KOBELCO CK1000-II, CKE900 Crawler Cranes OPERATION & MAINTENANCE Manual
Complete OPERATION & MAINTENANCE manual with Parts catalog for 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
RIGHT DECK HYD. LINES....680
MAIN VALVE HYD. LINES....688
GANTRY CYLINDER HYD. LINE....692
SWING CONTROL HYD. LINES ....696
ACCUMLATOR HYD. LINES....700
FLOOR CONTROL HYD. LINES....702
FLOOR CONTROL HYD. LINES....706
CONNECTOR ASSY (GANTRY VALVE)....708
BRAKE CONTROL HYD. LINES....710
4-SECTION VALVE INSTAL....712
3-SECTION VALVE HYD. LINES....714
RETURN HYD. LINES....716
DRAIN LINES....718
RETURN BLOCK HYD. LINES....722
CONTROL LINES....724
2-SECTION VALVE INSTAL....726
2-SECTION VALVE INSTAL (FUNCTION CUT/SWING PARKING BRAKE)....728
4-SECTION VALVE HYD. LINES....730
5-SECTION VALVE HYD. LINES....734
8-SECTION VALVE HYD. LINES....738
WINCH HYD. LINES (FOR FRONT & REAR DRUM)....740
WINCH HYD. LINES (FOR FRONT & REAR DRUM)....742
WINCH HYD. LINES (FOR BOOM DRUM)....744
VALVE INSTAL....746
OIL COOLER HYD. LINES....750
CLAMP ASSY....752
LOWER HYD. LINES....754
SWIVEL JOINT INSTAL....758
SWIVEL JOINT....762
HYD. OIL TANK ASSY (FOR STANDARD)(FOR FREE FALL)(TANK)....764
HYD. OIL COOLING LINES....768
CONNECTOR ASSY....772
CONNECTOR ASSY....774
POWER PLANT....0
POWER PLANT ASSY....776
PUMP ASSY....782
POWER DIVIDER....784
MUFFLER INSTAL....786
FUEL LINES....788
RADIATOR INSTAL....792
AIR CLEANER INSTAL....794
FUEL TANK ASSY....796
ELECTRIC SYSTEM....0
ELEC ASSY (R.H. DECK)....800
ELEC ASSY (REV. FRAME)....806
ELEC ASSY (FLOOR PLATE)....810
RELAY BOX ASSY....814
ELEC ASSY (L.H. GUARD)....816
ELEC ASSY (CAB)....818
ELEC ASSY (L.H. DECK)....822
WASHER TANK ASSY....828
BATTERY INSTAL....830
JUNCTION BOX ASSY....832
RELAY ASSY....834
CAB....0
CAB INSTAL....836
CAB ASSY....840
DOOR ASSY....848
RUBBER SHEET INSTAL (OPERATOR’S ROOM)....854
LOCK ASSY....856
SUN VISOR ASSY....858
ROLL BLIND....860
SASH ASSY....862
GUARD / COVER / PLATFORM....0
R.H. GUARD INSTAL....864
R.H. GUARD ASSY....866
L.H. GUARD INSTAL....870
L.H. GUARD ASSY....874
L.H. GUARD ASSY....878
INSULATION ASSY....880
INSULATION ASSY (L.H. GUARD)....884
DRUM COVER....886
SWING BEARING COVER....888
UNDER COVER ASSY....890
R.H. DECK ASSY....892
R.H. DECK INSTAL (UNDER OF CAB)....896
STEP ASSY....898
L.H. DECK INSTAL....900
GUARD ASSY (FRONT)....904
BOOM DRUM COVER ASSY....906
COVER ASSY (SWING FRAME)(SWING FRAME)....908
LOWER SYSTEM....0
PROPEL MOTOR ASSY....910
REDUCTION UNIT ASSY....912
IDLER ASSY....914
IDLER ADJUST ASSY....916
ROLLER ASSY....918
LOWER ROLLER ASSY....919
UPPER ROLLER ASSY....920
FRAME COVER ASSY....922
LINK ASSY....924
CYLINDER ASSY....926
STEP ASSY....930
AXLE ADAPTER ASSY....932
CRAWLER FRAME....934
LOWER FRAME....935
SHOE ASSY....936
CRANE ATTACHMENT....0
LOWER BOOM ASSY....938
UPP. BOOM ASSY....940
INSERT BOOM....942
BOOM GUY CABLE....944
BOOM POINT SHEAVE ASSY....946
IDLER SHEAVE ASSY....948
SPREADER GUIDE ASSY....950
CABLE ROLLER ASSY (FOR UPP.BOOM)....952
CABLE ROLLER (FOR INSERT BOOM)....954
UPPER SPREADER ASSY....956
LOWER SPREADER ASSY....958
BACKSTOP ASSY....960
BOOM BACKSTOP ASSY....962
JIB ASSY....964
STRUT ASSY....966
INSERT JIB....968
JIB GUY CABLE (FOR BASE BOOM SIDE)(FOR JIB SIDE)....970
JIB GUY CABLE....972
JIB POINT SHEAVE ASSY....974
AUX. SHEAVE ASSY....976
CABLE ROLLER ASSY (FOR INSERT JIB)....978
ANGLE METER INSTAL....980
WIRE ROPE ASSY (MAIN)(AUXLIARY)(THIRD)....982
WIRE ROPE ASSY (BOOM)....984
LUFFING ATTACHMENT....0
LUFFING JIB ASSY....986
REAR STRUT ASSY....988
FRONT STRUT ASSY....990
LOW. BOOM ASSY (FOR LUFFING)....992
UPP BOOM ASSY....994
BOOM POINT SHEAVE ASSY....996
IDLER SHEAVE ASSY....998
STRUT SHEAVE ASSY (FRONT STRUT)....1000
STRUT SHEAVE ASSY (REAR STRUT)....1002
SPECIAL INSERT BOOM....1004
INSERT BOOM....1006
IDLER SHEAVE ASSY....1008
LOWER JIB ASSY....1010
BACKSTOP ASSY, BOOM....1012
BOOM BACKSTOP ASSY....1014
JIB BACKSTOP ASSY....1016
JIB BACKSTOP ASSY....1018
JIB BACKSTOP ASSY....1020
HYD. OIL TANK INSTAL....1022
HYD. OIL TANK ASSY....1024
AUX. SHEAVE ASSY....1026
ANGLE METER ASSY....1028
TRAVELING KIT....1030
ROLLER ASSY....1032
SWITCH PANEL ASSY....1034
JIB ELEC ASSY....1036
LABEL (LUFFING BOOM / JIB / GUYLINE ARRANGEMENT)....1040
LABEL ASSY....1042
HOOK OVERHOIST LIMIT SWITCH (FOR LUFFING)....1044
LIMIT SWITCH ASSY....1046
WINCH ASSY, THIRD....1048
GANTRY....0
GANTRY ASSY....1050
SUB GANTRY ASSY....1054
GANTRY LUB. LINES....1058
TAGLINE ....0
TAGLINE HYD. LINES....1060
TAGLINE ASSY....1064
TAGLINE GUIDE ASSY....1066
GUIDE SHEAVE ASSY....1068
THIRD....0
CONTROL ASSY....1070
CONTROL ASSY....1072
BRAKE PEDAL ASSY....1074
DRUM LOCK ASSY....1076
DRUM LOCK LUB. LINES....1078
TRIMMER INSTAL....1080
WINCH INSTAL....1082
WINCH ASSY....1084
WINCH ASSY....1086
HYD. LINES ASSY....1088
WINCH HYD. LINES....1092
HYD. LINES ASSY....1096
4-SECTION VALVE HYD. LINES (MOTOR BRAKE)....1098
8-SECTION VALVE HYD LINES....1100
HYD. LINES ASSY....1102
CONNECTOR ASSY....1104
HYD. LINES ASSY....1106
HYD. LINES WINCH ....1108
CLUTCH VALVE INSTAL....1110
GANTRY SHEAVE ASSY....1112
IDLER SHEAVE ASSY....1116
DRUM COVER ASSY....1118
HARNESS ASSY....1122
SAFETY DEVICE....0
SAFETY DEVICE HARNESS (FOR GANTRY)....1124
SAFETY DEVICE HARNESS (FOR BASE MACHINE)....1126
SAFETY DEVICE HARNESS (BOOM ANGLE DETECTOR)....1128
OVERHOIST PREVENTIVE DEVICE (FOR BOOM BASE & INSERT BOOM)(FOR BOOM TIP)....1130
SAFETY DEVICE HARNESS (FOR JIB)....1134
OVERHOIST LIMIT SWITCH (MAIN HOOK)....1136
HOOK OVERHOIST LIMIT SWITCH (FOR AUX. SHEAVE & JIB)....1138
LIMIT SWITCH ASSY....1140
LIMIT SWITCH ASSY (BASE MACHINE SIDE)(BOOM SIDE)....1142
COUNTERWEIGHT / FRAME....0
COUNTERWEIGHT ASSY....1144
SWING ALARM LAMP....1146
REV. FRAME....1148
RUBBER ASSY....1150
CARBODY WEIGHT....1154
C/W REMOVAL DEVICE....1156
C/W REMOVAL HYD. LINES (C/W REMOVAL DEVICE)....1160
C/W REMOVAL HYD. LINES (C/W REMOVAL DEVICE)....1162
REMOTE CONTROL ASSY....1166
LABEL....0
LABEL (FOR BASE MACHINE)....1168
LABEL ASSY (FOR BASE MACHINE)....1176
LABEL ASSY (FOR ATTACHMENT)....1180
LABEL ASSY (SWITCH PANEL)....1182
OTHERS....0
AIR CONDITIONER (INDOOR UNIT)....1184
AIR CONDITIONER (OUTDOOR UNIT)....1190
AIR CONDITIONER UNIT....1194
UPPER FINAL....1198
UPPER FINAL....1200
UPPER FINAL (PEDAL COVER)....1202
UPPER FINAL (ANTI-SLIP)....1204
UPPER FINAL (ANTI-SLIP)....1206
TOOL ASSY....1208
SPARE PART KIT....1210
SEAT ASSY....1212
WIPER INSTAL (OPTION)....1214
WASHER TANK INSTAL (OPTION)....1216
CAMERA INSTAL (FOR DRUM / OPTION)....1218
CAMERA INSTAL (FOR REAR / OPTION)....1222
MONITOR INSTAL (OPTION)....1226
HARNESS ASSY (FOR MONITOR / OPTION)....1230
TELEVISION MONITOR (OPTION)....1232
RADIO INSTAL (COVER)(RADIO OPTION)....1234
FOOT ACCELERATOR (RIGHT)(RIGHT & LEFT / OPTION)(LEFT / OPTION)....1236
ONE-WAY CALL ASSY (OPTION)....1240
AUX. PLATFORM....1242
AUX. PLATFORM (OPTION)....1246
TRAVELING KIT (OPTION)....1250
DRUM TURN SENSOR INSTAL....1252
DRUM TURN SWITCH INSTAL....1254
DRUM TURN SENSOR GRIP INSTAL....1255
GRIP ASSY....1256
FAN ASSY (OPTION)....1258
MIRROR INSTAL (OPTION)....1260
PLATE ASSY....1262
SHEAVE ASSY (FOR CRAWLER REMOVAL / OPTION)....1264
HEAD GUARD (OPTION)....1266
EXTINGUISHER INSTAL (OPTION)....1268
HANDRAIL INSTAL (L.H. GUARD)....1270
GUARD INSTAL (CAB LEFT WINDOW)....1272
LEVEL GAUGE INSTAL (OPTION)....1274
LIFE HAMMER INSTAL (OPTION)....1276
INDEX OF PART NO.....1279
S5GH00002ZE04 - KOBELCO CK1000-II, CKE900 Crawler Crane OPERATION & MAINTENANCE MANUAL....1299
COVER....1299
TABLE OF CONTENTS....1301
SAFETY....1309
1. SPECIFICATION....1321
1.1 CK1000-II SPECIFICATION....1323
1.1.1 PERFORMANCE....1323
1.1.2 OUTSIDE DIMENSIONS....1323
1.1.3 DIMENSIONS AND WEIGHT OF EACH PARTS....1325
1.1.4 STABILITY IN SWINGING AND TRAVELING....1331
1.2 CKE900 SPECIFICATION....1333
1.2.1 PERFORMANCE....1333
1.2.2 OUTSIDE DIMENSIONS....1333
1.2.3 DIMENSIONS AND WEIGHT OF EACH PARTS....1335
1.2.4 STABILITY IN SWINGING AND TRAVELING....1341
2. MAINTENANCE STANDARDSTEST PROCEDURES....1343
2.1 MAINTENANCE STANDARD....1346
2.1.1 PIN, BUSHING, SPRING, LINING AND SHEAVE....1346
2.1.2 PROPEL DEVICE....1353
2.2 PERFORMANCE STANDARD AND TEST PROCEDURE....1359
2.2.1 OPERATING SPEED....1359
2.2.2 POINT AND METHOD OF MEASURING PRESSURE....1360
3. GENERAL WORK STANDARD....1365
3.1 TIGHTENING TORQUE OF CAPSCREWS AND NUTS....1367
3.1.1 METRIC COARSE THREADS....1367
3.1.2 METRIC FINE THREADS....1367
3.1.3 COARSE THREDS UNC....1368
3.1.4 FINE THREADS UNF....1368
3.1.5 TIGHTENING TORQUE OF HYDRAULIC FITTINGS....1369
3.2 STANDARD PARTS....1371
3.2.1 BOLT....1371
3.2.2 O-RING....1372
3.2.3 BACK-UP RING....1373
3.2.4 BITE FITTING....1374
3.3 CONVERSION TABLE....1376
3.3.1 UNIT CONVERSION....1376
3.3.2 MILLIMETER : INCH CONVERSION TABLE....1377
3.3.3 METER-FOOT CONVERSION TABLE....1379
3.3.4 GRADIENT CONVERSION TABLE....1380
3.4 TABLE OF UNIT WEIGHT....1381
4. POWER TRAIN....1383
4.1 INTRODUCTION....1385
4.2 ENGINE....1387
4.2.1 INTRODUCTION....1387
4.2.2 REMOVAL....1387
4.2.3 REPAIR AND MAINTENANCE....1388
4.2.4 RE-INSTALLATION....1389
4.3 PUMP DRIVE ASSEMBLY....1392
4.3.1 INTRODUCTION....1392
4.3.2 REMOVAL....1392
4.3.3 DISASSEMBLING THE POWER DIVIDER....1394
4.3.4 CHECK AND REPAIR OF THE POWER DIVIDER....1395
4.3.5 ASSEMBLING THE POWER DIVIDER....1396
4.3.6 RE-INSTALLATION....1397
5. HYDRAULIC SYSTEM....1403
5.1 LOCATION OF MAIN HYDRAULIC COMPONENTS....1405
5.2 HYDRAULIC CIRCUITS AND COMPONENTS....1406
5.2.1 HYDRAULIC CIRCUIT....1406
5.2.2 COMPONENT SPECIFICATIONS....1409
5.2.3 LOCATION OF HYDRAULIC COMPONENTS....1412
5.3 HYDRAULIC SYSTEM....1418
5.3.1 PREFACE....1418
5.3.2 OUTLINE....1418
5.3.3 OIL FLOW FROM NO.1 AND NO. 2 PUMPS....1420
5.3.4 OIL FLOW FROM No.3 PUMP....1422
5.3.5 OIL FLOW FROM NO.4 AND NO. 5 PUMPS(FOR MAIN AND AUX. WINCH DRUMS BRAKE COOLING CIRCUIT)....1423
5.3.6 OIL FLOW FROM NO.6 PUMP (CONTROL PUMP)....1425
5.3.7 OIL FLOW FROM No.7 PUMP (FOR AUXILIARY ACTUATOR CIRCUIT)....1428
5.4 VALVES....1429
6. HOIST SYSTEM....1439
6.1 APPARATUS AND LOCATION OF COMPONENTS....1441
6.2 CONSTRUCTION AND FUNCTION....1442
6.2.1 HYDRAULIC SCHEMATIC....1442
6.2.2 LIFTING A LOAD....1444
6.2.3 HOLDING A RAISED LOAD....1446
6.2.4 LOWERING A LOAD(POWERED LOWERING)....1448
6.2.5 FREEFALL OPERATION....1450
6.2.6 FREE FALL ACCELERATION....1454
6.3 DRUM AND REDUCTION UNIT....1456
6.3.1 DRUM....1456
6.3.2 REDUCTION UNIT....1458
6.4 ADJUSTMENT OF DRUM LOCK....1460
6.5 BRAKE PEDAL....1462
6.5.1 ASSEMBLY DRAWING....1462
6.5.2 ADJUSTING THE BRAKE PEDAL....1464
6.6 BLEEDING AIR FROM BRAKE CIRCUIT....1465
7. BOOM HOIST SYSTEM....1467
7.1 APPARATUS AND LOCATION OF COMPONENTS....1469
7.2 CONSTRUCTION AND FUNCTION....1470
7.2.1 HYDRAULIC SCHEMATIC....1470
7.2.2 RAISING THE BOOM....1472
7.2.3 NEUTRAL(MAINTAINING THE BOOM POSITION)....1474
7.2.4 LOWERING THE BOOM....1476
7.3 BOOM DRUM LOCK....1478
7.3.1 ASSEMBLY DRAWING....1478
7.3.2 ADJUSTING THE BOOM DRUM LOCK....1479
7.4 REDUCTION UNIT....1480
8. SWING SYSTEM....1483
8.1 APPARATUS AND LOCATION OF COMPONENTS....1485
8.2 CONSTRUCTION AND FUNCTION....1486
8.2.1 HYDRAULIC SCHEMATIC....1486
8.2.2 SWING....1488
8.2.3 STOPPING....1490
8.3 SWING REDUCTION UNIT....1492
8.4 SWING BEARING....1496
8.5 SWING LOCK....1498
9. PROPEL SYSTEM....1499
9.1 LOCATION OF THE MAJOR COMPONENTS....1501
9.2 CONSTRUCTION AND FUNCTION....1502
9.2.1 HYDRAULIC SCHEMATIC....1502
9.2.2 PROPELLING (RIGHT SIDE FORWARD)....1504
9.2.3 STOPPING....1506
9.3 PROPEL REDUCTION UNIT....1508
9.3.1 REDUCTION UNIT....1510
9.3.2 MOTOR....1512
9.4 ADJUSTMENT....1514
9.5 UPPER AND LOWER ROLLER AND AXLE ADAPTER TIGHTENING TORQUE....1515
10. ELECTRIC SYSTEM....1517
10.1 ELECTRICAL WIRING SCHEMATIC....1519
10.2 CONNECTOR LIST....1534
10.3 ARRANGEMENT OF ELECTRICAL PART....1586
10.3.1 ELECTRICAL PART OF CAB....1586
10.3.2 ELECTRICAL PART OF RIGHT DECK....1590
10.3.3 ELECTRICAL PART OF FLOOR PLATE & LEFT SIDE STAND PANEL....1598
10.3.4 ELECTRICAL PART OF REVOLVING FRAME....1603
10.3.5 ELECTRICAL PART OF LEFT DECK....1604
10.3.6 ELECTRICAL PART OF LEFT GUARD....1611
10.3.7 HARNESS PART NUMBER LIST (ALL MODELS)....1612
10.4 ELECTRICAL PART....1614
10.4.1 LOCATION AND USE OF FUSE....1614
10.4.2 FUSE BOX (GG73E00004F1)....1616
10.4.3 WIPER CONTROL RELAY (2479R1366)....1618
10.4.4 SWING FLASHER UNIT (2480U306)....1619
10.4.5 PRESSURE SWITCH (CONTROL PRESSURE CUT & FREE FALL)....1620
10.4.6 PRESSURE SENSOR....1621
10.4.7 RELAY BOX (GG24E00024F1)....1623
10.4.8 LEFT SIDE STAND PANEL....1628
10.5 TROUBLESHOOTING OF EXHAUST GAS THIRD REGULATION ENGINE....1632
10.5.1 FAILURE DIAGNOSIS FUNCTION....1632
10.5.2 HOW TO CHECK THE FAILURE CONTENTS....1633
10.5.3 CHECKING OF DIAGNOSIS LAMP FUNCTION....1638
10.5.4 ENGINE ECU....1639
11. LOAD SAFETY DEVICE....1643
11.1 PART NAMES AND FUNCTIONS....1645
11.1.1 FRONT VIEW....1645
11.1.2 CONFIGURATION OF SCREENS....1650
11.1.3 DATA TRANSMISSION BETWEEN CONTROLLER AND CARDS....1655
11.1.4 DETAILS OF INDICATORS ON MAIN DISPLAY SCREEN....1657
11.1.5 REAR VIEW....1661
11.1.6 ITEMS REQUIRED TO BE EXECUTED FOR REPLACEMENT OF CONTROLLER OR DATA CARDAND INSTRUCTIONS(IN A SIMILAR MANNER TO UPGRADE OF PROGRAM)....1666
11.2 PREPARATION FOR USE....1667
11.3 TURN THE POWER ON....1668
11.4 UPGRADING PROGRAMS....1669
11.4.1 PROCEDURES....1669
11.4.2 UPGRADING OF INDICATION PROGRAMS....1671
11.4.3 UPGRADING OF CONTROL PROGRAMS....1674
11.5 STATUS CHECK....1676
11.5.1 SIGNAL CHECK....1677
11.5.2 OPERATION PROGRESS....1679
11.5.3 COMMUNICATION DATA....1682
11.5.4 INDICATION OF ADJUSTMENT VALUE....1683
11.5.5 TROUBLE RECORD....1692
11.5.6 CHOICE OF LANGUAGE (CKE SERIES ONLY)....1694
11.5.7 LOAD RECORD (LOAD RECORD IN THE MAIN MENU)....1695
11.6 ADJUSTMENTS....1696
11.6.1 REMOVING THE INNER PANEL....1696
11.6.2 ADJUSTMENT....1697
11.6.3 LOAD ADJUSTMENT....1718
11.6.4 ADJUSTMENT DATA COPY (INITIALIZATION)....1720
11.6.5 VERSION CHECK....1726
11.7 ERROR CODE (ABNORMALITY DETECTION) AND COUNTERMEASURES....1727
11.8 CONTROL OUTPUT....1731
11.9 RELEASES....1743
11.9.1 RELEASE FUNCTION....1743
11.10 MECHANICAL SPECIFICATION....1751
11.10.1 ENVIRONMENTAL PERFORMANCE PARAMETERS....1751
11.10.2 LOAD CELL (CRANE)....1752
11.10.3 ANGLE SENSOR....1753
11.10.4 CONTROLLER....1754
11.11 EXTERNAL DIMENSIONS....1758
11.12 ELECTRIC SCHEMATIC DIAGRAM....1759
11.12.1 CRANE TYPE....1759
11.12.2 LUFFING TYPE....1760
11.13 CONTROLLER MALFUNCTION EMERGENCY MEASURES....1761
11.14 LOAD SAFETY DEVICE CHECK PROCEDURES....1762
12. GAUGE CLUSTER....1763
12.1 CONFIGURATION OF DISPLAY....1765
12.2 PRIORITY....1766
12.3 STATUS DISPLAY....1768
12.4 FAULT LOG DISPLAY....1777
13. TOTAL CONTROLLER....1783
13.1 ARRANGEMENT OF TOTAL CONTROLLER....1785
13.2 COMPOSITION OF SYSTEM....1786
13.2.1 OUTPUT RELATION TO CONTROLLER....1787
13.3 FUNCTION OF TOTAL CONTROLLER....1788
13.3.1 FRONT, REAR AND THIRD DRUM....1792
13.4 TOTAL CONTROLLER (HARDWARE)....1813
13.4.1 OUTLINE....1813
13.4.2 SPECIFICATIONS OF TOTAL CONTROLLER OUTPUT....1814
13.4.3 DETAILS OF TOTAL CONTROLLER CONNECTOR....1818
13.4.4 ARRANGEMENT OF TOTAL CONTROLLER CONNECTOR PIN....1819
13.4.5 PROPORTIONAL SOLENOID VALVE MEASURING POSITION (VOLTAGE)....1826
13.5 ADJUSTMENT OF TOTAL CONTROLLER....1828
13.5.1 NECESSITY OF ADJUSTMENT....1828
13.5.2 ADJUSTMENT PROCEDURES OF TOTAL CONTROLLER....1828
13.6 CONTROLLER MALFUNCTION EMERGENCY MEASURES....1835
14. AIR CONDITIONER....1837
14.1 OPERATION ITEMS....1838
14.2 SAFETY MONITOR FUNCTIONS....1839
14.3 DISASSEMBLY AND ASSEMBLY PROCEDURE....1842
14.3.1 SPECIAL CONSIDERATIONS DURING REPLACEMENT....1842
14.3.2 INTERIOR UNIT....1844
14.4 OPERATIONAL PRECAUTIONS....1853
14.5 INSPECTION AND MAINTENANCE....1854
14.5.1 INSPECTION/MAINTENANCE LIST....1854
14.5.2 INSPECTION/MAINTENANCE PROCEDURES....1854
14.6 ELECTRIC SYSTEM SCHEMATIC....1858
KOBELCO CK1000-II, CKE900 Crawler Cranes OPERATION & MAINTENANCE Manual
