H-200, Sector 63, Noida U.P. 201307, India TEL: +91-120-407-9989 FAX : +91-120-407-9990 1 Policy 2 Improvement 3 Trouble Shooting 4 Technical Information 5 Parts Information 6 Urgent Rework Bulletin No SV-KCI-2012-001 Issue date 24th Feb 2012 Subject: Applicable Area: Applicable Model: Counter Weight Lifting Gantry Cylinder Operation INDIA CKE2500, CKE2500-2 Applicable S/N: All 1.PREFACE This letter is to recommend you to pay further attention to safety operation of Counter Weight Lifting. However this is supplemental information only. All the crane operation should be done after you read Operation & Maintenance manual and understand the instructions. Improper operation may cause accidents and could result in serious injury or death. 2. ACCIDENT INFORMATION We were reported that cylinder bending occurred during Counter Weight lifting as follows. 1) Improper operation/manipulation of gantry cylinder At the time of aligning and inserting the support pins while lifting the counterweights, it is presumed that the C/W was not kept horizontally and/or the C/W was rapidly lowered down and given a heavy shock to the cylinder rod with high engine speed at more than 1000rpm. In accordance with the operator s manual, the C/W is to be slowly and carefully lifted or lowered, keeping the C/W horizontally. 2) Shaking the C/W while inserting the support pins To align and insert the pins, the operator probably operated the propel or slewing and the C/W got shaking, which may have caused the cylinder rod to be bent by applying the excessive load at one side. 3) Mounting/removing the counterweights on undulating and unleveled ground floor It is presumed that the C/W was not kept horizontally at more than 1.4 degree 1/2
3. CAUTION 3-1. Perform the work on firm and level ground. (within 1% of ground inclination). If the ground inclination exceeds 1%, bending load would be applied on counterweight raising cylinder and cylinder rod may be damaged by bending. 3-2. Perform the work with engine speed lower than 1000 rpm. If the engine speed exceeds 1000 rpm, cylinder speed would become higher and unexpected force would be applied on the cylinder at start or stop. 3-3. Adjust counterweight inclination only with [RAISE] side of cylinder control. If adjusted by one side only with [LOWER] side, load may concentrate on one side cylinder only at [LOWER] stop. If counterweight inclination occurs at cylinder retraction, adjust inclination once by [RAISE] side of cylinder control and then retract both (left and right) cylinders at the same time. 4. APPENDIX Please read carefully appendix for the abstract from Operation&Maintenanse Manual. This bulletin is not an authorization for the replacement and warranty claim submission. 2/2
4.10.2 INSTALLATION OF COUNTER-WEIGHTS TO MACHINE Perform the work on firm and level ground. (within 1% of ground inclination). If the ground inclination exceeds 1%, bending load would be applied on counterweight raising cylinder and cylinder rod may be damaged by bending. Perform the work with engine speed lower than 1000 rpm. If the engine speed exceeds 1000 rpm, cylinder speed would become higher and unexpected force would be applied on the cylinder at start or stop. 1. Installation of counterweight lifting guy cables (1) Walk the machine forward until the distance between the counterweights and the crawler is approx. 700 mm (2'4"). (2) Rotate the upper structure 180 degrees so that the gantry is located by the counterweights. (3) Walk the machine backward too far 70 mm (3") from the front of counterweight. Approx. 700mm (2 4 ) Approx. 70 mm (3 ) 4-77 CKE2500-2
(4) When the gantry is lowered, the mast is always raised. Be sure to adjust the mast angle to 45 degrees or less. (5) Connect the remote control cable to the receptacle located on the right side deck. PIN D Do not lower the mast assist arms until the mast is connected to the boom with the guy lines. Mast may fall backwards if raised to vertical position when assist arms are down stored. Failure to observe this precaution may result in serious injury or death. (6) Support the gantry with the cylinder, and remove the tension member fixing pin "D". 45 degrees RECEPTACLE A REMOTE CONTROL BOX (7) Operate the remote control box to lower the gantry and install the counterweight lifting guy lines to the counterweight hanger with pin "M". When lowering the gantry, take care so that the mast does not interfere with the mast arm. Otherwise, the mast or mast arm may be damaged. GUY LINE GUY LINE PIN M CKE2500-2 4-78
2. Installation of counterweights to swing frame (1) Operate the remote control to lift the counterweights. P Slowly lift the counterweight. Failure to observe this precaution may result in serious injury or death. When lifting the counterweights, equalize the motions of the right and the left cylinders to keep horizontality. Failure to observe this precaution may result in serious injury or death. PIN Q PIN Q Adjust counterweight inclination only with [RAISE] side of cylinder control. If adjusted by one side only with [LOWER] side, load may concentrate on one side cylinder only at [LOWER] stop. If counterweight inclination occurs at cylinder retraction, adjust inclination once by [RAISE] side of cylinder control and then retract both (left and right) cylinders at the same time. R P (2) Extend gantry cylinders to stroke end so as to align the pin holes "P" on the swing frame with the pin "Q" on the weight (A). (3) Set the weight support pin "Q" using handle. 4-79 CKE2500-2