Kobelco CRAWLER CRANE CKE600 SHOP MANUAL S5GB00001ZE05 – PDF DOWNLOAD

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Kobelco CRAWLER CRANE CKE600 SHOP MANUAL S5GB00001ZE05 – PDF DOWNLOAD

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Kobelco CRAWLER CRANE CKE600 SHOP MANUAL S5GB00001ZE05 – PDF DOWNLOAD

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Kobelco CRAWLER CRANE CKE600 SHOP MANUAL S5GB00001ZE05 – PDF DOWNLOAD

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 instructions
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 connectors.
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.
21. CAUTIONs for repair work with welding: Turn OFF the key switch, disconnect the negative terminal on battery
to power off the electrical circuit; provide grounding within 1 meter from a weld area; in advance, remove electronic
components (for example, controller) to prevent possible damage.
22. Dispose industrial wastes according to a relevant law or regulation.
23. Extremely careful during an inspection or maintenance work under the carrier. Remember the possibility of being
crashed.
When jacking up the machine for an inspection or maintenance work, place blocks below it to prevent accidental
falling.
24. Provide positive ventilation when refilling oils or fuel, rinsing parts, or starting the engine.
25. To remove a heavy component (20 kg or heavier), use a crane, etc. Always keep safety in mind.
26. Illegal or unauthorized, or otherwise nonconforming modification is strictly inhibited.
27. Do not allow oil or dust to deposit around the engine. Otherwise, fire accident can result.
28. Store removed attachments and components safely so that they do not drop or fall down.
29. Always use correct tools that have been well maintained.
30. To prevent personnel from being caught by a running fan, belt, shaft or the like, shut down the engine before
starting an inspection or maintenance work.
31. Battery liquid and oils are harmful to human health. If touching any of these materials, immediately wash it away.
32. Make sure to use the light oil for fuel.
CKE600

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Kobelco CRAWLER CRANE CKE600 SHOP MANUAL S5GB00001ZE05 – PDF DOWNLOAD

COVER.......................................................................................................  1
TABLE OF CONTENTS...........................................................................................  3
SAFETY...................................................................................................... 11
1. 	SPECIFICATION........................................................................................... 23
	1.1	SPECIFICATION....................................................................................... 25
		1.1.1	PERFORMANCE................................................................................... 25
		1.1.2	OUTSIDE DIMENSIONS............................................................................ 25
		1.1.3	DIMENSIONS AND WEIGHT OF EACH PARTS........................................................... 27
	1.2	STABILITY IN SWINGING AND TRAVELING................................................................. 34
2.  MAINTENANCE STANDARDS TEST PROCEDURES................................................................... 35
	2.1	MAINTENANCE STANDARD................................................................................ 37
		2.1.1	PIN, BUSHING, SPRING, LINING AND SHEAVE....................................................... 37
		2.1.2	PROPEL DEVICE................................................................................. 44
	2.2	PERFORMANCE STANDARD AND TEST PROCEDURE............................................................. 50
		2.2.1	OPERATING SPEED............................................................................... 50
		2.2.2	POINT AND METHOD OF MEASURING PRESSURE........................................................ 51
		2.2.3	SLEWING RING.................................................................................. 55
3. 	GENERAL WORK STANDARD................................................................................... 57
	3.1	TIGHTENING TORQUE OF CAPSCREWS AND NUTS............................................................. 59
		3.1.1	METRIC COARSE THREADS......................................................................... 59
		3.1.2	METRIC FINE THREADS........................................................................... 59
		3.1.3	COARSE THREDS UNC............................................................................. 60
		3.1.4	FINE THREADS UNF.............................................................................. 60
		3.1.5	TIGHTENING TORQUE OF HYDRAULIC FITTINGS....................................................... 61
	3.2	STANDARD PARTS...................................................................................... 63
		3.2.1	BOLT.......................................................................................... 63
		3.2.2	O-RING........................................................................................ 64
		3.2.3	BACK-UP RING.................................................................................. 65
		3.2.4	BITE FITTING.................................................................................. 66
	3.3	CONVERSION TABLE.................................................................................... 68
		3.3.1	UNIT CONVERSION............................................................................... 68
		3.3.2	MILLIMETER : INCH CONVERSION TABLE............................................................ 69
		3.3.3	METER-FOOT CONVERSION TABLE................................................................... 71
		3.3.4	GRADIENT CONVERSION TABLE..................................................................... 72
	3.4	TABLE OF UNIT WEIGHT................................................................................ 73
4. 	POWER TRAIN............................................................................................. 75
	4.1	INTRODUCTION........................................................................................ 77
	4.2	ENGINE.............................................................................................. 79
		4.2.1	INTRODUCTION.................................................................................. 79
		4.2.2	REMOVAL....................................................................................... 79
		4.2.3	REPAIR AND MAINTENANCE........................................................................ 80
		4.2.4	RE-INSTALLATION............................................................................... 81
	4.3	PUMP DRIVE ASSEMBLY................................................................................. 85
		4.3.1	INTRODUCTION.................................................................................. 85
		4.3.2	REMOVAL....................................................................................... 85
		4.3.3	DISASSEMBLING THE POWER DIVIDER............................................................... 87
		4.3.4	CHECK AND REPAIR OF THE POWER DIVIDER......................................................... 88
		4.3.5	ASSEMBLING THE POWER DIVIDER.................................................................. 89
		4.3.6	RE-INSTALLATION............................................................................... 90
5. 	HYDRAULIC SYSTEM........................................................................................ 95
	5.1	LOCATION OF MAIN HYDRAULIC COMPONENTS............................................................... 97
	5.2	HYDRAULIC CIRCUITS AND COMPONENTS................................................................... 98
		5.2.1	HYDRAULIC CIRCUIT............................................................................. 98
		5.2.2	COMPONENT SPECIFICATIONS......................................................................101
		5.2.3	LOCATION OF HYDRAULIC COMPONENTS..............................................................104
	5.3	HYDRAULIC SYSTEM....................................................................................111
		5.3.1	PREFACE.......................................................................................111
		5.3.2	OUTLINE.......................................................................................111
		5.3.3	OIL FLOW FROM No.1 and No. 2 PUMPS............................................................113
		5.3.4	OIL FLOW FROM No.3 PUMP.......................................................................116
		5.3.5 OIL FLOW FROM No.4 and No.5 PUMPS (FOR MAIN AND AUX. WINCH DRUMS BRAKE COOLING CIRCUIT) ......118
		5.3.6	OIL FLOW FROM No.6 PUMP (CONTROL PUMP)........................................................119
		5.3.7	OIL FLOW FROM No.7 PUMP (For Auxiliary Actuator Circuit)......................................122
	5.4	VALVES..............................................................................................123
6. 	HOIST SYSTEM............................................................................................133
	6.1	APPARATUS AND LOCATION OF COMPONENTS................................................................135
	6.2	CONSTRUCTION AND FUNCTION...........................................................................136
		6.2.1	HYDRAULIC SCHEMATIC...........................................................................136
		6.2.2	LIFTING A LOAD................................................................................138
		6.2.3	HOLDING A RAISED LOAD.........................................................................140
		6.2.4	LOWERING A LOAD...............................................................................142
		6.2.5	FREEFALL OPERATION............................................................................145
		6.2.6	FREE FALL ACCELERATION........................................................................148
		6.2.7	FRONT DRUM/REAR DRUM HYD-CIRCUIT SELECTION....................................................151
	6.3	ADJUSTMENT OF DRUM LOCK.............................................................................155
	6.4	BRAKE PEDAL.........................................................................................156
		6.4.1	ASSEMBLY DRAWING..............................................................................156
		6.4.2	ADJUSTING THE BRAKE PEDAL.....................................................................158
	6.5	BLEEDING AIR FROM BRAKE CIRCUIT.....................................................................159
7. 	BOOM HOIST SYSTEM.......................................................................................161
	7.1	APPARATUS AND LOCATION OF COMPONENTS................................................................163
	7.2	CONSTRUCTION AND FUNCTION...........................................................................165
		7.2.1	HYDRAULIC SCHEMATIC...........................................................................165
		7.2.2	RAISING THE BOOM..............................................................................166
		7.2.3	NEUTRAL.......................................................................................168
		7.2.4	LOWERING THE BOOM.............................................................................170
	7.3	BOOM DRUM LOCK......................................................................................172
		7.3.1	ASSEMBLY DRAWING..............................................................................172
		7.3.2	ADJUSTING THE BOOM DRUM LOCK..................................................................173
	7.4	REDUCTION UNIT......................................................................................174
8. 	SWING SYSTEM............................................................................................177
	8.1	APPARATUS AND LOCATION OF COMPONENTS................................................................179
	8.2	CONSTRUCTION AND FUNCTION...........................................................................180
		8.2.1	HYDRAULIC SCHEMATIC...........................................................................180
		8.2.2	SWING.........................................................................................182
		8.2.3	STOPPING......................................................................................184
	8.3	SWING REDUCTION UNIT................................................................................186
	8.4	SWING BEARING.......................................................................................190
	8.5	SWING LOCK..........................................................................................192
9. 	PROPEL SYSTEM...........................................................................................193
	9.1	LOCATION OF THE MAJOR COMPONENTS....................................................................195
	9.2	CONSTRUCTION AND FUNCTION...........................................................................196
		9.2.1	 HYDRAULIC SCHEMATIC..........................................................................196
		9.2.2	 PROPELLING (RIGHT SIDE FORWARD)..............................................................198
		9.2.3	STOPPING......................................................................................200
	9.3	PROPEL REDUCTION UNIT...............................................................................202
		9.3.1	REDUCTION UNIT................................................................................204
		9.3.2	MOTOR.........................................................................................206
	9.4	ADJUSTMENT..........................................................................................208
10. 	ELECTRIC SYSTEM........................................................................................209
	10.1	ELECTRICAL WIRING SCHEMATIC........................................................................211
	10.2	CONNECTOR LIST.....................................................................................222
	10.3	ARRANGEMENT OF ELECTRICAL PART.....................................................................273
		10.3.1	ELECTRICAL PART OF CAB.......................................................................273
		10.3.2	ELECTRICAL PART OF RIGHT DECK................................................................276
		10.3.3	ELECTRICAL PART OF FLOOR PLATE & LEFT SIDE STAND PANEL.......................................284
		10.3.4	ELECTRICAL PART OF REVOLVING FRAME...........................................................289
		10.3.5	ELECTRICAL PART OF LEFT DECK.................................................................290
		10.3.6	ELECTRICAL PART OF LEFT GUARD................................................................294
	10.4	ELECTRICAL PART....................................................................................295
		10.4.1	FUSE BOX (GG73E00004F1)......................................................................295
		10.4.2	WIPER CONTROL RELAY (2479R1366)..............................................................297
		10.4.3	SWING FLASHER UNIT (2480U306)................................................................298
		10.4.4	PRESSURE SWITCH (CONTROL PRESSURE CUT & FREE FALL)...........................................299
		10.4.5	PRESSURE SENSOR..............................................................................300
		10.4.6	RELAY BOX (GG24E00024F1).....................................................................302
			10.4.6.1	ARRANGEMENT OF CONNECTOR...............................................................302
			10.4.6.2	RELAY BOX SCHEMATIC....................................................................304
		10.4.7	LEFT SIDE STAND PANEL........................................................................307
	10.5	TROUBLESHOOTING OF EXHAUST GAS THIRD REGULATION ENGINE.............................................311
		10.5.1	 FAILURE DIAGNOSIS FUNCTION..................................................................311
		10.5.2	HOW TO CHECK THE FAILURE CONTENTS............................................................312
		10.5.3	CHECKING BLOWN-OFF DIAGNOSIS LAMPS...........................................................317
		10.5.4	ENGINE ECU...................................................................................318
11. 	LOAD SAFETY DEVICE.....................................................................................321
	11.1	PART NAMES AND FUNCTIONS...........................................................................323
		11.1.1	FRONT VIEW...................................................................................323
		11.1.2	CONFIGURATION OF SCREENS.....................................................................328
		11.1.3	DATA TRANSMISSION BETWEEN CONTROLLER AND CARDS...............................................331
		11.1.4	DETAILS OF INDICATORS ON MAIN DISPLAY SCREEN.................................................333
		11.1.5	REAR VIEW....................................................................................335
		11.1.6	ITEMS REQUIRED TO BE EXECUTED FOR REPLACEMENT OF CONTROLLER OR DATA CARD AND INSTRUCTIONS....340
	11.2	PREPARATION FOR USE................................................................................341
	11.3	TURN THE POWER ON..................................................................................342
	11.4	UPGRADING PROGRAMS.................................................................................343
		11.4.1	PROCEDURES...................................................................................343
		11.4.2	UPGRADING OF INDICATION PROGRAMS.............................................................345
		11.4.3	UPGRADING OF CONTROL PROGRAMS................................................................348
	11.5	STATUS CHECK.......................................................................................350
		11.5.1	SIGNAL CHECK.................................................................................351
		11.5.2	OPERATION PROGRESS...........................................................................353
		11.5.3	COMMUNICATION DATA...........................................................................356
		11.5.4	INDICATION OF ADJUSTMENT VALUE...............................................................357
			11.5.4.1	ANGLE SENSOR ADJUSTMENT VALUE..........................................................358
			11.5.4.2	LOAD CELL ZERO POINT ADJUSTMENT VALUE..................................................359
			11.5.4.3	ADJUSTMENT VALUE OF LOAD CELL FOR LINE-PULL............................................360
			11.5.4.4	RESULT OF MANUFACTURE ADJUSTMENTS "NO LOAD" AND "SOME LOAD"	11.........................361
			11.5.4.5	RESULT OF LOAD ADJUSTMENTS "NO LOAD" AND "SOME LOAD"...................................362
			11.5.4.6	ADJUSTMENT VALUE OF WORKING RADIUS.....................................................363
			11.5.4.7	ALTERATION OF ADJUSTED VALUE...........................................................364
			11.5.4.8	DELETION OF ADJUSTED VALUE.............................................................365
		11.5.5	LOAD RECORD..................................................................................366
		11.5.6	TROUBLE RECORD...............................................................................369
		11.5.7	CHOICE OF LANGUAGE...........................................................................371
		11.5.8	LOAD RECORD (LOAD RECORD IN THE MAIN MENU)...................................................372
	1.6	ADJUSTMENTS.........................................................................................373
		11.6.1	REMOVING THE INNER PANEL.....................................................................373
		11.6.2	ADJUSTMENT...................................................................................374
			11.6.2.1	ANGLE SENSOR ADJUSTMENT................................................................377
			11.6.2.2	LOAD CELL ZERO POINT ADJUSTMENT........................................................381
			11.6.2.3	LOAD-LESS ADJUSTMENT & SOME LOAD ADJUSTMENT............................................383
			11.6.2.4	LVL ADJUSTMENT (LVL SETTING)...........................................................389
			11.6.2.5	RADIUS ADJUSTMENT......................................................................392
		11.6.3	LOAD ADJUSTMENT..............................................................................394
		11.6.4	ADJUSTMENT DATA COPY (INITIALIZATION)........................................................396
			11.6.4.1	READING OF THE ADJUSTMENT DATA.........................................................398
			11.6.4.2	WRITING OF ADJUSTMENT DATA.............................................................400
			11.6.4.3	INITIALIZATION OF ADJUSTMENT DATA......................................................401
		11.6.5	VERSION CHECK................................................................................402
	11.7	ERROR CODE (ABNORMALITY DETECTION)  AND COUNTERMEASURES............................................403
	11.8	CONTROL OUTPUT.....................................................................................405
	11.9	RELEASES...........................................................................................410
		11.9.1	RELEASE FUNCTION.............................................................................410
			11.9.1.1	CRANE RELEASE CHART....................................................................410
			11.9.1.2	ALARM SOUND............................................................................412
			11.9.1.3	EXTERNAL INDICATOR LAMPS IN RELEASE CONDITION..........................................413
	11.10	MECHANICAL SPECIFICATION..........................................................................414
		11.10.1	ENVIRONMENTAL PERFORMANCE PARAMETERS........................................................414
		11.10.2	LOAD CELL (CRANE)...........................................................................415
		11.10.3	ANGLE SENSOR................................................................................416
		11.10.4	CONTROLLER..................................................................................417
			11.10.4.1	MODEL NAME............................................................................417
			11.10.4.2	SYSTEM INPUT/OUTPUT...................................................................417
			11.10.4.3	MONITOR DISPLAY.......................................................................419
			11.10.4.4	OPERATION SWITCH......................................................................419
			11.10.4.5	INTERNAL PROCESSING SYSTEM............................................................419
			11.10.4.6	MEMORY................................................................................419
			11.10.4.7	EXTERNAL STORAGE ELEMENT..............................................................420
			11.10.4.8	OTHERS................................................................................420
	11.11	EXTERNAL DIMENSIONS...............................................................................421
	11.12	ELECTRIC SCHEMATIC DIAGRAM........................................................................422
		11.12.1	CRANE TYPE..................................................................................422
	11.13	CONTROLLER MALFUNCTION EMERGENCY MEASURES.........................................................423
	11.14	LOAD SAFETY DEVICE CHECK PROCEDURES...............................................................424
12. 	GAUGE CLUSTER..........................................................................................425
	12.1	CONFIGURATION OF DISPLAY...........................................................................427
	12.2	PRIORITY...........................................................................................428
	12.3	STATUS DISPLAY.....................................................................................430
	12.4	FAULT LOG DISPLAY..................................................................................439
13. 	TOTAL CONTROLLER.......................................................................................445
	13.1	ARRANGEMENT OF TOTAL CONTROLLER....................................................................447
	13.2	COMPOSITION OF SYSTEM..............................................................................448
		13.2.1	OUTPUT RELATION TO CONTROLLER................................................................449
	13.3	FUNCTION OF TOTAL CONTROLLER.......................................................................450
	13.4	TOTAL CONTROLLER (HARDWARE)........................................................................473
		13.4.1	OUTLINE......................................................................................473
		13.4.2	SPECIFICATIONS OF TOTAL CONTROLLER OUTPUT....................................................474
		13.4.3	DETAILS OF TOTAL CONTROLLER CONNECTOR........................................................478
		13.4.4	ARRANGEMENT OF TOTAL CONTROLLER CONNECTOR PIN................................................479
		13.4.5	PROPORTIONAL SOLENOID VALVE MEASURING POSITION...............................................486
	13.5	ADJUSTMENT OF TOTAL CONTROLLER.....................................................................487
		13.5.1	NECESSITY OF ADJUSTMENT......................................................................487
		13.5.2	ADJUSTMENT PROCEDURES OF TOTAL CONTROLLER....................................................487
			13.5.2.1	OPTION SETTING.........................................................................487
			13.5.2.2	ADJUSTMENT OF HAND THROTTLE AND FOOT THROTTLE..........................................489
			13.5.2.3	ENGINE SPEED ADJUSTMENT................................................................490
			13.5.2.4	WHEN ADJUSTMENT OF TOTAL CONTROLLER IS IMPOSSIBLE......................................491
			13.5.2.5	INITIAL ADJUSTMENT OF LIFTING HEIGHT GAUGE.............................................492
14. 	AIR CONDITIONER........................................................................................495
	14.1	OPERATION ITEMS....................................................................................497
	14.2	SAFETY MONITOR FUNCTIONS...........................................................................498
	14.3	DISASSEMBLY AND ASSEMBLY PROCEDURE.................................................................501
		14.3.1	SPECIAL CONSIDERATIONS DURING REPLACEMENT....................................................501
		14.3.2	INTERIOR UNIT................................................................................503
			14.3.2.1	CASE DISASSEMBLY.......................................................................503
			14.3.2.2	THERMOSTAT REPLACEMENT.................................................................506
			14.3.2.3	EVAPORATOR OR EXPANSION VALVE REPLACEMENT..............................................507
			14.3.2.4	HEATER CORE REPLACEMENT................................................................508
			14.3.2.5	INTAKE DUMPER ACTUATOR REPLACEMENT.....................................................509
			14.3.2.6	WATER VALVE ACTUATOR OR WATER VALVE REPLACEMENT........................................510
			14.3.2.7	MODE ACTUATOR REPLACEMENT..............................................................511
			14.3.2.8	BLOWER MOTOR ASSEMBLY REPLACEMENT......................................................511
	14.4	OPERATIONAL PRECAUTIONS............................................................................512
	14.5	INSPECTION AND MAINTENANCE.........................................................................513
		14.5.1	INSPECTION/MAINTENANCE LIST..................................................................513
		14.5.2	INSPECTION/MAINTENANCE PROCEDURES............................................................513
	14.6	ELECTRIC SYSTEM SCHEMATIC..........................................................................517

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