Kobelco Crane CK850-II Operation & Maintenance Manual S2GG24011ZE09 – PDF DOWNLOAD

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Kobelco Crane CK850-II Operation & Maintenance Manual S2GG24011ZE09 – PDF DOWNLOAD

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Kobelco Crane CK850-II Operation & Maintenance Manual S2GG24011ZE09 – PDF DOWNLOAD

Language : English
Pages : 348
Downloadable : Yes
File Type : PDF

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Kobelco Crane CK850-II Operation & Maintenance Manual S2GG24011ZE09 – PDF DOWNLOAD

SAFE OPERATING PRACTICES FOR MOBILE CRANES:
INTRODUCTION:

• Because cranes have the ability to lift heavy loads to great heights, they also have a potential
  for accidents if safe operating practices are not followed. This book will help you prevent
  accidents that could result in inju- ry, death, or property damage.
• General safe practices for working on machinery must be followed as well as the safe operating
  practices rec- ommended here.

OPERATOR’S RESPONSIBILITY:

The operator is the best safety feature in any crane. Safety must always be the operator’s most
important concern. He must refuse to operate when he knows it is unsafe and consult his supervisor
when safety is in doubt.

• He must read and understand the Operator’s Manual and see that the machine is in proper order
  before op- erating.
• He must understand how to read the rating plate and know that his machine can safely lift each load
  before attempting to lift it.
• He must never lift a load without knowing the length of the boom, the weight of the load, and the
  load radius or boom angle.
• Never attempt to operate the crane at conditions ex- ceeding those shown on the rating chart. Such
  opera- tion can cause tipping or structural failure of the crane that can result in damage, injury,
  or death.
• He must be alert, physically fit, and free from the influ- ences of alcohol, drugs, or medications
  that might af- fect his eyesight, hearing, reactions, judgment.
• He must see that unnecessary people, equipment, and material are kept out of the work area. The
  area around the machine should be properly barricaded.
• When an operator’s vision is restricted or when operat- ing in hazardous places such as near
  electrical power lines or around people, a signalman must be used. Be- cause the operator is not
  always in the best position to judge distances and can not see all parts of the jobsite, a
  signalman may also be necessary at other times. Op- erators must understand standard crane signals
  and take signals only from designated signalmen

TABLE OF CONTENTS:

Kobelco Crane CK850-II Operation & Maintenance Manual S2GG24011ZE09 – PDF DOWNLOAD

COVER....................................................................................................................  1
TABLE OF CONTENTS........................................................................................................  3
IMPORTANT INFORMATION....................................................................................................  9
1. SAFE OPERATING PRACTICES FOR MOBILE CRANES............................................................................ 19
2. OPERATION............................................................................................................. 39
	2.1 TERMINOLOGY OF MACHINE EACH PART................................................................................. 39
	2.2 LOCATIONS AND TERMS OF OPERATING CONTROLS........................................................................ 40
		2.2.1 OPERATING SWITCHES......................................................................................... 44
		2.2.2 GAUGE CLUSTER.............................................................................................. 54
		2.2.3 HANDLING THE AIR CONDITIONER............................................................................... 66
		2.2.4 AM/FM RADIO (OPTION)....................................................................................... 68
	2.3 CRANE OPERATION.................................................................................................. 70
		2.3.1 ADJUSTING THE OPERATOR'S SEAT.............................................................................. 70
		2.3.2 ADJUSTING THE CONTROL LEVER DIRECTION...................................................................... 70
		2.3.3 STARTING AND STOPPING THE ENGINE........................................................................... 71
		2.3.4 FUNCTION LOCK LEVER........................................................................................ 75
		2.3.5 PROPELLING OPERATION....................................................................................... 76
		2.3.6 SWINGING OPERATION......................................................................................... 78
		2.3.7 BOOM RAISING/LOWERING OPERATION............................................................................ 79
		2.3.8 HOOK RAISING/LOWERING OPERATION............................................................................ 81
	2.4 FREE FALL OPERATION.............................................................................................. 84
	2.5 CLAMSHELL OPERATION.............................................................................................. 87
	2.6 HANDLING OF HYDRAULIC TAGLINE (OPTION)........................................................................... 89
3. LOAD SAFETY DEVICE.................................................................................................... 91
	3.1 ARRANGEMENT OF EQUIPMENTS........................................................................................ 91
	3.2 TYPE AND FUNCTIONS OF EQUIPMENTS................................................................................. 94
	3.3 CONNECTING PROCEDURE OF WIRING...................................................................................100
		3.3.1 CRANE ATTACHMENT...........................................................................................100
	3.4 FUNCTION OF CONTROLLER/MONITOR...................................................................................105
	3.5 OPERATING PROCEDURE OF CONTROLLER................................................................................109
		3.5.1 SETTING SCREEN.............................................................................................110
		3.5.2 SETTING OF THE CRANE CONFIGURATION.........................................................................115
		3.5.3 SELECTION OF MAIN/AUX. LIFTING.............................................................................121
		3.5.4 SETTING OF WORKING AREA LIMIT VALUE........................................................................122
		3.5.5 SETTING OF THE TIME........................................................................................125
	3.6 WARNING ALARM AND AUTOMATIC STOP.................................................................................127
		3.6.1 ITEMS OF WARNING ALARM AND AUTOMATIC STOP..................................................................127
		3.6.2 CONTENTS OF AUTOMATIC STOP.................................................................................128
		3.6.3 RELEASE OF AUTOMATIC STOP..................................................................................130
	3.7 INSPECTION.......................................................................................................135
		3.7.1 INSPECTION BEFORE RAISING THE BOOM AFTER ASSEMBLY OF ATTACHMENT IS COMPLETED...............................135
		3.7.2 INSPECTION AFTER ERECTING THE ATTACHMENT...................................................................138
	3.8 CAUTION FOR HANDLING THE LOAD SAFETY DEVICE......................................................................139
	3.9 INDICATION OF ERRORS AND REMEDY..................................................................................140
	3.10 INDICATION OF MESSAGE AND ALARM.................................................................................141
	3.11 CONFIRMATION OF FUNCTION FOR LOAD SAFETY DEVICE.................................................................142
4. UNLOADING/LOADING THE BASIC MACHINE...................................................................................143
	4.1 UNLOADING THE BASIC MACHINE FROM THE TRAILER.....................................................................144
	4.2 LOADING THE MACHINE ON A TRAILER.................................................................................144
5. ASSEMBLY/DISASSEMBLY OF BASIC MACHINE.................................................................................145
	5.1 EXTENDING/RETRACTING THE CRAWLERS................................................................................146
		5.1.1 EXTENDING THE CRAWLERS.....................................................................................146
		5.1.2 RETRACTING THE CRAWLER.....................................................................................149
	5.2 ERECTING/LOWERING THE GANTRY.....................................................................................152
		5.2.1 ERECTING THE GANTRY........................................................................................152
		5.2.2 LOWERING THE GANTRY........................................................................................154
	5.3 INSTALLATION, REMOVAL OF THE COUNTERWEIGHT (WHEN USING THE AUXILIARY CRANE)......................................155
		5.3.1 INSTALLATION OF THE COUNTERWEIGHT..........................................................................155
		5.3.2 REMOVAL OF THE COUNTERWEIGHT...............................................................................158
		5.3.3 INSTALLING/REMOVING CARBODY WEIGHTS........................................................................159
	5.4 INSTALLATION, REMOVAL OF THE COUNTERWEIGHT.......................................................................160
		5.4.1 SETTING OF LMI.............................................................................................160
		5.4.2 PREPARATIONS FOR OPERATION.................................................................................165
		5.4.3 INSTALLATION PROCEDURES....................................................................................170
		5.4.4 DISASSEMBLY PROCEDURES.....................................................................................175
		5.4.5 OPERATION OF CYLINDER WHEN SETTING LOW GANTRY POSITION (FIXATION OF TENSION BAR CONNECTION) (FIG. 5-25)....179
6. ASSEMBLY/DISASSEMBLY OF CRANE ATTACHMENT..............................................................................181
	6.1 ASSEMBLING THE ATTACHMENT........................................................................................182
		6.1.1 ARRANGEMENT OF BOOM/JIB/GUY LINE...........................................................................182
		6.1.2 INSTALLING THE BACKSTOPS...................................................................................189
		6.1.3 INSTALLING THE BOOM BASE...................................................................................190
		6.1.4 INSTALLING THE BACKSTOPS TO THE REVOLVING FRAME............................................................191
		6.1.5 INSTALLING THE UPPER SPREADER..............................................................................191
		6.1.6 REEVING THE WIRE ROPE INTO THE UPPER AND LOWER SPREADER....................................................192
		6.1.7 INSTALLING THE BOOM TIP....................................................................................194
		6.1.8 INSTALLATION OF THE BASIC GUY LINE.........................................................................195
		6.1.9 MAIN HOIST WIRE ROPE REEVING...............................................................................195
		6.1.10 CONNECTING THE INSERT BOOMS...............................................................................198
		6.1.11 INSTALLING THE CABLE ROLLERS..............................................................................207
		6.1.12 CONNECTING THE BOOM GUY LINES.............................................................................207
		6.1.13 CAUTION FOR CANTILEVER....................................................................................209
		6.1.14 ASSEMBLING THE JIB........................................................................................209
		6.1.15 REEVING OF REAR DRUM WIRE ROPE............................................................................213
		6.1.16 INSTALLING THE AUXILIARY SHEAVE...........................................................................215
		6.1.17 REEVING THE REAR DRUM WIRE ROPE TO THE AUXILIARY SHEAVE...................................................216
	6.2 ERECTING THE ATTACHMENT..........................................................................................217
		6.2.1 CONFIRMATION BEFORE ERECTING THE ATTACHMENT................................................................217
		6.2.2 ERECTING THE ATTACHMENT....................................................................................218
	6.3 LOWERING THE ATTACHMENT..........................................................................................220
		6.3.1 LOWERING THE ATTACHMENT....................................................................................221
	6.4 DISASSEMBLING THE ATTACHMENT.....................................................................................222
		6.4.1 TREATMENT OF OVERHOIST LIMIT SWITCH WIRING.................................................................222
		6.4.2 WINDING UP THE FRONT DRUM/REAR DRUM WIRE ROPES.............................................................222
		6.4.3 DISASSEMBLING THE JIB......................................................................................223
		6.4.4 REMOVING THE BOOM GUY LINE.................................................................................224
		6.4.5 DISASSEMBLING THE BOOM.....................................................................................225
		6.4.6 REMOVING THE BOOM BASE.....................................................................................226
		6.4.7 REMOVAL OF THE COUNTERWEIGHT...............................................................................227
		6.4.8 LOWERING THE GANTRY........................................................................................227
	6.5 CAUTION WHEN TRANSPORTING BOOM...................................................................................228
7. WIRE ROPE.............................................................................................................229
	7.1 HANDLING OF WIRE ROPE............................................................................................229
		7.1.1 UNREELING METHOD OF WIRE ROPE..............................................................................229
		7.1.2 WINDING WIRE ROPE ONTO THE DRUM............................................................................230
		7.1.3 INSTALLING THE ROPE SOCKET.................................................................................231
		7.1.4 SPECIFICATION OF WIRE ROPE.................................................................................231
		7.1.5 WIRE ROPE LENGTH...........................................................................................232
8. MAINTENANCE...........................................................................................................235
	8.1 CHECKS...........................................................................................................240
		8.1.1 CHECKS OF THE UPPER........................................................................................240
			8.1.1.1 CHECK OF UPPER DAILY OR EVERY 8 HOURS................................................................242
			8.1.1.2 CHECK OF UPPER MONTHLY OR EVERY 100 HOURS............................................................247
			8.1.1.3 CHECK OF UPPER SEMI-ANNUALLY OR EVERY 600 HOURS......................................................251
			8.1.1.4 CHECK OF UPPER WEEKLY OR EVERY 50 HOURS..............................................................252
		8.1.2 CHECK OF LOWER.............................................................................................254
			8.1.2.1 CHECK OF LOWER DAILY OR EVERY 8 HOURS................................................................256
			8.1.2.2 CHECK OF LOWER MONTHLY OR EVERY 100 HOURS............................................................257
			8.1.2.3 CHECK OF LOWER QUARTERLY OR EVERY 250 HOURS..........................................................259
			8.1.2.4 CHECK OF LOWER SEMI-ANNUALLY OR EVERY 600 HOURS......................................................259
		8.1.3 CHECK OF ATTACHMENT........................................................................................260
			8.1.3.1 CHECK OF ATTACHMENT DAILY OR EVERY 8 HOURS...........................................................262
	8.2 OIL/GREASE SUPPLY AND WATER SERVICE..............................................................................268
		8.2.1 UPPER LUBRICATION (INCL. WATER SUPPLY).....................................................................272
		8.2.2 LOWER LUBRICATION..........................................................................................274
		8.2.3 ATTACHMENT LUBRICATION.....................................................................................276
		8.2.4 GREASE.....................................................................................................278
		8.2.5 ENGINE OIL.................................................................................................281
		8.2.6 FUEL.......................................................................................................282
		8.2.7 COOLANT....................................................................................................283
		8.2.8 HYDRAULIC OIL..............................................................................................285
		8.2.9 GEAR OIL...................................................................................................287
	8.3 CLEANING/WASHING/CHANGE OF FILTER ELEMENT AND STRAINER...........................................................292
	8.4 CHECK OF BATTERY.................................................................................................302
	8.5 ARRANGEMENT AND USE OF FUSE......................................................................................305
	8.6 OPERATION UNDER UNUSUAL CONDITIONS...............................................................................307
	8.7 MACHINE STORAGE..................................................................................................309
	8.8 TIGHTENING TORQUE VALUES.........................................................................................310
	8.9 SECURITY PARTS TO BE REPLACED PERIODICALLY.......................................................................312
	8.10 ADJUSTMENT......................................................................................................313
		8.10.1 ADJUSTMENT OF FRONT AND REAR DRUM LOCKS...................................................................313
		8.10.2 ADJUSTMENT OF BOOM DRUM LOCK..............................................................................314
		8.10.3 ADJUSTMENT OF THIRD DRUM LOCK.............................................................................315
		8.10.4 ADJUSTMENT OF CRAWLER SHOES...............................................................................316
	8.11 CONSUMABLE PARTS LIST...........................................................................................317
9. REFERENCE MATERIALS...................................................................................................323
	9.1 SPECIFICATION....................................................................................................323
		9.1.1 PERFORMANCE................................................................................................323
		9.1.2 OUTSIDE DIMENSIONS.........................................................................................323
	9.2 DIMENSIONS AND WEIGHT OF EACH PARTS..............................................................................325
		9.2.1 BASE MACHINE...............................................................................................325
		9.2.2 COUNTERWEIGHT..............................................................................................326
		9.2.3 ATTACHMENT.................................................................................................327
	9.3 STABILITY IN SWINGING AND TRAVELING..............................................................................330
	9.4 SYSTEM SCHEMATIC.................................................................................................331
		9.4.1 HYDRAULIC SYSTEM SCHEMATIC.................................................................................331
		9.4.2 ELECTRICAL WIRING SCHEMATIC................................................................................332

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