KOBELCO CK1600, CKE1350 Crawler Cranes OPERATION & MAINTENANCE Manual

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Price: US$ 35.00

Complete OPERATION & MAINTENANCE manual with Parts Manual for KOBELCO CK1600, CKE1350 Crawler Cranes.

KOBELCO CK1600, CKE1350 Electrical Circuit Chart.pdf
S2GN00003ZE10 - KOBELCO CK1600 Crawler Crane OPERATION & MAINTENANCE MANUAL.pdf
S2GN10002ZE08 - KOBELCO CK1600 (LUFFING) Crawler Crane OPERATION & MAINTENANCE MANUAL.pdf
S3GN12003ZO01 - KOBELCO CK1600 Crawler Crane Parts Manual.pdf
S5GN00003ZE08 - KOBELCO CK1600, CKE1350 Crawler Crane OPERATION & MAINTENANCE MANUAL.pdf

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Total Pages: 2,322 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English

TABLE OF CONTENTS
KOBELCO CK1600, CKE1350 Electrical Circuit Chart....1
S2GN00003ZE10 - KOBELCO CK1600 Crawler Crane OPERATION & MAINTENANCE MANUAL....33
  COVER....33
  TABLE OF CONTENTS....35
  IMPORTANT INFORMATION....41
  1. SAFE OPERATING PRACTICES FOR MOBILE CRANES....49
  2. OPERATION....69
    2.1 TERMINOLOGY OF MACHINE EACH PART....69
    2.2 LOCATIONS AND TERMS OF OPERATING CONTROLS....70
      2.2.1 OPERATING SWITCHES....74
      2.2.2 GAUGE CLUSTER CONFIGURATION....84
      2.2.3 OPERATING THE AIR CONDITIONER....98
      2.2.4 AM/FM RADIO (OPTION)....100
    2.3 CRANE OPERATION....102
      2.3.1 ADJUSTING THE OPERATOR'S SEAT....102
      2.3.2 ADJUSTING THE CONTROL LEVER DIRECTION....102
      2.3.3 STARTING AND STOPPING THE ENGINE....103
      2.3.4 FUNCTION LOCK LEVER....106
      2.3.5 PROPELLING OPERATION....107
      2.3.6 SWINGING OPERATION....109
      2.3.7 BOOM RAISING/LOWERING OPERATION....112
      2.3.8 HOOK RAISING/LOWERING OPERATION....114
    2.4 FREE FALL OPERATION....117
    2.5 HANDLING OF REEVING WINCH (OPTION)....120
  3. LOAD SAFETY DEVICE....123
    3.1 ARRANGEMENT OF EQUIPMENTS....123
    3.2 TYPE AND FUNCTIONS OF EQUIPMENTS....126
    3.3 CONNECTING PROCEDURE OF WIRING....132
      3.3.1 CRANE ATTACHMENT....132
    3.4 FUNCTION OF CONTROLLER/MONITOR....137
    3.5 OPERATING PROCEDURE OF CONTROLLER....141
      3.5.1 SETTING SCREEN....142
      3.5.2 SETTING OF THE CRANE CONFIGURATION....147
      3.5.3 SELECTION OF MAIN/AUX. LIFTING....152
      3.5.4 SETTING OF WORKING AREA LIMIT VALUE....153
      3.5.5 SETTING OF THE TIME....157
    3.6 WARNING ALARM AND AUTOMATIC STOP....159
      3.6.1 ITEMS OF WARNING ALARM AND AUTOMATIC STOP....159
      3.6.2 CONTENTS OF AUTOMATIC STOP....160
      3.6.3 RELEASE OF AUTOMATIC STOP....162
    3.7 INSPECTION....168
      3.7.1 INSPECTION BEFORE RAISING THE BOOM AFTER ASSEMBLY OF ATTACHMENT IS COMPLETED....168
      3.7.2 INSPECTION AFTER ERECTING THE ATTACHMENT....171
    3.8 CAUTION FOR HANDLING THE LOAD SAFETY DEVICE....172
    3.9 INDICATION OF ERRORS AND REMEDY....173
    3.10 INDICATION OF MESSAGE AND ALARM....174
    3.11 CONFIRMATION OF FUNCTION FOR LOAD SAFETY DEVICE....176
  4. ASSEMBLY OF THE MACHINE....177
    4.1 STABILITY IN SWINGING AND TRAVELING....177
      4.1.1 WITHOUT BOOM BASE....177
      4.1.2 WITH BOOM BASE....179
    4.2 TRANSLIFTER....180
      4.2.1 COMPOSITION OF TRANSLIFTER....180
      4.2.2 HANDLING TRANSLIFTERS (1) - (4)....181
    4.3 UNLOADING BASE MACHINE....184
      4.3.1 ERECTING GANTRY....185
      4.3.2 SETTING TRANSLIFTERS....187
      4.3.3 UNLOADING BASE MACHINE FROM TRAILER....191
    4.4 INSTALLATION OF THE CARBODY WEIGHT (OPTION)....193
    4.5 INSTALLATION OF CRAWLER....195
      4.5.1 INSTALLATION OF THE FIRST CRAWLER....195
      4.5.2 INSTALLATION OF THE SECOND CRAWLER....200
    4.6 INSTALLATION OF THE COUNTERWEIGHT....202
      4.6.1 ASSEMBLING THE COUNTERWEIGHTS....202
      4.6.2 REMOVING THE HOOK BLOCK FROM THE BASE BOOM....206
      4.6.3 SETTING THE COUNTER-WEIGHT LINK....206
      4.6.4 INSTALLATION OF COUNTERWEIGHTS TO MACHINE....207
    4.7 ASSEMBLING ATTACHMENTS....212
      4.7.1 ASSEMBLY OF BOOM AND FIXED JIB....212
      4.7.2 ASSEMBLY OF THE JIB....227
      4.7.3 INSTALLATION OF THE AUXILIARY SHEAVE....232
    4.8 REEVING THE WIRE ROPE FOR CRANE AND AUXILIARY SHEAVE....233
      4.8.1 REEVING THE FRONT DRUM WIRE ROPE FOR CRANE....233
      4.8.2 REEVING THE REAR DRUM WIRE ROPE TO THE AUXILIARY SHEAVE....235
      4.8.3 REEVING OF REAR DRUM WIRE ROPE....236
    4.9 ERECTING THE ATTACHMENT....238
      4.9.1 CONNECTING THE SAFETY DEVICE....238
      4.9.2 CHECK THE SAFETY DEVICE....238
      4.9.3 CONFIRMATION BEFORE ERECTING THE ATTACHMENT....238
      4.9.4 ERECTING THE ATTACHMENT....239
      4.9.5 CHECK BEFORE STARTING THE WORK....239
  5. ASSEMBLY/DISASSEMBLY OF DISASSEMBLY OF THE MACHINE....241
    5.1 LOWERING THE ATTACHMENT....243
      5.1.1 LOWERING THE ATTACHMENT....243
    5.2 DISCONNECTING THE WIRING FOR SAFETY DEVICE....244
    5.3 REMOVING THE BOOM GUY LINE....245
      5.3.1 INSTALLATION OF THE UPPER SPREADER TO THE BOOM BASE....245
      5.3.2 REMOVE THE BOOM GUY LINE....245
    5.4 REMOVING THE COUNTERWEIGHT....246
      5.4.1 DISCONNECT THE BOOM BASE FROM THE INSERT BOOM....246
      5.4.2 REMOVE THE COUNTER-WEIGHTS FROM THE MACHINE....246
      5.4.3 INSTALLATION OF THE HOOK BLOCK TO THE BOOM BASE....251
      5.4.4 DISASSEMBLY OF THE COUNTERWEIGHT....251
    5.5 DISASSEMBLING THE ATTACHMENT....253
      5.5.1 REMOVING UPPER AND INSERT BOOMS....253
    5.6 REMOVAL OF THE CRAWLERS....254
      5.6.1 SETTING THE TRANSLIFTER (Refer to 4.3.2)....254
      5.6.2 REMOVAL OF THE CRAWLERS....255
    5.7 REMOVAL OF THE CARBODY WEIGHTS....261
    5.8 LOADING THE BASE MACHINE....262
      5.8.1 LOADING THE BASE MACHINE ON THE TRAILER....262
      5.8.2 LOWERING THE BOOM BASE....264
      5.8.3 LOWERING THE GANTRY....265
      5.8.4 FOLDING THE TRANSLIFTER....266
      5.8.5 CAUTION WHEN TRANSPORTING THE BASE MACHINE....267
      5.8.6 HANDLING OF TRAVELING KIT (OPTION)....268
  6. WIRE ROPE....269
    6.1 HANDLING OF WIRE ROPE....269
      6.1.1 UNREELING METHOD OF WIRE ROPE....269
      6.1.2 WINDING WIRE ROPE ONTO THE DRUM....270
      6.1.3 INSTALLING THE ROPE SOCKET....272
      6.1.4 SPECIFICATION OF WIRE ROPE....272
      6.1.5 WIRE ROPE LENGTH....273
  7. MAINTENANCE....275
    7.1 CHECKS....280
      7.1.1 CHECKS OF THE UPPER....281
        7.1.1.1 UPPER STRUCTURE INSPECTIONS-DAILY OR EVERY 8 HOURS....282
        7.1.1.2 UPPER STRUCTURE INSPECTIONS-MONTHLY OR EVERY 100 HOURS....287
        7.1.1.3 CHECK OF UPPER SEMI-ANNUALLY OR EVERY 600 HOURS....291
        7.1.1.4 CHECK OF UPPER WEEKLY OR EVERY 50 HOURS....292
      7.1.2 CHECK OF LOWER....294
        7.1.2.1 CHECK OF LOWER DAILY OR EVERY 8 HOURS....296
        7.1.2.2 CHECK OF LOWER MONTHLY OR EVERY 100 HOURS....297
        7.1.2.3 CHECK OF LOWER QUARTERLY EVERY 3 MONTHS OR EVERY 250 HOURS....299
        7.1.2.4 CHECK OF LOWER SEMI-ANNUALLY OR EVERY 600 HOURS....299
      7.1.3 CHECK OF ATTACHMENT....300
        7.1.3.1 CHECK OF ATTACHMENT DAILY OR EVERY 5 HOURS....302
    7.2 OIL/GREASE SUPPLY AND WATER SERVICE....309
      7.2.1 UPPER LUBRICATION (INCL. WATER SUPPLY)....312
      7.2.2 LOWER LUBRICATION....314
      7.2.3 ATTACHMENT LUBRICATION....316
      7.2.4 GREASE....318
      7.2.5 ENGINE OIL....324
      7.2.6 FUEL....325
      7.2.7 COOLANT....326
      7.2.8 HYDRAULIC OIL....328
      7.2.9 GEAR OIL....330
    7.3 CLEANING/WASHING/CHANGING FILTER ELEMENT AND STRAINER....336
    7.4 BATTERY INSPECTION....347
    7.5 LOCATION AND USE OF FUSE....350
    7.6 OPERATION UNDER UNUSUAL CONDITIONS....352
    7.7 MACHINE STORAGE....354
    7.8 TIGHTENING TORQUE VALUES....355
    7.9 SECURITY PARTS TO BE REPLACED PERIODICALLY....357
    7.10 ADJUSTMENT....358
      7.10.1 ADJUSTMENT OF FRONT AND REAR DRUM LOCKS....358
      7.10.2 ADJUSTMENT OF BOOM DRUM LOCK....359
      7.10.3 ADJUSTMENT OF THIRD DRUM LOCK....360
      7.10.4 CRAWLER SHOES ADJUSTMENT....361
    7.11 CONSUMABLE PARTS LIST....362
  8. REFERENCE MATERIALS....367
    8.1 SPECIFICATION....367
      8.1.1 PERFORMANCE....367
      8.1.2 OUTSIDE DIMENSIONS....367
    8.2 DIMENSIONS AND WEIGHT OF EACH PARTS....369
      8.2.1 BASE MACHINE....369
      8.2.2 COUNTERWEIGHT....371
      8.2.3 ATTACHMENT....372
    8.3 SYSTEM SCHEMATIC....375
      8.3.1 HYDRAULIC SCHEMATIC....375
      8.3.2 ELECTRIC SYSTEM SCHEMATIC....378
  9. INITIAL ASSEMBLY OF THE MACHINE....393
    9.1 UPPER STRUCTURE (WITH CARBODY) LIFTING PROCEDURES....394
      9.1.1 INSTALLATION....394
    9.2 LOADING/UNLOADING OF THE MACHINE FROM/ONTO A TRAILER....395
      9.2.1 LOADING ONTO A TRAILER....395
      9.2.2 UNLOADING FROM A TRAILER....395
    9.3 INSTALLATION OF THE CARBODY WEIGHT (OPTION)....399
    9.4 INSTALLATION OF THE CRAWLER....400
      9.4.1 INSTALLATION OF THE FIRST CRAWLER....400
      9.4.2 INSTALLATION OF THE SECOND CRAWLER....404
    9.5 INSTALLATION OF THE GANTRY TO THE SWING FRAME....405
    9.6 INSTALLATION OF THE BOOM BASE....409
      9.6.1 INSTALLATION OF THE BOOM BASE....409
    9.7 INSTALLATION OF THE BACKSTOP....410
    9.8 INSTALLING THE UPPER AND LOWER SPREADER....411
S2GN10002ZE08 - KOBELCO CK1600 (LUFFING) Crawler Crane OPERATION & MAINTENANCE MANUAL....419
  COVER....419
  TABLE OF CONTENTS....421
  IMPORTANT INFORMATION....427
  1. SAFE OPERATING PRACTICES FOR MOBILE CRANES....437
  2. OPERATION....457
    2.1 TERMINOLOGY OF MACHINE EACH PART....457
      2.1.1 LUFFING UPPER BOOM ATTACHMENT....457
      2.1.2 LUFFING JIB ATTACHMENT....458
    2.2 LOCATIONS AND TERMS OF OPERATING CONTROLS....459
      2.2.1 OPERATING SWITCHES....463
      2.2.2 GAUGE CLUSTER CONFIGURATION....473
      2.2.3 OPERATING THE AIR CONDITIONER....487
      2.2.4 AM/FM RADIO (OPTION)....489
    2.3 CRANE OPERATION....491
      2.3.1 ADJUSTING THE OPERATOR'S SEAT....491
      2.3.2 ADJUSTING THE CONTROL LEVER DIRECTION....491
      2.3.3 STARTING AND STOPPING THE ENGINE....492
      2.3.4 FUNCTION LOCK LEVER....495
      2.3.5 PROPELLING OPERATION....496
      2.3.6 SWINGING OPERATION....498
      2.3.7 BOOM RAISING/LOWERING OPERATION....501
      2.3.8 HOOK RAISING/LOWERING OPERATION....503
    2.4 LUFFING JIB OPERATION....506
      2.4.1 JIB RAISING/LOWERING OPERATION....507
      2.4.2 HOOK HOIST DRUM CONTROL....509
    2.5 FREE FALL OPERATION....510
    2.6 HANDLING OF REEVING WINCH (OPTION)....513
  3. LOAD SAFETY DEVICE....515
    3.1 ARRANGEMENT OF EQUIPMENTS....515
    3.2 TYPE AND FUNCTIONS OF EQUIPMENTS....519
    3.3 CONNECTING PROCEDURE OF WIRING....527
      3.3.1 CRANE ATTACHMENT....527
      3.3.2 LUFFING ATTACHMENT....531
    3.4 FUNCTION OF CONTROLLER/MONITOR....536
    3.5 OPERATING PROCEDURE OF CONTROLLER....540
      3.5.1 SETTING SCREEN....541
      3.5.2 SETTING OF THE CRANE CONFIGURATION....546
      3.5.3 SELECTION OF MAIN/JIB/AUX. LIFTING....551
      3.5.4 SETTING OF WORKING AREA LIMIT VALUE....552
      3.5.5 SETTING OF THE TIME....556
    3.6 WARNING ALARM AND AUTOMATIC STOP....558
      3.6.1 ITEMS OF WARNING ALARM AND AUTOMATIC STOP....558
      3.6.2 CONTENTS OF AUTOMATIC STOP....560
      3.6.3 RELEASE OF AUTOMATIC STOP....564
    3.7 INSPECTION....570
      3.7.1 INSPECTION BEFORE RAISING THE BOOM AFTER ASSEMBLY OF ATTACHMENT IS COMPLETED....570
      3.7.2 INSPECTION AFTER ERECTING THE ATTACHMENT....576
    3.8 CAUTION FOR HANDLING THE LOAD SAFETY DEVICE....577
    3.9 INDICATION OF ERRORS AND REMEDY....578
    3.10 INDICATION OF MESSAGE AND ALARM....579
    3.11 CONFIRMATION OF FUNCTION FOR LOAD SAFETY DEVICE....581
  4. ASSEMBLY OF THE MACHINE....583
    4.1 STABILITY IN SWINGING AND TRAVELING....583
      4.1.1 WITHOUT BOOM BASE....583
      4.1.2 WITH BOOM BASE....585
    4.2 TRANSLIFTER....586
      4.2.1 COMPOSITION OF TRANSLIFTER....586
      4.2.2 HANDLING TRANSLIFTERS (1) - (4)....587
    4.3 UNLOADING BASE MACHINE....590
      4.3.1 ERECTING GANTRY....591
      4.3.2 SETTING TRANSLIFTERS....593
      4.3.3 UNLOADING BASE MACHINE FROM TRAILER....597
    4.4 INSTALLATION OF THE CARBODY WEIGHT (OPTION)....599
    4.5 INSTALLATION OF CRAWLER....601
      4.5.1 INSTALLATION OF THE FIRST CRAWLER....601
      4.5.2 INSTALLATION OF THE SECOND CRAWLER....605
    4.6 INSTALLATION OF THE COUNTERWEIGHT....607
      4.6.1 ASSEMBLING THE COUNTERWEIGHTS....607
      4.6.2 REMOVING THE HOOK BLOCK FROM THE BASE BOOM....611
      4.6.3 SETTING THE COUNTER-WEIGHT LINK....611
      4.6.4 INSTALLATION OF COUNTERWEIGHTS TO MACHINE....612
    4.7 ASSEMBLING CRANE WITH LUFFING BOOM TIP ATTACHMENTS....617
      4.7.1 ASSEMBLY OF BOOM/GUY LINE....617
      4.7.2 ASSEMBLING OF BOOM/GUY LINE (Using an assisting crane)....623
      4.7.3 ASSEMBLING OF BOOM/GUY LINE (Self-erection with boom base on the base machine)....631
      4.7.4 INSTALLATION OF AUXILIARY SHEAVE....636
      4.7.5 REEVING FRONT DRUM WIRE ROPE FOR CRANE....637
      4.7.6 REEVING REAR DRUM WIRE ROPE TO AUXILIARY SHEAVE....639
    4.8 ASSEMBLING THE LUFFING ATTACHMENTS....640
      4.8.1 ARRANGEMENT OF BOOM/JIB/GUY LINE....640
      4.8.2 ASSEMBLING OF BOOM/JIB/GUY LINE (Using an assisting crane)....645
      4.8.3 ASSEMBLING OF BOOM/JIB/GUY LINE (Self-election with boom base on the base machine)....659
      4.8.4 REEVING FRONT DRUM WIRE ROPE FOR CRANE....673
    4.9 ERECTING ATTACHMENT....676
      4.9.1 CONNECTING SAFETY DEVICE....676
      4.9.2 CHECKING SAFETY DEVICE....676
      4.9.3 CONFIRMATION BEFORE ERECTING ATTACHMENT....676
      4.9.4 ERECTING THE CRANE ATTACHMENT....677
      4.9.5 CHECK BEFORE STARTING WORK....678
      4.9.6 ERECTING THE LUFFING ATTACHMENT....679
      4.9.7 CHECK BEFORE STARTING THE WORK....683
  5. DISASSEMBLY OF THE MACHINE....685
    5.1 LOWERING THE ATTACHMENT....687
      5.1.1 LOWERING THE ATTACHMENT....687
    5.2 LOWERING THE LUFFING ATTACHMENT....688
      5.2.1 LOWERING THE ATTACHMENT....689
    5.3 WINDING UP THE FRONT DRUM/REAR DRUM WIRE ROPES....692
    5.4 DISCONNECTING THE WIRING FOR SAFETY DEVICE....692
    5.5 WINDING UP THE JIB DRUM WIRE ROPE....693
    5.6 REMOVING BOOM GUY LINE....693
      5.6.1 INSTALLATION OF UPPER SPREADER TO BOOM BASE....693
      5.6.2 DISCONNECT BOOM BASE FROM INSERT BOOM....693
    5.7 COUNTERWEIGHT REMOVAL....695
      5.7.1 REMOVAL OF COUNTERWEIGHTS....695
      5.7.2 INSTALLATION OF THE HOOK BLOCK TO THE BOOM BASE....700
      5.7.3 DISASSEMBLY OF THE COUNTERWEIGHT....700
    5.8 DISASSEMBLING CRANE WITH LUFFING BOOM TIP ATTACHMENT....702
      5.8.1 REMOVING THE AUXILIARY SHEAVE....702
      5.8.2 REMOVAL OF BOOM GUY LINE....702
      5.8.3 REMOVING UPPER AND INSERT BOOMS....703
    5.9 DISASSEMBLY OF LUFFING ATTACHMENT....704
      5.9.1 DISASSEMBLING THE LUFFING JIB....704
      5.9.2 DISASSEMBLING THE LUFFING BOOM TIP ASSEMBLY....705
    5.10 REMOVAL OF THE CRAWLERS....706
      5.10.1 SETTING THE TRANSLIFTER....706
      5.10.2 REMOVAL OF THE CRAWLERS....707
    5.11 REMOVAL OF THE CARBODY WEIGHTS (OPTION)....713
    5.12 LOADING THE BASE MACHINE....714
      5.12.1 LOADING THE BASE MACHINE ON THE TRAILER....714
      5.12.2 LOWERING THE BOOM BASE....716
      5.12.3 LOWERING THE GANTRY....717
      5.12.4 FOLDING THE TRANSLIFTER....718
      5.12.5 CAUTION WHEN TRANSPORTING THE BASE MACHINE....719
      5.12.6 HANDLING OF TRAVELING KIT (OPTION)....720
    5.13 LOWERING THE ATTACHMENT (JIB INSIDE HOLDING STYLE)....721
  6. WIRE ROPE....727
    6.1 HANDLING OF WIRE ROPE....727
      6.1.1 UNREELING METHOD OF WIRE ROPE....727
      6.1.2 WINDING WIRE ROPE ONTO THE DRUM....728
      6.1.3 INSTALLING THE ROPE SOCKET....730
      6.1.4 SPECIFICATION OF WIRE ROPE....730
      6.1.5 WIRE ROPE LENGTH....731
  7. MAINTENANCE....733
    7.1 CHECKS....738
      7.1.1 CHECKS OF THE UPPER....739
        7.1.1.1 UPPER STRUCTURE INSPECTIONS-DAILY OR EVERY 8 HOURS....740
        7.1.1.2 UPPER STRUCTURE INSPECTIONS-MONTHLY OR EVERY 100 HOURS....745
        7.1.1.3 CHECK OF UPPER SEMI-ANNUALLY OR EVERY 600 HOURS....749
        7.1.1.4 CHECK OF UPPER WEEKLY OR EVERY 50 HOURS....750
      7.1.2 CHECK OF LOWER....752
        7.1.2.1 CHECK OF LOWER DAILY OR EVERY 8 HOURS....754
        7.1.2.2 CHECK OF LOWER MONTHLY OR EVERY 100 HOURS....755
        7.1.2.3 CHECK OF LOWER QUARTERLY EVERY 3 MONTHS OR EVERY 250 HOURS....757
        7.1.2.4 CHECK OF LOWER SEMI-ANNUALLY OR EVERY 600 HOURS....757
      7.1.3 CHECK OF ATTACHMENT....758
        7.1.3.1 CHECK OF ATTACHMENT DAILY OR EVERY 5 HOURS....760
    7.2 OIL/GREASE SUPPLY AND WATER SERVICE....768
      7.2.1 UPPER LUBRICATION (INCL. WATER SUPPLY)....772
      7.2.2 LOWER LUBRICATION....774
      7.2.3 ATTACHMENT LUBRICATION....776
      7.2.4 GREASE....778
      7.2.5 ENGINE OIL....784
      7.2.6 FUEL....785
      7.2.7 COOLANT....786
      7.2.8 HYDRAULIC OIL....788
      7.2.9 GEAR OIL....790
    7.3 CLEANING/WASHING/CHANGING FILTER ELEMENT AND STRAINER....796
    7.4 BATTERY INSPECTION....807
    7.5 LOCATION AND USE OF FUSE....810
    7.6 OPERATION UNDER UNUSUAL CONDITIONS....812
    7.7 MACHINE STORAGE....814
    7.8 TIGHTENING TORQUE VALUES....815
    7.9 SECURITY PARTS TO BE REPLACED PERIODICALLY....817
    7.10 ADJUSTMENT....818
      7.10.1 ADJUSTMENT OF FRONT AND REAR DRUM LOCKS....818
      7.10.2 ADJUSTMENT OF BOOM DRUM LOCK....819
      7.10.3 ADJUSTMENT OF THIRD DRUM LOCK....820
      7.10.4 CRAWLER SHOES ADJUSTMENT....821
    7.11 CONSUMABLE PARTS LIST....822
  8. REFERENCE MATERIALS....827
    8.1 SPECIFICATION....827
      8.1.1 PERFORMANCE....827
      8.1.2 PERFORMANCE OF LUFFING JIB....827
      8.1.3 OUTSIDE DIMENSIONS....828
    8.2 DIMENSIONS AND WEIGHT OF EACH PARTS....831
      8.2.1 BASE MACHINE....831
      8.2.2 COUNTERWEIGHT....833
      8.2.3 ATTACHMENT....834
    8.3 SYSTEM SCHEMATIC....838
      8.3.1 HYDRAULIC SCHEMATIC....838
      8.3.2 ELECTRIC SYSTEM SCHEMATIC....840
  9. INITIAL ASSEMBLY OF THE MACHINE....855
    9.1 UPPER STRUCTURE (WITH CARBODY) LIFTING PROCEDURES....856
      9.1.1 INSTALLATION....856
    9.2 LOADING/UNLOADING OF THE MACHINE FROM/ONTO A TRAILER....857
      9.2.1 LOADING ONTO A TRAILER....857
      9.2.2 UNLOADING FROM A TRAILER....857
    9.3 INSTALLATION OF THE CARBODY WEIGHT (OPTION)....861
    9.4 INSTALLATION OF THE CRAWLER....862
      9.4.1 INSTALLATION OF THE FIRST CRAWLER....862
      9.4.2 INSTALLATION OF THE SECOND CRAWLER....866
    9.5 INSTALLATION OF THE GANTRY TO THE SWING FRAME....867
    9.6 INSTALLATION OF THE BOOM BASE....871
      9.6.1 INSTALLATION OF THE BOOM BASE....871
    9.7 INSTALLATION OF THE BACKSTOP....872
    9.8 INSTALLING THE UPPER AND LOWER SPREADER....873
S3GN12003ZO01 - KOBELCO CK1600 Crawler Crane Parts Manual....881
  COVER....881
  CONTENTS....886
  CONTROL SYSTEM....0
    CONTROL ASSY....898
    CONTROL LEVER ASSY (BOOM / MAIN / AUX.)....902
    CONTROL LEVER ASSY (SWING)....906
    CONTROL LEVER ASSY (PROPEL)....910
    REMOTE CONTROL V.INSTAL (BOOM / FRONT / REAR)....912
    SWING LOCK ASSY....914
    GRIP ASSY (OPTION)....916
    FLOOR PLATE ASSY....918
    GRIP ASSY (BOOM)....920
    PANEL ASSY....922
    PANEL ASSY (LEFT STAND / WITHOUT FREE FALL)(LEFT STAND / WITH FREE FALL)....924
    LABEL ASSY....926
    PANEL ASSY (LEFT STAND)....928
    PANEL ASSY....930
    PANEL ASSY (BYPASS SWITCH)....932
    TRIMMER INSTAL (FOR LUFFING)....934
    DRUM LOCK ASSY (FRONT / REAR)....936
    DRUM LOCK ASSY (BOOM)....938
    LUB.LINES (FRONT / REAR)....942
    LUB. LINES (BOOM)....944
    MONITOR INSTAL    ....946
    RADIO INSTAL (OPTION)(COVER INSTAL)....948
  WINCH SYSTEM (WITHOUT BRAKE)....0
    WINCH INSTAL ASSY (WITHOUT FREE FALL)....950
    WINCH ASSY (FRONT)....954
    WINCH ASSY (REAR)....958
    REDUCTION ASSY SWING (FRONT)(REAR)....962
  WINCH SYSTEM (WITH BRAKE)....0
    WINCH INSTAL ASSY (WITHOUT FREE FALL)....950
    WINCH ASSY (FRONT)....954
    WINCH ASSY (REAR)....958
    REDUCTION ASSY SWING (FRONT)(REAR)....962
    WINCH INSTAL ASSY (WITH FREE FALL)....966
    WINCH ASSY (FRONT)(WITH FREE FALL)....970
    WINCH ASSY (REAR)(WITH FREE FALL)....972
    WINCH ASSY (WITH FREE FALL)....974
    BRAKE PEDAL ASSY....976
    LAMP ASSY, INSTAL (WITH FREE FALL)....980
    BRAKE INSTAL (WITH FREE FALL)....982
    3-SECTION VALVE HYD. LINES....984
    4-SECTION VALVE INSTAL (WITH FREE FALL)....986
    HYD LINES. RETURN (WITH FREE FALL)....988
    CONTROL LINES, FLOOR (WITH FREE FALL)....990
  BOOM HOIST SYSTEM....0
    WINCH INSTAL ASSY (BOOM)....992
    WINCH INSTAL (BOOM HOIST)....996
  SWING SYSTEM....0
    SWING REDUCT INSTAL....1000
    SWING REDUCT INSTAL....1002
    SWING BEARING INSTAL....1004
    SWING REDUCTION ASSY....1006
    SWING BEARING LUB. LINES....1010
  LINES....0
    PUMP HYD. LINES (SUCTION)....1012
    PUMP HYD. LINES (CONTROL)....1016
    PUMP HYD. LINES (DELIVERY)....1020
    RIGHT DECK HYD. LINES....1022
    MAIN VALVE HYD. LINES....1028
    ACCUMLATOR INSTAL....1030
    FLOOR CONTROL HYD. LINES....1032
    RETURN ・ DRAIN HYD. LINES....1038
    CONTROL HYD. LINES (FOR WITHOUT FREE FALL)....1042
    RETURN HYD. LINES....1044
    RETURN BLOCK HYD. LINES....1046
    SWING MOTOR HYD. LINES....1048
    SWING MOTOR HYD. LINES....1050
    2-SECTION VALVE....1054
    2-SECTION VALVE....1058
    4-SECTION VALVE (MOTOR BRAKE)....1060
    5-SECTION VALVE (LIMIT STOP)....1062
    8-SECTION VALVE (WITH SHUTTLE VALVE)....1064
    WINCH HYD. LINES (FOR FRONT & REAR DRUM)....1066
    WINCH HYD. LINES (FOR BOOM)....1070
    OIL COOLER HYD. LINES....1072
    GANTRY VALVE LINES....1074
    CLAMP ASSY....1078
    LOW. HYD. LINES....1082
    SWIVEL JOINT INSTAL....1086
    SWIVEL JOINT....1088
    HYD. OIL TANK ASSY....1090
    HYD. OIL COOLING LINES    ....1094
    CONNECTOR ASSY....1098
    CONNECTOR ASSY....1100
  POWER PLANT....0
    POWER PLANT ASSY....1102
    PUMP INSTAL (WITH FREE FALL)....1108
    POWER DIVIDER....1110
    MUFFLER INSTAL....1114
    FUEL LINES....1116
    RADIATOR INSTAL....1118
    AIR CLEANER INSTAL    ....1120
    FUEL TANK ASSY....1122
  ELECTRIC SYSTEM....0
    ELEC ASSY (R.H. DECK)....1126
    ELEC ASSY (REV. FRAME)....1132
    ELEC ASSY (FLOOR PLATE)....1136
    RELAY BOX ASSY....1140
    ELEC ASSY (L.H. GUARD)....1142
    ELEC ASSY (CAB)....1144
    ELEC ASSY (L.H. DECK)....1148
    WASHER TANK ASSY....1154
    WASHER TANK INSTAL....1156
    BATTERY INSTAL....1158
    JUNCTION BOX ASSY....1160
    RELAY ASSY....1162
    HARNESS ASSY (FOR HEAT UP / OPTION)....1164
  CAB / GUARD / PLATFORM....0
    CAB INSTAL....1166
    CAB ASSY....1170
    DOOR ASSY....1178
    RUBBER SHEET INSTAL (OPERATOR’S ROOM)....1184
    LOCK ASSY....1186
    WIPER INSTAL (FOR FRONT LOWER WINDOW / OPTION)....1188
    SUN VISOR ASSY....1190
    ROLL BLIND....1192
    SASH ASSY....1194
    R.H. GUARD INSTAL....1196
    R.H. GUARD ASSY....1200
    L.H. GUARD INSTAL....1204
    L.H. GUARD ASSY....1208
    L.H. GUARD ASSY....1212
    GUARD ASSY (FRONT GUARD)....1214
    INSULATION ASSY....1216
    DRUM GUARD ASSY (FRONT / REAR)....1220
    SWING BEARING COVER....1224
    COVER INSTAL (SWING FRAME)....1226
    UNDER COVER ASSY....1230
    R.H. DECK INSTAL....1232
    R.H. DECK INSTAL (UNDER OF CAB)....1236
    L.H. DECK INSTAL....1240
    BOOM DRUM COVER INSTAL....1244
    STEP ASSY....1246
    COVER ASSY (REV.FRAME)....1248
    COVER ASSY....1250
  LOWER SYSTEM....0
    PROPEL MOTOR ASSY....1252
    IDLER ASSY....1254
    IDLER ADJUST ASSY....1256
    ROLLER ASSY (UPPER / LOWER)....1258
    ROLLER ASSY, TRACL....1260
    ROLLER ASSY, UPP....1262
    FRAME COVER ASSY....1264
    CRAWLER FRAME CONNECT PIN....1266
    SHOE ASSY....1270
    TRANSLIFTER ASSY....1272
    TRANSLIFTER HYD. LINES....1274
    CRAWLER REMOVAL DEVICE....1278
    HOOK OVER HOIST L/S (CRAWLER REMOVAL DEVICE)....1280
    ROLLER ASSY....1282
  CRANE ATTACHMENT....0
    LOW. BOOM ASSY....1284
    UPP. BOOM ASSY....1286
    INSERT BOOM....1288
    INSERT BOOM....1290
    INSERT BOOM....1292
    INSERT BOOM....1294
    BOOM POINT SHEAVE ASSY....1296
    IDLER SHEAVE ASSY....1300
    GUIDE ASSY....1302
    GUY CABLE....1304
    GUY CABLE....1306
    GUIDE ROLLER ASSY (FOR INSERT BOOM)....1308
    LONG BOOM TIP....1310
    JIB ASSY....1312
    INSERT JIB ASSY....1314
    GUY CABLE....1316
    STRUT ASSY....1318
    JIB POINT SHEAVE ASSY....1320
    CABLE ROLLER ASSY (FOR INSERT JIB)....1322
    UPPER SPREADER ASSY....1324
    BOOM BACK STOP ASSY....1326
    BACKSTOP....1328
    AUX. SHEAVE ASSY....1330
    WIRE ROPE ASSY....1332
    TOWER ASSY....1336
    LOWER SPREADER ASSY....1340
    UPPER SPREADER ASSY....1342
    AUX. SHEAVE ASSY....1344
    GUIDE ROLLER / GUIDE SHEAVE ASSY....1346
    TRAVELING KIT....1348
    RAIL ASSY....1350
    LUFFING BOOM TIP....1352
    BOOM POINT SHEAVE ASSY....1354
    BOOM IDLER SHEAVE ASSY....1356
    STRUT BACKSTOP ASSY....1358
    BACKSTOP ARM INSTAL....1360
    BUSHING ASSY....1362
    GUIDE ROLLER ASSY....1364
    STRUT ASSY....1366
    INSERT BOOM ASSY....1368
    GUIDE SHEAVE ASSY....1370
    STEP ASSY....1372
    UPPER JIB ASSY....1374
    JIB TIP ASSY....1376
    JIB POINT SHEAVE ASSY....1378
    JIB IDLER SHEAVE ASSY....1380
    JIB GUIDE ROLLER ASSY....1382
    LINK ASSY....1384
    LOW JIB ASSY....1386
    JIB BACKSTOP ASSY....1388
    TAPER INSERT JIB....1390
    INSERT JIB....1392
    INSERT JIB....1394
    INSERT JIB....1396
    INSERT JIB....1398
    GUIDE ROLLER ASSY....1400
    GUY CABLE ASSY....1402
    GUY CABLE ASSY....1404
  GANTRY....0
    GANTRY ASSY....1406
    LOWER SPREADER ASSY....1410
    SUB GANTRY ASSY....1412
    GANTRY LUB. LINES....1416
  TAGLINE (OPTION)....0
    TAGLINE HYD. LINES....1420
    TAGLINE ASSY....1424
    TAGLINE GUIDE SHEAVE....1426
    TAGLINE SHEAVE ASSY....1428
    ELEC. ASSY....1430
  BOOM FOOT PIN & REEVING WINCH (OPTION)....0
    BOOM FOOT PIN / REEVING WINCH HYD. LINES (OPTION)....1432
    REEVING WINCH ASSY (OPTION)....1438
    WINCH ASSY....1440
    ROLLER INSTAL....1442
    LABEL ASSY....1444
  THIRD (OPTION)....0
    WINCH INSTAL (THIRD)....1446
    WINCH ASSY....1450
    CONTROL LEVER ASSY....1452
    TRIMMER INSTAL....1454
    MAIN HYD. LINES ASSY....1456
    CONTROL HYD. LINES....1458
    PLUG ASSY (FREE LESS)(WITH FREE)....1460
    ACCUMLATOR INSTAL....1464
    WINCH HYD. LINES....1466
    WINCH HYD. LINES....1470
    DRUM LOCK ASSY....1472
    DRUM LOCK LUB. LINES....1474
    4-SECTION VALVE (MOTOR BRAKE)....1476
    8-SECTION VALVE (WITH SHUTTLE VALVE)....1478
    5-SECTION VALVE (LIMIT STOP)....1480
    DRUM COVER ASSY....1482
    IDLER SHEAVE ASSY....1484
    HARNESS ASSY....1486
    SHEAVE ASSY (FOR THIRD)....1488
  SAFETY DEVICE....0
    SAFETY DEVICE HARNESS (FOR GANTRY)....1492
    SAFETY DEVICE HARNESS (FOR BASE)....1496
    SAFETY DEVICE HARNESS (FOR LOWER BOOM)(FOR LONG BOOM)(FOR UPPER BOOM)....1498
    SAFETY DEVICE HARNESS (BOOM ANGLE SENSOR INSTAL)....1502
    SAFETY DEVICE HARNESS (FOR JIB)....1504
    ELECTRIC PARTS INSTAL....1506
    ANGLE SENSOR INSTAL....1510
    BOOM OVERHOIST L/S....1512
    HOOK OVERHOIST L/S (FOR CRANE)....1514
    HOOK OVERHOIST LIMIT SWITCH (FOR AUX. SHEAVE & JIB)....1516
    LIMIT SWITCH ASSY....1518
  COUNTERWEIGHT / FRAME....0
    COUNTERWEIGHT ASSY....1520
    COUNTERWEIGHT ASSY (OPTION)....1522
    CARBODY WEIGHT ASSY (OPTION)....1524
    SWING ALARM LAMP ASSY....1528
    C/W REMOVAL DEVICE (LINE IN)(LINE OUT)....1530
    REMOTE CONTROL ASSY....1534
    C/W REMOVAL DEVICE....1536
    REV. FRAME ASSY....1540
    RUBBER INSTAL....1542
  LABEL....0
    LABEL ASSY (BASE / WITHOUT FREE FALL)....1546
    LABEL ASSY (BASE / WITH FREE FALL)....1554
    LABEL ASSY....1562
    LABEL (FOR LOW. BOOM)(FOR UPP.BOOM)(FOR UPP.BOOM / ROPE SOCKET)....1566
    LABEL (CRANE)....1568
    LABEL ASSY (JIB)....1569
    LABEL ASSY (FOR LUFFING)....1570
  OTHERS....0
    AIR CONDITIONER (INDOOR UNIT)....1572
    AIR CONDITIONER (OUTDOOR UNIT)....1576
    AIR CONDITIONER UNIT....1580
    UPPER FINAL....1584
    UPPER FINAL (ENGINE CONTROL)....1586
    UPPER FINAL....1588
    UPPER FINAL (BASE)....1590
    UPPER FINAL (ANTI SLIP)....1592
    TOOL ASSY....1594
    TOOL ASSY (BOOM CONNECTION PIN STORING / OPTION)....1596
    SPARE PART KIT....1600
    TOOL ASSY....1602
    WIRE ROPE (FOR COUNTERWEIGHT / OPTION)....1604
    SLIG ASSY (OPTION)....1606
    SEAT ASSY....1608
    STEP ASSY (FOR INSERT BOOM / OPTION)(FOR TAPER BOOM / OPTION)....1610
    SEAT ASSY, BOOM (OPTION)....1612
    MONITOR INSTAL (OPTION)....1618
    DRUM TURN SENSOR INSTAL (OPTION)....1622
    FOOT ACCELERATOR (RIGHT)(RIGHT & LEFT / OPTION)(LEFT / OPTION)....1624
    CALL ASSY / ONE-WAY CALL (OPTION)....1628
    AUX. PLATFORM (OPTION)....1630
    TRAVELING KIT....1634
    DRUM TURN SENSOR INSTAL....1636
    SWITCH INSTAL (FOR DRUM TURN SENSOR)....1638
    DRUM TURN SENSOR GRIP INSTAL....1639
    GRIP ASSY....1640
    BOOM GUARD ASSY (FOR BOOM TIP / OPTION)....1642
    HANDRAIL ASSY (OPTION ・FOR BOOM BASE)(OPTION ・FOR INSERT BOOM)(OPTION ・FOR INSERT BOOM)....1644
    HOLDER ASSY....1646
    WIND SENSOR (STD./ OPTION)(CRANE UPP.BOOM / OPTION)(ADD.HARNESS / OPTION)(CRANE LONG / OPTION)(CRANE & LUFFING / OPTION)(LUFFING / OPTION)....1648
    LAMP ASSY, MARKER (OPTION)....1656
    BOOM NESTING (OPTION)....1658
    TRAVELING KIT (GUY CABLE / OPTION)....1660
    TRAVELING KIT (GUY CABLE / OPTION)....1662
    BOOM FOOT PIN ASSY (OPTION)....1664
    WINCH HYD. LINES (HEAT SYSTEM / OPTION)....1666
    SWITCH PANEL ASSY (HEAT SYSTEM / OPTION)....1670
    PLATE ASSY (OPTION)....1672
    HEAD GUARD ASSY (OPTION)....1674
    ALARM ASSY (OPTION)....1676
    EXTINGUISHER INSTAL (OPTION)....1678
    HANDRAIL INSTAL (L.H.GUARD FRONT)....1680
    GUARD INSTAL (LEFT WINDOW)....1682
    CONTROL PEDAL ASSY (BOOM / THIRD / OPTION)....1684
    GUARD LEVEL INSTAL....1690
    LIFE HAMMER INSTAL (OPTION)....1692
  INDEX OF PART NO.....1695
S5GN00003ZE08 - KOBELCO CK1600, CKE1350 Crawler Crane OPERATION & MAINTENANCE MANUAL....1719
  COVER....1719
  TABLE OF CONTENTS....1721
  SAFETY....1729
  1. SPECIFICATION....1741
    1.1 CKE1350 SPECIFICATION....1743
      1.1.1 PERFORMANCE....1743
      1.1.2 PERFORMANCE OF LUFFING JIB....1743
      1.1.3 OUTSIDE DIMENSIONS....1744
      1.1.4 DIMENSIONS AND WEIGHT OF EACH PARTS....1749
      1.1.5 CKE1350 STABILITY IN SWINGING AND TRAVELING....1758
    1.2 CK1600 SPECIFICATION....1761
      1.2.1 PERFORMANCE....1761
      1.2.2 PERFORMANCE OF LUFFING JIB....1761
      1.2.3 OUTSIDE DIMENSIONS....1762
    1.3 DIMENSIONS AND WEIGHT OF EACH PARTS....1767
      1.3.1 BASE MACHINE....1767
      1.3.2 COUNTERWEIGHT....1769
      1.3.3 ATTACHMENT....1770
      1.3.4 STABILITY IN SWINGING AND TRAVELING....1773
  2. MAINTENANCE STANDARDSTEST PROCEDURES....1777
    2.1 MAINTENANCE STANDARD....1779
      2.1.1 PIN, BUSHING, SPRING, LINING AND SHEAVE....1779
      2.1.2 PROPEL DEVICE....1786
      2.1.3 PROPEL BRAKE PLATE....1794
    2.2 PERFORMANCE STANDARD AND TEST PROCEDURE....1795
      2.2.1 OPERATING SPEED....1795
      2.2.2 POINT AND METHOD OF MEASURING PRESSURE....1796
      2.2.3 SLEWING RING....1801
  3. GENERAL WORK STANDARD....1803
    3.1 TIGHTENING TORQUE OF CAPSCREWS AND NUTS....1805
      3.1.1 METRIC COARSE THREADS....1805
      3.1.2 METRIC FINE THREADS....1805
      3.1.3 COARSE THREDS UNC....1806
      3.1.4 FINE THREADS UNF....1806
      3.1.5 TIGHTENING TORQUE OF HYDRAULIC FITTINGS....1807
    3.2 STANDARD PARTS....1809
      3.2.1 BOLT....1809
      3.2.2 O-RING....1810
      3.2.3 BACK-UP RING....1811
      3.2.4 BITE FITTING....1812
    3.3 CONVERSION TABLE....1814
      3.3.1 UNIT CONVERSION....1814
      3.3.2 MILLIMETER : INCH CONVERSION TABLE....1815
      3.3.3 METER-FOOT CONVERSION TABLE....1817
      3.3.4 GRADIENT CONVERSION TABLE....1818
    3.4 TABLE OF UNIT WEIGHT....1819
  4. POWER TRAIN....1821
    4.1 INTRODUCTION....1823
    4.2 ENGINE....1825
      4.2.1 INTRODUCTION....1825
      4.2.2 REMOVAL....1825
      4.2.3 REPAIR AND MAINTENANCE....1826
      4.2.4 RE-INSTALLATION....1827
    4.3 PUMP DRIVE ASSEMBLY....1830
      4.3.1 INTRODUCTION....1830
      4.3.2 REMOVAL....1830
      4.3.3 DISASSEMBLING THE POWER DIVIDER....1832
      4.3.4 CHECK AND REPAIR OF THE POWER DIVIDER....1833
      4.3.5 ASSEMBLING THE POWER DIVIDER....1834
      4.3.6 RE-INSTALLATION....1835
  5. HYDRAULIC SYSTEM....1841
    5.1 LOCATION OF MAIN HYDRAULIC COMPONENTS....1843
    5.2 HYDRAULIC CIRCUITS AND COMPONENTS....1844
      5.2.1 HYDRAULIC CIRCUIT....1844
      5.2.2 COMPONENT SPECIFICATIONS....1848
      5.2.3 LOCATION OF HYDRAULIC COMPONENTS....1852
    5.3 HYDRAULIC SYSTEM....1863
      5.3.1 PREFACE....1863
      5.3.2 OUTLINE....1863
      5.3.3 OIL FLOW FROM No.1 and No. 2 PUMPS....1864
      5.3.4 OIL FLOW FROM No.3 AND No.4 PUMPS....1866
      5.3.5 OIL FLOW FROM No.5 PUMP (CONTROL PUMP)....1868
      5.3.6 OIL FLOW FROM No.6 PUMP (FOR AUXILIARY ACTUATOR CIRCUIT)....1871
    5.4 VALVES....1874
  6. HOIST SYSTEM....1881
    6.1 APPARATUS AND LOCATION OF COMPONENTS....1883
    6.2 CONSTRUCTION AND FUNCTION....1884
      6.2.1 HYDRAULIC SCHEMATIC....1884
      6.2.2 LIFTING A LOAD....1886
      6.2.3 HOLDING A RAISED LOAD....1888
      6.2.4 LOWERING A LOAD (POWERED LOWERING)....1890
      6.2.5 FREE FALL OPERATION....1892
      6.2.6 FREE FALL ACCELERATION....1896
    6.3 DRUM LOCK....1898
      6.3.1 ASEEMBLY DRAWING....1898
      6.3.2 ADJUSTMENT OF DRUM LOCK....1899
    6.4 WINCH ASSEMBLY....1900
      6.4.1 WINCH INSTAL....1900
      6.4.2 WINCH ASSEMBLY / REDUCTION UNIT WITHOUT FREE FALL (STD.)....1901
      6.4.3 WINCH ASSEMBLY WITH FREE FALL (OPT.)....1903
    6.5 BRAKE PEDAL....1904
      6.5.1 ASSEMBLY DRAWING....1904
      6.5.2 ADJUSTING THE BRAKE PEDAL....1906
    6.6 BLEEDING AIR FROM BRAKE CIRCUIT....1907
  7. BOOM HOIST SYSTEM....1909
    7.1 APPARATUS AND LOCATION OF COMPONENTS....1911
    7.2 CONSTRUCTION AND FUNCTION....1913
      7.2.1 HYDRAULIC SCHEMATIC....1913
      7.2.2 RAISING THE BOOM....1914
      7.2.3 NEUTRAL(MAINTAINING THE BOOM POSITION)....1916
      7.2.4 LOWERING THE BOOM....1918
    7.3 BOOM DRUM LOCK....1920
      7.3.1 ASSEMBLY DRAWING....1920
      7.3.2 ADJUSTING THE BOOM DRUM LOCK....1921
    7.4 DRUM AND REDUCTION UNIT....1922
      7.4.1 BOOM WINCH ASSEMBLY....1922
      7.4.2 BOOM DRUM AND REDUCTION UNIT ASSEMBLY....1924
  8. SWING SYSTEM....1927
    8.1 APPARATUS AND LOCATION OF COMPONENTS....1929
    8.2 CONSTRUCTION AND FUNCTION....1930
      8.2.1 HYDRAULIC SCHEMATIC....1930
      8.2.2 SWING....1932
      8.2.3 STOPPING....1935
    8.3 SWING REDUCTION UNIT....1938
    8.4 SWING BEARING....1940
    8.5 SWING LOCK....1942
  9. PROPEL SYSTEM....1943
    9.1 LOCATION OF THE MAJOR COMPONENTS....1945
    9.2 CONSTRUCTION AND FUNCTION....1946
      9.2.1 HYDRAULIC SCHEMATIC....1946
      9.2.2 PROPELLING (RIGHT SIDE FORWARD)....1948
      9.2.3 STOPPING....1950
    9.3 PROPEL REDUCTION UNIT....1952
      9.3.1 MOTOR AND REDUCTION UNIT....1954
    9.4 ADJUSTMENT....1956
  10. ELECTRIC SYSTEM....1957
    10.1 ELECTRICAL WIRING SCHEMATIC....1959
    10.2 CONNECTOR LIST....1970
    10.3 ARRANGEMENT OF ELECTRICAL PART....2022
      10.3.1 ELECTRICAL PART OF CAB....2022
      10.3.2 ELECTRICAL PART OF RIGHT DECK....2026
      10.3.3 ELECTRICAL PART OF FLOOR PLATE & LEFT SIDE STAND PANEL....2034
      10.3.4 ELECTRICAL PART OF REVOLVING FRAME....2039
      10.3.5 ELECTRICAL PART OF LEFT DECK....2042
      10.3.6 ELECTRICAL PART OF LEFT GUARD....2049
      10.3.7 HARNESS PART NUMBER LIST (ALL MODELS)....2050
    10.4 ELECTRICAL PART....2052
      10.4.1 LOCATION AND USE OF FUSE....2052
      10.4.2 FUSE BOX (GG73E00004F1)....2054
      10.4.3 WIPER CONTROL UNIT (2480U306)....2056
      10.4.4 SWING FLASHER UNIT (2480U306)....2057
      10.4.5 PRESSURE SWITCH (CONTROL PRESSURE CUT & FREE FALL) (GG52S00006P1)....2058
      10.4.6 PRESSURE SENSOR....2059
      10.4.7 RELAY BOX (GG24E00024F1)....2061
      10.4.8 LEFT SIDE STAND PANEL....2066
    10.5 TROUBLESHOOTING OF EXHAUST GAS THIRD REGULATION ENGINE....2070
      10.5.1 FAILURE DIAGNOSIS FUNCTION....2070
      10.5.2 HOW TO CHECK THE FAILURE CONTENTS....2071
      10.5.3 CHECKING OF DIAGNOSIS LAMP FUNCTION....2076
      10.5.4 ENGINE ECU....2077
  11. LOAD SAFETY DEVICE....2081
    11.1 PART NAMES AND FUNCTIONS....2083
      11.1.1 FRONT VIEW....2083
      11.1.2 CONFIGURATION OF SCREENS....2088
      11.1.3 DATA TRANSMISSION BETWEEN CONTROLLER AND CARDS....2093
      11.1.4 DETAILS OF INDICATORS ON MAIN DISPLAY SCREEN....2095
      11.1.5 REAR VIEW....2099
      11.1.6 ITEMS REQUIRED TO BE EXECUTED FOR REPLACEMENT OF CONTROLLER OR DATA CARDAND INSTRUCTIONS(IN A SIMILAR MANNER TO UPGRADE OF PROGRAM)....2104
    11.2 PREPARATION FOR USE....2105
    11.3 TURN THE POWER ON....2106
    11.4 UPGRADING PROGRAMS....2107
      11.4.1 PROCEDURES....2107
      11.4.2 UPGRADING OF INDICATION PROGRAMS....2109
      11.4.3 UPGRADING OF CONTROL PROGRAMS....2112
    11.5 STATUS CHECK....2114
      11.5.1 SIGNAL CHECK....2115
      11.5.2 OPERATION PROGRESS....2117
      11.5.3 COMMUNICATION DATA....2120
      11.5.4 INDICATION OF ADJUSTMENT VALUE....2121
      11.5.5 TROUBLE RECORD....2130
      11.5.6 CHOICE OF LANGUAGE (CKE SERIES ONLY)....2132
      11.5.7 LOAD RECORD (LOAD RECORD IN THE MAIN MENU)....2133
    11.6 ADJUSTMENTS....2134
      11.6.1 REMOVING THE INNER PANEL....2134
      11.6.2 ADJUSTMENT....2135
      11.6.3 LOAD ADJUSTMENT....2156
      11.6.4 ADJUSTMENT DATA COPY (INITIALIZATION)....2159
      11.6.5 VERSION CHECK....2165
    11.7 ERROR CODE (ABNORMALITY DETECTION) AND COUNTERMEASURES....2166
    11.8 CONTROL OUTPUT....2170
    11.9 RELEASES....2182
      11.9.1 RELEASE FUNCTION....2182
    11.10 MECHANICAL SPECIFICATION....2190
      11.10.1 ENVIRONMENTAL PERFORMANCE PARAMETERS....2190
      11.10.2 LOAD CELL (CRANE)....2191
      11.10.3 ANGLE SENSOR....2192
      11.10.4 CONTROLLER....2193
    11.11 EXTERNAL DIMENSIONS....2197
    11.12 ELECTRIC SCHEMATIC DIAGRAM....2198
      11.12.1 CRANE TYPE....2198
      11.12.2 LUFFING TYPE....2199
    11.13 CONTROLLER MALFUNCTION EMERGENCY MEASURES....2200
    11.14 LOAD SAFETY DEVICE CHECK PROCEDURES....2201
  12. GAUGE CLUSTER....2203
    12.1 CONFIGURATION OF DISPLAY....2205
    12.2 PRIORITY....2206
    12.3 STATUS DISPLAY....2208
    12.4 FAULT LOG DISPLAY....2218
  13. TOTAL CONTROLLER....2223
    13.1 ARRANGEMENT OF TOTAL CONTROLLER....2225
    13.2 COMPOSITION OF SYSTEM....2226
      13.2.1 OUTPUT RELATION TO CONTROLLER....2227
    13.3 FUNCTION OF TOTAL CONTROLLER....2228
    13.4 TOTAL CONTROLLER (HARDWARE)....2253
      13.4.1 OUTLINE....2253
      13.4.2 SPECIFICATIONS OF TOTAL CONTROLLER OUTPUT....2254
      13.4.3 DETAILS OF TOTAL CONTROLLER CONNECTOR....2258
      13.4.4 ARRANGEMENT OF TOTAL CONTROLLER CONNECTOR PIN....2259
      13.4.5 PROPORTIONAL SOLENOID VALVE MEASURING POSITION (VOLTAGE)....2266
    13.5 ADJUSTMENT OF TOTAL CONTROLLER....2268
      13.5.1 NECESSITY OF ADJUSTMENT....2268
      13.5.2 ADJUSTMENT PROCEDURES OF TOTAL CONTROLLER....2268
    13.6 CONTROLLER MALFUNCTION EMERGENCY MEASURES....2275
  14. AIR CONDITIONER....2277
    14.1 OPERATION ITEMS....2279
    14.2 SAFETY MONITOR FUNCTIONS....2280
    14.3 DISASSEMBLY AND ASSEMBLY PROCEDURE....2283
      14.3.1 SPECIAL CONSIDERATIONS DURING REPLACEMENT....2283
      14.3.2 INTERIOR UNIT....2285
    14.4 OPERATIONAL PRECAUTIONS....2294
    14.5 INSPECTION AND MAINTENANCE....2295
      14.5.1 INSPECTION/MAINTENANCE LIST....2295
      14.5.2 INSPECTION/MAINTENANCE PROCEDURES....2295
    14.6 ELECTRIC SYSTEM SCHEMATIC....2299

KOBELCO CK1600, CKE1350 Crawler Cranes OPERATION & MAINTENANCE Manual

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