Kobelco CK850-II CKE800 CKE700 Crawler Crane Shop Manual S5GG00005ZE04 – PDF DOWNLOAD

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Kobelco CK850-II CKE800 CKE700 Crawler Crane Shop Manual S5GG00005ZE04 – PDF DOWNLOAD

FILE DETAILS:

Kobelco CK850-II CKE800 CKE700 Crawler Crane Shop Manual S5GG00005ZE04 – PDF DOWNLOAD

Language : English
Pages : 554
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Kobelco CK850-II CKE800 CKE700 Crawler Crane Shop Manual S5GG00005ZE04 – PDF DOWNLOAD

SAFETY:
PRECAUTIONS FOR INSPECTION AND MAINTENANCE:
1. Service and maintenance must be performed only by authorized personnel who are qualified in
compliance with a relevant law or regulation.
2. Regular maintenance or inspection should be quickly performed after shutting down the machine
and ensuring safety to personnel and equipment.
Post an “INSPECTION IN PROGRESS. DO NOT START.” warning sign on a readily visible location.

GENERAL SAFETY PRECAUTIONS:
1. Wear safety shoes, helmets and clothing suitable for the job. Also use protective goggles,
mask, gloves, etc., as required.
2. To ensure safe and correct maintenance, carefully study this SHOP MANUAL and get fully
familiar with the in- structions in it.
3. Place the machine in a safe place. Always maintain safe clearance around the machine.
4. Before starting crane operation, hold a safety meeting. Also, make agreement on standardized
hand signals.
5. When inspecting or handling the battery or oil, do not use exposed flame nearby. To avoid fire
accident, only use explosion-proof lighting equipment.
6. Start an inspection or maintenance work only after shutting down the engine.
7. Certain machine components remain hot immediately after the engine is shut down. Do not touch
them.
8. Before removing the radiator cap, wait until the coolant water gets sufficiently cool. Next,
carefully loosen the cap and release radiator pressure, and them remove the cap.
9. Before inspecting or maintaining an electrical system on the machine, power off the machine
by, for example, disconnecting the battery cables.
10. When working at a high lift area, always wear a safety belt.
11. When leaving the operator’s cab for an inspection or maintenance work, post an “INSPECTION IN
PROGRESS. DO NOT START.” warning sign on a readily visible location. Also, lock the cab for
security.
12. Before starting a cleaning or lubrication work on the machine, always shut down the engine.
13. While adjusting tire pressure, be absolutely careful about rupture of a tire, flying of wheel
part.
14. Use genuine KOBELCO replacement parts and oils only.
15. Always keep the oil containers clean. Protect them against ingress of dust or moisture. Also,
fill clean, fresh oils only.
16. Once a maintenance work is complete, clean the machine.
Protect grease nipples, breathers, and oil level gages against ingress of dust.
17. Always keep the subjects of regular inspection clean to allow problems such as oil leakage,
crack, looseness, etc., to be readily detected.
18. During car washing, do not allow high pressure steam to be directly applied to electrical
components and con- nectors.
19. After removing O-rings, oil seals, gaskets, etc., clean the mounting seats. Then, install
fresh O-rings, oil seals, gaskets, etc. Also, remember to thinly apply oil to the seal faces of
these parts before installation.
20. Before disconnecting pressurized piping, release the inside pressure.

TABLE OF CONTENTS:

Kobelco CK850-II CKE800 CKE700 Crawler Crane Shop Manual S5GG00005ZE04 – PDF DOWNLOAD

1 SPECIFICATION
1 1 CK850-II SPECIFICATION 1-3
1 1 1 PERFORMANCE 1-3
1 1 2 OUTSIDE DIMENSIONS 1-3
1 1 3 DIMENSIONS AND WEIGHT OF EACH PARTS 1-5
1 1 4 CK850-II STABILITY IN SWINGING AND TRAVELING 1-10
1 2 CKE800/CKE700 SPECIFICATION 1-11
1 2 1 PERFORMANCE 1-11
1 2 2 OUTSIDE DIMENSIONS 1-11
1 2 3 DIMENSIONS AND WEIGHT OF EACH PARTS 1-13
1 2 4 CKE800 STABILITY IN SWINGING AND TRAVELING 1-19
1 2 5 CKE700 STABILITY IN SWINGING AND TRAVELING 1-21
2 MAINTENANCE STANDARDS
TEST PROCEDURES
2 1 MAINTENANCE STANDARD 2-3
2 1 1 PIN, BUSHING, SPRING, LINING AND SHEAVE 2-3
2 1 2 PROPEL DEVICE 2-10
2 2 PERFORMANCE STANDARD AND TEST PROCEDURE 2-16
2 2 1 OPERATING SPEED 2-16
2 2 2 POINT AND METHOD OF MEASURING PRESSURE 2-17
2 2 3 SLEWING RING 2-21
3 GENERAL WORK STANDARD
3 1 TIGHTENING TORQUE OF CAPSCREWS AND NUTS 3-3
3 1 1 METRIC COARSE THREADS 3-3
3 1 2 METRIC FINE THREADS 3-3
3 1 3 COARSE THREDS UNC 3-4
3 1 4 FINE THREADS UNF 3-4
3 1 5 TIGHTENING TORQUE OF HYDRAULIC FITTINGS 3-5
3 2 STANDARD PARTS 3-7
3 2 1 BOLT 3-7
3 2 2 O-RING 3-8
3 2 3 BACK-UP RING 3-9
3 2 4 BITE FITTING 3-10
3 3 CONVERSION TABLE 3-12
3 3 1 UNIT CONVERSION 3-12
3 3 2 MILLIMETER : INCH CONVERSION TABLE 3-13
TABLE OF CONTENTS
CK850-II / CKE700 / CKE800 2
3 3 3 METER-FOOT CONVERSION TABLE 3-15
3 3 4 GRADIENT CONVERSION TABLE 3-16
3 4 TABLE OF UNIT WEIGHT 3-17
4 POWER TRAIN
4 1 INTRODUCTION 4-3
4 2 ENGINE 4-5
4 2 1 INTRODUCTION 4-5
4 2 2 REMOVAL 4-5
4 2 3 REPAIR AND MAINTENANCE 4-6
4 2 4 RE-INSTALLATION 4-7
4 3 PUMP DRIVE ASSEMBLY 4-11
4 3 1 INTRODUCTION 4-11
4 3 2 REMOVAL 4-11
4 3 3 DISASSEMBLING THE POWER DIVIDER 4-13
4 3 4 CHECK AND REPAIR OF THE POWER DIVIDER 4-14
4 3 5 ASSEMBLING THE POWER DIVIDER 4-15
4 3 6 RE-INSTALLATION 4-16
5 HYDRAULIC SYSTEM
5 1 LOCATION OF MAIN HYDRAULIC COMPONENTS 5-3
5 2 HYDRAULIC CIRCUITS AND COMPONENTS 5-4
5 2 1 HYDRAULIC CIRCUIT 5-4
5 2 2 COMPONENT SPECIFICATIONS 5-7
5 2 3 LOCATION OF HYDRAULIC COMPONENTS 5-10
5 3 HYDRAULIC SYSTEM 5-17
5 3 1 PREFACE 5-17
5 3 2 OUTLINE 5-17
5 3 3 OIL FLOW FROM No 1 and No 2 PUMPS 5-19
5 3 4 OIL FLOW FROM No 3 PUMP 5-22
5 3 5 OIL FLOW FROM No 4 and No 5 PUMPS
(FOR MAIN AND AUX WINCH DRUMS BRAKE COOLING CIRCUIT) 5-24
5 3 6 OIL FLOW FROM No 6 PUMP (CONTROL PUMP) 5-25
5 3 7 OIL FLOW FROM No 7 PUMP (FOR AUXILIARY ACTUATOR CIRCUIT) 5-28
5 4 VALVES 5-29
6 HOIST SYSTEM
6 1 APPARATUS AND LOCATION OF COMPONENTS 6-3
6 2 CONSTRUCTION AND FUNCTION 6-4
6 2 1 HYDRAULIC SCHEMATIC 6-4
TABLE OF CONTENTS
3 CK850-II / CKE700 / CKE800
6 2 2 LIFTING A LOAD 6-6
6 2 3 HOLDING A RAISED LOAD 6-8
6 2 4 LOWERING A LOAD
(POWERED LOWERING) 6-10
6 2 5 FREEFALL OPERATION 6-13
6 2 6 FREE FALL ACCELERATION 6-16
6 2 7 FRONT DRUM/REAR DRUM HYD-CIRCUIT SELECTION 6-19
6 3 ADJUSTMENT OF DRUM LOCK 6-22
6 4 BRAKE PEDAL 6-24
6 4 1 ASSEMBLY DRAWING 6-24
6 4 2 ADJUSTING THE BRAKE PEDAL 6-26
6 5 BLEEDING AIR FROM BRAKE CIRCUIT 6-27
7 BOOM HOIST SYSTEM
7 1 APPARATUS AND LOCATION OF COMPONENTS 7-3
7 2 CONSTRUCTION AND FUNCTION 7-5
7 2 1 HYDRAULIC SCHEMATIC 7-5
7 2 2 RAISING THE BOOM 7-6
7 2 3 NEUTRAL
(MAINTAINING THE BOOM POSITION) 7-8
7 2 4 LOWERING THE BOOM 7-10
7 3 BOOM DRUM LOCK 7-12
7 3 1 ASSEMBLY DRAWING 7-12
7 3 2 ADJUSTING THE BOOM DRUM LOCK 7-13
7 4 REDUCTION UNIT 7-14
8 SWING SYSTEM
8 1 APPARATUS AND LOCATION OF COMPONENTS 8-3
8 2 CONSTRUCTION AND FUNCTION 8-4
8 2 1 HYDRAULIC SCHEMATIC 8-4
8 2 2 SWING 8-6
8 2 3 STOPPING 8-8
8 3 SWING REDUCTION UNIT 8-10
8 4 SWING BEARING 8-14
8 5 SWING LOCK 8-16
9 PROPEL SYSTEM
9 1 LOCATION OF THE MAJOR COMPONENTS 9-3
9 2 CONSTRUCTION AND FUNCTION 9-4
TABLE OF CONTENTS
CK850-II / CKE700 / CKE800 4
9 2 1 HYDRAULIC SCHEMATIC 9-4
9 2 2 PROPELLING (RIGHT SIDE FORWARD) 9-6
9 2 3 STOPPING 9-8
9 3 PROPEL REDUCTION UNIT 9-10
9 3 1 REDUCTION UNIT 9-12
9 3 2 MOTOR 9-14
9 4 ADJUSTMENT 9-16
10 ELECTRIC SYSTEM
10 1 ELECTRICAL WIRING SCHEMATIC 10-3
10 2 CONNECTOR LIST 10-15
10 3 ARRANGEMENT OF ELECTRICAL PART 10-67
10 3 1 ELECTRICAL PART OF CAB 10-67
10 3 2 ELECTRICAL PART OF RIGHT DECK 10-70
10 3 3 ELECTRICAL PART OF FLOOR PLATE & LEFT SIDE STAND PANEL 10-78
10 3 4 ELECTRICAL PART OF REVOLVING FRAME 10-83
10 3 5 ELECTRICAL PART OF LEFT DECK 10-84
10 3 6 ELECTRICAL PART OF LEFT GUARD 10-88
10 3 7 HARNESS PART NUMBER LIST (ALL MODELS) 10-89
10 4 ELECTRICAL PART 10-91
10 4 1 LOCATION AND USE OF FUSE 10-91
10 4 2 FUSE BOX (GG73E00004F1) 10-93
10 4 3 WIPER CONTROL RELAY (2479R1366) 10-95
10 4 4 SWING FLASHER UNIT (2480U306) 10-96
10 4 5 PRESSURE SWITCH (CONTROL PRESSURE CUT & FREE FALL) 10-97
10 4 6 PRESSURE SENSOR 10-98
10 4 7 RELAY BOX (GG24E00024F1) 10-100
10 4 7 1 ARRANGEMENT OF CONNECTOR 10-100
10 4 7 2 RELAY BOX SCHEMATIC 10-102
10 4 8 LEFT SIDE STAND PANEL 10-105
10 5 TROUBLESHOOTING OF EXHAUST GAS THIRD REGULATION ENGINE 10-109
10 5 1 FAILURE DIAGNOSIS FUNCTION 10-109
10 5 2 HOW TO CHECK THE FAILURE CONTENTS 10-110
10 5 3 CHECKING OF DIAGNOSIS LAMP FUNCTION 10-115
10 5 4 ENGINE ECU 10-116
11 LOAD SAFETY DEVICE
11 1 PART NAMES AND FUNCTIONS 11-3
11 1 1 FRONT VIEW 11-3
11 1 2 CONFIGURATION OF SCREENS 11-8
TABLE OF CONTENTS
5 CK850-II / CKE700 / CKE800
11 1 3 DATA TRANSMISSION BETWEEN CONTROLLER AND CARDS 11-13
11 1 4 DETAILS OF INDICATORS ON MAIN DISPLAY SCREEN 11-15
11 1 5 REAR VIEW 11-19
11 1 6 ITEMS REQUIRED TO BE EXECUTED FOR REPLACEMENT OF
CONTROLLER OR DATA CARD AND INSTRUCTIONS
(IN A SIMILAR MANNER TO UPGRADE OF PROGRAM) 11-24
11 2 PREPARATION FOR USE 11-25
11 3 TURN THE POWER ON 11-26
11 4 UPGRADING PROGRAMS 11-27
11 4 1 PROCEDURES 11-27
11 4 2 UPGRADING OF INDICATION PROGRAMS 11-29
11 4 3 UPGRADING OF CONTROL PROGRAMS 11-32
11 5 STATUS CHECK 11-34
11 5 1 SIGNAL CHECK 11-35
11 5 2 OPERATION PROGRESS 11-37
11 5 3 COMMUNICATION DATA 11-40
11 5 4 INDICATION OF ADJUSTMENT VALUE 11-41
11 5 4 1 ANGLE SENSOR ADJUSTMENT VALUE 11-42
11 5 4 2 LOAD CELL ZERO POINT ADJUSTMENT VALUE 11-43
11 5 4 3 ADJUSTMENT VALUE OF LOAD CELL FOR LINE-PULL 11-44
11 5 4 4 RESULT OF MANUFACTURE ADJUSTMENTS “NO LOAD” AND
“SOME LOAD” 11-45
11 5 4 5 RESULT OF LOAD ADJUSTMENTS “NO LOAD” AND “SOME LOAD” 11-46
11 5 4 6 ADJUSTMENT VALUE OF WORKING RADIUS 11-47
11 5 4 7 ALTERATION OF ADJUSTED VALUE 11-48
11 5 4 8 DELETION OF ADJUSTED VALUE 11-49
11 5 5 TROUBLE RECORD 11-50
11 5 6 CHOICE OF LANGUAGE (CKE SERIOUS ONLY) 11-52
11 5 7 LOAD RECORD (LOAD RECORD IN THE MAIN MENU) 11-53
11 6 ADJUSTMENTS 11-54
11 6 1 REMOVING THE INNER PANEL 11-54
11 6 2 ADJUSTMENT 11-55
11 6 2 1 ANGLE SENSOR ADJUSTMENT 11-58
11 6 2 2 LOAD CELL ZERO POINT ADJUSTMENT 11-62
11 6 2 3 LOAD-LESS ADJUSTMENT & SOME LOAD ADJUSTMENT 11-64
11 6 2 4 LVL ADJUSTMENT (LVL SETTING) 11-71
11 6 2 5 RADIUS ADJUSTMENT 11-74
11 6 3 LOAD ADJUSTMENT 11-76
11 6 4 ADJUSTMENT DATA COPY (INITIALIZATION) 11-78
11 6 4 1 READING OF THE ADJUSTMENT DATA 11-80
11 6 4 2 WRITING OF ADJUSTMENT DATA 11-82
11 6 4 3 INITIALIZATION OF ADJUSTMENT DATA 11-83
11 6 5 VERSION CHECK 11-84
TABLE OF CONTENTS
CK850-II / CKE700 / CKE800 6
11 7 ERROR CODE (ABNORMALITY DETECTION) AND COUNTERMEASURES 11-85
11 8 CONTROL OUTPUT 11-89
11 9 RELEASES 11-101
11 9 1 RELEASE FUNCTION 11-101
11 9 1 1 CRANE RELEASE CHART 11-101
11 9 1 2 ALARM SOUND 11-107
11 9 1 3 EXTERNAL INDICATOR LAMPS IN RELEASE CONDITION 11-108
11 10MECHANICAL SPECIFICATION 11-109
11 10 1ENVIRONMENTAL PERFORMANCE PARAMETERS 11-109
11 10 2LOAD CELL (CRANE) 11-110
11 10 3ANGLE SENSOR 11-111
11 10 4CONTROLLER 11-112
11 10 4 1MODEL NAME 11-112
11 10 4 2SYSTEM INPUT/OUTPUT 11-112
11 10 4 3MONITOR DISPLAY 11-114
11 10 4 4OPERATION SWITCH 11-114
11 10 4 5INTERNAL PROCESSING SYSTEM 11-114
11 10 4 6MEMORY 11-114
11 10 4 7EXTERNAL STORAGE ELEMENT 11-115
11 10 4 8OTHERS 11-115
11 11EXTERNAL DIMENSIONS 11-116
11 12ELECTRIC SCHEMATIC DIAGRAM 11-117
11 12 1CRANE TYPE 11-117
11 12 2LUFFING TYPE 11-118
11 13CONTROLLER MALFUNCTION EMERGENCY MEASURES 11-119
11 14LOAD SAFETY DEVICE CHECK PROCEDURES 11-120
12 GAUGE CLUSTER
12 1 CONFIGURATION OF DISPLAY 12-3
12 2 PRIORITY 12-4
12 3 STATUS DISPLAY 12-6
12 4 FAULT LOG DISPLAY 12-15
13 TOTAL CONTROLLER
13 1 ARRANGEMENT OF TOTAL CONTROLLER 13-3
13 2 COMPOSITION OF SYSTEM 13-4
13 2 1 OUTPUT RELATION TO CONTROLLER 13-5
13 3 FUNCTION OF TOTAL CONTROLLER 13-6
13 4 TOTAL CONTROLLER (HARDWARE) 13-29
13 4 1 OUTLINE 13-29
13 4 2 SPECIFICATIONS OF TOTAL CONTROLLER OUTPUT 13-30
TABLE OF CONTENTS
7 CK850-II / CKE700 / CKE800
13 4 3 DETAILS OF TOTAL CONTROLLER CONNECTOR 13-34
13 4 4 ARRANGEMENT OF TOTAL CONTROLLER CONNECTOR PIN 13-35
13 4 5 PROPORTIONAL SOLENOID VALVE MEASURING POSITION (VOLTAGE)13-42
13 5 ADJUSTMENT OF TOTAL CONTROLLER 13-44
13 5 1 NECESSITY OF ADJUSTMENT 13-44
13 5 2 ADJUSTMENT PROCEDURES OF TOTAL CONTROLLER 13-44
13 5 2 1 OPTION SETTING 13-44
13 5 2 2 ADJUSTMENT OF HAND THROTTLE AND FOOT THROTTLE 13-46
13 5 2 3 ENGINE SPEED ADJUSTMENT 13-47
13 5 2 4 WHEN ADJUSTMENT OF TOTAL CONTROLLER IS IMPOSSIBLE 13-48
13 5 2 5 INITIAL ADJUSTMENT OF LIFTING HEIGHT GAUGE 13-49
13 6 CONTROLLER MALFUNCTION EMERGENCY MEASURES 13-51
14 AIR CONDITIONER
14 1 OPERATION ITEMS 14-3
14 2 SAFETY MONITOR FUNCTIONS 14-4
14 3 DISASSEMBLY AND ASSEMBLY PROCEDURE 14-7
14 3 1 SPECIAL CONSIDERATIONS DURING REPLACEMENT 14-7
14 3 2 INTERIOR UNIT 14-9
14 3 2 1 CASE DISASSEMBLY 14-9
14 3 2 2 THERMOSTAT REPLACEMENT 14-12
14 3 2 3 EVAPORATOR OR EXPANSION VALVE REPLACEMENT 14-13
14 3 2 4 HEATER CORE REPLACEMENT 14-14
14 3 2 5 INTAKE DUMPER ACTUATOR REPLACEMENT 14-15
14 3 2 6 WATER VALVE ACTUATOR OR WATER VALVE REPLACEMENT 14-16
14 3 2 7 MODE ACTUATOR REPLACEMENT 14-17
14 3 2 8 BLOWER MOTOR ASSEMBLY REPLACEMENT 14-17
14 4 OPERATIONAL PRECAUTIONS 14-18
14 5 INSPECTION AND MAINTENANCE 14-19
14 5 1 INSPECTION/MAINTENANCE LIST 14-19
14 5 2 INSPECTION/MAINTENANCE PROCEDURES 14-19
14 6 ELECTRIC SYSTEM SCHEMATIC 14-23

Need help? Contact: [email protected]

PLEASE NOTE:

• This is the SAME exact manual used by your dealers to fix your vehicle.
• The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
• Any queries / doubts regarding your purchase, please feel free to contact [email protected]

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