KOBELCO CK850-II Crawler Crane OPERATION & MAINTENANCE Manual
Complete OPERATION & MAINTENANCE manual with Parts catalog for KOBELCO CK850-II Crawler Crane.
KOBELCO CK850-II, CKE800-1, CKE700-1 Electrical Circuit Chart.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
IDLER ADJUST ASSY....727
ROLLER ASSY....729
LOWER ROLLER ASSY....730
UPPER ROLLER ASSY....731
FRAME COVER ASSY....733
LINK ASSY....735
CYLINDER ASSY....737
STEP ASSY....739
AXLE ADAPTER ASSY....741
CRAWLER FRAME....745
LOWER FRAME....746
SHOE ASSY....747
CRANE ATTACHMENT....0
LOW. BOOM ASSY....749
UPP. BOOM ASSY....751
INSERT BOOM....753
BOOM GUY CABLE....755
BOOM POINT SHEAVE ASSY....757
IDLER SHEAVE ASSY....759
SPREADER GUIDE ASSY (FOR CRANE)....761
CABLE ROLLER ASSY (FOR UPP.BOOM)....763
CABLE ROLLER ASSY (FOR INSERT BOOM)....765
UPPER SPREADER ASSY....767
LOWER SPREADER ASSY....769
BACKSTOP ASSY....771
BACKSTOP ASSY....773
JIB ASSY....775
INSERT JIB....777
JIB GUY CABLE (FOR BASE BOOM SIDE)(FOR JIB SIDE)....779
JIB GUY CABLE....781
JIB POINT SHEAVE ASSY....783
AUX. SHEAVE ASSY....785
STRUT ASSY....787
CABLE ROLLER ASSY (FOR INSERT JIB)....789
ANGLE METER INSTAL (OPTION)....791
WIRE ROPE ASSY (MAIN)(AUX.)....793
WIRE ROPE ASSY (BOOM)....795
ROPE SOCKET ASSY....797
GANTRY....0
GANTRY ASSY....799
SUB GANTRY ASSY....803
GANTRY LUB. LINES....807
TAGLINE (OPTION)....0
TAGLINE ASSY....809
TAGLINE HYD. LINES....813
TAGLINE GUIDE ASSY....815
GUIDE SHEAVE ASSY ....817
THIRD (OPTION)....0
CONTROL ASSY....819
CONTROL LEVER ASSY....821
BRAKE PEDAL ASSY....823
DRUM LOCK ASSY....825
DRUM LOCK LUB. LINES....827
TRIMMER INSTAL....829
WINCH INSTAL....831
WINCH ASSY....835
HYD. LINES ASSY....837
HYD. LINES ASSY....841
HYD. LINES ASSY....845
4-SECTION VALVE HYD. LINES (MOTOR BRAKE)....847
8-SECTION VALVE HYD LINES....849
HYD. LINES ASSY....851
CONNECTOR ASSY....853
HYD. LINES ASSY....855
HYD. LINES ASSY....857
CLUTCH VALVE INSTAL....859
GANTRY SHEAVE ASSY....861
IDLER SHEAVE ASSY....863
DRUM COVER ASSY....865
HARNESS ASSY....867
SAFETY DEVICE....0
SAFETY DEVICE HARNESS (FOR GANTRY)....869
SAFETY DEVICE HARNESS (FOR BASE MACHINE)....871
ANGLE DETECTOR INSTAL....873
OVERHOIST PREVENTIVE DEVICE (FOR BOOM BASE & INSERT BOOM)(FOR BOOM TIP)....875
SAFETY DEVICE HARNESS (FOR JIB)....879
OVERHOIST LIMIT SWITCH (MAIN HOOK)....881
OVERHOIST LIMIT SWITCH (JIB & AUX. SHEAVE)....883
LIMIT SWITCH ASSY....885
LIMIT SWITCH ASSY (BASE MACHINE SIDE)(BOOM SIDE)....887
COUNTERWEIGHT ASSY....889
SWING ALARM LAMP....891
REV. FRAME....893
RUBBER ASSY....895
CARBODY WEIGHT....899
C/W REMOVAL DEVICE....901
C/W REMOVAL HYD. LINES (C/W REMOVAL DEVICE)....905
HYD. LINES, C/W....909
REMOTE CONTROL ASSY....911
LABEL....0
LABEL (FOR BASE MACHINE)....913
LABEL ASSY (FOR BASE MACHINE)....921
LABEL ASSY (FOR ATTACHMENT)....925
LABEL ASSY (SWITCH PANEL)....927
OTHERS....0
AIR CONDITIONER (INDOOR UNIT)....929
AIR CONDITIONER (OUTDOOR UNIT)....935
AIR CONDITIONER UNIT....939
UPPER FINAL....943
UPPER FINAL....945
UPPER FINAL....947
UPPER FINAL (PEDAL COVER)....949
UPPER FINAL....951
UPPER FINAL....953
TOOL ASSY....955
SPARE PART KIT....957
SEAT ASSY....959
CAMERA INSTAL (FOR DRUM / OPTION)....961
CAMERA INSTAL (FOR REAR / OPTION)....965
MONITOR INSTAL (OPTION)....969
HARNESS ASSY (OPTION)....973
RADIO INSTAL (COVER)(RADIO OPTION)....975
FOOT ACCELERATOR (RIGHT)(RIGHT&LEFT/OPTION)(LEFT / OPTION)....977
ONE-WAY CALL ASSY (OPTION)....981
AUX. PLATFORM (OPTION)....983
AUX. PLATFORM (OPTION)....987
TRAVELING KIT (OPTION)....991
DRUM TURN SENSOR INSTAL....993
DRUM TURN SENSOR SWITCH INSTAL....995
DRUM TURN SENSOR GRIP INSTAL....996
GRIP ASSY....997
WASHER TANK ASSY (OPTION)....999
WIPER ASSY (FRONT WINDOW LOWER / OPTION)....1001
HEAD GUARD (OPTION)....1003
EXTINGUISHER INSTAL (OPTION)....1005
HANDRAIL INSTAL (L.H. GUARD)....1007
GUARD INSTAL (LEFT WINDOW)....1009
LEVEL GAUGE INSTAL (OPTION)....1011
LIFE HAMMER INSTAL (OPTION)....1013
INDES OF PART NO.....1016
S5GG00005ZE04 - KOBELCO CK850-II, CKE700, CKE800 Crawler Crane OPERATION & MAINTENANCE MANUAL....1035
COVER....1035
TABLE OF CONTENTS....1037
SAFETY....1045
1. SPECIFICATION....1057
1.1 CK850-II SPECIFICATION....1059
1.1.1 PERFORMANCE....1059
1.1.2 OUTSIDE DIMENSIONS....1059
1.1.3 DIMENSIONS AND WEIGHT OF EACH PARTS....1061
1.1.4 CK850-II STABILITY IN SWINGING AND TRAVELING....1066
1.2 CKE800/CKE700 SPECIFICATION....1067
1.2.1 PERFORMANCE....1067
1.2.2 OUTSIDE DIMENSIONS....1067
1.2.3 DIMENSIONS AND WEIGHT OF EACH PARTS....1069
1.2.4 CKE800 STABILITY IN SWINGING AND TRAVELING....1075
1.2.5 CKE700 STABILITY IN SWINGING AND TRAVELING....1077
2. MAINTENANCE STANDARDS TEST PROCEDURES....1079
2.1 MAINTENANCE STANDARD....1081
2.1.1 PIN, BUSHING, SPRING, LINING AND SHEAVE....1081
2.1.2 PROPEL DEVICE....1088
2.2 PERFORMANCE STANDARD AND TEST PROCEDURE....1094
2.2.1 OPERATING SPEED....1094
2.2.2 POINT AND METHOD OF MEASURING PRESSURE....1095
2.2.3 SLEWING RING....1099
3. GENERAL WORK STANDARD....1101
3.1 TIGHTENING TORQUE OF CAPSCREWS AND NUTS....1103
3.1.1 METRIC COARSE THREADS....1103
3.1.2 METRIC FINE THREADS....1103
3.1.3 COARSE THREDS UNC....1104
3.1.4 FINE THREADS UNF....1104
3.1.5 TIGHTENING TORQUE OF HYDRAULIC FITTINGS....1105
3.2 STANDARD PARTS....1107
3.2.1 BOLT....1107
3.2.2 O-RING....1108
3.2.3 BACK-UP RING....1109
3.2.4 BITE FITTING....1110
3.3 CONVERSION TABLE....1112
3.3.1 UNIT CONVERSION....1112
3.3.2 MILLIMETER : INCH CONVERSION TABLE....1113
3.3.3 METER-FOOT CONVERSION TABLE....1115
3.3.4 GRADIENT CONVERSION TABLE....1116
3.4 TABLE OF UNIT WEIGHT....1117
4. POWER TRAIN....1119
4.1 INTRODUCTION....1121
4.2 ENGINE....1123
4.2.1 INTRODUCTION....1123
4.2.2 REMOVAL....1123
4.2.3 REPAIR AND MAINTENANCE....1124
4.2.4 RE-INSTALLATION....1125
4.3 PUMP DRIVE ASSEMBLY....1129
4.3.1 INTRODUCTION....1129
4.3.2 REMOVAL....1129
4.3.3 DISASSEMBLING THE POWER DIVIDER....1131
4.3.4 CHECK AND REPAIR OF THE POWER DIVIDER....1132
4.3.5 ASSEMBLING THE POWER DIVIDER....1133
4.3.6 RE-INSTALLATION....1134
5. HYDRAULIC SYSTEM....1139
5.1 LOCATION OF MAIN HYDRAULIC COMPONENTS....1141
5.2 HYDRAULIC CIRCUITS AND COMPONENTS....1142
5.2.1 HYDRAULIC CIRCUIT....1142
5.2.2 COMPONENT SPECIFICATIONS....1145
5.2.3 LOCATION OF HYDRAULIC COMPONENTS....1148
5.3 HYDRAULIC SYSTEM....1155
5.3.1 PREFACE....1155
5.3.2 OUTLINE....1155
5.3.3 OIL FLOW FROM No.1 and No. 2 PUMPS....1157
5.3.4 OIL FLOW FROM No.3 PUMP....1160
5.3.5 OIL FLOW FROM No.4 and No.5 PUMPS (FOR MAIN AND AUX. WINCH DRUMS BRAKE COOLING CIRCUIT)....1162
5.3.6 OIL FLOW FROM No.6 PUMP (CONTROL PUMP)....1163
5.3.7 OIL FLOW FROM No.7 PUMP (FOR AUXILIARY ACTUATOR CIRCUIT)....1166
5.4 VALVES....1167
6. HOIST SYSTEM....1177
6.1 APPARATUS AND LOCATION OF COMPONENTS....1179
6.2 CONSTRUCTION AND FUNCTION....1180
6.2.1 HYDRAULIC SCHEMATIC....1180
6.2.2 LIFTING A LOAD....1182
6.2.3 HOLDING A RAISED LOAD....1184
6.2.4 LOWERING A LOAD (POWERED LOWERING)....1186
6.2.5 FREEFALL OPERATION....1189
6.2.6 FREE FALL ACCELERATION....1192
6.2.7 FRONT DRUM/REAR DRUM HYD-CIRCUIT SELECTION....1195
6.3 ADJUSTMENT OF DRUM LOCK....1198
6.4 BRAKE PEDAL....1200
6.4.1 ASSEMBLY DRAWING....1200
6.4.2 ADJUSTING THE BRAKE PEDAL....1202
6.5 BLEEDING AIR FROM BRAKE CIRCUIT....1203
7. BOOM HOIST SYSTEM....1205
7.1 APPARATUS AND LOCATION OF COMPONENTS....1207
7.2 CONSTRUCTION AND FUNCTION....1209
7.2.1 HYDRAULIC SCHEMATIC....1209
7.2.2 RAISING THE BOOM....1210
7.2.3 NEUTRAL (MAINTAINING THE BOOM POSITION)....1212
7.2.4 LOWERING THE BOOM....1214
7.3 BOOM DRUM LOCK....1216
7.3.1 ASSEMBLY DRAWING....1216
7.3.2 ADJUSTING THE BOOM DRUM LOCK....1217
7.4 REDUCTION UNIT....1218
8. SWING SYSTEM....1221
8.1 APPARATUS AND LOCATION OF COMPONENTS....1223
8.2 CONSTRUCTION AND FUNCTION....1224
8.2.1 HYDRAULIC SCHEMATIC....1224
8.2.2 SWING....1226
8.2.3 STOPPING....1228
8.3 SWING REDUCTION UNIT....1230
8.4 SWING BEARING....1234
8.5 SWING LOCK....1236
9. PROPEL SYSTEM....1237
9.1 LOCATION OF THE MAJOR COMPONENTS....1239
9.2 CONSTRUCTION AND FUNCTION....1240
9.2.1 HYDRAULIC SCHEMATIC....1240
9.2.2 PROPELLING (RIGHT SIDE FORWARD)....1242
9.2.3 STOPPING....1244
9.3 PROPEL REDUCTION UNIT....1246
9.3.1 REDUCTION UNIT....1248
9.3.2 MOTOR....1250
9.4 ADJUSTMENT....1252
10. ELECTRIC SYSTEM....1253
10.1 ELECTRICAL WIRING SCHEMATIC....1255
10.2 CONNECTOR LIST....1267
10.3 ARRANGEMENT OF ELECTRICAL PART....1319
10.3.1 ELECTRICAL PART OF CAB....1319
10.3.2 ELECTRICAL PART OF RIGHT DECK....1322
10.3.3 ELECTRICAL PART OF FLOOR PLATE & LEFT SIDE STAND PANEL....1330
10.3.4 ELECTRICAL PART OF REVOLVING FRAME....1335
10.3.5 ELECTRICAL PART OF LEFT DECK....1336
10.3.6 ELECTRICAL PART OF LEFT GUARD....1340
10.3.7 HARNESS PART NUMBER LIST (ALL MODELS)....1341
10.4 ELECTRICAL PART....1343
10.4.1 LOCATION AND USE OF FUSE....1343
10.4.2 FUSE BOX (GG73E00004F1)....1345
10.4.3 WIPER CONTROL RELAY (2479R1366)....1347
10.4.4 SWING FLASHER UNIT (2480U306)....1348
10.4.5 PRESSURE SWITCH (CONTROL PRESSURE CUT & FREE FALL)....1349
10.4.6 PRESSURE SENSOR....1350
10.4.7 RELAY BOX (GG24E00024F1)....1352
10.4.8 LEFT SIDE STAND PANEL....1357
10.5 TROUBLESHOOTING OF EXHAUST GAS THIRD REGULATION ENGINE....1361
10.5.1 FAILURE DIAGNOSIS FUNCTION....1361
10.5.2 HOW TO CHECK THE FAILURE CONTENTS....1362
10.5.3 CHECKING OF DIAGNOSIS LAMP FUNCTION....1367
10.5.4 ENGINE ECU....1368
11. LOAD SAFETY DEVICE....1371
11.1 PART NAMES AND FUNCTIONS....1373
11.1.1 FRONT VIEW....1373
11.1.2 CONFIGURATION OF SCREENS....1378
11.1.3 DATA TRANSMISSION BETWEEN CONTROLLER AND CARDS....1383
11.1.4 DETAILS OF INDICATORS ON MAIN DISPLAY SCREEN....1385
11.1.5 REAR VIEW....1389
11.1.6 ITEMS REQUIRED TO BE EXECUTED FOR REPLACEMENT OF CONTROLLER OR DATA CARD AND INSTRUCTIONS....1394
11.2 PREPARATION FOR USE....1395
11.3 TURN THE POWER ON....1396
11.4 UPGRADING PROGRAMS....1397
11.4.1 PROCEDURES....1397
11.4.2 UPGRADING OF INDICATION PROGRAMS....1399
11.4.3 UPGRADING OF CONTROL PROGRAMS....1402
11.5 STATUS CHECK....1404
11.5.1 SIGNAL CHECK....1405
11.5.2 OPERATION PROGRESS....1407
11.5.3 COMMUNICATION DATA....1410
11.5.4 INDICATION OF ADJUSTMENT VALUE....1411
11.5.5 TROUBLE RECORD....1420
11.5.6 CHOICE OF LANGUAGE (CKE SERIOUS ONLY)....1422
11.5.7 LOAD RECORD (LOAD RECORD IN THE MAIN MENU)....1423
11.6 ADJUSTMENTS....1424
11.6.1 REMOVING THE INNER PANEL....1424
11.6.2 ADJUSTMENT....1425
11.6.3 LOAD ADJUSTMENT....1446
11.6.4 ADJUSTMENT DATA COPY (INITIALIZATION)....1448
11.6.5 VERSION CHECK....1454
11.7 ERROR CODE (ABNORMALITY DETECTION) AND COUNTERMEASURES....1455
11.8 CONTROL OUTPUT....1459
11.9 RELEASES....1471
11.9.1 RELEASE FUNCTION....1471
11.10 MECHANICAL SPECIFICATION....1479
11.10.1 ENVIRONMENTAL PERFORMANCE PARAMETERS....1479
11.10.2 LOAD CELL (CRANE)....1480
11.10.3 ANGLE SENSOR....1481
11.10.4 CONTROLLER....1482
11.11 EXTERNAL DIMENSIONS....1486
11.12 ELECTRIC SCHEMATIC DIAGRAM....1487
11.12.1 CRANE TYPE....1487
11.12.2 LUFFING TYPE....1488
11.13 CONTROLLER MALFUNCTION EMERGENCY MEASURES....1489
11.14 LOAD SAFETY DEVICE CHECK PROCEDURES....1490
12. GAUGE CLUSTER....1491
12.1 CONFIGURATION OF DISPLAY....1493
12.2 PRIORITY....1494
12.3 STATUS DISPLAY....1496
12.4 FAULT LOG DISPLAY....1505
13. TOTAL CONTROLLER....1511
13.1 ARRANGEMENT OF TOTAL CONTROLLER....1513
13.2 COMPOSITION OF SYSTEM....1514
13.2.1 OUTPUT RELATION TO CONTROLLER....1515
13.3 FUNCTION OF TOTAL CONTROLLER....1516
13.4 TOTAL CONTROLLER (HARDWARE)....1539
13.4.1 OUTLINE....1539
13.4.2 SPECIFICATIONS OF TOTAL CONTROLLER OUTPUT....1540
13.4.3 DETAILS OF TOTAL CONTROLLER CONNECTOR....1544
13.4.4 ARRANGEMENT OF TOTAL CONTROLLER CONNECTOR PIN....1545
13.4.5 PROPORTIONAL SOLENOID VALVE MEASURING POSITION (VOLTAGE)....1552
13.5 ADJUSTMENT OF TOTAL CONTROLLER....1554
13.5.1 NECESSITY OF ADJUSTMENT....1554
13.5.2 ADJUSTMENT PROCEDURES OF TOTAL CONTROLLER....1554
13.6 CONTROLLER MALFUNCTION EMERGENCY MEASURES....1561
14. AIR CONDITIONER....1563
14.1 OPERATION ITEMS....1565
14.2 SAFETY MONITOR FUNCTIONS....1566
14.3 DISASSEMBLY AND ASSEMBLY PROCEDURE....1569
14.3.1 SPECIAL CONSIDERATIONS DURING REPLACEMENT....1569
14.3.2 INTERIOR UNIT....1571
14.4 OPERATIONAL PRECAUTIONS....1580
14.5 INSPECTION AND MAINTENANCE....1581
14.5.1 INSPECTION/MAINTENANCE LIST....1581
14.5.2 INSPECTION/MAINTENANCE PROCEDURES....1581
14.6 ELECTRIC SYSTEM SCHEMATIC....1585
KOBELCO CK850-II Crawler Crane OPERATION & MAINTENANCE Manual
