KOBELCO CK2000, CKE1800 Crawler Cranes OPERATION & MAINTENANCE Manual
Complete OPERATION & MAINTENANCE Manual with Parts Catalog for KOBELCO CK2000, CKE1800 Crawler Cranes.
KOBELCO CK2000, CKE1800 Electrical Circuit Chart.pdf
S2JC10003ZE09 - KOBELCO CK2000 Crawler Crane OPERATION & MAINTENANCE MANUAL.pdf
S3JC00003ZO01 - KOBELCO CK2000 Crawler Crane Parts Manual.pdf
S5JC00002ZE05 - KOBELCO CK2000, CKE1800 Crawler Crane OPERATION & MAINTENANCE MANUAL.pdf
PRODUCT DETAILS:
Total Pages: 1,812 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
KOBELCO CK2000, CKE1800 Electrical Circuit Chart....1
S2JC10003ZE09 - KOBELCO CK2000 Crawler Crane OPERATION & MAINTENANCE MANUAL....34
COVER....34
TABLE OF CONTENTS....36
IMPORTANT INFORMATION....42
1. SAFE OPERATING PRACTICES FOR MOBILE CRANES....72
2. OPERATION....92
2.1 TERMINOLOGY OF MACHINE EACH PART....92
2.1.1 CRANE ATTACHMENT....92
2.1.2 LUFFING JIB ATTACHMENT....93
2.2 LOCATIONS AND TERMS OF OPERATING CONTROLS....94
2.2.1 OPERATING SWITCHES....98
2.2.2 GAUGE CLUSTER CONFIGURATION....107
2.2.3 OPERATING THE AIR CONDITIONER....120
2.2.4 AM/FM RADIO (OPTION)....122
2.3 CRANE OPERATION....124
2.3.1 ADJUSTING THE OPERATOR'S SEAT....124
2.3.2 ADJUSTING THE CONTROL LEVER DIRECTION....124
2.3.3 STARTING AND STOPPING THE ENGINE....125
2.3.4 FUNCTION LOCK LEVER....128
2.3.5 PROPELLING OPERATION....129
2.3.6 SWINGING OPERATION....131
2.3.7 BOOM RAISING/LOWERING OPERATION....134
2.3.8 HOOK RAISING/LOWERING OPERATION....136
2.4 FREE FALL OPERATION....139
2.5 LUFFING JIB OPERATION....142
2.5.1 JIB RAISING/LOWERING OPERATION....143
2.5.2 HOOK HOIST DRUM CONTROL....145
2.6 HANDLING OF REEVING WINCH (OPTION)....147
3. LOAD SAFETY DEVICE....150
3.1 ARRANGEMENT OF EQUIPMENTS....150
3.2 TYPE AND FUNCTIONS OF EQUIPMENTS....154
3.3 CONNECTING PROCEDURE OF WIRING....160
3.3.1 CRANE ATTACHMENT....160
3.3.2 LUFFING ATTACHMENT....165
3.4 FUNCTION OF CONTROLLER/MONITOR....170
3.5 OPERATING PROCEDURE OF CONTROLLER....174
3.5.1 SETTING SCREEN....175
3.5.2 SETTING OF THE CRANE CONFIGURATION....181
3.5.3 SELECTION OF MAIN/JIB/AUX. LIFTING....186
3.5.4 SETTING OF WORKING AREA LIMIT VALUE....187
3.5.5 SETTING OF THE TIME....191
3.6 WARNING ALARM AND AUTOMATIC STOP....193
3.6.1 ITEMS OF WARNING ALARM AND AUTOMATIC STOP....193
3.6.2 CONTENTS OF AUTOMATIC STOP....195
3.6.3 RELEASE OF AUTOMATIC STOP....200
3.7 INSPECTION....207
3.7.1 INSPECTION BEFORE RAISING THE BOOM AFTER ASSEMBLY OF ATTACHMENT IS COMPLETED....207
3.7.2 INSPECTION AFTER ERECTING THE ATTACHMENT....213
3.8 CAUTION FOR HANDLING THE LOAD SAFETY DEVICE....214
3.9 INDICATION OF ERRORS AND REMEDY....215
3.10 INDICATION OF MESSAGE AND ALARM....216
3.11 CONFIRMATION OF FUNCTION FOR LOAD SAFETY DEVICE....218
4. ASSEMBLY OF THE MACHINE....220
4.1 STABILITY IN SWINGING AND TRAVELING....220
4.1.1 WITHOUT BOOM BASE....220
4.1.2 WITH BOOM BASE....222
4.2 TRANSLIFTER....223
4.2.1 COMPOSITION OF THE TRANSLIFTER....223
4.2.2 HANDLING TRANSLIFTERS (1) - (4)....224
4.3 UNLOADING THE BASE MACHINE....227
4.3.1 ERECTING THE GANTRY....228
4.3.2 SETTING THE TRANSLIFTERS....229
4.3.3 UNLOAD THE BASE MACHINE FROM THE TRAILER....232
4.3.4 INSTALLATION OF THE HOOK BLOCK TO THE BASE BOOM....233
4.4 INSTALLATION OF THE CARBODY WEIGHT....235
4.5 INSTALLATION OF THE CRAWLER....238
4.5.1 INSTALLATION OF THE FIRST CRAWLER....238
4.5.2 INSTALLATION OF THE SECOND CRAWLER....242
4.6 ASSEMBLING THE ATTACHMENT....244
4.6.1 ASSEMBLY OF THE BOOM....244
4.6.2 ASSEMBLY OF THE JIB....253
4.6.3 INSTALLATION OF THE AUXILIARY SHEAVE....259
4.7 ASSEMBLING THE LUFFING ATTACHMENT....260
4.7.1 ARRANGEMENT OF BOOM / LUFFING JIB / GUY LINE....262
4.7.2 CONNECTING LUFFING BOOM TIP ASSEMBLY....272
4.7.3 INSTALLING THE AUXILIARY SHEAVE FOR LUFFING....273
4.7.4 ASSEMBLING THE LUFFING JIB....274
4.7.5 INSTALLING STRUT GUY LINE....275
4.8 INSTALLATION OF THE COUNTERWEIGHT....276
4.8.1 ASSEMBLING THE COUNTERWEIGHTS....276
4.8.2 REMOVING THE HOOK BLOCK FROM THE BASE BOOM....279
4.8.3 SETTING THE COUNTER-WEIGHT LINK....280
4.8.4 INSTALLATION OF COUNTERWEIGHTS TO MACHINE....281
4.9 CONNECTING THE BOOM....286
4.9.1 CONNECTING THE BASE BOOM TO THE INSERT BOOM....286
4.9.2 INSTALLATION OF THE GUY LINE....287
4.10 ASSEMBLING THE LUFFING JIB ATTACHMENT....291
4.10.1 INSTALLING LUFFING JIB HOIST WIRE ROPE....291
4.10.2 CONNECTING STRUT GUY LINE....291
4.10.3 INSTALLING STRUT BACKSTOP....292
4.10.4 INSTALLING JIB GUY LINE....293
4.11 REEVING THE WIRE ROPE FOR CRANE, JIB AND AUXILIARY SHEAVE....294
4.11.1 REEVING THE FRONT DRUM WIRE ROPE FOR CRANE WITHOUT LUFFING JIB....294
4.11.2 REEVING REAR DRUM WIRE ROPE TO THE JIB....298
4.11.3 REEVING THE REAR DRUM WIRE ROPE TO THE AUXILIARY SHEAVE....300
4.12 REEVING THE WIRE ROPE FOR CRANE WITH LUFFING ATTACHMENT....301
4.13 ERECTING THE ATTACHMENT....304
4.13.1 CONNECTING THE SAFETY DEVICE (Refer to Chapter 3.)....304
4.13.2 CONFIRMATION BEFORE ERECTING THE ATTACHMENT....304
4.13.3 ERECTING THE ATTACHMENT....305
4.13.4 CHECK BEFORE STARTING THE WORK....306
4.14 ERECTING THE LUFFING ATTACHMENT....307
4.14.1 CONNECTING SAFETY DEVICE....307
4.14.2 CONFIRMATION BEFORE ERECTING THE LUFFING ATTACHMENT....310
4.14.3 ERECTING LUFFING ATTACHMENT....311
4.14.4 CHECK BEFORE STARTING THE WORK....314
5. DISASSEMBLY OF THE ATTACHMENT....316
5.1 LOWERING THE ATTACHMENT....318
5.1.1 LOWERING THE ATTACHMENT....318
5.2 LOWERING THE LUFFING ATTACHMENT....319
5.2.1 LOWERING THE ATTACHMENT....320
5.3 WINDING UP THE FRONT DRUM/REAR DRUM WIRE ROPES....323
5.4 REMOVING JIB GUY LINE....324
5.4.1 REMOVE THE JIB GUY LINE OF THE FRONT STRUT SIDE....324
5.4.2 REMOVE THE JIB GUY LINE OF THE REAR STRUT SIDE....325
5.5 DISCONNECTING THE WIRING FOR SAFETY DEVICE....327
5.6 REMOVING THE BOOM GUY LINE....330
5.6.1 INSTALLATION OF THE UPPER SPREADER TO THE BOOM BASE....330
5.6.2 REMOVE THE BOOM GUY LINE....330
5.7 REMOVE THE COUNTER-WEIGHTS....331
5.7.1 DISCONNECT THE BOOM BASE FROM THE INSERT BOOM....331
5.7.2 REMOVE THE COUNTERWEIGHTS FROM THE MACHINE....332
5.7.3 INSTALLATION OF THE HOOK BLOCK TO THE BOOM BASE....336
5.7.4 DISASSEMBLY OF THE COUNTERWEIGHT....337
5.8 DISASSEMBLING THE ATTACHMENT....339
5.8.1 DISASSEMBLING THE JIB....339
5.8.2 REMOVING GUY LINES....341
5.8.3 REMOVING UPPER AND INSERT BOOMS....342
5.9 DISASSEMBLY OF LUFFING ATTACHMENT....342
5.9.1 DISASSEMBLING THE LUFFING JIB....343
5.9.2 DISASSEMBLING THE LUFFING BOOM TIP ASSEMBLY....344
5.9.3 CAUTION WHEN TRANS-PORTING LUFFING BOOM TIP ASSEMBLY....345
5.10 REMOVAL OF THE CRAWLERS....346
5.10.1 SETTING THE TRANSLIFTER (Refer to 4.3.1.)....346
5.10.2 REMOVAL OF THE CRAWLERS....346
5.11 REMOVAL OF THE CARBODY WEIGHTS....351
5.12 REMOVAL OF THE HOOK BLOCK FROM BASE BOOM....352
5.13 LOADING THE BASE MACHINE....353
5.13.1 LOADING THE BASE MACHINE ON THE TRAILER....353
5.13.2 FOLDING THE TRANSLIFTER....353
5.13.3 LOWERING THE GANTRY....355
5.13.4 CAUTION WHEN TRANSPORTING THE BASE MACHINE....356
5.13.5 TRANSPORTATION OF NO.1 COUNTERWEIGHT AND LADDER....356
6. WIRE ROPE....358
6.1 UNREELING WIRE ROPE....358
6.1.1 UNREELING WIRE ROPE....358
6.1.2 WINDING WIRE ROPE ONTO DRUM....359
6.1.3 INSTALLING THE ROPES....361
6.1.4 SPECIFICATION OF WIRE ROPE....361
6.1.5 WIRE ROPE LENGTH....362
7. MAINTENANCE....366
7.1 INSPECTIONS....371
7.1.1 UPPER STRUCTURE PARTS AND DEVICES TO BE INSPECTED....371
7.1.1.1 UPPER STRUCTURE INSPECTIONS-DAILY OR EVERY 8 HOURS....373
7.1.1.2 UPPER STRUCTURE INSPECTIONS-MONTHLY OR EVERY 100 HOURS....378
7.1.1.3 UPPER STRUCTURE INSPECTIONS-SEMI-ANNUALLY OR EVERY 600 HOURS....382
7.1.1.4 UPPER STRUCTURE INSPECTIONS-WEEKLY OR EVERY 50 HOURS....383
7.1.2 LOWER STRUCTURE PARTS AND DEVICE TO BE INSPECTED....385
7.1.2.1 LOWER STRUCTURE INSPECTIONS-DAILY OR EVERY 8 HOURS....386
7.1.2.2 LOWER STRUCTURE INSPECTIONS-MONTHLY OR EVERY 100 HOURS....387
7.1.2.3 LOWER STRUCTURE INSPECTIONS-QUARTERLY OR EVERY 250 HOURS....389
7.1.2.4 LOWER STRUCTURE INSPECTIONS-SEMI-ANNUALLY OR EVERY 600 HOURS....389
7.1.3 ATTACHMENT PARTS AND DEVICES TO BE INSPECTED....391
7.1.3.1 ATTACHMENT INSPECTIONS-DAILY OR EVERY 8 HOURS....393
7.1.4 REPLACEMENT STANDARDS FOR WIRE ROPE....397
7.2 OIL/GREASE SUPPLY AND WATER SERVICE....402
7.2.1 UPPER STRUCTURE LUBRICATION (INCLUDING WATER SUPPLY)....405
7.2.2 LOWER STRUCTURE LUBRICATION....407
7.2.3 ATTACHMENT LUBRICATION....409
7.2.4 GREASE....411
7.2.5 ENGINE OIL....419
7.2.6 FUEL....420
7.2.7 COOLANT....421
7.2.8 HYDRAULIC OIL....423
7.2.9 GEAR OIL....426
7.3 CLEANING/WASHING/CHANGING FILTER ELEMENT AND STRAINER....431
7.4 BATTERY INSPECTION....442
7.5 LOCATION AND USE OF FUSE....445
7.6 OPERATION UNDER UNUSUAL CONDITIONS....447
7.7 MACHINE STORAGE....449
7.8 TIGHTENING TORQUE VALUES....450
7.9 SECURITY PARTS TO BE REPLACED PERIODICALLY....452
7.10 ADJUSTMENT....453
7.10.1 ADJUSTMENT OF FRONT AND REAR DRUM LOCKS....453
7.10.2 ADJUSTMENT OF BOOM DRUM LOCK....454
7.10.3 ADJUSTMENT OF THIRD (LUFFING JIB) DRUM LOCK....455
7.10.4 CRAWLER SHOES ADJUSTMENT....455
7.11 CONSUMABLE PARTS LIST....456
8. REFERENCE MATERIALS....462
8.1 SPECIFICATION....462
8.1.1 PERFORMANCE....462
8.1.2 PERFORMANCE OF LUFFING JIB....462
8.1.3 OUTSIDE DIMENSIONS....463
8.2 DIMENSIONS AND WEIGHT OF EACH PARTS....465
8.2.1 BASE MACHINE....465
8.2.2 COUNTERWEIGHT....466
8.2.3 ATTACHMENT....467
8.3 SYSTEM SCHEMATIC....473
8.3.1 HYDRAULIC SYSTEM SCHEMATIC....473
8.3.2 ELECTRIC SYSTEM SCHEMATIC....475
9. INITIAL ASSEMBLY OF THE MACHINE....490
9.1 UPPER STRUCTURE (WITH CARBODY) LIFTING PROCEDURES....491
9.1.1 INSTALLATION OF BOOM FOOT LIFTING BRACKET....491
9.1.2 INSTALLATION....492
9.2 LOADING/UNLOADING OF THE MACHINE FROM/ONTO A TRAILER....493
9.2.1 LOADING ONTO A TRAILER....493
9.2.2 UNLOADING FROM A TRAILER....493
9.3 INSTALLATION OF THE CARBODY WEIGHT....497
9.4 INSTALLATION OF THE CRAWLER....498
9.4.1 INSTALLATION OF THE FIRST CRAWLER....498
9.4.2 INSTALLATION OF THE SECOND CRAWLER....503
9.5 INSTALLATION OF THE GANTRY TO THE SWING FRAME....505
9.6 INSTALLATION OF THE BOOM BASE....508
9.6.1 REMOVAL OF THE BACKSTOP....508
9.6.2 INSTALLATION OF THE BOOM BASE....508
9.7 INSTALLATION OF THE BACKSTOP....510
9.8 INSTALLING THE UPPER AND LOWER SPREADER....511
S3JC00003ZO01 - KOBELCO CK2000 Crawler Crane Parts Manual....518
COVER....518
CONTENTS....523
CONTROL SYSTEM....0
MONITOR INSTAL....579
LUB. LINES FOR DRUM LOCK (BOOM)....577
LUB. LINES (FRONT / REAR)....575
DRUM LOCK ASSY (BOOM)....573
DRUM LOCK ASSY (FRONT / REAR)....571
LAMP & SWITCH ASSY (WITH FREE FALL)....569
PANEL ASSY (BYPASS SWITCH)....567
PANEL ASSY....565
PANEL ASSY (LEFT STAND)....563
LABEL ASSY....561
PANEL ASSY (LEFT STAND)....559
PANEL ASSY....557
BRAKE PEDAL ASSY....553
GRIP ASSY (BOOM)....551
SWING LOCK ASSY....549
REMOTE CONTROL V.INSTAL (BOOM / FRONT / REAR)....547
CONTROL LEVER ASSY (PROPEL / FUNCTION LOCK)....545
CONTROL LEVER ASSY (SWING)....541
CONTROL LEVER ASSY (BOOM / MAIN / AUX.)....537
CONTROL ASSY....533
WINCH SYSTEM (WITH FREE FALL)....0
WINCH INSTAL (WITH FREE FALL (FRONT / REAR)....581
WINCH ASSY (FRONT)....583
WINCH ASSY (REAR)....585
WINCH ASSY....587
WINCH SYSTEM (WITHOUT FREE FALL)....0
WINCH INSTAL (WITHOUT FREE FALL / FRONT & REAR)....589
WINCH INSTAL (FRONT)....591
WINCH ASSY (REAR)....595
REDUCTION UNIT ASSY....599
BOOM HOIST SYSTEM....0
WINCH INSTAL (BOOM)....603
WINCH ASSY....605
REDUCTION UNIT ASSY....607
SWING SYSTEM....0
REDUCTION INSTAL, SWING....609
SWING MOTOR ASSY....611
SWING REDUCTION ASSY....613
SWING BEARING ASSY....615
SWING BEARING LUB. LINES....617
LINES....0
PUMP HYD. LINES (SUCTION)....619
PUMP HYD. LINES (CONTROL)....621
PUMP HYD. LINES (DELIVERY)....625
RIGHT DECK HYD. LINES....627
MAIN VALVE CONTROL HYD. LINES....633
SWING MOTOR HYD. LINES....635
SWING MOTOR HYD. LINES (BLOCK)....639
ACCUMLATOR HYD. LINES....641
FLOOR PLATE HYD. LINES....643
FLOOR CONTROL HYD. LINES....645
BRAKE HYD. LINES....649
BRAKE CONTROL HYD. LINES....651
4-SECTION VALVE HYD. LINES....653
3-SECTION VALVE HYD. LINES....655
HYD.CONTROL LINES....657
DRAIN HYD. LINES....659
RETURN BLOCK HYD. LINES....663
2-SECTION VALVE HYD. LINES (SWING MODE / PROPEL SPEED SELECT)....665
2-SECTION VALVE HYD. LINES (FUNCTION CUT / SWING PARKING BRAKE)....667
4-SECTION VALVE HYD. LINES....669
5-SECTION VALVE HYD. LINES....671
8-SECTION VALVE HYD. LINES....673
WINCH HYD. LINES (FOR FRONT&REAR DRUM)....675
WINCH HYD. LINES (FOR BOOM)....679
COOLING HYD. LINES....681
CONNECTOR ASSY (MANIFOLD)....685
CONNECTOR ASSY (WINCH)....687
OIL COOLER HYD. LINES....689
CLAMP ASSY....691
LOWER HYD. LINES....695
SWIVEL JOINT INSTAL....699
SWIVEL JOINT....701
HYD. OIL TANK ASSY....703
HYD. OIL TANK ASSY....705
POWER PLANT....0
POWER PLANT ASSY....711
PUMP INSTAL....717
POWER DIVIDER....719
MUFFLER INSTAL....721
FUEL LINES....723
RADIATOR INSTAL....725
AIR CLEANER INSTAL....727
FUEL TANK ASSY....729
ELECTRIC SYSTEM....0
ELEC ASSY (RIGHT DECK)....731
ELEC ASSY (REV. FRAME)....735
ELEC ASSY (FLOOR PLATE)....739
RELAY BOX ASSY....743
ELEC ASSY (L.H. GUARD)....745
ELEC ASSY....747
ELEC ASSY (LEFT DECK)....751
RELAY ASSY....757
WASHER TANK ASSY....759
WASHER TANK INSTAL (OPTION)....761
BATTERY INSTAL....763
CAB / GUARD / PLATFORM....0
CAB INSTAL....765
CAB ASSY....769
DOOR ASSY....777
RUBBER SHEET INSTAL (OPERATOR’S ROOM)....783
LOCK ASSY....785
SUN VISOR ASSY....787
ROLL BLIND....789
SASH ASSY....791
L.H. GUARD INSTAL....793
L.H. GUARD ASSY....797
L.H. GUARD ASSY....799
L.H. GUARD ASSY....803
INSULATION ASSY....805
INSULATION ASSY....809
DRUM COVER ASSY....811
SWING BEARING COVER ASSY....813
DRUM COVER (BOOM DRUM)....815
SWING MOTOR COVER ASSY....817
UNDER COVER ASSY (LEFT)....819
UNDER COVER ASSY (RIGHT)....821
AUX. PLATFORM ASSY (OPERATORS ROOM)....823
AUX. PLATFORM ASSY....827
RIGHT DECK INSTAL....829
RIGHT DECK INSTAL (UNDER OF CAB)....831
L.H. DECK INSTAL....833
STEP INSTAL (RIGHT DECK)....837
HANDRAIL....839
FRONT GUARD ASSY....841
LOWER SYSTEM....0
PROPEL MOTOR ASSY....843
REDUCTION UNIT ASSY....845
IDLER ASSY....847
IDLER ADJUST ASSY....849
ROLLER ASSY....851
LOWER ROLLER ASSY....852
UPPER ROLLER ASSY....853
FRAME COVER ASSY....855
CRAWLER FRAME CONNECTING PIN....857
SHOE ASSY (42inch / OPTION)....861
SHOE ASSY (48inch)....862
TRANSLIFTER ASSY....863
TRANSLIFTER HYD. LINES....865
CRANE ATTACHMENT....0
LOWER BOOM ASSY....869
UPPER BOOM ASSY....873
UPP. BOOM ASSY....875
INSERT BOOM (3.0m (10ft))....877
INSERT BOOM (6.1m (20ft))....878
INSERT BOOM (9.1m (30ft))....879
INSERT BOOM (12.2m (40ft))....880
BOOM POINT SHEAVE ASSY....881
BOOM POINT SHEAVE ASSY....883
IDLER SHEAVE ASSY (ADD.FOR 3RD DRUM)....885
IDLER SHEAVE ASSY....887
SPREADER GUIDE ASSY....889
GUY CABLE ASSY (φ30)(3.0m (10ft))(6.1m (20ft))(9.1m (30ft))....891
GUY CABLE ASSY (φ30)(12.2m (40ft))....893
CABLE ROLLER ASSY (FOR INSERT BOOM)....895
BOOM POINT SHEAVE ASSY....897
IDLER SHEAVE ASSY....899
JIB ASSY....901
INSERT JIB ASSY (3.0m (10ft))....903
INSERT JIB ASSY (6.1m (20ft))....904
STRUT ASSY....905
JIB POINT SHEAVE ASSY....907
JIB GUY CABLE (6.1m (20ft))(BOOM SIDE(WHEN 30ft INSERT BOOM)(WHEN 40ft INSERT BOOM)(FOR OFFSET ANGLE 30゜)(JIB SIDE)....909
CABLE ROLLER ASSY (FOR INSERT JIB)....911
UPPER SPREADER ASSY....913
LOWER SPREADER ASSY....915
BOOM BACKSTOP ASSY(LF & CR)....917
BACKSTOP ASSY (CRANE)....921
AUX. SHEAVE ASSY....925
WIRE ROPE ASSY....927
LUFFING CRANE....0
LUFFING ASSY....929
BOOM POINT SHEAVE ASSY....931
IDLER SHEAVE ASSY....933
FRONT STRUT ASSY....935
STRUT SHEAVE ASSY....937
REAR STRUT ASSY....939
STRUT SHEAVE ASSY....941
GUIDE SHEAVE ASSY....943
LOWER JIB ASSY....945
STRUT BACKSTOP ASSY....947
BACKSTOP ASSY....949
HYD. OIL TANK INSTAL....951
HYD. OIL TANK ASSY....953
HYD. OIL TANK....955
JIB BACKSTOP ASSY....957
UPPER JIB ASSY....961
JIB POINT SHEAVE ASSY....963
IDLER SHEAVE ASSY....965
CABLE ROLLER ASSY....967
INSERT JIB (3.0m (10ft))(6.1m (20ft))(12.2m (40ft))....969
CABLE ROLLER ASSY (FOR LUFFING INSERT JIB)....971
TRAVELING KIT....975
GUY CABLE (φ30)(LUFFING BASE)....977
GUY CABLE (φ30)(STRUNT BASE) ....978
GUY CABLE (φ34)(3.0m (10ft))(6.1m (20ft))(12.2m (40ft))(LUFFING JIB BASE)....979
GUY CABLE (φ34)....981
GANTRY....0
GANTRY ASSY....983
SUB GANTRY ASSY....987
REEVING WINCH....0
REEVING WINCH INSTAL....991
REEVING WINCH ASSY....993
REEVING WINCH HYD. LINES....995
GUIDE ROLLER INSTAL....999
ROLLER INSTAL....1001
GUIDE ROLLER INSTAL (OPTION)....1003
ROLLER ASSY....1005
JIB (THIRD) WINCH SYSTEM....0
CONTROL ASSY (JIB)....1007
DRUM LOCK ASSY (JIB)....1009
DRUM LOCK LUB. LINES (JIB)....1011
POTENTIOMETER INSTAL (FOR JIB DRUM)....1013
JIB WINCH INSTAL....1015
JIB WINCH ASSY....1017
WINCH HYD. LINES (JIB / THIRD)....1021
JIB / THIRD MAIN HYD. LINES....1023
JIB / THIRD CONTROL HYD. LINES....1027
4-SECTION VALVE HYD. LINES....1029
5-SECTION VALVE HYD. LINES....1031
VALVE INSTAL....1033
JIB / THIRD CONTROL HYD. LINES....1035
PLUG INSTAL....1037
GANTRY SHEAVE ASSY (JIB)....1039
DRUM COVER ASSY (JIB DRUM)....1041
HARNESS ASSY (JIB)....1043
OVEALOAD SAFETY DEVICE (LIM)....0
SAFETY DEVICE HARNESS (FOR GANTRY)....1045
SAFETY DEVICE HARNESS (FOR BASE MACHINE)....1049
SAFETY DEVICE HARNESS (FOR BOOM BASE & INSERT BOOM)(FOR BOOM TIP)(FOR ANGLE DETECTOR)....1051
SAFETY DEVICE HARNESS (FOR LUFFING)....1055
SAFETY DEVICE HARNESS (FOR JIB)....1061
HOOK OVERHOIST LIMIT SWITCH (FOR CRANE)....1063
HOOK OVERHOIST LIMIT SWITCH (FOR LUFFING)....1065
HOOK OVERHOIST LIMIT SWITCH (FOR AUX. SHEAVE & JIB)....1067
HOOK OVERHOIST LIMIT SWITCH....1069
LIMIT SWITCH ASSY....1071
BOOM OVERHOIST LIMIT SWITCH....1073
COUNTERWEIGHT / FRAME....0
COUNTERWEIGHT ASSY....1075
CARBODY WEIGHT....1077
SWING ALARM ASSY....1081
REVOLVING FRAME ASSY....1083
RUBBER INSTAL....1085
CARBODY ASSY....1089
COUNTERWEIGHT REMOVAL DEVICE....1091
PIN ASSY....1097
HYD. LINES ASSY (FOR C/W REMOVAL)....1099
VALVE INSTAL....1103
VALVE INSTAL....1105
REMOTE CONTROL ASSY....1107
LABEL....0
LABEL ASSY....1109
LABEL ASSY (FOR LUFFING)....1119
OTHERS....0
AIR CONDITIONER (INDOOR UNIT)....1121
AIR CONDITIONER (OUTDOOR UNIT)....1125
UPPER FINAL (ENGINE CONTROL)....1129
UPP. FINAL (SHEAT)....1133
UPPER FINAL....1135
UPPER FINAL....1137
UPPER FINAL (PEDAL COVER)....1139
TOOL ASSY....1141
TOOL ASSY....1143
SPARE PART KIT....1145
SEAT ASSY....1147
BOOM STEP ASSY (OPTION)....1149
LIGHT INSTAL (OPTION)....1155
BOOM FOOT PIN REMOVAL DEVICE....1159
RADIO INSTAL....1161
PEDAL ASSY....1163
TRAVELING KIT....1165
BRACKET ASSY (OPTION)....1169
TRAVELING KIT (FOR INSERT BOOM GUY LINE / OPTION)....1171
TRAVELING KIT (FOR INSERT JIB GUY LINE / OPTION)....1173
DRUM TURN SENSOR INSTAL....1175
SWITCH INSTAL (FOR DRUM TURN SENSOR)....1177
DRUM TURN SENSOR GRIP INSTAL....1178
GRIP ASSY....1179
FAN INSTAL (15cm FAN / OPTION)....1181
PEDAL ASSY (OPTION)(FOR BOOM & JIB CONTROL)....1183
ANEMOMETER (ADD.PART FOR CRANE / OPTION)....1189
BOOM NESTING (OPTION)....1197
BOOM FOOT PIN REMOVAL DEVICE....1199
PLATE ASSY....1201
SLING (OPTION)....1203
HEAD GUARD (OPTION)....1205
ALARM ASSY (OPTION)....1207
EXTINGUISHER INSTAL (OPTION)....1209
NOISE FILTER (FOR WIPER MOTOR / OPTION)....1211
PEDAL SENSOR INSTAL (OPTION)....1213
BOOM CONTROL PEDAL INSTAL (OPTION)....1215
LEVEL GAUGE INSTAL (OPTION)....1217
LIFE HAMMER INSTAL (OPTION)....1219
INDEX OF PART NO.....1222
S5JC00002ZE05 - KOBELCO CK2000, CKE1800 Crawler Crane OPERATION & MAINTENANCE MANUAL....1247
COVER....1247
TABLE OF CONTENTS....1249
SAFETY....1257
1. SPECIFICATION....1269
1.1 CK2000 SPECIFICATION....1271
1.1.1 PERFORMANCE....1271
1.1.2 PERFORMANCE OF LUFFING JIB....1271
1.1.3 OUTSIDE DIMENSIONS....1272
1.1.4 DIMENSIONS AND WEIGHT OF EACH PARTS....1274
1.1.5 WITHOUT BOOM BASE....1282
1.1.6 WITH BOOM BASE....1284
1.2 CKE1800 SPECIFICATION....1285
1.2.1 PERFORMANCE....1285
1.2.2 PERFORMANCE OF LUFFING JIB....1285
1.2.3 OUTSIDE DIMENSIONS....1286
1.2.4 DIMENSIONS AND WEIGHT OF EACH PARTS....1291
1.2.5 WITHOUT BOOM BASE....1300
1.2.6 WITH BOOM BASE....1302
2. MAINTENANCE STANDARDSTEST PROCEDURES....1303
2.1 MAINTENANCE STANDARD....1305
2.1.1 PIN, BUSHING, SPRING, LINING AND SHEAVE....1305
2.1.2 PROPEL DEVICE....1316
2.2 PERFORMANCE STANDARD AND TEST PROCEDURE....1323
2.2.1 OPERATING SPEED....1323
2.2.2 POINT AND METHOD OF MEASURING PRESSURE....1324
2.2.3 SLEWING RING....1328
3. GENERAL WORK STANDARD....1329
3.1 TIGHTENING TORQUE OF CAPSCREWS AND NUTS....1331
3.1.1 METRIC COARSE THREADS....1331
3.1.2 METRIC FINE THREADS....1331
3.1.3 COARSE THREDS UNC....1332
3.1.4 FINE THREADS UNF....1332
3.1.5 TIGHTENING TORQUE OF HYDRAULIC FITTINGS....1333
3.2 STANDARD PARTS....1335
3.2.2 O-RING....1336
3.2.3 BACK-UP RING....1337
3.2.4 BITE FITTING....1338
3.3 CONVERSION TABLE....1340
3.3.1 UNIT CONVERSION....1340
3.3.2 MILLIMETER : INCH CONVERSION TABLE....1341
3.3.3 METER-FOOT CONVERSION TABLE....1343
3.3.4 GRADIENT CONVERSION TABLE....1344
3.4 TABLE OF UNIT WEIGHT....1345
4. POWER TRAIN....1347
4.1 INTRODUCTION....1349
4.2 ENGINE....1351
4.2.1 INTRODUCTION....1351
4.2.2 REMOVAL....1351
4.2.3 REPAIR AND MAINTENANCE....1352
4.2.4 RE-INSTALLATION....1353
4.3 PUMP DRIVE ASSEMBLY....1356
4.3.1 INTRODUCTION....1356
4.3.2 REMOVAL....1356
4.3.3 DISASSEMBLING THE POWER DIVIDER....1358
4.3.4 CHECK AND REPAIR OF THE POWER DIVIDER....1359
4.3.5 ASSEMBLING THE POWER DIVIDER....1360
4.3.6 RE-INSTALLATION....1361
5. HYDRAULIC SYSTEM....1367
5.1 HYDRAULIC CIRCUITS AND COMPONENTS....1369
5.2 HYDRAULIC CIRCUIT....1370
5.3 COMPONENT SPECIFICATION....1374
5.3.1 LOCATION OF HYDRAULIC COMPONENTS....1378
5.4 HYDRAULIC SYSTEM....1386
5.4.1 PREFACE....1386
5.4.2 OUTLINE....1386
5.4.3 OIL FLOW FROM No.1 and No. 2 PUMPS....1388
5.4.4 OIL FLOW FROM No.3 AND No.4 PUMPS....1390
5.4.5 OIL FLOW FROM No.5 PUMP (CONTROL PUMPS)....1391
5.4.6 OIL FLOW FROM No.6 PUMP (FOR AUXILIARY ACTUATOR CIRCUIT)....1394
5.5 VALVES....1397
6. HOIST SYSTEM....1405
6.1 APPARATUS AND LOCATION OF COMPONENTS....1407
6.2 CONSTRUCTION AND FUNCTION....1408
6.2.1 HYDRAULIC SCHEMATIC....1408
6.2.2 LIFTING A LOAD....1410
6.2.3 HOLDING A RAISED LOAD....1412
6.2.4 LOWERING A LOAD (POWERED LOWERING)....1414
6.2.5 FREE FALL OPERATION....1417
6.2.6 FREE FALL ACCELERATION....1420
6.3 DRUM LOCK....1422
6.3.1 ASEEMBLY DRAWING....1422
6.3.2 ADJUSTMENT OF DRUM LOCK....1423
6.4 WINCH ASSEMBLY....1424
6.4.1 WINCH INSTAL....1424
6.4.2 WINCH ASSEMBLY / REDUCTION UNIT WITHOUT FREE FALL (STD.)....1425
6.4.3 WINCH ASSEMBLY WITH FREE FALL (OPT.)....1427
6.5 BRAKE PEDAL....1428
6.5.1 ASSEMBLY DRAWING....1428
6.5.2 ADJUSTING THE BRAKE PEDAL....1430
6.6 BLEEDING AIR FROM BRAKE CIRCUIT....1431
7. BOOM HOIST SYSTEM....1433
7.1 APPARATUS AND LOCATION OF COMPONENTS....1435
7.2 CONSTRUCTION AND FUNCTION....1437
7.2.1 HYDRAULIC SCHEMATIC....1437
7.2.2 RAISING THE BOOM....1438
7.2.3 NEUTRAL(MAINTAINING THE BOOM POSITION)....1440
7.2.4 LOWERING THE BOOM....1442
7.3 BOOM DRUM LOCK....1444
7.3.1 ASSEMBLY DRAWING....1444
7.3.2 ADJUSTING THE BOOM DRUM LOCK....1445
7.4 DRUM AND REDUCTION UNIT....1446
7.4.1 BOOM WINCH ASSEMBLY....1446
7.4.2 BOOM DRUM AND REDUCTION UNIT ASSEMBLY....1448
8. SWING SYSTEM....1451
8.1 APPARATUS AND LOCATION OF COMPONENTS....1453
8.2 CONSTRUCTION AND FUNCTION....1455
8.2.1 HYDRAULIC SCHEMATIC....1455
8.2.2 SWING....1456
8.2.3 STOPPING....1460
8.3 SWING REDUCTION UNIT....1464
8.4 SWING BEARING....1466
8.5 SWING LOCK....1468
9. PROPEL SYSTEM....1469
9.1 LOCATION OF THE MAJOR COMPONENTS....1471
9.2 CONSTRUCTION AND FUNCTION....1472
9.2.1 HYDRAULIC SCHEMATIC....1472
9.2.2 PROPELLING (RIGHT SIDE FORWARD)....1474
9.2.3 STOPPING....1476
9.3 PROPEL REDUCTION UNIT....1478
9.3.1 REDUCTION UNIT....1480
9.3.2 MOTOR....1482
9.4 ADJUSTMENT....1484
10. ELECTRIC SYSTEM....1485
10.1 ELECTRICAL WIRING SCHEMATIC....1487
10.2 CONNECTOR LIST....1501
10.3 ARRANGEMENT OF ELECTRICAL PART....1553
10.3.1 ELECTRICAL PART OF CAB....1553
10.3.2 ELECTRICAL PART OF RIGHT DECK....1557
10.3.3 ELECTRICAL PART OF FLOOR PLATE & LEFT SIDE STAND PANEL....1561
10.3.4 ELECTRICAL PART OF REVOLVING FRAME....1566
10.3.5 ELECTRICAL PART OF LEFT DECK....1568
10.3.6 ELECTRICAL PART OF LEFT GUARD....1574
10.3.7 HARNESS PART NUMBER LIST (ALL MODELS)....1575
10.4 ELECTRICAL PART....1577
10.4.1 LOCATION AND USE OF FUSE....1577
10.4.2 FUSE BOX (GG73E00004F1)....1579
10.4.3 WIPER CONTROL RELAY(2480U1366)....1581
10.4.4 SWING FLASHER UNIT (2480U306)....1582
10.5 PRESSURE SWITCH(CONTROL PRESSURE CUT & FREE FALL)....1583
10.6 PRESSURE SENSOR....1585
10.7 RELAY BOX (GG24E00024F1)....1587
10.7.1 ARRANGEMENT OF CONNECTOR....1587
10.7.2 RELAY BOX SCHEMATIC....1589
10.8 LEFT SIDE STAND PANEL (WITH FREE FALL)....1592
10.9 BYPASS SWITCH PANEL....1596
10.10 TROUBLESHOOTING OF EXHAUST GAS THIRD REGULATION ENGINE....1597
10.10.1 FAILURE DIAGNOSIS FUNCTION....1597
10.10.2 HOW TO CHECK THE FAILURE CONTENTS....1598
10.10.3 CHECKING OF DIAGNOSIS LAMP FUNCTION....1603
10.10.4 ENGINE ECU....1604
11. LOAD SAFETY DEVICE....1607
11.1 PART NAMES AND FUNCTIONS....1609
11.1.1 FRONT VIEW....1609
11.1.2 CONFIGURATION OF SCREENS....1614
11.1.3 DATA TRANSMISSION BETWEEN CONTROLLER AND CARDS....1619
11.1.4 DETAILS OF INDICATORS ON MAIN DISPLAY SCREEN....1621
11.1.5 REAR VIEW....1625
11.1.6 ITEMS REQUIRED TO BE EXECUTED FOR REPLACEMENT OF CONTROLLER OR DATA CARDAND INSTRUCTIONS(IN A SIMILAR MANNER TO UPGRADE OF PROGRAM)....1630
11.2 PREPARATION FOR USE....1631
11.3 TURN THE POWER ON....1632
11.4 UPGRADING PROGRAMS....1633
11.4.1 PROCEDURES....1633
11.4.2 UPGRADING OF INDICATION PROGRAMS....1635
11.4.3 UPGRADING OF CONTROL PROGRAMS....1638
11.5 STATUS CHECK....1640
11.5.1 SIGNAL CHECK....1641
11.5.2 OPERATION PROGRESS....1643
11.5.3 COMMUNICATION DATA....1646
11.5.4 INDICATION OF ADJUSTMENT VALUE....1647
11.5.5 TROUBLE RECORD....1656
11.5.6 CHOICE OF LANGUAGE(CKE series only)....1658
11.5.7 LOAD RECORD (LOAD RECORD IN THE MAIN MENU)....1659
11.6 ADJUSTMENTS....1660
11.6.1 REMOVING THE INNER PANEL....1660
11.6.2 ADJUSTMENT....1661
11.6.3 LOAD ADJUSTMENT....1682
11.6.4 ADJUSTMENT DATA COPY (INITIALIZATION)....1684
11.6.5 VERSION CHECK....1690
11.7 ERROR CODE (ABNORMALITY DETECTION) AND COUNTERMEASURES....1691
11.8 CONTROL OUTPUT....1695
11.9 RELEASES....1707
11.9.1 RELEASE FUNCTION....1707
11.10 MECHANICAL SPECIFICATION....1715
11.10.1 ENVIRONMENTAL PERFORMANCE PARAMETERS....1715
11.10.2 LOAD CELL (CRANE)....1716
11.10.3 ANGLE SENSOR....1717
11.10.4 CONTROLLER....1719
11.11 EXTERNAL DIMENSIONS....1723
11.12 ELECTRIC SCHEMATIC DIAGRAM....1724
11.12.1 CRANE TYPE....1724
11.12.2 LUFFING TYPE....1725
11.13 CONTROLLER MALFUNCTION EMERGENCY MEASURES....1726
11.14 LOAD SAFETY DEVICE CHECK PROCEDURES....1727
12. GAUGE CLUSTER....1729
12.1 CONFIGURATION OF DISPLAY....1731
12.2 PRIORITY....1732
12.3 STATUS DISPLAY....1734
12.4 FAULT LOG DISPLAY....1744
13. TOTAL CONTROLLER....1749
13.1 ARRANGEMENT OF TOTAL CONTROLLER....1751
13.2 COMPOSITION OF SYSTEM....1752
13.2.1 OUTPUT RELATION TO CONTROLLER....1753
13.3 FUNCTION OF TOTAL CONTROLLER....1754
13.4 TOTAL CONTROLLER (HARDWARE)....1780
13.4.1 OUTLINE....1780
13.4.2 SPECIFICATIONS OF TOTAL CONTROLLER OUTPUT....1781
13.4.3 DETAILS OF TOTAL CONTROLLER CONNECTOR....1786
13.4.4 ARRANGEMENT OF TOTAL CONTROLLER CONNECTOR PIN....1787
13.4.5 PROPORTIONAL SOLENOID VALVE MEASURING POSITION....1794
13.5 ADJUSTMENT OF TOTAL CONTROLLER....1796
13.5.1 NECESSITY OF ADJUSTMENT....1796
13.5.2 ADJUSTMENT PROCEDURES OF TOTAL CONTROLLER....1796
13.6 CONTROLLER MALFUNCTION EMERGENCY MEASURES....1804
14. AIR CONDITIONER....1805
14.1 OPERATION ITEMS....1807
14.2 SAFETY MONITOR FUNCTIONS....1808
14.3 DISASSEMBLY AND ASSEMBLY PROCEDURE....1811
14.3.1 SPECIAL CONSIDERATIONS DURING REPLACEMENT....1811
14.3.2 INTERIOR UNIT....1813
14.4 OPERATIONAL PRECAUTIONS....1822
14.5 INSPECTION AND MAINTENANCE....1823
14.5.1 INSPECTION/MAINTENANCE LIST....1823
14.5.2 INSPECTION/MAINTENANCE PROCEDURES....1823
14.6 ELECTRIC SYSTEM SCHEMATIC....1827
15. TRANSLIFTER SYSTEM....1829
15.1 LOCATION OF MAIN COMPONENTS....1831
15.2 CONSTRUCTION AND WORKING PRINCIPLE....1834
15.2.1 OUTLINE....1834
15.3 WORKING PRINCIPLE....1836
15.3.1 RAISING THE TRANSLIFTER....1836
15.3.2 LOWERING THE TRANSLIFTER....1838
15.4 REMOTE CONTROL SWITCH....1840
KOBELCO CK2000, CKE1800 Crawler Cranes OPERATION & MAINTENANCE Manual
