Kobelco CKE600 Crawler Crane Operation & Maintenance Manual - S2GB30003ZE06

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This manual PDF download describes procedures for operation, handling, lubrication, maintenance, checking, and adjustment for the CKE600 Kobelco Crawler Crane. It will help the operator or anyone realize peak performance through effective, economical and safe machine operation and maintenance.


APPLICABLE MODELS :

Kobelco CKE600 Crawler Crane
Serial Numbers : From GB04-03001


TABLE OF CONTENTS :

1. SAFE OPERATING PRACTICES FOR MOBILE CRANES
2. OPERATION
3. LOAD SAFETY DEVICE
4. UNLOADING/LOADING THE BASIC MACHINE
5. ASSEMBLY/DISASSEMBLY OF BASIC MACHINE
6. ASSEMBLY/DISASSEMBLY OF CRANE ATTACHMENT
7. WIRE ROPE
8. MAINTENANCE
9. REFERENCE MATERIALS


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Book Code : S2GB30003ZE06
Total Pages : 359


This manual provides rules and guidelines which will help you use this machine safely and effectively. The precautions in this manual must be followed at all times when performing operation and maintenance.

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COVER
TABLE OF CONTENTS
IMPORTANT INFORMATION

1. SAFE OPERATING PRACTICES FOR MOBILE CRANES

2. OPERATION
    2.1 TERMINOLOGY OF MACHINE EACH PART
    2.2 LOCATIONS AND TERMS OF OPERATING CONTROLS
        2.2.1 HANDLING OF EACH SWITCH
        2.2.3 HANDLING THE AIR CONDITIONER
        2.2.4 AM/FM RADIO (OPTION)
    2.3 CRANE OPERATION
        2.3.1 ADJUSTING THE OPERATOR'S SEAT
        2.3.2 1WAY CALL (TRANSMITTER) (OPTION)
        2.3.3 ADJUSTING THE CONTROL LEVER DIRECTION
        2.3.4 STARTING AND STOPPING THE ENGINE
        2.3.5 FUNCTION LOCK LEVER
        2.3.6 PROPELLING OPERATION
        2.3.7 SWINGING OPERATION
        2.3.8 BOOM RAISING/LOWERING OPERATION
        2.3.9 HOOK RAISING/LOWERING OPERATION
    2.4 FREE FALL OPERATION
    2.5 CLAMSHELL OPERATION
    2.6 HANDLING OF HYDRAULIC TAGLINE (OPTION)
    2.7 HANDLING OF VIBROHAMMER
    
3. LOAD SAFETY DEVICE
    3.1 ARRANGEMENT OF EQUIPMENTS
    3.2 TYPE AND FUNCTIONS OF EQUIPMENTS
    3.3 CONNECTING PROCEDURE OF WIRING
        3.3.1 CRANE ATTACHMENT
    3.4 FUNCTION OF CONTROLLER/MONITOR
    3.5 OPERATING PROCEDURE OF CONTROLLER
        3.5.1 SETTING OF THE CRANE CONFIGURATION
        3.5.2 SELECTION OF MAIN/AUX. LIFTING
        3.5.3 SETTING OF WORKING AREA LIMIT VALUE
        3.5.4 SETTING OF THE TIME
        3.5.5 LOAD RECORD
    3.6 WARNING ALARM AND AUTOMATIC STOP
        3.6.1 ITEMS OF WARNING ALARM AND AUTOMATIC STOP
        3.6.2 CONTENTS OF AUTOMATIC STOP
        3.6.3 RELEASE OF AUTOMATIC STOP
    3.7 INSPECTION
        3.7.1 INSPECTION BEFORE RAISING THE BOOM AFTER ASSEMBLY OF
        3.7.2 INSPECTION AFTER ERECTING THE ATTACHMENT
    3.8 CAUTION FOR HANDLING THE LOAD SAFETY DEVICE
    3.9 INDICATION OF ERRORS AND REMEDY
    3.10 INDICATION OF MESSAGE AND ALARM
    3.11 CONFIRMATION OF FUNCTION FOR LOAD SAFETY DEVICE
    
4. UNLOADING/LOADING THE BASIC MACHINE
    4.1 UNLOADING THE BASIC MACHINE FROM THE TRAILER
    4.2 LOADING THE MACHINE ON A TRAILER
    
5. ASSEMBLY/DISASSEMBLY OF BASIC MACHINE
    5.1 EXTENDING/RETRACTING THE CRAWLERS
        5.1.1 EXTENDING THE CRAWLERS
        5.1.2 RETRACTING THE CRAWLER
    5.2 ERECTING/LOWERING THE GANTRY
        5.2.1 ERECTING THE GANTRY
        5.2.2 LOWERING THE GANTRY
    5.3 INSTALLATION, REMOVAL OF THE COUNTERWEIGHT
        5.3.1 INSTALLATION OF THE COUNTERWEIGHT
        5.3.2 REMOVAL OF THE COUNTERWEIGHT
    5.4 INSTALLATION, REMOVAL OF THE COUNTERWEIGHT
        5.4.1 SETTING OF LMI
        5.4.2 PREPARATIONS FOR OPERATION
        5.4.3 INSTALLATION PROCEDURES
        5.4.4 DISASSEMBLY PROCEDURES
        5.4.5 OPERATION OF CYLINDER WHEN SETTING LOW GANTRY POSITION
        
6. ASSEMBLY/DISASSEMBLY OF CRANE ATTACHMENT
    6.1 ASSEMBLING THE ATTACHMENT
        6.1.1 ARRANGEMENT OF BOOM/JIB/GUY LINE
        6.1.2 INSTALLING THE BACKSTOPS
        6.1.3 INSTALLING THE BOOM BASE
        6.1.4 INSTALLING THE BACKSTOPS TO THE REVOLVING FRAME
        6.1.5 INSTALLING THE UPPER SPREADER
        6.1.6 REEVING THE WIRE ROPE INTO THE UPPER AND LOWER SPREADER
        6.1.7 INSTALLING THE BOOM TIP
        6.1.8 INSTALLATION OF THE BASIC GUY LINE
        6.1.9 MAIN HOIST WIRE ROPE REEVING
        6.1.10 CONNECTING THE INSERT BOOMS
        6.1.11 INSTALLING THE CABLE ROLLERS
        6.1.12 CONNECTING THE BOOM GUY LINES
        6.1.13 CAUTION FOR CANTILEVER
        6.1.14 ASSEMBLING THE JIB
        6.1.15 REEVING OF REAR DRUM WIRE ROPE
        6.1.16 INSTALLING THE AUXILIARY SHEAVE
        6.1.17 REEVING THE REAR DRUM WIRE ROPE TO THE AUXILIARY SHEAVE
    6.2 ERECTING THE ATTACHMENT
        6.2.1 CONFIRMATION BEFORE ERECTING THE ATTACHMENT
        6.2.2 ERECTING THE ATTACHMENT
    6.3 LOWERING THE ATTACHMENT
        6.3.1 LOWERING THE ATTACHMENT
    6.4 DISASSEMBLING THE ATTACHMENT
        6.4.1 TREATMENT OF OVERHOIST LIMIT SWITCH WIRING
        6.4.2 WINDING UP THE FRONT DRUM/REAR DRUM WIRE ROPES
        6.4.3 DISASSEMBLING THE JIB
        6.4.4 REMOVING THE BOOM GUY LINE
        6.4.5 DISASSEMBLING THE BOOM
        6.4.6 REMOVING THE BASE BOOM
        6.4.7 REMOVAL OF THE COUNTERWEIGHT
        6.4.8 LOWERING THE GANTRY
    6.5 CAUTION WHEN TRANSPORTING BOOM
    
7. WIRE ROPE
    7.1 HANDLING OF WIRE ROPE
        7.1.1 UNREELING METHOD OF WIRE ROPE
        7.1.2 WINDING WIRE ROPE ONTO THE DRUM
        7.1.3 INSTALLING THE ROPE SOCKET
        7.1.4 SPECIFICATION OF WIRE ROPE
        7.1.5 WIRE ROPE LENGTH
        
8. MAINTENANCE
    8.1 CHECKS
        8.1.1 CHECKS OF THE UPPER
            8.1.1.1 CHECK OF UPPER DAILY OR EVERY 8 HOURS
            8.1.1.2 CHECK OF UPPER MONTHLY OR EVERY 100 HOURS
            8.1.1.3 CHECK OF UPPER SEMI-ANNUALLY OR EVERY 600 HOURS
            8.1.1.4 CHECK OF UPPER WEEKLY OR EVERY 50 HOURS
        8.1.2 CHECK OF LOWER
            8.1.2.1 CHECK OF LOWER DAILY OR EVERY 8 HOURS
            8.1.2.2 CHECK OF LOWER MONTHLY OR EVERY 100 HOURS
            8.1.2.3 CHECK OF LOWER QUARTERLY OR EVERY 250 HOURS
            8.1.2.4 CHECK OF LOWER SEMI-ANNUALLY OR EVERY 600 HOURS
        8.1.3 CHECK OF ATTACHMENT
            8.1.3.1 CHECK OF ATTACHMENT DAILY OR EVERY 8 HOURS
    8.2 OIL/GREASE SUPPLY AND WATER SERVICE
        8.2.1 UPPER LUBRICATION (INCL. WATER SUPPLY)
        8.2.2 LOWER LUBRICATION
        8.2.3 ATTACHMENT LUBRICATION
        8.2.4 GREASE
        8.2.5 ENGINE OIL
        8.2.6 FUEL
        8.2.7 COOLANT
        8.2.8 HYDRAULIC OIL
        8.2.9 GEAR OIL
    8.3 CLEANING/WASHING/CHANGE OF FILTER ELEMENT AND STRAINER
    8.4 CHECK OF BATTERY
    8.5 ARRANGEMENT AND USE OF FUSE
    8.6 OPERATION UNDER UNUSUAL CONDITIONS
    8.7 MACHINE STORAGE
    8.8 TIGHTENING TORQUE VALUES
    8.9 SECURITY PARTS TO BE REPLACED PERIODICALLY
    8.10 ADJUSTMENT
        8.10.1 ADJUSTMENT OF FRONT AND REAR DRUM LOCKS
        8.10.2 ADJUSTMENT OF BOOM DRUM LOCK
        8.10.3 ADJUSTMENT OF THIRD DRUM LOCK
        8.10.4 HANDLING OF WIRE ROPE OVER-UNWINDING PREVENTIVE DEVICE
        8.10.5 ADJUSTMENT OF CRAWLER SHOES
    8.11 CONSUMABLE PARTS LIST
    
9. REFERENCE MATERIALS
    9.1 SPECIFICATION
        9.1.1 PERFORMANCE
        9.1.2 OUTSIDE DIMENSIONS
    9.2 DIMENSIONS AND WEIGHT OF EACH PARTS
        9.2.1 BASE MACHINE
        9.2.2 COUNTERWEIGHT
        9.2.3 ATTACHMENT
    9.3 STABILITY IN SWINGING AND TRAVELING
    9.4 SYSTEM SCHEMATIC
        9.4.1 HYDRAULIC SYSTEM SCHEMATIC
        9.4.2 ELECTRICAL WIRING SCHEMATIC
        
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