Kobelco CRAWLER CRANE CK1000-II CKE900 SHOP MANUAL S5GH00002ZE04 – PDF DOWNLOAD

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Kobelco CRAWLER CRANE CK1000-II CKE900 SHOP MANUAL S5GH00002ZE04 – PDF DOWNLOAD

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Kobelco CRAWLER CRANE CK1000-II CKE900 SHOP MANUAL S5GH00002ZE04 – PDF DOWNLOAD

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Kobelco CRAWLER CRANE CK1000-II CKE900 SHOP MANUAL S5GH00002ZE04 – PDF DOWNLOAD

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 instructions
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 connectors.
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.
21. CAUTIONs for repair work with welding: Turn OFF the key switch, disconnect the negative terminal on battery
to power off the electrical circuit; provide grounding within 1 meter from a weld area; in advance, remove electronic
components (for example, controller) to prevent possible damage.
22. Dispose industrial wastes according to a relevant law or regulation.
23. Extremely careful during an inspection or maintenance work under the carrier. Remember the possibility of being
crashed.
When jacking up the machine for an inspection or maintenance work, place blocks below it to prevent accidental
falling.
24. Provide positive ventilation when refilling oils or fuel, rinsing parts, or starting the engine.
SAFETY
CK1000-II/CKE900 0-12
25. To remove a heavy component (20 kg or heavier), use a crane, etc. Always keep safety in mind.
26. I llegal or unauthorized, or otherwise nonconforming modification is strictly inhibited.
27. Do not allow oil or dust to deposit around the engine. Otherwise, fire accident can result.
28. Store removed attachments and components safely so that they do not drop or fall down.
29. Always use correct tools that have been well maintained.
30. To prevent personnel from being caught by a running fan, belt, shaft or the like, shut down the engine before
starting an inspection or maintenance work.
31. Battery liquid and oils are harmful to human health. If touching any of these materials, immediately wash it away.
32. Make sure to use the light oil for fuel.

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Kobelco CRAWLER CRANE CK1000-II CKE900 SHOP MANUAL S5GH00002ZE04 – PDF DOWNLOAD

COVER.................................................................................................................................................  1
TABLE OF CONTENTS.....................................................................................................................................  3
SAFETY................................................................................................................................................ 11
1. SPECIFICATION...................................................................................................................................... 23
	1.1 CK1000-II SPECIFICATION....................................................................................................................... 25
		1.1.1 PERFORMANCE............................................................................................................................. 25
		1.1.2 OUTSIDE DIMENSIONS...................................................................................................................... 25
		1.1.3 DIMENSIONS AND WEIGHT OF EACH PARTS..................................................................................................... 27
		1.1.4 STABILITY IN SWINGING AND TRAVELING..................................................................................................... 33
	1.2 CKE900 SPECIFICATION.......................................................................................................................... 35
		1.2.1 PERFORMANCE............................................................................................................................. 35
		1.2.2 OUTSIDE DIMENSIONS...................................................................................................................... 35
		1.2.3 DIMENSIONS AND WEIGHT OF EACH PARTS..................................................................................................... 37
		1.2.4 STABILITY IN SWINGING AND TRAVELING..................................................................................................... 43
2. MAINTENANCE STANDARDSTEST PROCEDURES............................................................................................................... 45
	2.1 MAINTENANCE STANDARD.......................................................................................................................... 48
		2.1.1 PIN, BUSHING, SPRING, LINING AND SHEAVE................................................................................................. 48
		2.1.2 PROPEL DEVICE........................................................................................................................... 55
	2.2 PERFORMANCE STANDARD AND TEST PROCEDURE....................................................................................................... 61
		2.2.1 OPERATING SPEED......................................................................................................................... 61
		2.2.2 POINT AND METHOD OF MEASURING PRESSURE.................................................................................................. 62
3. GENERAL WORK STANDARD.............................................................................................................................. 67
	3.1 TIGHTENING TORQUE OF CAPSCREWS AND NUTS....................................................................................................... 69
		3.1.1 METRIC COARSE THREADS................................................................................................................... 69
		3.1.2 METRIC FINE THREADS..................................................................................................................... 69
		3.1.3 COARSE THREDS UNC....................................................................................................................... 70
		3.1.4 FINE THREADS UNF........................................................................................................................ 70
		3.1.5 TIGHTENING TORQUE OF HYDRAULIC FITTINGS................................................................................................. 71
	3.2 STANDARD PARTS................................................................................................................................ 73
		3.2.1 BOLT.................................................................................................................................... 73
		3.2.2 O-RING.................................................................................................................................. 74
		3.2.3 BACK-UP RING............................................................................................................................ 75
		3.2.4 BITE FITTING............................................................................................................................ 76
	3.3 CONVERSION TABLE.............................................................................................................................. 78
		3.3.1 UNIT CONVERSION......................................................................................................................... 78
		3.3.2 MILLIMETER : INCH CONVERSION TABLE...................................................................................................... 79
		3.3.3 METER-FOOT CONVERSION TABLE............................................................................................................. 81
		3.3.4 GRADIENT CONVERSION TABLE............................................................................................................... 82
	3.4 TABLE OF UNIT WEIGHT.......................................................................................................................... 83
4. POWER TRAIN........................................................................................................................................ 85
	4.1 INTRODUCTION.................................................................................................................................. 87
	4.2 ENGINE........................................................................................................................................ 89
		4.2.1 INTRODUCTION............................................................................................................................ 89
		4.2.2 REMOVAL................................................................................................................................. 89
		4.2.3 REPAIR AND MAINTENANCE.................................................................................................................. 90
		4.2.4 RE-INSTALLATION......................................................................................................................... 91
	4.3 PUMP DRIVE ASSEMBLY........................................................................................................................... 94
		4.3.1 INTRODUCTION............................................................................................................................ 94
		4.3.2 REMOVAL................................................................................................................................. 94
		4.3.3 DISASSEMBLING THE POWER DIVIDER......................................................................................................... 96
		4.3.4 CHECK AND REPAIR OF THE POWER DIVIDER................................................................................................... 97
		4.3.5 ASSEMBLING THE POWER DIVIDER............................................................................................................ 98
		4.3.6 RE-INSTALLATION......................................................................................................................... 99
5. HYDRAULIC SYSTEM...................................................................................................................................105
	5.1 LOCATION OF MAIN HYDRAULIC COMPONENTS.........................................................................................................107
	5.2 HYDRAULIC CIRCUITS AND COMPONENTS.............................................................................................................108
		5.2.1 HYDRAULIC CIRCUIT.......................................................................................................................108
		5.2.2 COMPONENT SPECIFICATIONS................................................................................................................111
		5.2.3 LOCATION OF HYDRAULIC COMPONENTS........................................................................................................114
	5.3 HYDRAULIC SYSTEM..............................................................................................................................120
		5.3.1 PREFACE.................................................................................................................................120
		5.3.2 OUTLINE.................................................................................................................................120
		5.3.3 OIL FLOW FROM NO.1 AND NO. 2 PUMPS......................................................................................................122
		5.3.4 OIL FLOW FROM No.3 PUMP.................................................................................................................124
		5.3.5 OIL FLOW FROM NO.4 AND NO. 5 PUMPS(FOR MAIN AND AUX. WINCH DRUMS BRAKE COOLING CIRCUIT).................................................125
		5.3.6 OIL FLOW FROM NO.6 PUMP (CONTROL PUMP)..................................................................................................127
		5.3.7 OIL FLOW FROM No.7 PUMP (FOR AUXILIARY ACTUATOR CIRCUIT)................................................................................130
	5.4 VALVES........................................................................................................................................131
6. HOIST SYSTEM.......................................................................................................................................141
	6.1 APPARATUS AND LOCATION OF COMPONENTS..........................................................................................................143
	6.2 CONSTRUCTION AND FUNCTION.....................................................................................................................144
		6.2.1 HYDRAULIC SCHEMATIC.....................................................................................................................144
		6.2.2 LIFTING A LOAD..........................................................................................................................146
		6.2.3 HOLDING A RAISED LOAD...................................................................................................................148
		6.2.4 LOWERING A LOAD(POWERED LOWERING).......................................................................................................150
		6.2.5 FREEFALL OPERATION......................................................................................................................152
		6.2.6 FREE FALL ACCELERATION..................................................................................................................156
	6.3 DRUM AND REDUCTION UNIT.......................................................................................................................158
		6.3.1 DRUM....................................................................................................................................158
		6.3.2 REDUCTION UNIT..........................................................................................................................160
	6.4 ADJUSTMENT OF DRUM LOCK.......................................................................................................................162
	6.5 BRAKE PEDAL...................................................................................................................................164
		6.5.1 ASSEMBLY DRAWING........................................................................................................................164
		6.5.2 ADJUSTING THE BRAKE PEDAL...............................................................................................................166
	6.6 BLEEDING AIR FROM BRAKE CIRCUIT...............................................................................................................167
7. BOOM HOIST SYSTEM..................................................................................................................................169
	7.1 APPARATUS AND LOCATION OF COMPONENTS..........................................................................................................171
	7.2 CONSTRUCTION AND FUNCTION.....................................................................................................................172
		7.2.1 HYDRAULIC SCHEMATIC.....................................................................................................................172
		7.2.2 RAISING THE BOOM........................................................................................................................174
		7.2.3 NEUTRAL(MAINTAINING THE BOOM POSITION)..................................................................................................176
		7.2.4 LOWERING THE BOOM.......................................................................................................................178
	7.3 BOOM DRUM LOCK................................................................................................................................180
		7.3.1 ASSEMBLY DRAWING........................................................................................................................180
		7.3.2 ADJUSTING THE BOOM DRUM LOCK............................................................................................................181
	7.4 REDUCTION UNIT................................................................................................................................182
8. SWING SYSTEM.......................................................................................................................................185
	8.1 APPARATUS AND LOCATION OF COMPONENTS..........................................................................................................187
	8.2 CONSTRUCTION AND FUNCTION.....................................................................................................................188
		8.2.1 HYDRAULIC SCHEMATIC.....................................................................................................................188
		8.2.2 SWING...................................................................................................................................190
		8.2.3 STOPPING................................................................................................................................192
	8.3 SWING REDUCTION UNIT..........................................................................................................................194
	8.4 SWING BEARING.................................................................................................................................198
	8.5 SWING LOCK....................................................................................................................................200
9. PROPEL SYSTEM......................................................................................................................................201
	9.1 LOCATION OF THE MAJOR COMPONENTS..............................................................................................................203
	9.2 CONSTRUCTION AND FUNCTION.....................................................................................................................204
		9.2.1 HYDRAULIC SCHEMATIC.....................................................................................................................204
		9.2.2 PROPELLING (RIGHT SIDE FORWARD).........................................................................................................206
		9.2.3 STOPPING................................................................................................................................208
	9.3 PROPEL REDUCTION UNIT.........................................................................................................................210
		9.3.1 REDUCTION UNIT..........................................................................................................................212
		9.3.2 MOTOR...................................................................................................................................214
	9.4 ADJUSTMENT....................................................................................................................................216
	9.5 UPPER AND LOWER ROLLER AND AXLE ADAPTER TIGHTENING TORQUE.....................................................................................217
10. ELECTRIC SYSTEM...................................................................................................................................219
	10.1 ELECTRICAL WIRING SCHEMATIC..................................................................................................................221
	10.2 CONNECTOR LIST...............................................................................................................................236
	10.3 ARRANGEMENT OF ELECTRICAL PART...............................................................................................................288
		10.3.1 ELECTRICAL PART OF CAB.................................................................................................................288
		10.3.2 ELECTRICAL PART OF RIGHT DECK..........................................................................................................292
		10.3.3 ELECTRICAL PART OF FLOOR PLATE & LEFT SIDE STAND PANEL.................................................................................300
		10.3.4 ELECTRICAL PART OF REVOLVING FRAME.....................................................................................................305
		10.3.5 ELECTRICAL PART OF LEFT DECK...........................................................................................................306
		10.3.6 ELECTRICAL PART OF LEFT GUARD..........................................................................................................313
		10.3.7 HARNESS PART NUMBER LIST (ALL MODELS)..................................................................................................314
	10.4 ELECTRICAL PART..............................................................................................................................316
		10.4.1 LOCATION AND USE OF FUSE...............................................................................................................316
		10.4.2 FUSE BOX (GG73E00004F1)................................................................................................................318
		10.4.3 WIPER CONTROL RELAY (2479R1366)........................................................................................................320
		10.4.4 SWING FLASHER UNIT (2480U306)..........................................................................................................321
		10.4.5 PRESSURE SWITCH (CONTROL PRESSURE CUT & FREE FALL).....................................................................................322
		10.4.6 PRESSURE SENSOR........................................................................................................................323
		10.4.7 RELAY BOX (GG24E00024F1)...............................................................................................................325
		10.4.8 LEFT SIDE STAND PANEL..................................................................................................................330
	10.5 TROUBLESHOOTING OF EXHAUST GAS THIRD REGULATION ENGINE.......................................................................................334
		10.5.1 FAILURE DIAGNOSIS FUNCTION.............................................................................................................334
		10.5.2 HOW TO CHECK THE FAILURE CONTENTS......................................................................................................335
		10.5.3 CHECKING OF DIAGNOSIS LAMP FUNCTION....................................................................................................340
		10.5.4 ENGINE ECU.............................................................................................................................341
11. LOAD SAFETY DEVICE................................................................................................................................345
	11.1 PART NAMES AND FUNCTIONS.....................................................................................................................347
		11.1.1 FRONT VIEW.............................................................................................................................347
		11.1.2 CONFIGURATION OF SCREENS...............................................................................................................352
		11.1.3 DATA TRANSMISSION BETWEEN CONTROLLER AND CARDS.........................................................................................357
		11.1.4 DETAILS OF INDICATORS ON MAIN DISPLAY SCREEN...........................................................................................359
		11.1.5 REAR VIEW..............................................................................................................................363
		11.1.6 ITEMS REQUIRED TO BE EXECUTED FOR REPLACEMENT OF CONTROLLER OR DATA CARDAND INSTRUCTIONS(IN A SIMILAR MANNER TO UPGRADE OF PROGRAM)....368
	11.2 PREPARATION FOR USE..........................................................................................................................369
	11.3 TURN THE POWER ON............................................................................................................................370
	11.4 UPGRADING PROGRAMS...........................................................................................................................371
		11.4.1 PROCEDURES.............................................................................................................................371
		11.4.2 UPGRADING OF INDICATION PROGRAMS.......................................................................................................373
		11.4.3 UPGRADING OF CONTROL PROGRAMS..........................................................................................................376
	11.5 STATUS CHECK.................................................................................................................................378
		11.5.1 SIGNAL CHECK...........................................................................................................................379
		11.5.2 OPERATION PROGRESS.....................................................................................................................381
		11.5.3 COMMUNICATION DATA.....................................................................................................................384
		11.5.4 INDICATION OF ADJUSTMENT VALUE.........................................................................................................385
		11.5.5 TROUBLE RECORD.........................................................................................................................394
		11.5.6 CHOICE OF LANGUAGE (CKE SERIES ONLY)...................................................................................................396
		11.5.7 LOAD RECORD (LOAD RECORD IN THE MAIN MENU).............................................................................................397
	11.6 ADJUSTMENTS..................................................................................................................................398
		11.6.1 REMOVING THE INNER PANEL...............................................................................................................398
		11.6.2 ADJUSTMENT.............................................................................................................................399
		11.6.3 LOAD ADJUSTMENT........................................................................................................................420
		11.6.4 ADJUSTMENT DATA COPY (INITIALIZATION)..................................................................................................422
		11.6.5 VERSION CHECK..........................................................................................................................428
	11.7 ERROR CODE (ABNORMALITY DETECTION) AND COUNTERMEASURES.......................................................................................429
	11.8 CONTROL OUTPUT...............................................................................................................................433
	11.9 RELEASES.....................................................................................................................................445
		11.9.1 RELEASE FUNCTION.......................................................................................................................445
	11.10 MECHANICAL SPECIFICATION....................................................................................................................453
		11.10.1 ENVIRONMENTAL PERFORMANCE PARAMETERS..................................................................................................453
		11.10.2 LOAD CELL (CRANE).....................................................................................................................454
		11.10.3 ANGLE SENSOR..........................................................................................................................455
		11.10.4 CONTROLLER............................................................................................................................456
	11.11 EXTERNAL DIMENSIONS.........................................................................................................................460
	11.12 ELECTRIC SCHEMATIC DIAGRAM..................................................................................................................461
		11.12.1 CRANE TYPE............................................................................................................................461
		11.12.2 LUFFING TYPE..........................................................................................................................462
	11.13 CONTROLLER MALFUNCTION EMERGENCY MEASURES...................................................................................................463
	11.14 LOAD SAFETY DEVICE CHECK PROCEDURES.........................................................................................................464
12. GAUGE CLUSTER.....................................................................................................................................465
	12.1 CONFIGURATION OF DISPLAY.....................................................................................................................467
	12.2 PRIORITY.....................................................................................................................................468
	12.3 STATUS DISPLAY...............................................................................................................................470
	12.4 FAULT LOG DISPLAY............................................................................................................................479
13. TOTAL CONTROLLER..................................................................................................................................485
	13.1 ARRANGEMENT OF TOTAL CONTROLLER..............................................................................................................487
	13.2 COMPOSITION OF SYSTEM........................................................................................................................488
		13.2.1 OUTPUT RELATION TO CONTROLLER..........................................................................................................489
	13.3 FUNCTION OF TOTAL CONTROLLER.................................................................................................................490
		13.3.1 FRONT, REAR AND THIRD DRUM.............................................................................................................494
	13.4 TOTAL CONTROLLER (HARDWARE)..................................................................................................................515
		13.4.1 OUTLINE................................................................................................................................515
		13.4.2 SPECIFICATIONS OF TOTAL CONTROLLER OUTPUT..............................................................................................516
		13.4.3 DETAILS OF TOTAL CONTROLLER CONNECTOR..................................................................................................520
		13.4.4 ARRANGEMENT OF TOTAL CONTROLLER CONNECTOR PIN..........................................................................................521
		13.4.5 PROPORTIONAL SOLENOID VALVE MEASURING POSITION (VOLTAGE)...............................................................................528
	13.5 ADJUSTMENT OF TOTAL CONTROLLER...............................................................................................................530
		13.5.1 NECESSITY OF ADJUSTMENT................................................................................................................530
		13.5.2 ADJUSTMENT PROCEDURES OF TOTAL CONTROLLER..............................................................................................530
	13.6 CONTROLLER MALFUNCTION EMERGENCY MEASURES....................................................................................................537
14. AIR CONDITIONER...................................................................................................................................539
	14.1 OPERATION ITEMS..............................................................................................................................540
	14.2 SAFETY MONITOR FUNCTIONS.....................................................................................................................541
	14.3 DISASSEMBLY AND ASSEMBLY PROCEDURE...........................................................................................................544
		14.3.1 SPECIAL CONSIDERATIONS DURING REPLACEMENT..............................................................................................544
		14.3.2 INTERIOR UNIT..........................................................................................................................546
	14.4 OPERATIONAL PRECAUTIONS......................................................................................................................555
	14.5 INSPECTION AND MAINTENANCE...................................................................................................................556
		14.5.1 INSPECTION/MAINTENANCE LIST............................................................................................................556
		14.5.2 INSPECTION/MAINTENANCE PROCEDURES......................................................................................................556
	14.6 ELECTRIC SYSTEM SCHEMATIC....................................................................................................................560

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• This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
• Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.

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