................................................................................353
		10.5.3 CHECKING OF DIAGNOSIS LAMP FUNCTION....................................................................................................358
		10.5.4 ENGINE ECU.............................................................................................................................359
11. LOAD SAFETY DEVICE................................................................................................................................363
	11.1 PART NAMES AND FUNCTIONS.....................................................................................................................365
		11.1.1 FRONT VIEW.............................................................................................................................365
		11.1.2 CONFIGURATION OF SCREENS...............................................................................................................370
		11.1.3 DATA TRANSMISSION BETWEEN CONTROLLER AND CARDS.........................................................................................375
		11.1.4 DETAILS OF INDICATORS ON MAIN DISPLAY SCREEN...........................................................................................377
		11.1.5 REAR VIEW..............................................................................................................................381
		11.1.6 ITEMS REQUIRED TO BE EXECUTED FOR REPLACEMENT OF CONTROLLER OR DATA CARDAND INSTRUCTIONS(IN A SIMILAR MANNER TO UPGRADE OF PROGRAM)....386
	11.2 PREPARATION FOR USE..........................................................................................................................387
	11.3 TURN THE POWER ON............................................................................................................................388
	11.4 UPGRADING PROGRAMS...........................................................................................................................389
		11.4.1 PROCEDURES.............................................................................................................................389
		11.4.2 UPGRADING OF INDICATION PROGRAMS.......................................................................................................391
		11.4.3 UPGRADING OF CONTROL PROGRAMS..........................................................................................................394
	11.5 STATUS CHECK.................................................................................................................................396
		11.5.1 SIGNAL CHECK...........................................................................................................................397
		11.5.2 OPERATION PROGRESS.....................................................................................................................399
		11.5.3 COMMUNICATION DATA.....................................................................................................................402
		11.5.4 INDICATION OF ADJUSTMENT VALUE.........................................................................................................403
		11.5.5 TROUBLE RECORD.........................................................................................................................412
		11.5.6 CHOICE OF LANGUAGE (CKE SERIES ONLY)...................................................................................................414
		11.5.7 LOAD RECORD (LOAD RECORD IN THE MAIN MENU).............................................................................................415
	11.6 ADJUSTMENTS..................................................................................................................................416
		11.6.1 REMOVING THE INNER PANEL...............................................................................................................416
		11.6.2 ADJUSTMENT.............................................................................................................................417
		11.6.3 LOAD ADJUSTMENT........................................................................................................................438
		11.6.4 ADJUSTMENT DATA COPY (INITIALIZATION)..................................................................................................441
		11.6.5 VERSION CHECK..........................................................................................................................447
	11.7 ERROR CODE (ABNORMALITY DETECTION) AND COUNTERMEASURES.......................................................................................448
	11.8 CONTROL OUTPUT...............................................................................................................................452
	11.9 RELEASES.....................................................................................................................................464
		11.9.1 RELEASE FUNCTION.......................................................................................................................464
	11.10 MECHANICAL SPECIFICATION....................................................................................................................472
		11.10.1 ENVIRONMENTAL PERFORMANCE PARAMETERS..................................................................................................472
		11.10.2 LOAD CELL (CRANE).....................................................................................................................473
		11.10.3 ANGLE SENSOR..........................................................................................................................474
		11.10.4 CONTROLLER............................................................................................................................475
	11.11 EXTERNAL DIMENSIONS.........................................................................................................................479
	11.12 ELECTRIC SCHEMATIC DIAGRAM..................................................................................................................480
		11.12.1 CRANE TYPE............................................................................................................................480
		11.12.2 LUFFING TYPE..........................................................................................................................481
	11.13 CONTROLLER MALFUNCTION EMERGENCY MEASURES...................................................................................................482
	11.14 LOAD SAFETY DEVICE CHECK PROCEDURES.........................................................................................................483
12. GAUGE CLUSTER.....................................................................................................................................485
	12.1 CONFIGURATION OF DISPLAY.....................................................................................................................487
	12.2 PRIORITY.....................................................................................................................................488
	12.3 STATUS DISPLAY...............................................................................................................................490
	12.4 FAULT LOG DISPLAY............................................................................................................................500
13. TOTAL CONTROLLER..................................................................................................................................505
	13.1 ARRANGEMENT OF TOTAL CONTROLLER..............................................................................................................507
	13.2 COMPOSITION OF SYSTEM........................................................................................................................508
		13.2.1 OUTPUT RELATION TO CONTROLLER..........................................................................................................509
	13.3 FUNCTION OF TOTAL CONTROLLER.................................................................................................................510
	13.4 TOTAL CONTROLLER (HARDWARE)..................................................................................................................535
		13.4.1 OUTLINE................................................................................................................................535
		13.4.2 SPECIFICATIONS OF TOTAL CONTROLLER OUTPUT..............................................................................................536
		13.4.3 DETAILS OF TOTAL CONTROLLER CONNECTOR..................................................................................................540
		13.4.4 ARRANGEMENT OF TOTAL CONTROLLER CONNECTOR PIN..........................................................................................541
		13.4.5 PROPORTIONAL SOLENOID VALVE MEASURING POSITION (VOLTAGE)...............................................................................548
	13.5 ADJUSTMENT OF TOTAL CONTROLLER...............................................................................................................550
		13.5.1 NECESSITY OF ADJUSTMENT................................................................................................................550
		13.5.2 ADJUSTMENT PROCEDURES OF TOTAL CONTROLLER..............................................................................................550
	13.6 CONTROLLER MALFUNCTION EMERGENCY MEASURES....................................................................................................557
14. AIR CONDITIONER...................................................................................................................................559
	14.1 OPERATION ITEMS..............................................................................................................................561
	14.2 SAFETY MONITOR FUNCTIONS.....................................................................................................................562
	14.3 DISASSEMBLY AND ASSEMBLY PROCEDURE...........................................................................................................565
		14.3.1 SPECIAL CONSIDERATIONS DURING REPLACEMENT..............................................................................................565
		14.3.2 INTERIOR UNIT..........................................................................................................................567
	14.4 OPERATIONAL PRECAUTIONS......................................................................................................................576
	14.5 INSPECTION AND MAINTENANCE...................................................................................................................577
		14.5.1 INSPECTION/MAINTENANCE LIST............................................................................................................577
		14.5.2 INSPECTION/MAINTENANCE PROCEDURES......................................................................................................577
	14.6 ELECTRIC SYSTEM SCHEMATIC....................................................................................................................581

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