Kobelco CK1000-II CKE900 Crawler Crane Operation & Maintenance Workshop Manual PDF - MKOBCK1000.zip

Full OPERATION & MAINTENANCE manual including a Parts catalog covering the KOBELCO CK850-II Crawler Crane.

KOBELCO CK1000-2, CKE900-1 Electrical Circuit Chart.pdf

S2GH14011ZE09 - KOBELCO CK1000-II Crawler Crane OPERATION & MAINTENANCE MANUAL.pdf

S2GH15001ZE03 - KOBELCO CK1000-II LUFFING Crawler Crane OPERATION & MAINTENANCE MANUAL.pdf

S3GH10012ZO04 - KOBELCO CK1000-II Crawler Crane Parts Manual.pdf

S5GH00002ZE04 - KOBELCO CK1000-II, CKE900 Crawler Crane OPERATION & MAINTENANCE MANUAL.pdf

PRODUCT DETAILS:

Total Pages: 1,863 pages

File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)

Language: English

TABLE OF CONTENTS

KOBELCO CK1000-2, CKE900-1 Electrical Circuit Chart....1

S2GH14011ZE09 - KOBELCO CK1000-II Crawler Crane OPERATION & MAINTENANCE MANUAL....31

COVER....31

TABLE OF CONTENTS....33

IMPORTANT INFORMATION....39

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....82

2.2.3 OPERATING THE AIR CONDITIONER....95

2.2.4 AM/FM RADIO (OPTION)....97

2.3 CRANE OPERATION....99

2.3.1 ADJUSTING THE OPERATOR'S SEAT....99

2.3.2 ADJUSTING THE CONTROL LEVER DIRECTION....99

2.3.3 STARTING AND STOPPING THE ENGINE....100

2.3.4 FUNCTION LOCK LEVER....104

2.3.5 PROPELLING OPERATION....105

2.3.6 SWINGING OPERATION....107

2.3.7 BOOM RAISING/LOWERING OPERATION....109

2.3.8 HOOK RAISING/LOWERING OPERATION....111

2.4 FREE FALL OPERATION....114

2.5 HANDLING OF REEVING WINCH (OPTION)....117

2.6 HANDLING OF HYDRAULIC TAGLINE (OPTION)....119

3. LOAD SAFETY DEVICE....121

3.1 ARRANGEMENT OF EQUIPMENTS....121

3.2 TYPE AND FUNCTIONS OF EQUIPMENTS....124

3.3 CONNECTING PROCEDURE OF WIRING....129

3.3.1 CRANE ATTACHMENT....129

3.4 FUNCTION OF CONTROLLER/MONITOR....134

3.5 OPERATING PROCEDURE FOR CONTROLLER....138

3.5.1 SETTING SCREEN....139

3.5.2 SETTING OF THE CRANE CONFIGURATION....144

3.5.3 SELECTING MAIN/AUX LIFTING....150

3.5.4 SETTING OF WORKING AREA LIMIT VALUE....151

3.5.5 SETTING THE TIME....154

3.6 WARNING ALARMS AND AUTOMATIC STOPS....156

3.6.1 WARNING ALARMS AND AUTOMATIC STOP INDICATORS....156

3.6.2 CONTENTS FOR AUTOMATIC STOP....157

3.6.3 RELEASING AUTOMATIC STOP....159

3.7 INSPECTION....165

3.7.1 BEFORE RAISING THE BOOM (UPON COMPLETION OF ATTACHMENT ASSEMBLY)....165

3.7.2 INSPECTION AFTER ERECTING THE ATTACHMENT....168

3.8 CAUTIONS FOR HANDLING THE LOAD SAFETY DEVICE....169

3.9 ERROR MESSAGES AND CORRECTIONS....170

3.10 TABLE OF ERROR MESSAGES AND ALARMS....171

3.11 CONFIRMING PROPER FUNCTIONING OF LOAD SAFETY DEVICE....172

4. ASSEMBLY OF THE MACHINE....173

4.1 UNLOADING THE BASIC MACHINE FROM THE TRAILER....174

4.2 LOADING THE MACHINE ON A TRAILER....174

5. ASSEMBLY/DISASSEMBLY OF BASIC MACHINE....174

5.1 EXTENDING/RETRACTING THE CRAWLERS....176

5.1.1 EXTENDING THE CRAWLERS....176

5.1.2 RETRACTING THE CRAWLER....178

5.2 INSTALLING/REMOVING AXLE EXTENSION ADAPTERS....180

5.2.1 INSTALLING AXLE EXTENSION ADAPTERS....180

5.2.2 REMOVING AXLE EXTENSION ADAPTERS....181

5.3 ERECTING/LOWERING THE GANTRY....182

5.3.1 ERECTING THE GANTRY....182

5.3.2 LOWERING THE GANTRY....184

5.4 INSTALLATION, REMOVAL OF THE COUNTERWEIGHT....185

5.4.1 INSTALLATION OF THE COUNTERWEIGHT....186

5.4.2 REMOVAL OF THE COUNTERWEIGHT....190

5.4.3 INSTALLING/REMOVING CARBODY WEIGHTS....191

5.5 INSTALLATION, REMOVAL OF THE COUNTERWEIGHT....192

5.5.1 SETTING OF LMI....192

5.5.2 PREPARATIONS FOR OPERATION....196

5.5.3 INSTALLATION PROCEDURES....201

5.5.4 DISASSEMBLY PROCEDURES....207

5.5.5 OPERATION OF CYLINDER WHEN SETTING LOW GANTRY POSITION....212

6. ASSEMBLY/DISASSEMBLY OF CRANE ATTACHMENT....215

6.1 ASSEMBLING THE ATTACHMENT....217

6.1.1 ARRANGEMENT OF BOOM/JIB/GUY LINE....217

6.1.2 INSTALLING THE BACKSTOPS....224

6.1.3 INSTALLING THE BOOM BASE....225

6.1.4 INSTALLING THE BACKSTOPS TO THE REVOLVING FRAME....226

6.1.5 INSTALLING THE UPPER SPREADER....226

6.1.6 REEVING THE WIRE ROPE INTO THE UPPER AND LOWER SPREADER....227

6.1.7 INSTALLING THE BOOM TIP....229

6.1.8 INSTALLATION OF THE BASIC GUY LINE....230

6.1.9 MAIN HOIST WIRE ROPE REEVING....231

6.1.10 CONNECTING THE INSERT BOOMS....233

6.1.11 INSTALLING THE CABLE ROLLERS....241

6.1.12 CONNECTING THE BOOM GUY LINES....242

6.1.13 CAUTION FOR CANTILEVER....244

6.1.14 ASSEMBLING THE JIB....244

6.1.15 REEVING OF REAR DRUM WIRE ROPE....248

6.1.16 INSTALLING THE AUXILIARY SHEAVE....250

6.1.17 REEVING THE REAR DRUM WIRE ROPE TO THE AUXILIARY SHEAVE....251

6.2 ERECTING THE ATTACHMENT....252

6.2.1 CONFIRMATION BEFORE ERECTING THE ATTACHMENT....252

6.2.2 ERECTING THE ATTACHMENT....253

6.3 LOWERING THE ATTACHMENT....255

6.3.1 LOWERING THE ATTACHMENT....256

6.4 DISASSEMBLING THE ATTACHMENT....257

6.4.1 TREATMENT OF OVERHOIST LIMIT SWITCH WIRING....257

6.4.2 WINDING UP THE FRONT DRUM/REAR DRUM WIRE ROPES....257

6.4.3 DISASSEMBLING THE JIB....258

6.4.4 REMOVING THE BOOM GUY LINE....259

6.4.5 DISASSEMBLING THE BOOM....260

6.4.6 REMOVING THE BOOM BASE....261

6.4.7 REMOVAL OF THE COUNTERWEIGHT....262

6.4.8 LOWERING THE GANTRY....262

6.5 CAUTION WHEN TRANSPORTING BOOM....263

7. WIRE ROPE....265

7.1 HANDLING OF WIRE ROPE....265

7.1.1 UNREELING METHOD OF WIRE ROPE....265

7.1.2 WINDING WIRE ROPE ONTO THE DRUM....266

7.1.3 INSTALLING THE ROPE SOCKET....267

7.1.4 SPECIFICATION OF WIRE ROPE....267

7.1.5 WIRE ROPE LENGTH....268

8. MAINTENANCE....269

8.1 CHECKS....274

8.1.1 CHECKS OF THE UPPER....274

8.1.1.1 CHECK OF UPPER DAILY OR EVERY 8HOURS....276

8.1.1.2 CHECK OF UPPER MONTHLY OR EVERY 100 HOURS....281

8.1.1.3 CHECK OF UPPER SEMI-ANNUALLY OR EVERY 600 HOURS....285

8.1.1.4 CHECK OF UPPER WEEKLY OR EVERY 50 HOURS....286

8.1.2 CHECK OF LOWER....288

8.1.2.1 CHECK OF LOWER DAILY OR EVERY 8 HOURS....290

8.1.2.2 CHECK OF LOWER MONTHLY OR EVERY 100 HOURS....291

8.1.2.3 CHECK OF LOWER QUARTERLY OR EVERY 250 HOURS....293

8.1.2.4 CHECK OF LOWER SEMI-ANNUALLY OR EVERY 600 HOURS....294

8.1.3 CHECK OF ATTACHMENT....296

8.1.3.1 CHECK OF ATTACHMENT DAILY OR EVERY 8 HOURS....298

8.2 OIL/GREASE SUPPLY AND WATER SERVICE....304

8.2.1 UPPER LUBRICATION (INCL. WATER SUPPLY)....308

8.2.2 LOWER LUBRICATION....310

8.2.3 ATTACHMENT LUBRICATION....312

8.2.4 GREASE....314

8.2.5 ENGINE OIL....317

8.2.6 FUEL....318

8.2.7 COOLANT....319

8.2.8 HYDRAULIC OIL....321

8.2.9 GEAR OIL....323

8.3 CLEANING/WASHING/CHANGE OF FILTER ELEMENT AND STRAINER....328

8.4 CHECK OF BATTERY....338

8.5 ARRANGEMENT AND USE OF FUSE....341

8.6 OPERATION UNDER UNUSUAL CONDITIONS....343

8.7 MACHINE STORAGE....345

8.8 TIGHTENING TORQUE VALUES....346

8.9 SECURITY PARTS TO BE REPLACED PERIODICALLY....348

8.10 ADJUSTMENT....349

8.10.1 ADJUSTMENT OF FRONT AND REAR DRUM LOCKS....349

8.10.2 ADJUSTMENT OF BOOM DRUM LOCK....350

8.10.3 ADJUSTMENT OF THIRD DRUM LOCK....351

8.10.4 ADJUSTMENT OF CRAWLER SHOES....352

8.11 CONSUMABLE PARTS LIST....353

9. REFERENCE MATERIALS....359

9.1 SPECIFICATION....359

9.1.1 PERFORMANCE....359

9.1.2 OUTSIDE DIMENSIONS....359

9.2 DIMENSIONS AND WEIGHT OF EACH PARTS....361

9.2.1 BASE MACHINE....361

9.2.2 COUNTERWEIGHT....362

9.2.3 ATTACHMENT....363

9.3 STABILITY IN SWINGING AND TRAVELING....365

9.4 SYSTEM SCHEMATIC....367

9.4.1 HYDRAULIC SYSTEM SCHEMATIC....367

9.4.2 ELECTRICAL WIRING SCHEMATIC....368

S2GH15001ZE03 - KOBELCO CK1000-II LUFFING Crawler Crane OPERATION & MAINTENANCE MANUAL....385

COVER....385

TABLE OF CONTENTS....387

IMPORTANT INFORMATION....391

1. SAFE OPERATING PRACTICES FOR MOBILE CRANES....401

2. OPERATION....421

2.1 TERMINOLOGY OF MACHINE EACH PART....421

2.2 LOCATIONS AND TERMS OF OPERATING CONTROLS....422

2.2.1 OPERATING SWITCHES....424

2.3 LUFFING JIB OPERATION....425

2.3.1 LUFFING BOOM RAISING/LOWERING OPERATION....426

2.3.2 JIB RAISING/LOWERING OPERATION....427

2.3.3 HOOK RAISING/LOWERING OPERATION....429

2.4 FREE FALL OPERATION....432

3. LOAD SAFETY DEVICE....435

3.1 LOCATION OF DEVICES....435

3.2 TYPE AND FUNCTIONS OF DEVICES....438

3.3 CONNECTING PROCEDURE OF WIRING....445

3.3.1 LUFFING ATTACHMENT....445

3.4 FUNCTION OF CONTROLLER/MONITOR....451

3.5 OPERATING PROCEDURE OF CONTROLLER....455

3.5.1 SETTING SCREEN....456

3.5.2 SETTING OF THE CRANE CONFIGURATION....460

3.5.3 SELECTION OF MAIN/JIB/AUX. LIFTING....465

3.5.4 SETTING OF WORKING AREA LIMIT VALUE....466

3.5.5 SETTING OF THE TIME....469

3.6 WARNING ALARM AND AUTOMATIC STOP....471

3.6.1 ITEMS OF WARNING ALARM AND AUTOMATIC STOP....471

3.6.2 CONTENTS OF AUTOMATIC STOP....472

3.6.3 RELEASE OF AUTOMATIC STOP....474

3.7 INSPECTION....480

3.7.1 INSPECTION BEFORE RAISING THE BOOM AFTER ASSEMBLY OF ATTACHMENT IS COMPLETED....480

3.7.2 INSPECTION AFTER ERECTING THE ATTACHMENT....484

3.8 CAUTION FOR HANDLING THE LOAD SAFETY DEVICE....485

3.9 INDICATION OF ERRORS AND REMEDY....486

3.10 INDICATION OF MESSAGE AND ALARM....487

3.11 CONFIRMATION OF FUNCTION FOR LOAD SAFETY DEVICE....489

4. ASSEMBLY/DISASSEMBLY OF CRANE ATTACHMENT WITH LUFFING JIB....491

4.1 ASSEMBLY OF LUFFING ATTACHMENT....493

4.1.1 ARRANGEMENT OF BOOM/ JIB/ GUY LINE....493

4.1.2 REMOVING CRANE BOOM AND GUY LINE....501

4.1.3 INSTALLING LUFFING BOOM BASE....501

4.1.4 INSTALLING THE BACKSTOPS TO THE REVOLVING FRAME....502

4.1.5 INSTALLING SPECIAL INSERT BOOM (WITH IDLER SHEAVE)....502

4.1.6 CAUTION FOR CANTILEVER....503

4.1.7 CONNECTING LUFFING BOOM TIP ASSEMBLY....504

4.1.8 INSTALLING JIB ATTACHMENT....506

4.1.9 ASSEMBLY OF JIB....506

4.1.10 INSTALLING STRUT GUY LINE....507

4.1.11 INSTALLING JIB HOIST WIRE ROPE....508

4.1.12 CONNECTING STRUT GUY LINE AND STRUT BACKSTOP....509

4.1.13 INSTALLING JIB GUY LINE....513

4.1.14 REEVING OF FRONT AND REAR DRUM WIRE ROPES....514

4.1.15 CONNECTING SAFETY DEVICE....517

4.2 ERECTING THE LUFFING ATTACHMENT....520

4.2.1 CONFIRMATION BEFORE ERECTING THE LUFFING ATTACHMENT....520

4.2.2 ERECTING LUFFING ATTACHMENT....521

4.2.3 CHECK BEFORE STARTING THE WORK....524

4.3 LOWERING THE ATTACHMENT....525

4.3.1 LOWERING THE ATTACHMENT....525

4.4 DISASSEMBLY OF LUFFING ATTACHMENT....529

4.4.1 DISCONNECTION OF WIRING FOR SAFETY DEVICE....530

4.4.2 WINDING UP THE FRONT DRUM/REAR DRUM WIRE ROPES....530

4.4.3 DISASSEMBLY OF JIB....531

4.4.4 DISASSEMBLY OF LUFFING BOOM TIP ASSEMBLY....534

4.4.5 DISASSEMBLING INSERT BOOM....536

4.4.6 REMOVING BASE BOOM....536

4.5 CAUTION WHEN TRANS-PORTING LUFFING BOOM TIP ASSEMBLY....537

5. WIRE ROPE....539

5.1 SPECIFICATION OF WIRE ROPE....539

5.2 WIRE ROPE LENGTH....539

6. MAINTENANCE....543

6.1 CHECKS....548

6.1.1 CHECKS OF THE UPPER....548

6.2 OIL/GREASE SUPPLY....554

6.2.1 ATTACHMENT....554

6.2.2 GREASE....556

6.2.3 HYDRAULIC OIL....557

7. REFERENCE MATERIALS....559

7.1 SPECIFICATION....559

7.1.1 PERFORMANCE....559

7.2 DIMENSIONS AND WEIGHT OF EACH PARTS....561

7.2.1 ATTACHMENT....561

7.3 SYSTEM SCHEMATIC....564

7.3.1 ELECTRICAL WIRING SCHEMATIC....564

S3GH10012ZO04 - KOBELCO CK1000-II Crawler Crane Parts Manual....581

COVER....581

CONTROL SYSTEM....0

CONTROL ASSY....598

CONTROL LEVER ASSY (BOOM / MAIN / AUX.)....602

CONTROL LEVER ASSY (SWING)(CRAWLER)....606

CONTROL LEVER ASSY (CRAWLER)....610

CONTROL LEVER ASSY (PROPEL)(PROPEL)....612

REMOTE CONTROL VALVE INSTAL (BOOM / FRONT / REAR)....614

SWING LOCK ASSY....616

BRAKE PEDAL ASSY....618

GRIP ASSY....622

FLOOR PLATE ASSY....624

GRIP ASSY (BOOM)....626

PANEL ASSY....628

PANEL ASSY....630

PANEL ASSY (LEFT STAND)....632

PANEL ASSY (LEFT SIDE)....634

PANEL ASSY (BYPASS SWITCH)....635

LAMP & SWITCH ASSY (WITH FREE FALL)....636

DRUM LOCK ASSY (FRONT / REAR)....638

DRUM LOCK ASSY (BOOM)....640

LUB.LINES (FRONT / REAR)....642

LUB.LINES (BOOM)....644

MONITOR INSTAL....645

WINCH SYSTEM....0

WINCH INSTAL (φ26)(WITH FREE FALL / FRONT)(WITH FREE FALL / REAR)....646

WINCH ASSY (φ26)(FRONT)(REAR)....650

WINCH ASSY (φ26)(FRONT)....652

WINCH ASSY (φ26)(REAR)....654

REDUCTION UNIT ASSY (φ26)....656

BOOM HOIST SYSTEM....0

WINCH INSTAL ASSY (BOOM (φ16))....658

WINCH ASSY....660

SWING SYSTEM....0

SWING MOTOR ASSY....662

SWING MOTOR ASSY....664

SWING REDUCTION ASSY....666

SWING BEARING ASSY....670

SWING BEARING LUB. LINES ....672

LINES....0

PUMP HYD. LINES (CONTROL)....676

PUMP HYD. LINES (DELIVERY)....678