KOBELCO CK2500-II, CKE2500-II Crawler Crane Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for KOBELCO CK2500-II, CKE2500-II Crawler Crane, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
KOBELCO CK2500-II, CKE2500-II Crawler Cranes workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
KOBELCO CK2500-2, CKE2500-2 Electrical Circuit Chart.pdf
S2JD10016ZE10 - KOBELCO Crawler Crane CK2500-II OPERATION & MAINTENANCE MANUAL.pdf
S3JD10005ZO02 - KOBELCO CK2500-II Crawler Crane Parts Manual.pdf
S5JD00002ZE06 - KOBELCO CK2500-II, CKE2500-II Crawler Crane Workshop Manual.pdf
PRODUCT DETAILS:
Total Pages: 1,822 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
KOBELCO CK2500-2, CKE2500-2 Electrical Circuit Chart....1
S2JD10016ZE10 - KOBELCO Crawler Crane CK2500-II OPERATION & MAINTENANCE MANUAL....33
COVER....33
TABLE OF CONTENTS....35
IMPORTANT INFORMATION....41
1. SAFE OPERATING PRACTICES FOR MOBILE CRANES....55
2. OPERATION....75
2.1 TERMINOLOGY OF MACHINE PARTS....75
2.1.1 CRANE ATTACHMENT....75
2.1.2 LUFFING JIB ATTACHMENT....76
2.2 LOCATIONS AND TERMS OF OPERATING CONTROLS....77
2.2.1 OPERATING SWITCHES....81
2.2.2 GAUGE CLUSTER CONFIGURATION....90
2.2.3 OPERATING THE AIR CONDITIONER....102
2.2.4 AM/FM RADIO (OPTION)....104
2.3 CRANE OPERATION....106
2.3.1 ADJUSTING THE OPERATOR'S SEAT....106
2.3.2 ADJUSTING THE CONTROL LEVER DIRECTION....106
2.3.3 STARTING AND STOPPING THE ENGINE....107
2.3.4 FUNCTION LOCK LEVER....111
2.3.5 PROPELLING OPERATION....111
2.3.6 SWINGING OPERATION....113
2.3.7 BOOM RAISING/LOWERING OPERATION....115
2.3.8 HOOK RAISING/LOWERING OPERATION....117
2.3.9 JIB RAISING/LOWERING OPERATION....119
2.4 FREE FALL OPERATION (OPTION)....120
2.5 CLAMSHELL OPERATION....122
2.6 HANDLING OF HYDRAULIC TAGLINE (OPTIONAL)....124
2.7 HANDLING OF REEVING WINCH (OPTION)....125
3. LOAD SAFETY DEVICE....127
3.1 ARRANGEMENT OF EQUIPMENT....127
3.2 TYPE AND FUNCTIONS OF DEVICES....132
3.3 CONNECTING PROCEDURE FOR WIRING....138
3.3.1 CRANE ATTACHMENT AND FIXED JIB ATTACHMENT....138
3.3.2 LUFFING ATTACHMENT....142
3.3.3 MAST....146
3.4 NECESSARY ACTIONS FOR ALTERATION OF LUFFING AND CRANE....147
3.4.1 CHANGE OF CABLE FOR CRANE HOOK OVERHOIST OF LUFFING HOOK OVERHOIST LIMIT SWITCHES....147
3.5 FUNCTION OF CONTROLLER/MONITOR....148
3.5.1 OPERATING PROCEDURE OF CONTROLLER....152
3.5.2 SETTING SCREEN....153
3.5.3 SETTING OF THE CRANE CONFIGURATION....158
3.5.4 SELECTION OF MAIN/JIB/AUX. LIFTING....163
3.5.5 SETTING OF WORKING AREA LIMIT VALUE....164
3.5.6 SETTING OF THE TIME....167
3.6 WARNING ALARMS AND AUTOMATIC STOPS....169
3.6.1 WARNING ALARMS AND AUTOMATIC STOP INDICATORS....169
3.6.2 CONTENTS FOR AUTOMATIC STOP....171
3.6.3 RELEASE OF AUTOMATIC STOP....174
3.7 INSPECTION....181
3.7.1 INSPECTION BEFORE RAISING THE BOOM AFTER ASSEMBLY OF ATTACHMENT IS COMPLETED....181
3.7.2 INSPECTION AFTER ERECTING THE ATTACHMENT....186
3.8 CAUTIONS FOR HANDLING THE LOAD SAFETY DEVICE....186
3.9 ERROR MESSAGES AND CORRECTIONS....187
3.10 TABLE OF ERROR MESSAGES AND ALARMS....188
3.11 CONFIRMATION OF FUNCTIONING FOR LOAD SAFETY DEVICE....189
4. ASSEMBLY OF THE MACHINE....191
4.1 STABILITY IN SWINGING AND TRAVELING....191
4.2 TRANSLIFTER....193
4.2.1 COMPOSITION OF TRANSLIFTER....193
4.2.2 HANDLING TRANSLIFTERS (1)-(4)....194
4.3 UNLOADING BASE MACHINE....196
4.3.1 SETTING TRANSLIFTERS....197
4.3.2 UNLOADING BASE MACHINE FROM TRAILER....200
4.3.3 RAISING MAST....201
4.3.4 INSTALLATION OF THE HOOK BLOCK TO THE MAST....205
4.4 INSTALLATION OF CARBODY WEIGHT....207
4.5 INSTALLATION OF CRAWLER....209
4.5.1 SETTING OF LMI....209
4.5.2 INSTALLATION OF THE FIRST CRAWLER....211
4.5.3 INSTALLATION OF THE SECOND CRAWLER....215
4.6 ASSEMBLING CRANE ATTACHMENTS....217
4.6.1 ARRANGEMENT OF BOOM / GUY LINE....217
4.6.2 ASSEMBLY OF JIB....232
4.6.3 INSTALLATION OF AUXILIARY SHEAVE....237
4.7 ASSEMBLING THE LUFFING ATTACHMENT....238
4.7.1 ARRANGEMENT OF BOOM / LUFFING JIB / GUY LINE....240
4.7.2 INSTALLING INSERT TAPER BOOM....251
4.7.3 CONNECTING LUFFING BOOM TIP ASSEMBLY....251
4.7.4 INSTALLING THE AUXILIARY SHEAVE FOR LUFFING....253
4.7.5 ASSEMBLING THE LUFFING JIB....253
4.7.6 INSTALLING STRUT GUY LINE....254
4.8 INSTALLATION OF THE BOOM BASE....255
4.8.1 SETTING THE BACKSTOP AND GUIDE ROLLER....255
4.8.2 CONNECTING THE BOOM BASE TO THE INSERT BOOM....256
4.8.3 INSTALLATION OF THE BOOM GUY LINE....257
4.9 INSTALLATION OF THE THIN TYPE COUNTERWEIGHT....258
4.9.1 ASSEMBLING THE COUNTERWEIGHTS....258
4.9.2 INSTALLATION OF COUNTERWEIGHTS TO MACHINE....260
4.10 CONNECTING THE ATTACHMENT TO THE BASE MACHINE....263
4.10.1 REMOVE THE HOOK BLOCK FROM THE MAST....263
4.10.2 CONNECTING THE BOOM BASE TO THE BASE MACHINE....264
4.11 ASSEMBLING THE LUFFING JIB ATTACHMENT....270
4.11.1 INSTALLING LUFFING JIB HOIST WIRE ROPE....270
4.11.2 CONNECTING STRUT GUY LINE....270
4.11.3 INSTALLING STRUT BACKSTOP....271
4.11.4 INSTALLING JIB GUY LINE....274
4.12 REEVING THE WIRE ROPE....275
4.12.1 REEVING THE FRONT DRUM WIRE ROPE FOR CRANE WITHOUT LUFFING JIB....275
4.12.2 REEVING THE REAR DRUM WIRE ROPE FOR JIB....279
4.12.3 REEVING THE REAR DRUM WIRE ROPE FOR AUXILIARY SHEAVE....281
4.12.4 REEVING THE WIRE ROPE FOR LUFFING ATTACHMENT....282
4.13 ERECTING ATTACHMENT....285
4.13.1 CONNECTING SAFETY DEVICE (Refer to Chapter 3.)....285
4.13.2 CONFIRMATION BEFORE ERECTING THE ATTACHMENT....285
4.13.3 ERECTING ATTACHMENT....286
4.13.4 CHECK BEFORE STARTING WORK....287
4.14 ERECTING LUFFING ATTACHMENT....288
4.14.1 CONNECTING SAFETY DEVICE....288
4.14.2 CONFIRMATION BEFORE ERECTING LUFFING ATTACHMENT....291
4.14.3 ERECTING LUFFING ATTACHMENT....292
4.14.4 CHECK BEFORE STARTING THE WORK....295
5. DISASSEMBLY OF THE MACHINE....297
5.1 LOWERING ATTACHMENT....299
5.1.1 LOWERING ATTACHMENT....299
5.2 LOWERING LUFFING ATTACHMENT....301
5.2.1 LOWERING THE ATTACHMENT....302
5.2.2 REMOVING THE GUY LINE....311
5.3 REMOVE THE ATTACHMENT FROM THE BASE MACHINE....313
5.4 INSTALLATION OF THE HOOK BLOCK TO THE MAST....319
5.5 REMOVING THE COUNTERWEIGHTS....322
5.5.1 REMOVAL OF COUNTERWEIGHTS....322
5.5.2 DISASSEMBLING OF COUNTERWEIGHTS....325
5.6 DISASSEMBLING THE ATTACHMENT....326
5.6.1 REMOVE THE BOOM BASE TO THE INSERT BOOM....326
5.6.2 REMOVE THE GUY LINE....328
5.6.3 DISASSEMBLING THE JIB....329
5.6.4 REMOVING THE AUXILIARY SHEAVE....331
5.6.5 DISASSEMBLING THE BOOM TIP AND INSERT BOOM....331
5.7 DISASSEMBLY OF LUFFING ATTACHMENT....332
5.7.1 DISASSEMBLING THE LUFFING JIB....333
5.7.2 DISASSEMBLING THE LUFFING BOOM....334
5.7.3 CAUTION WHEN TRANSPORTING LUFFING BOOM TIP ASSEMBLY....335
5.7.4 HANDLING BOOM NESTING (OPTION)....335
5.8 REMOVAL OF THE CRAWLERS....336
5.8.1 SETTING THE TRANSLIFTER (REFER TO 4.2.)....336
5.8.2 REMOVING CRAWLERS....336
5.9 REMOVAL OF THE CARBODY WEIGHT....346
5.10 LOADING THE MACHINE....350
5.10.1 LOWERING THE MAST AND GANTRY....350
5.10.2 LOADING THE BASE MACHINE ON THE TRAILER....352
5.10.3 FOLDING THE TRANSLIFTER....353
6. WIRE ROPE....355
6.1 HANDLING WIRE ROPE....355
6.1.1 UNREELING WIRE ROPE....355
6.1.2. WINDING WIRE ROPE ONTO DRUM....355
6.1.3 INSTALLING THE ROPES....357
6.1.4 SPECIFICATION OF WIRE ROPE....357
6.1.5 WIRE ROPE LENGTH....358
7. MAINTENANCE....363
7.1 INSPECTIONS....368
7.1.1 UPPER STRUCTURE PARTS AND DEVICES TO BE INSPECTED....368
7.1.2 LOWER STRUCTURE PARTS AND DEVICE TO BE INSPECTED....380
7.1.3 ATTACHMENT PARTS AND DEVICES TO BE INSPECTED....386
7.1.4 REPLACEMENT STANDARDS FOR WIRE ROPE....391
7.2 OIL / GREASE SUPPLY AND WATER SERVICE....395
7.2.1 UPPER STRUCTURE LUBRICATION (INCLUDING WATER SUPPLY)....398
7.2.2 LOWER STRUCTURE LUBRICATION....400
7.2.3 ATTACHMENT STRUCTURE LUBRICATION....402
7.2.4 GREASE....404
7.2.5 ENGINE OIL....412
7.2.6 FUEL....413
7.2.7 COOLANT....414
7.2.8 HYDRAULIC OIL....416
7.2.9 GEAR OIL....418
7.3 CLEANING / WASHING / CHANGING FILTER ELEMENT AND STRAINER....423
7.4 BATTERY INSPECTION....432
7.5 LOCATION AND USE OF FUSE....434
7.6 OPERATION UNDER UNUSUAL CONDITIONS....436
7.7 MACHINE STORAGE....437
7.8 TIGHTENING TORQUE VALUES....438
7.9 SECURITY PARTS TO BE REPLACED PERIODICALLY....440
7.10 ADJUSTMENT....441
7.10.1 ADJUSTMENT OF FRONT AND REAR DRUM LOCKS....441
7.10.2 ADJUSTMENT OF BOOM DRUM LOCK....441
7.10.3 ADJUSTMENT OF LUFFING JIB DRUM LOCK....442
7.10.4 CRAWLER SHOES ADJUSTMENT....443
7.11 CONSUMABLE PARTS LIST....444
8. REFERENCE MATERIALS....449
8.1 SPECIFICATION....449
8.1.1 PERFORMANCE....449
8.1.2 PERFORMANCE OF LUFFING JIB....449
8.1.3 OUTSIDE DIMENSIONS....450
8.2 DIMENSIONS AND WEIGHT OF EACH PARTS....452
8.2.1 BASE MACHINE....452
8.2.2 COUNTERWEIGHT....453
8.2.3 ATTACHMENT....455
8.3 SYSTEM SCHEMATIC....460
8.3.1 HYDRAULIC SYSTEM SCHEMATIC....460
8.3.2 ELECTRICAL WIRING SCHEMATIC....463
9. INITIAL ASSEMBLY OF THE MACHINE....477
9.1 INSTALLATION OF THE MAST....477
9.2 REEVING OF THE BOOM HOIST WIRE ROPE....480
9.2.1 REEVING THE GUIDE WIRE ROPE....481
9.2.2 CONNECT THE REEVING ROPE AND BOOM HOIST WIRE....481
9.2.3 INSTALLATION OF THE BOOM HOIST WIRE ROPE....482
9.2.4 RAISE THE GANTRY AND MAST....483
9.2.5 LOWERING THE MAST FORWARD....485
9.2.6 INSTALLATION OF THE 2ND DEAD END OF BOOM HOIST WIRE ROPE....486
9.2.7 LOWERING THE MAST AND GANTRY....487
9.3 UPPER STRUCTURE (WITH CARBODY) LIFTING PROCEDURES....489
9.3.1 INSTALLATION OF BOOM FOOT LIFTING BRACKET....489
S3JD10005ZO02 - KOBELCO CK2500-II Crawler Crane Parts Manual....494
COVER....494
CONTENTS....499
CONTROL SYSTEM....0
CONTROL ASSY....509
CONTROL ASSY (FOR LUFFING JIB / OPTION)....513
CONTROL LEVER ASSY (BOOM / MAIN / AUX.)....515
CONTROL LEVER ASSY (SWING)....519
CONTROL LEVER ASSY (PROPEL)....523
REMOTE CONTROL V.INSTAL (BOOM / FRONT / REAR)....525
SWING LOCK ASSY....527
GRIP ASSY....529
FLOOR PLATE ASSY....531
GRIP ASSY (BOOM)....533
PANEL ASSY....535
PANEL ASSY (LEFT STAND)....537
PANEL ASSY (LEFT STAND)....539
PANEL ASSY (LEFT SIDE)....541
PANEL ASSY (BYPASS SWITCH)....542
TRIMMER INSTAL (FOR LUFFING)....543
DRUM LOCK ASSY (FRONT / REAR)....545
LUB.LINES (FRONT / REAR)....547
MONITOR INSTAL....549
COVER ASSY....551
RADIO INSTAL (OPTION)(COVER INSTAL)....553
WINCH SYSTEM (FREE FALL LESS)....0
WINCH INSTAL....555
WINCH ASSY (FRONT)....559
WINCH ASSY (REAR)....561
REDUCTION ASSY SWING (FRONT)(REAR) ....565
WINCH SYSTEM (WITH FREE FALL)....0
WINCH HYD. LINES (WITH FREE FALL)....595
CONTROL LINES, FLOOR (WITH FREE FALL)....593
4-SECTION VALVE HYD. LINES (WITH FREE FALL)....591
3-SECTION VALVE HYD. LINES (WITH FREE FALL)....589
BRAKE INSTAL (WITH FREE FALL)....587
LAMP & SWITCH ASSY (WITH FREE FALL)....585
BRAKE PEDAL ASSY....581
BRAKE ASSY....579
REDUCTION UNIT ASSY....577
WINCH ASSY (WITH FREE FALL)....575
WINCH ASSY (REAR / WITH FREE FALL)....573
WINCH INSTAL (FRONT DRUM)(REAR DRUM)....569
REDUCTION ASSY SWING (FRONT)(REAR) ....565
WINCH ASSY (REAR)....561
WINCH ASSY (FRONT)....559
WINCH INSTAL....555
BOOM WINCH SYSTEM ....0
WINCH INSTAL....603
WINCH ASSY....605
REDUCTION UNIT ASSY....609
JIB WINCH....611
WINCH INSTAL (FOR LUFFING JIB)....611
WINCH ASSY....615
WINCH ASSY....617
REDUCTION UNIT ASSY....619
GUIDE SHEAVE ASSY....621
DRUM LOCK ASSY....623
LOCK ASSY....625
DRUM COVER ASSY....627
WINCH HYD. LINES (ATTACHMENT SIDE)....629
WINCH HYD. LINES (BASE MACHINE SIDE)....631
WINCH HYD. LINES (BASE MACHINE SIDE)....635
8-SECTION VALVE HYD. LINES....637
4-SECTION VALVE HYD. LINES....639
SWING SYSTEM....0
SWING REDUCT INSTAL....641
SWING REDUCTION ASSY....643
SWING REDUCTION ASSY....645
SWING BEARING ASSY....649
SWING BEARING LUB. LINES....651
LINES....0
UPP. PUMP HYD. LINES....653
PUMP HYD. LINES (SUCTION)....661
PUMP HYD. LINES (CONTROL)....663
PUMP HYD. LINES (DELIVERY)....667
VALVE HYD. LINES....669
VALVE CONTROL LINES....673
ACCUMLATOR INSTAL....679
FLOOR CONTROL HYD. LINES....681
DRAIN HYD. LINES....683
MAIN VALVE ASSY....687
MAIN VALVE HYD. LINES ....689
MAIN VALVE ASSY (BOOM)....691
8-SECTION VALVE INSTAL....693
2-SECTION VALVE INSTAL....695
RETURN HYD. LINES....697
RETURN BLOCK HYD. LINES....699
SWING MOTOR HYD. LINES....701
2-SECTIONS VALVE....705
CONTROL LINES, SWING....707
4-SECTIONS VALVE (MOTOR BRAKE)....711
5-SECTIONS VALVE (LIMIT STOP)....715
WINCH HYD. LINES (FOR FRONT)(FOR REAR DRUM)....717
WINCH HYD. LINES (FOR BOOM)....721
OIL COOLER HYD. LINES....723
LOW. HYD. LINES....725
SWIVEL JOINT INSTAL....729
SWIVEL JOINT....731
HYD. OIL TANK ASSY....733
HYD. OIL TANK ASSY....735
HYD. LINES ASSY....741
VALVE ASSY....745
VALVE ASSY....747
POWER PLANT....0
POWER PLANT ASSY....749
PUMP INSTAL....755
POWER DIVIDER....757
MUFFLER INSTAL....759
FUEL LINES....761
RADIATOR INSTAL....763
AIR CLEANER INSTAL....765
FUEL TANK ASSY....767
ELECTRIC SYSTEM....0
ELEC ASSY (R.H. DECK)....769
ELEC ASSY (REV. FRAME)....773
ELEC ASSY (FLOOR PLATE)....779
RELAY BOX ASSY....783
ELEC ASSY (L.H. GUARD)....785
ELEC ASSY (CAB / STANDARD)(CAB / M/L CONTROLLER)....787
ELEC ASSY (LEFT DECK)....791
WASHER TANK INSTAL....797
WASHER TANK ASSY....799
BATTERY INSTAL....801
RELAY ASSY....803
CAB / GUARD....0
CAB INSTAL....805
CAB ASSY....809
DOOR ASSY....817
RUBBER SHEET INSTAL (OPERATOR’S ROOM)....823
WIPER INSTAL....825
LOCK ASSY....827
ROLL BLIND....829
SASH ASSY....831
L.H. GUARD INSTAL....833
L.H. GUARD ASSY....837
L.H. GUARD ASSY....841
FRONT GUARD ASSY....843
INSULATION ASSY....845
INSULATION ASSY....849
DRUM GUARD ASSY (FRONT / REAR)....851
SWING BEARING COVER....855
COVER ASSY (SWING FRAME)....857
UNDER COVER ASSY....859
R.H. UNDER COVER ASSY....861
R.H. UNDER COVER ASSY....863
UNDER COVER ASSY....865
AUX. PLATFORM ASSY....867
R.H. DECK INSTAL....869
R.H. DECK INSTAL (UNDER OF CAB)....871
L.H. DECK INSTAL....873
STEP ASSY....877
STEP ASSY....881
LOWER SYSTEM....0
PROPEL MOTOR ASSY....883
REDUCTION UNIT ASSY....885
IDLER ASSY....887
IDLER ADJUST ASSY....889
ROLLER ASSY (UPPER / LOWER)....891
ROLLER ASSY, TRACK....893
ROLLER ASSY, UPP....895
FRAME COVER ASSY....897
CRAWLER FRAME CONNECTING PIN....899
SHOE ASSY (48inch)....903
SHOE ASSY (52inch)....905
TRANSLIFTER ASSY....907
TRANSLIFTER HYD. LINES ....909
CRANE ATTACHMENT....0
LOW. BOOM ASSY....913
UPP. BOOM ASSY....915
INSERT BOOM....917
INSERT BOOM....919
INSERT BOOM....921
BOOM POINT SHEAVE ASSY....923
IDLER SHEAVE ASSY....925
GUY CABLE (φ34)....927
BOOM GUY CABLE....929
GUY CABLE (φ34)....931
GUIDE ROLLER ASSY....933
GUIDE ROLLER ASSY....935
ANGLE MATER INSTAL (BOOM)....937
CABLE ROLLER ASSY....939
JIB ASSY....941
INSERT JIB ASSY....943
STRUT ASSY....945
JIB POINT SHEAVE ASSY....947
JIB GUY CABLE....949
CABLE GUIDE ROLLER ASSY....951
BOOM BACK STOP ASSY....953
AUX. SHEAVE ASSY....959
WIRE ROPE ASSY....961
LUFFING ATTACHMENT....0
LUFFING JIB ASSY....965
UPPER BOOM ASSY....967
TAPER BOOM ASSY....969
FRONT STRUT ASSY....971
STRUT SHEAVE ASSY (FRONT STRUT)....973
REAR STRUT ASSY....975
STRUT SHEAVE ASSY (REAR STRUT)....979
LOW. JIB ASSY....981
STRUT BACKSTOP ASSY....983
BACK STOP ASSY....985
HYD. OIL TANK INSTAL....987
HYD. OIL TANK ASSY....989
HYD, OIL TANK....991
JIB BACKSTOP ASSY....993
UPP. JIB ASSY....995
JIB POINT SHEAVE ASSY....997
IDLER SHEAVE ASSY....999
CABLE ROLLER ASSY (FOR UPP. BOOM)....1001
INSERT JIB....1003
CABLE ROLLER ASSY (FOR LUFFING INSERT JIB)....1005
AUX. SHEAVE ASSY....1007
PANEL ASSY....1009
TRAVELING KIT....1011
GANTRY....0
GANTRY ASSY....1013
SUB GANTRY ASSY....1015
SHEAVE ASSY....1017
FRAME ASSY....1019
MAST ASSY....1021
MAST ASSY....1025
ROLLER ASSY....1029
REEVING WINCH....0
REEVING WINCH ASSY....1031
REEVING WINCH ASSY....1033
WINCH HYD. LINES....1035
WINCH HYD. LINES....1037
GUIDE ROLLER ASSY....1041
ROLLER ASSY....1045
ROLLER ASSY....1047
GUIDE ROLLER ASSY / OPTION (FOR UPP. BOOM)....1049
SAFETY DEVICE....0
SAFETY DEVICE HARNESS (FOR GANTRY)....1051
SAFETY DEVICE HARNESS (FOR MAST)....1055
SAFETY DEVICE HARNESS (FOR BASE)....1059
SAFETY DEVICE HARNESS (BOOM ANGLE SENSOR INSTAL)....1063
OVERHOIST PREVENTIVE DEVICE (FOR CRANE BOOM)....1065
SAFETY DEVICE HARNESS (FOR JIB)....1069
OVERHOIST PREVENTIVE DEVICE (FOR LUFFING)....1071
ANGLE SENSOR INSTAL....1077
LIMIT SWITCH ASSY (BOOM OVERHOIST L/S)(BOOM)....1079
HOOK OVERHOIST L/S (FOR CRANE)....1081
HOOK OVERHOIST LIMIT SWITCH (FOR AUX. SHEAVE & JIB)....1083
OVERHOIST LIMIT SWITCH (FOR LUFFING)....1085
LIMIT SWITCH ASSY....1087
COUNTERWEIGHT / FRAME....0
COUNTERWEIGHT ASSY....1089
CARBODY WEIGHT ASSY....1091
SWING ALARM LAMP ASSY....1095
REV. FRAME....1097
REV. FRAME ASSY....1099
RUBBER ASSY....1101
COUNTERWEIGHT REMOVAL....1103
PIN ASSY....1107
HYD. LINES ASSY....1109
VALVE ASSY....1113
VALVE ASSY....1115
ELEC ASSY....1117
LABEL....0
LABEL (WITHOUT FREE FALL)....1119
LABEL (WITH FREE FALL)....1129
LABEL ASSY (FOR CRANE)....1137
OTHERS....0
AIR CONDITIONER (INDOOR UNIT)....1141
LIFE HAMMER INSTAL (OPTION)....1231
LEVEL GAUGE INSTAL (OPTION)....1229
BOOM CONTROL PEDAL INSTAL (OPTION)....1227
OVER PAYOUT PREVENTIVE DEVICE (FOR DRUM SELECT / OPTION)....1223
GUARD INSTAL (LEFT WINDOW / OPTION)....1221
HANDRAIL INSTAL (OPTION)....1219
EXTINGUISHER INSTAL (OPTION)....1217
ALARM ASSY (OPTION)....1215
HEAD GUARD (OPTION)....1213
PLATE ASSY....1211
HYD. LINES (HEATING SYSTEM)....1209
BOOM FOOT PIN ASSY....1207
TRAVELING KIT (GUY CABLE)....1205
TRAVELING KIT (GUY CABLE / OPTION)....1203
TRAVELING KIT (FOR GUY CABLE)....1201
BOOM NESTING (OPTION)....1199
WINDOW SENSOR (FOR CRANE)(ADD.PART FOR CRANE)....1195
FAN INSTAL (15cm FAN)....1193
AUX. PLATFORM....1191
CALL ASSY / ONE-WAY CALL....1189
FOOT ACCELERATOR (RIGHT & LEFT)(RIGHT)(LEFT)....1185
SWITCH INSTAL (FOR DRUM TURN SENSOR)....1183
SENSOR INSTAL....1181
MONITOR INSTAL....1177
BOOM HANDRAIL / OPTION....1175
STEP ASSY, BOOM (FOR 10ft INSERT BOOM)(FOR 20ft INSERT BOOM)(FOR 40ft INSERT BOOM)....1173
STEP ASSY, BOOM (FOR INSERT BOOM)(FOR BOOM TIP)....1171
STEP ASSY, BOOM (FOR UPP. BOOM)(FOR LOW. JIB)....1169
SPARE PART KIT....1167
TOOL ASSY....1165
TOOL ASSY....1163
UPPER FINAL....1161
SEAT ASSY....1159
UPPER FINAL (ANTI-SLIP)....1157
UPPER FINAL....1155
UPPER FINAL....1153
UPPER FINAL....1151
AIR CONDITIONER (OUTDOOR UNIT)....1147
INDEX OF PART NO.....1234
S5JD00002ZE06 - KOBELCO CK2500-II, CKE2500-II Crawler Crane Workshop Manual....1258
COVER....1258
TABLE OF CONTENTS....1260
SAFETY....1268
1. SPECIFICATION....1298
1.1 CK2500-II SPECIFICATION....1300
1.1.1 PERFORMANCE....1300
1.1.2 PERFORMANCE OF LUFFING JIB....1300
1.1.3 OUTSIDE DIMENSIONS....1301
1.1.4 DIMENSIONS AND WEIGHT OF EACH PARTS....1303
1.1.5 CK2500-II STABILITY IN SWINGING AND TRAVELING....1311
1.2 CKE2500-II SPECIFICATION....1312
1.2.1 PERFORMANCE....1312
1.2.2 PERFORMANCE OF LUFFING JIB....1312
1.2.3 OUTSIDE DIMENSIONS....1313
1.2.4 DIMENSIONS AND WEIGHT OF EACH PARTS....1315
1.2.5 CKE2500-II STABILITY IN SWINGING AND TRAVELING....1325
2. MAINTENANCE STANDARDS....1326
2.1 MAINTENANCE STANDARD....1328
2.1.1 PIN, BUSHING, SPRING, LINING AND SHEAVE....1328
2.1.2 PROPEL DEVICE....1335
2.2 PERFORMANCE STANDARD AND TEST PROCEDURE....1341
2.2.1 OPERATING SPEED....1341
2.2.2 POINT AND METHOD OF MEASURING PRESSURE....1342
2.2.3 SLEWING RING....1348
3. GENERAL WORK STANDARD....1350
3.1 TIGHTENING TORQUE OF CAPSCREWS AND NUTS....1352
3.1.1 METRIC COARSE THREADS....1352
3.1.2 METRIC FINE THREADS....1352
3.1.3 COARSE THREDS UNC....1353
3.1.4 FINE THREADS UNF....1353
3.1.5 TIGHTENING TORQUE OF HYDRAULIC FITTINGS....1354
3.2 STANDARD PARTS....1356
3.2.1 BOLT....1356
3.2.2 O-RING....1357
3.2.3 BACK-UP RING....1358
3.2.4 BITE FITTING....1359
3.3 CONVERSION TABLE....1361
3.3.1 UNIT CONVERSION....1361
3.3.2 MILLIMETER : INCH CONVERSION TABLE....1362
3.3.3 METER-FOOT CONVERSION TABLE....1364
3.3.4 GRADIENT CONVERSION TABLE....1365
3.4 TABLE OF UNIT WEIGHT....1366
4. POWER TRAIN....1368
4.1 INTRODUCTION....1370
4.2 ENGINE....1372
4.2.1 INTRODUCTION....1372
4.2.2 REMOVAL....1372
4.2.3 REPAIR AND MAINTENANCE....1373
4.2.4 RE-INSTALLATION....1374
4.3 PUMP DRIVE ASSEMBLY....1377
4.3.1 INTRODUCTION....1377
4.3.2 REMOVAL....1377
4.3.3 DISASSEMBLING THE POWER DIVIDER....1379
4.3.4 CHECK AND REPAIR OF THE POWER DIVIDER....1380
4.3.5 ASSEMBLING THE POWER DIVIDER....1381
4.3.6 RE-INSTALLATION....1382
5. HYDRAULIC SYSTEM....1388
5.1 LOCATION OF MAIN HYDRAULIC COMPONENTS....1390
5.2 HYDRAULIC CIRCUITS AND COMPONENTS....1391
5.2.1 HYDRAULIC CIRCUIT....1391
5.2.2 COMPONENT SPECIFICATIONS....1395
5.2.3 LOCATION OF HYDRAULIC COMPONENTS....1399
5.3 HYDRAULIC SYSTEM....1407
5.3.1 PREFACE....1407
5.3.2 OUTLINE....1407
5.3.3 OIL FLOW FROM No.1 and No. 2 PUMPS....1409
5.3.4 OIL FLOW FROM No.3 AND No.4 PUMPS....1411
5.3.5 OIL FLOW FROM No.5 PUMP (CONTROL PUMP)....1414
5.3.6 OIL FLOW FROM No.6 PUMP (FOR AUXILIARY ACTUATOR CIRCUIT)....1418
5.4 VALVES....1421
6. HOIST SYSTEM....1428
6.1 APPARATUS AND LOCATION OF COMPONENTS....1430
6.2 CONSTRUCTION AND FUNCTION....1431
6.2.1 HYDRAULIC SCHEMATIC....1431
6.2.2 LIFTING A LOAD....1433
6.2.3 HOLDING A RAISED LOAD....1435
6.2.4 LOWERING A LOAD (POWERED LOWERING)....1437
6.2.5 FREE FALL OPERATION....1440
6.2.6 FREE FALL ACCELERATION....1443
6.3 DRUM LOCK....1445
6.3.1 ASEEMBLY DRAWING....1445
6.3.2 ADJUSTMENT OF DRUM LOCK....1446
6.4 WINCH ASSEMBLY....1447
6.4.1 WINCH INSTAL....1447
6.4.2 WINCH ASSEMBLY / REDUCTION UNIT WITHOUT FREE FALL (STD.)....1448
6.4.3 WINCH ASSEMBLY WITH FREE FALL (OPT.)....1450
6.5 BRAKE PEDAL....1451
6.5.1 ASSEMBLY DRAWING....1451
6.5.2 ADJUSTING THE BRAKE PEDAL....1453
6.6 BLEEDING AIR FROM BRAKE CIRCUIT....1454
7. BOOM HOIST SYSTEM....1456
7.1 APPARATUS AND LOCATION OF COMPONENTS....1458
7.2 CONSTRUCTION AND FUNCTION....1460
7.2.1 HYDRAULIC SCHEMATIC....1460
7.2.2 RAISING THE BOOM....1461
7.2.3 NEUTRAL....1463
7.2.4 LOWERING THE BOOM....1465
7.3 BOOM DRUM LOCK....1467
7.3.1 ASSEMBLY DRAWING....1467
7.3.2 ADJUSTING THE BOOM DRUM LOCK....1468
7.4 DRUM AND REDUCTION UNIT....1469
7.4.1 BOOM WINCH ASSEMBLY....1469
7.4.2 BOOM DRUM AND REDUCTION UNIT ASSEMBLY....1470
8. SWING SYSTEM....1472
8.1 APPARATUS AND LOCATION OF COMPONENTS....1474
8.2 CONSTRUCTION AND FUNCTION....1475
8.2.1 HYDRAULIC SCHEMATIC....1475
8.2.2 SWING....1476
8.2.3 STOPPING....1480
8.3 SWING REDUCTION UNIT....1483
8.4 SWING BEARING....1485
8.5 SWING LOCK....1487
9. PROPEL SYSTEM....1488
9.1 LOCATION OF THE MAJOR COMPONENTS....1490
9.2 CONSTRUCTION AND FUNCTION....1491
9.2.1 HYDRAULIC SCHEMATIC....1491
9.2.2 PROPELLING (RIGHT SIDE FORWARD)....1493
9.2.3 STOPPING....1495
9.3 PROPEL REDUCTION UNIT....1497
9.3.1 REDUCTION UNIT....1499
9.3.2 MOTOR....1501
9.4 ADJUSTMENT....1503
10. ELECTRIC SYSTEM....1504
10.1 ELECTRICAL WIRING SCHEMATIC....1506
10.2 CONNECTOR LIST....1520
10.3 ARRANGEMENT OF ELECTRICAL PART....1572
10.3.1 ELECTRICAL PART OF CAB....1572
10.3.2 ELECTRICAL PART OF RIGHT DECK....1576
10.3.3 ELECTRICAL PART OF FLOOR PLATE & LEFT SIDE STAND PANEL....1580
10.3.4 ELECTRICAL PART OF REVOLVING FRAME....1585
10.3.5 ELECTRICAL PART OF LEFT DECK....1587
10.3.6 ELECTRICAL PART OF LEFT GUARD....1593
10.3.7 HARNESS PART NUMBER LIST (ALL MODELS)....1594
10.4 ELECTRICAL PART....1596
10.4.1 LOCATION AND USE OF FUSE....1596
10.4.2 FUSE BOX (GG73E00004F1)....1598
10.4.3 WIPER CONTROL RELAY(2480U1366)....1600
10.4.4 SWING FLASHER UNIT (2480U306)....1601
10.5 PRESSURE SWITCH....1602
10.6 PRESSURE SENSOR....1604
10.7 RELAY BOX (GG24E00024F1)....1606
10.7.1 ARRANGEMENT OF CONNECTOR....1606
10.7.2 RELAY BOX SCHEMATIC....1608
10.8 LEFT SIDE STAND PANEL (WITH FREE FALL)....1611
10.9 BYPASS SWITCH PANEL....1615
10.10 TROUBLESHOOTING OF EXHAUST GAS THIRD REGULATION ENGINE....1616
10.10.1 FAILURE DIAGNOSIS FUNCTION....1616
10.10.2 HOW TO CHECK THE FAILURE CONTENTS....1617
10.10.3 CHECKING OF DIAGNOSIS LAMP FUNCTION....1622
10.10.4 ENGINE ECU....1623
11. LOAD SAFETY DEVICE....1626
11.1 PART NAMES AND FUNCTIONS....1628
11.1.1 FRONT VIEW....1628
11.1.2 CONFIGURATION OF SCREENS....1633
11.1.3 DATA TRANSMISSION BETWEEN CONTROLLER AND CARDS....1638
11.1.4 DETAILS OF INDICATORS ON MAIN DISPLAY SCREEN....1640
11.1.5 REAR VIEW....1644
11.1.6 ITEMS REQUIRED TO BE EXECUTED FOR REPLACEMENT OF CONTROLLER OR DATA CARD....1649
11.2 PREPARATION FOR USE....1650
11.3 TURN THE POWER ON....1651
11.4 UPGRADING PROGRAMS....1652
11.4.1 PROCEDURES....1652
11.4.2 UPGRADING OF INDICATION PROGRAMS....1654
11.4.3 UPGRADING OF CONTROL PROGRAMS....1657
11.5 STATUS CHECK....1659
11.5.1 SIGNAL CHECK....1660
11.5.2 OPERATION PROGRESS....1662
11.5.3 COMMUNICATION DATA....1665
11.5.4 INDICATION OF ADJUSTMENT VALUE....1666
11.5.4.1 ANGLE SENSOR ADJUSTMENT VALUE....1667
11.5.4.2 LOAD CELL ZERO POINT ADJUSTMENT VALUE....1668
11.5.4.3 ADJUSTMENT VALUE OF LOAD CELL FOR LINE-PULL....1669
11.5.4.4 RESULT OF MANUFACTURE ADJUSTMENTS "NO LOAD" AND "SOME LOAD"....1670
11.5.4.5 RESULT OF LOAD ADJUSTMENTS "NO LOAD" AND "SOME LOAD"....1671
11.5.4.6 ADJUSTMENT VALUE OF WORKING RADIUS....1672
11.5.4.7 ALTERATION OF ADJUSTED VALUE....1673
11.5.4.8 DELETION OF ADJUSTED VALUE....1674
11.5.5 TROUBLE RECORD....1675
11.5.6 CHOICE OF LANGUAGE (CKE SERIES ONLY)....1677
11.5.7 LOAD RECORD (LOAD RECORD IN THE MAIN MENU)....1678
11.6 ADJUSTMENTS....1679
11.6.1 REMOVING THE INNER PANEL....1679
11.6.2 ADJUSTMENT....1680
11.6.2.1 ANGLE SENSOR ADJUSTMENT....1683
11.6.2.2 LOAD CELL ZERO POINT ADJUSTMENT....1687
11.6.2.3 LOAD-LESS ADJUSTMENT & SOME LOAD ADJUSTMENT....1689
11.6.2.4 LVL ADJUSTMENT (LVL SETTING)....1696
11.6.2.5 RADIUS ADJUSTMENT....1699
11.6.3 LOAD ADJUSTMENT....1701
11.6.4 ADJUSTMENT DATA COPY (INITIALIZATION)....1704
11.6.4.1 READING OF THE ADJUSTMENT DATA....1706
11.6.4.2 WRITING OF ADJUSTMENT DATA....1708
11.6.4.3 INITIALIZATION OF ADJUSTMENT DATA....1709
11.6.5 VERSION CHECK....1710
11.7 ERROR CODE (ABNORMALITY DETECTION) AND COUNTERMEASURES....1711
11.8 CONTROL OUTPUT....1715
11.9 RELEASES....1727
11.9.1 RELEASE FUNCTION....1727
11.9.1.1 CRANE RELEASE CHART....1727
11.9.1.2 ALARM SOUND....1733
11.9.1.3 EXTERNAL INDICATOR LAMPS IN RELEASE CONDITION....1734
11.10 MECHANICAL SPECIFICATION....1735
11.10.1 ENVIRONMENTAL PERFORMANCE PARAMETERS....1735
11.10.2 LOAD CELL (CRANE)....1736
11.10.3 ANGLE SENSOR....1737
11.10.4 CONTROLLER....1738
11.11 EXTERNAL DIMENSIONS....1742
11.12 ELECTRIC SCHEMATIC DIAGRAM....1743
11.12.1 CRANE TYPE....1743
11.12.2 LUFFING TYPE....1744
11.13 CONTROLLER MALFUNCTION EMERGENCY MEASURES....1745
11.14 LOAD SAFETY DEVICE CHECK PROCEDURES....1746
12. GAUGE CLUSTER....1748
12.1 CONFIGURATION OF DISPLAY....1750
12.2 PRIORITY....1751
12.3 STATUS DISPLAY....1753
12.4 FAULT LOG DISPLAY....1763
13. TOTAL CONTROLLER....1768
13.1 ARRANGEMENT OF TOTAL CONTROLLER....1770
13.2 COMPOSITION OF SYSTEM....1771
13.2.1 OUTPUT RELATION TO CONTROLLER....1772
13.3 FUNCTION OF TOTAL CONTROLLER....1773
13.4 TOTAL CONTROLLER (HARDWARE)....1798
13.4.1 OUTLINE....1798
13.4.2 SPECIFICATIONS OF TOTAL CONTROLLER OUTPUT....1799
13.4.3 DETAILS OF TOTAL CONTROLLER CONNECTOR....1803
13.4.4 ARRANGEMENT OF TOTAL CONTROLLER CONNECTOR PIN....1804
13.4.5 PROPORTIONAL SOLENOID VALVE MEASURING POSITION (VOLTAGE)....1811
13.5 ADJUSTMENT OF TOTAL CONTROLLER....1813
13.5.1 NECESSITY OF ADJUSTMENT....1813
13.5.2 ADJUSTMENT PROCEDURES OF TOTAL CONTROLLER....1813
13.6 CONTROLLER MALFUNCTION EMERGENCY MEASURES....1820
14. AIR CONDITIONER....1822
14.1 OPERATION ITEMS....1824
14.2 SAFETY MONITOR FUNCTIONS....1825
14.3 DISASSEMBLY AND ASSEMBLY PROCEDURE....1828
14.3.1 SPECIAL CONSIDERATIONS DURING REPLACEMENT....1828
14.3.2 INTERIOR UNIT....1830
14.4 OPERATIONAL PRECAUTIONS....1839
14.5 INSPECTION AND MAINTENANCE....1840
14.5.1 INSPECTION/MAINTENANCE LIST....1840
14.5.2 INSPECTION/MAINTENANCE PROCEDURES....1840
14.6 ELECTRIC SYSTEM SCHEMATIC....1844
15. TRANSLIFTER SYSTEM....1846
15.1 LOCATION OF MAIN COMPONENTS....1848
15.2 CONSTRUCTION AND WORKING PRINCIPLE....1851
15.2.1 OUTLINE....1851
15.3 WORKING PRINCIPLE....1853
15.3.1 RAISING THE TRANSLIFTER....1853
15.3.2 LOWERING THE TRANSLIFTER....1855
15.4 REMOTE CONTROL SWITCH....1857
16. JIB HOIST SYSTEM....1858
16.1 APPARATUS AND LOCATION OF COMPONENTS....1860
16.2 CONSTRUCTION AND FUNCTION....1861
16.2.1 HYDRAULIC SCHEMATIC....1862
16.2.2 RAISING THE JIB....1863
16.2.3 NEUTRAL (MAINTAINING THE JIB POSITION)....1865
16.2.4 LOWERING THE JIB....1867
16.3 JIB DRUM LOCK....1869
16.3.1 ASSEMBLY DRAWING....1869
16.3.2 ADJUSTING THE JIB DRUM LOCK....1870
KOBELCO CK2500-II, CKE2500-II Crawler Crane Repair Service Manual
