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
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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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