Kobelco CK850-II Crawler Crane Operation & Maintenance Manual with CKE700 CKE800 Parts Catalog PDF - MKOBCK850.zip
Full OPERATION & MAINTENANCE manual including the Parts catalog for the KOBELCO CK850-II Crawler Crane.
KOBELCO CK850-II, CKE800-1, CKE700-1 Electrical Wiring Diagram.pdf
S2GG24001ZE09 - KOBELCO CK850-II Crawler Crane OPERATION & MAINTENANCE MANUAL.pdf
S3GG14012ZO05 - KOBELCO Crawler Crane CK850-II Parts Manual.pdf
S5GG00005ZE04 - KOBELCO CK850-II, CKE700, CKE800 Crawler Crane OPERATION & MAINTENANCE MANUAL.pdf
PRODUCT DETAILS:
Total Pages: 1,533 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
KOBELCO CK850-II, CKE800-1, CKE700-1 Electrical Circuit Chart....1
S2GG24001ZE09 - KOBELCO CK850-II Crawler Crane OPERATION & MAINTENANCE MANUAL....32
COVER....32
TABLE OF CONTENTS....34
IMPORTANT INFORMATION....40
1. SAFE OPERATING PRACTICES FOR MOBILE CRANES....50
2. OPERATION....70
2.1 TERMINOLOGY OF MACHINE EACH PART....70
2.2 LOCATIONS AND TERMS OF OPERATING CONTROLS....71
2.2.1 OPERATING SWITCHES....75
2.2.2 GAUGE CLUSTER....85
2.2.3 HANDLING THE AIR CONDITIONER....97
2.2.4 AM/FM RADIO (OPTION)....99
2.3 CRANE OPERATION....101
2.3.1 ADJUSTING THE OPERATOR'S SEAT....101
2.3.2 ADJUSTING THE CONTROL LEVER DIRECTION....101
2.3.3 STARTING AND STOPPING THE ENGINE....102
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....110
2.3.8 HOOK RAISING/LOWERING OPERATION....112
2.4 FREE FALL OPERATION....115
2.5 CLAMSHELL OPERATION....118
2.6 HANDLING OF HYDRAULIC TAGLINE (OPTION)....120
3. LOAD SAFETY DEVICE....122
3.1 ARRANGEMENT OF EQUIPMENTS....122
3.2 TYPE AND FUNCTIONS OF EQUIPMENTS....125
3.3 CONNECTING PROCEDURE OF WIRING....131
3.3.1 CRANE ATTACHMENT....131
3.4 FUNCTION OF CONTROLLER/MONITOR....136
3.5 OPERATING PROCEDURE OF CONTROLLER....140
3.5.1 SETTING SCREEN....141
3.5.2 SETTING OF THE CRANE CONFIGURATION....146
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....156
3.6 WARNING ALARM AND AUTOMATIC STOP....158
3.6.1 ITEMS OF WARNING ALARM AND AUTOMATIC STOP....158
3.6.2 CONTENTS OF AUTOMATIC STOP....159
3.6.3 RELEASE OF AUTOMATIC STOP....161
3.7 INSPECTION....166
3.7.1 INSPECTION BEFORE RAISING THE BOOM AFTER ASSEMBLY OF ATTACHMENT IS COMPLETED....166
3.7.2 INSPECTION AFTER ERECTING THE ATTACHMENT....169
3.8 CAUTION FOR HANDLING THE LOAD SAFETY DEVICE....170
3.9 INDICATION OF ERRORS AND REMEDY....171
3.10 INDICATION OF MESSAGE AND ALARM....172
3.11 CONFIRMATION OF FUNCTION FOR LOAD SAFETY DEVICE....173
4. UNLOADING/LOADING THE BASIC MACHINE....174
4.1 UNLOADING THE BASIC MACHINE FROM THE TRAILER....175
4.2 LOADING THE MACHINE ON A TRAILER....175
5. ASSEMBLY/DISASSEMBLY OF BASIC MACHINE....176
5.1 EXTENDING/RETRACTING THE CRAWLERS....177
5.1.1 EXTENDING THE CRAWLERS....177
5.1.2 RETRACTING THE CRAWLER....180
5.2 ERECTING/LOWERING THE GANTRY....183
5.2.1 ERECTING THE GANTRY....183
5.2.2 LOWERING THE GANTRY....185
5.3 INSTALLATION, REMOVAL OF THE COUNTERWEIGHT (WHEN USING THE AUXILIARY CRANE)....186
5.3.1 INSTALLATION OF THE COUNTERWEIGHT....186
5.3.2 REMOVAL OF THE COUNTERWEIGHT....189
5.3.3 INSTALLING/REMOVING CARBODY WEIGHTS....190
5.4 INSTALLATION, REMOVAL OF THE COUNTERWEIGHT....191
5.4.1 SETTING OF LMI....191
5.4.2 PREPARATIONS FOR OPERATION....196
5.4.3 INSTALLATION PROCEDURES....201
5.4.4 DISASSEMBLY PROCEDURES....206
5.4.5 OPERATION OF CYLINDER WHEN SETTING LOW GANTRY POSITION (FIXATION OF TENSION BAR CONNECTION) (FIG. 5-25)....210
6. ASSEMBLY/DISASSEMBLY OF CRANE ATTACHMENT....212
6.1 ASSEMBLING THE ATTACHMENT....213
6.1.1 ARRANGEMENT OF BOOM/JIB/GUY LINE....213
6.1.2 INSTALLING THE BACKSTOPS....220
6.1.3 INSTALLING THE BOOM BASE....221
6.1.4 INSTALLING THE BACKSTOPS TO THE REVOLVING FRAME....222
6.1.5 INSTALLING THE UPPER SPREADER....222
6.1.6 REEVING THE WIRE ROPE INTO THE UPPER AND LOWER SPREADER....223
6.1.7 INSTALLING THE BOOM TIP....225
6.1.8 INSTALLATION OF THE BASIC GUY LINE....226
6.1.9 MAIN HOIST WIRE ROPE REEVING....226
6.1.10 CONNECTING THE INSERT BOOMS....229
6.1.11 INSTALLING THE CABLE ROLLERS....238
6.1.12 CONNECTING THE BOOM GUY LINES....238
6.1.13 CAUTION FOR CANTILEVER....240
6.1.14 ASSEMBLING THE JIB....240
6.1.15 REEVING OF REAR DRUM WIRE ROPE....244
6.1.16 INSTALLING THE AUXILIARY SHEAVE....246
6.1.17 REEVING THE REAR DRUM WIRE ROPE TO THE AUXILIARY SHEAVE....247
6.2 ERECTING THE ATTACHMENT....248
6.2.1 CONFIRMATION BEFORE ERECTING THE ATTACHMENT....248
6.2.2 ERECTING THE ATTACHMENT....249
6.3 LOWERING THE ATTACHMENT....251
6.3.1 LOWERING THE ATTACHMENT....252
6.4 DISASSEMBLING THE ATTACHMENT....253
6.4.1 TREATMENT OF OVERHOIST LIMIT SWITCH WIRING....253
6.4.2 WINDING UP THE FRONT DRUM/REAR DRUM WIRE ROPES....253
6.4.3 DISASSEMBLING THE JIB....254
6.4.4 REMOVING THE BOOM GUY LINE....255
6.4.5 DISASSEMBLING THE BOOM....256
6.4.6 REMOVING THE BOOM BASE....257
6.4.7 REMOVAL OF THE COUNTERWEIGHT....258
6.4.8 LOWERING THE GANTRY....258
6.5 CAUTION WHEN TRANSPORTING BOOM....259
7. WIRE ROPE....260
7.1 HANDLING OF WIRE ROPE....260
7.1.1 UNREELING METHOD OF WIRE ROPE....260
7.1.2 WINDING WIRE ROPE ONTO THE DRUM....261
7.1.3 INSTALLING THE ROPE SOCKET....262
7.1.4 SPECIFICATION OF WIRE ROPE....262
7.1.5 WIRE ROPE LENGTH....263
8. MAINTENANCE....266
8.1 CHECKS....271
8.1.1 CHECKS OF THE UPPER....271
8.1.1.1 CHECK OF UPPER DAILY OR EVERY 8 HOURS....273
8.1.1.2 CHECK OF UPPER MONTHLY OR EVERY 100 HOURS....278
8.1.1.3 CHECK OF UPPER SEMI-ANNUALLY OR EVERY 600 HOURS....282
8.1.1.4 CHECK OF UPPER WEEKLY OR EVERY 50 HOURS....283
8.1.2 CHECK OF LOWER....285
8.1.2.1 CHECK OF LOWER DAILY OR EVERY 8 HOURS....287
8.1.2.2 CHECK OF LOWER MONTHLY OR EVERY 100 HOURS....288
8.1.2.3 CHECK OF LOWER QUARTERLY OR EVERY 250 HOURS....290
8.1.2.4 CHECK OF LOWER SEMI-ANNUALLY OR EVERY 600 HOURS....290
8.1.3 CHECK OF ATTACHMENT....291
8.1.3.1 CHECK OF ATTACHMENT DAILY OR EVERY 8 HOURS....293
8.2 OIL/GREASE SUPPLY AND WATER SERVICE....299
8.2.1 UPPER LUBRICATION (INCL. WATER SUPPLY)....303
8.2.2 LOWER LUBRICATION....305
8.2.3 ATTACHMENT LUBRICATION....307
8.2.4 GREASE....309
8.2.5 ENGINE OIL....312
8.2.6 FUEL....313
8.2.7 COOLANT....314
8.2.8 HYDRAULIC OIL....316
8.2.9 GEAR OIL....318
8.3 CLEANING/WASHING/CHANGE OF FILTER ELEMENT AND STRAINER....323
8.4 CHECK OF BATTERY....333
8.5 ARRANGEMENT AND USE OF FUSE....336
8.6 OPERATION UNDER UNUSUAL CONDITIONS....338
8.7 MACHINE STORAGE....340
8.8 TIGHTENING TORQUE VALUES....341
8.9 SECURITY PARTS TO BE REPLACED PERIODICALLY....343
8.10 ADJUSTMENT....344
8.10.1 ADJUSTMENT OF FRONT AND REAR DRUM LOCKS....344
8.10.2 ADJUSTMENT OF BOOM DRUM LOCK....345
8.10.3 ADJUSTMENT OF THIRD DRUM LOCK....346
8.10.4 ADJUSTMENT OF CRAWLER SHOES....347
8.11 CONSUMABLE PARTS LIST....348
9. REFERENCE MATERIALS....354
9.1 SPECIFICATION....354
9.1.1 PERFORMANCE....354
9.1.2 OUTSIDE DIMENSIONS....354
9.2 DIMENSIONS AND WEIGHT OF EACH PARTS....356
9.2.1 BASE MACHINE....356
9.2.2 COUNTERWEIGHT....357
9.2.3 ATTACHMENT....358
9.3 STABILITY IN SWINGING AND TRAVELING....361
9.4 SYSTEM SCHEMATIC....362
9.4.1 HYDRAULIC SYSTEM SCHEMATIC....362
9.4.2 ELECTRICAL WIRING SCHEMATIC....363
S3GG14012ZO05 - KOBELCO Crawler Crane CK850-II Parts Manual....380
COVER....380
CONTENTS....386
CONTROL SYSTEM....0
CONTROL ASSY....395
CONTROL LEVER ASSY (BOOM / MAIN / AUX.)....399
CONTROL LEVER ASSY (SWING)(SWING)....403
CONTROL LEVER ASSY (CRAWLER)....407
CONTROL LEVER ASSY (PROPEL / FUNCTION LOCK)....409
REMOTE CONTROL VALVE INSTAL (BOOM / FRONT / REAR)....411
SWING LOCK ASSY....413
BRAKE PEDAL ASSY....417
GRIP ASSY....421
FLOOR PLATE ASSY....423
GRIP ASSY (BOOM)....425
PANEL ASSY....427
PANEL ASSY....429
PANEL ASSY (LEFT STAND)....431
PANEL ASSY (LEFT SIDE)....433
PANEL ASSY (BYPASS SWITCH)....434
PANEL ASSY (FREE FALL LAMP)....435
DRUM LOCK ASSY (FRONT / REAR)....437
DRUM LOCK ASSY (BOOM)....439
LUB.LINES (FRONT / REAR)....441
LUB.LINES (BOOM)....443
MONITOR INSTAL....444
WINCH SYSTEM (WITH FREE FALL)....0
WINCH INSTAL (WITH FREE FALL / FRONT)(WITH FREE FALL / REAR)....445
WINCH ASSY (FRONT)....449
WINCH ASSY (REAR)....453
REDUCTION UNIT ASSY....457
WINCH SYSTEM (WITHOUT FREE FALL)....0
WINCH INSTAL (WITHOUT FREE FALL / FRONT)(WITHOUT FREE FALL / REAR)....459
WINCH ASSY (FRONT)....463
WINCH ASSY (REAR)....465
REDUCTION UNIT....467
HYD. LINES, CONTROL....469
BOOM HOIST SYSTEM....0
WINCH INSTAL ASSY (φ16)(BOOM)....471
WINCH ASSY....473
SWING SYSTEM....0
SWING REDUCT INSTAL....475
SWING MOTOR ASSY....477
SWING REDUCTION ASSY....479
SWING BEARING ASSY....483
SWING BEARING LUB. LINES....485
LINES....0
PUMP HYD. LINES (SUCTION)....487
PUMP HYD. LINES (CONTROL)....489
PUMP HYD. LINES (DELIVERY)....491
RIGHT DECK HYD. LINES....493
MAIN VALVE HYD. LINES....499
GANTRY CYLINDER HYD. LINE....503
SWING CONTROL HYD. LINES....507
ACCUMLATOR HYD. LINES....511
FLOOR CONTROL HYD. LINES ....513
FLOOR CONTROL HYD. LINES....517
CONNECTOR ASSY (GANTRY VALVE)....519
BRAKE CONTROL HYD. LINES....521
VALVE INSTAL....523
3-SECTION VALVE HYD. LINES....525
RETURN HYD. LINES....527
DRAIN LINES....529
RETURN BLOCK HYD. LINES....533
2-SECTION VALVE INSTAL....535
2-SECTION VALVE INSTAL (FUNCTION CUT / SWING PARKING BRAKE)....537
4-SECTION VALVE HYD. LINES....539
5-SECTION VALVE HYD. LINES....543
8-SECTION VALVE HYD. LINES....547
WINCH HYD. LINES (FOR FRONT & REAR DRUM)....549
WINCH HYD. LINES (FOR BOOM DRUM)....553
VALVE INSTAL....555
OIL COOLER HYD. LINES....559
CLAMP ASSY....561
LOWER HYD. LINES....563
SWIVEL JOINT INSTAL....565
SWIVEL JOINT....569
HYD. OIL TANK ASSY (FOR STANDARD)(FOR FREE FALL)(TANK)....571
HYD. OIL COOLING LINES....575
POWER PLANT....0
POWER PLANT ASSY....581
PUMP ASSY....587
POWER DIVIDER....589
MUFFLER INSTAL....593
FUEL LINES....595
RADIATOR INSTAL....599
AIR CLEANER INSTAL....601
FUEL TANK ASSY....603
ELECTRIC SYSTEM....0
ELEC ASSY (R.H. DECK)....607
ELEC ASSY (REV. FRAME)....613
ELEC ASSY (FLOOR PLATE)....617
RELAY BOX ASSY....621
ELEC ASSY (L.H. GUARD)....623
ELEC ASSY (CAB)....625
ELEC ASSY (L.H. DECK)....629
WASHER TANK ASSY....633
WASHER TANK ASSY....635
BATTERY INSTAL....637
JUNCTION BOX ASSY....639
RELAY ASSY....641
CAB / GUARD / PLATFORM ....0
CAB INSTAL....643
CAB ASSY....647
DOOR ASSY....655
RUBBER SHEET INSTAL (OPERATOR’S ROOM)....661
WIPER ASSY (FRONT WINDOW LOWER)....663
SUN VISOR ASSY....665
ROLL BLIND....667
SASH ASSY....669
R.H. GUARD INSTAL....671
R.H. GUARD ASSY....673
L.H. GUARD INSTAL....677
L.H. GUARD ASSY....681
COVER ASSY....685
INSULATION ASSY....687
INSULATION ASSY (L.H. GUARD)....691
DRUM COVER....693
SWING BEARING COVER....697
UNDER COVER ASSY....699
R.H. DECK ASSY....701
R.H. DECK INSTAL (UNDER OF CAB)....705
STEP ASSY....707
L.H. DECK INSTAL....709
GUARD ASSY (FRONT)....713
BOOM DRUM COVER ASSY....715
COVER ASSY (SWING FRAME)....717
COVER ASSY....719
LOWER SYSTEM....0
PROPEL MOTOR ASSY....721
REDUCTION UNIT ASSY....723
IDLER ASSY....725