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    Kobelco CK Cke2500-2f (S5jd00002ze03)

    Uploaded by

    Robin Huang

    Copyright:

    © All Rights Reserved
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    CRAWLER CRANE SHOP MANUAL CK2500-11 model ¢KE2500-Il KOBELCO BOOK CODE —_: $60000022E03 Aagicae | Appa Mating | —_Oate of ksve ean exasoou | Fem sooxoaona | moons | ssuoooazeoi cxEZ001,| From JOD402001 | 200608 | aiboo0022602 00508 | s5iooou2ze03 TABLE OF CONTENTS SAFETY 4. SPECIFICATION 1.1 CK2500-II SPECIFICATION. 11 PERFORMANCE, 1.1.2. PERFORMANCE OF LUFFING JIB 1.13. OUTSIDE DIMENSIONS. 414 DIMENSIONS AND WEIGHT OF EACH PARTS. 1.4.4.1 BASE MACHINE 4142 COUNTERWEIGHT. 41.43 ATTACHMENT 11.5 CK25001II STABILITY IN SWINGING AND TRAVELING. 1.2. CKE2500-II SPECIFICATION 1.21 PERFORMANCE. 1.22 PERFORMANCE OF LUFFING JIB 1.23. OUTSIDE DIMENSIONS. 1.2.4 DIMENSIONS AND WEIGHT OF EACH PARTS. 1.2.4.1 BASE MACHINE. 12.42 COUNTERWEIGHT. 1.2.43 ATTACHMENT 4.25 CKE2500-II STABILITY IN SWINGING AND TRAVELING. 2. MAINTENANCE STANDARDS TEST PROCEDURES 24. MAINTENANCE STANDARD. 2.11 PIN, BUSHING, SPRING, LINING AND SHEAVE. 2.4.2 PROPEL DEVICE, 2.2. PERFORMANCE STANDARD AND TEST PROCEDURE. 22.1 OPERATING SPEED 22.2 POINT AND METHOD OF MEASURING PRESSURE. 22.3. SLEWING RING 3. GENERAL WORK STANDARD 3.1. TIGHTENING TORQUE OF CAPSCREWS AND NUTS: 3.1.1 METRIC COARSE THREADS. 3.12 METRIC FINE THREADS, 3.1.3 COARSE THREDS UNC. 3.1.6 FINE THREADS UNF. 3.15 TIGHTENING TORQUE OF HYDRAULIC FITTINGS. 32. STANDARD PARTS. 321 BOLT 322 O-RING. 13 13 13. 14 16 16 17 19 114 118 1.18 118 116 118 118 +19 121 1.28 23 23 240 246 246 247 223 33 33 a3 35 37 a7 38 323 324 ‘TABLE OF CONTENTS BACK-UP RING. BITE FITTING. 3.3. CONVERSION TABLE. 33.1 332 333 334 UNIT CONVERSION MILLIMETER : INCH CONVERSION TABLE. METER-FOOT CONVERSION TABLE GRADIENT CONVERSION TABLE 3.4 TABLE OF UNIT WEIGHT 4, POWER TRAIN 4.4. INTRODUCTION, 42. ENGINE 424 422 423 424 INTRODUCTION REMOVAL REPAIR AND MAINTENANCE RE-INSTALLATION, 43 PUMP DRIVE ASSEMBLY. 434 432 433 434 435 438 INTRODUCTION. REMOVAL DISASSEMBLING THE POWER DIVIDER. (CHECK AND REPAIR OF THE POWER DIVIDER, ASSEMBLING THE POWER DIVIDER, RE-INSTALLATION. 5. HYDRAULIC SYSTEM 5.1 LOCATION OF MAIN HYDRAULIC COMPONENTS 52 HYDRAULIC CIRCUITS AND COMPONENTS. 524 522 523 HYDRAULIC CIRCUIT. COMPONENT SPECIFICATIONS. LOCATION OF HYDRAULIC COMPONENTS. 53 HYDRAULIC SYSTEM 53.1 532 533 534 535 536 PREFACE, OUTLINE: CL FLOW FROM No.1 and No. 2 PUMPS. CL. FLOW FROM No.3 AND No.4 PUMPS IL FLOW FROM No.5 PUMP (Control Purp) IL FLOW FROM No.6 PUMP (For Auxiliary Actuator Circuit). 54 VALVES 340 342 312 343 345 346 37 410 410 410 ana 413 44 45 63 54 54 58 B12 519 519 519 521 523 525 5.29 532 ‘TABLE OF CONTENTS. 6. HOIST SYSTEM 6.1 APPARATUS AND LOCATION OF COMPONENTS. 62 CONSTRUCTION AND FUNCTION 624 622 623 624 625 626 HYDRAULIC SCHEMATIC. LIFTING A LOAD. HOLDING A RAISED LOAD. LOWERING A LOAD (POWERED LOWERING) FREE FALL OPERATION FREE FALL ACCELERATION, 63 DRUMLOCK. eat 632 ASEEMBLY DRAWING. ADJUSTMENT OF DRUM LOCK. 64 WINCH ASSEMBLY 644 642 643 WINCH INSTAL. WINCH ASSEMBLY / REDUCTION UNIT WITHOUT FREE FALL (STD)). WINCH ASSEMBLY WITH FREE FALL (OPT) 65. BRAKE PEDAL, 6st 652 ASSEMBLY DRAWING. ADJUSTING THE BRAKE PEDAL 66. BLEEDING AIR FROM BRAKE CIRCUIT. 7. BOOM HOIST SYSTEM 7.1. APPARATUS AND LOCATION OF COMPONENTS: 7.2 CONSTRUCTION AND FUNCTION 724 722 723 724 HYDRAULIC SCHEMATIC. RAISING THE BOOM. NEUTRAL (MAINTAINING THE BOOM POSITION). LOWERING THE BOOM. 7.3. BOOM DRUM LOCK, 734 732 ASSEMBLY DRAWING. ADJUSTING THE BOOM DRUM LOCK. 7.4 DRUM AND REDUCTION UNIT 744 742 BOOM WINCH ASSEMBLY ‘BOOM DRUM AND REDUCTION UNIT ASSEMBLY 8, SWING SYSTEM 8.1 APPARATUS AND LOCATION OF COMPONENTS. 82 CONSTRUCTION AND FUNCTION 24 HYDRAULIC SCHEMATIC. 63 ea ea 66 cy 6-10 13 616 eg 618 19 620 620 621 623 624 624 628 627 73 75 75 78 78 740 Taz 742 743 744 744 745 a3 85 TABLE OF CONTENTS 822 SWING 823. STOPPING. 83 SWING REDUCTION UNIT 8.4 SWING BEARING. 88 SWING LOCK 9, PROPEL SYSTEM 9.1 LOCATION OF THE MAJOR COMPONENTS 9.2. CONSTRUCTION AND FUNCTION 9.2.1 HYDRAULIC SCHEMATIC. 822 PROPELLING (RIGHT SIDE FORWARD). 92.3 STOPPING. 93 PROPEL REDUCTION UNIT. 9.3.1 REDUCTION UNIT. 932 MOTOR 9.4 ADJUSTMENT. 10. ELECTRIC SYSTEM 10.1 ELECTRICAL WIRING SCHEMATIC. 10.2 CONNECTOR LIST. 10.3 ARRANGEMENT OF ELECTRICAL PART. 10.3.1 ELECTRICAL PART OF CAB 410.32 ELECTRICAL PART OF RIGHT DECK, 40.3.3 ELECTRICAL PART OF FLOOR PLATE & LEFT SIDE STAND PANEL 10.3.4 ELECTRICAL PART OF REVOLVING FRAME. 10.3.6 ELECTRICAL PART OF LEFT DECK. 10.3.6 ELECTRICAL PART OF LEFT GUARD. 10.4 ELECTRICAL PART. 10.4.1 FUSE BOX (GG73E00004F1) 10.42 WIPER CONTROL RELAY(2480U 1366) 40.4.3 SWING FLASHER UNIT (24800308) 10.5 PRESSURE SWITCH (CONTROL PRESSURE CUT & FREE FALL). 10.6 PRESSURE SENSOR 10,7 RELAY BOX (GG24E00024F1) 10.7.1 ARRANGEMENT OF CONNECTOR 10.7.2 RELAY BOX SCHEMATIC. 10.8 LEFT SIDE STAND PANEL (WITH FREE FALL) 10.9 BYPASS SWITCH PANEL 10,10 ROUBLESHOOTING OF EXHAUST GAS THIRD REGULATION ENGINE. 4 36 810 a4 346 18 eere 08 910 oz ona 016 103 10-47 10.68 10-68 10-72 10-76 1081 10-83 10-89 10-90 10-90 10-92 10-93 10.04 10.96 10-98 10-98 10-100 10-103 10-107 10-108 ‘TABLE OF CONTENTS 10.10.1 FAILURE DIAGNOSIS FUNCTION 10.10.2HOW TO CHECK THE FAILURE CONTENTS 10.10.3CHECKING BLOWN-OFF DIAGNOSIS LAMPS. 10.10.4ENGINE ECU 14. LOAD SAFETY DEVICE 11.1 PART NAMES AND FUNCTIONS. 11.4.4 FRONT VIEW. 11.4.2 CONFIGURATION OF SCREENS [CKE SERIES] 11.4.3 DATA TRANSMISSION BETWEEN CONTROLLER AND CARDS. 11.4.4 DETAILS OF INDICATORS ON MAIN DISPLAY SCREEN. 11.1.5 REAR VIEW. 11.1.6 ITEMS REQUIRED TO BE EXECUTED FOR REPLACEMENT OF CONTROLLER OR DATA CARD AND INSTRUCTIONS. (In. similar manner to upgrade of program) 11.2 PREPARATION FOR USE. 11.3 TURN THE POWER ON 11.4 UPGRADING PROGRAMS. 11.4.1 PROCEDURES 11.42 UPGRADING OF INDICATION PROGRAMS. 11.4.3 UPGRADING OF CONTROL PROGRAMS 411.8 STATUS CHECK, 11.5.1 SIGNAL CHECK. 11.52 OPERATION PROGRESS 11.5.3 COMMUNICATION DATA. 11.5.4 INDICATION OF ADJUSTMENT VALUE. 1.54.1. ANGLE SENSOR ADJUSTMENT VALUE. 115.42 LOAD CELL ZERO POINT ADJUSTMENT VALUE 11.543 ADJUSTMENT VALUE OF LOAD CELL FOR LINE-PULL 11.544 RESULT OF MANUFACTURE ADJUSTMENTS "NO LOAD" AND "SOME LOAD’ 11.548 RESULT OF LOAD ADJUSTMENTS "NO LOAD" AND "SOME LOAD" 11.548 ADJUSTMENT VALUE OF WORKING RADIUS. 1115.47 ALTERATION OF ADJUSTED VALUE 11.548 DELETION OF ADJUSTED VALUE. 11.5.5 LOAD RECORD 41.5.8 TROUBLE RECORD 11.5.7 CHOICE OF LANGUAGE (CKE SERIES ONLY). 11.8.8 LOAD RECORD (LOAD RECORD IN THE MAIN MENU) 11.6 ADJUSTMENTS. 11.6.1 REMOVING THE INNER PANEL. 41.8.2 ADJUSTMENT. 10-108 40-109 10-114 10-118 113 113 18 11413 11415 11-19 11-24 11.28 1126 1427 1127 1129 41-32 1134 11.38 11.7 11-40 1141 11-42 11-43 11-44 11-45 11-48 11-47 11-48 11-49 11-60 11-53 1155 11-58 11-87 1187 11-58 TABLE OF CONTENTS 11.62.1 ANGLE SENSOR ADJUSTMENT 11.622 LOAD CELL ZERO POINT ADJUSTMENT. 14.6.23 LOAD-LESS ADJUSTMENT & SOME LOAD ADJUSTMENT 1116.24 LVLADJUSTMENT (LVL SETTING) 1162.5 RADIUS ADJUSTMENT. 11.83 LOAD ADJUSTMENT. 11.64 ADJUSTMENT DATA COPY (INITIALIZATION), 11.6.4.1 READING OF THE ADJUSTMENT DATA 14.6.42 WRITING OF ADJUSTMENT DATA, 11.843 INITIALIZATION OF ADJUSTMENT DATA, 11.65 VERSION CHECK, 11.7 ERROR CODE (ABNORMALITY DETECTION) AND COUNTERMEASURES: 11.8 CONTROL OUTPUT. 11.9 RELEASES 11.9.1 RELEASE FUNCTION 17.91.1 CRANE RELEASE CHART 419.12 ALARM SOUND 419.13 EXTERNAL INDICATOR LAMPS IN RELEASE CONDITION 11-10MECHANICAL SPECIFICATION. 11.10.1ENVIRONMENTAL PERFORMANCE PARAMETERS, 411.10.2LOAD CELL (CRANE). 11.10.3ANGLE SENSOR 44.10. 4CONTROLLER, 1.10.4. MODEL NAME, 1.10.4 2SYSTEM INPUTIOUTPUT 1.10.4. 3MONITOR DISPLAY. 11.10.4.40PERATION SWITCH 11.10.4.5INTERNAL PROCESSING SYSTEM 1110.4. 6MEMORY. 11.10.4,7 EXTERNAL STORAGE ELEMENT 11.10.46 8OTHERS. {11.1EXTERNAL DIMENSIONS. {11.]2ELECTRIC SCHEMATIC DIAGRAM 11.12, RANE TYPE 11.12,2LUFFING TYPE, 1.ASCONTROLLER MALFUNCTION EMERGENCY MEASURES. .ASLOAD SAFETY DEVICE CHECK PROCEDURES. 12. GAUGE CLUSTER 12.1 CONFIGURATION OF DISPLAY. 12.2 PRIORITY 423 STATUS DISPLAY. 412.4 FAULT LOG DISPLAY. 1161 11-65 1187 1173 1176 11:78 1181 11.83 11-85 11-86 1187 11-88 11-90 4402 4-102 14-402 14-108 14-108 14110 snt0 att sae 11413 11413 114113 1415 11115 11115 11115 114116 11416 wa4t7 11418 1418 11419 11-120 1121 23 124 126 1246 ‘TABLE OF CONTENTS 13. TOTAL CONTROLLER 18.1 ARRANGEMENT OF TOTAL CONTROLLER 18.2 COMPOSITION OF SYSTEM. 18.2.1 OUTPUT RELATION TO CONTROLLER 18.3 FUNCTION OF TOTAL CONTROLLER. 19.4 TOTAL CONTROLLER (HARDWARE) 13.41 OUTLINE 18.4.2 SPECIFICATIONS OF TOTAL CONTROLLER OUTPUT. 13.43 DETAILS OF TOTAL CONTROLLER CONNECTOR 18.4.4 ARRANGEMENT OF TOTAL CONTROLLER CONNECTOR PIN 18.4.8 PROPORTIONAL SOLENOID VALVE MEASURING POSITION. 18.5 ADJUSTMENT OF TOTAL CONTROLLER 18.5.1 NECESSITY OF ADJUSTMENT. 18.5.2 ADJUSTMENT PROCEDURES OF TOTAL CONTROLLER, 1352.1 OPTION SETTING 13.522 ADJUSTMENT OF HAND THROTTLE AND FOOT THROTTLE. 13.523 ENGINE SPEED ADJUSTMENT. 1352.4 WHEN ADJUSTMENT OF TOTAL CONTROLLER IS IMPOSSIBLE 43.525 INITIAL ADJUSTMENT OF LIFTING HEIGHT GAUGE 14, AIR CONDITIONER 14.4 OPERATION ITEMS. 142 SAFETY MONITOR FUNCTIONS 143 DISASSEMBLY AND ASSEMBLY PROCEDURE. 14.3.1 SPECIAL CONSIDERATIONS DURING REPLACEMENT. 1432 INTERIOR UNIT 1432.1 CASE DISASSEMBLY. 14322 THERMOSTAT REPLACEMENT. 14323 EVAPORATOR OR EXPANSION VALVE REPLACEMENT. 1432.4 HEATER CORE REPLACEMENT. 14325 INTAKE DUMPER ACTUATOR REPLACEMENT. 14326 WATER VALVE ACTUATOR OR WATER VALVE REPLACEMENT. 14327 MODE ACTUATOR REPLACEMENT 14328 BLOWER MOTOR ASSEMBLY REPLACEMENT 14.4 OPERATIONAL PRECAUTIONS. 145 INSPECTION AND MAINTENANCE. 44.5.1 INSPECTIONIMAINTENANCE LIST. 14.52 INSPECTIONIMAINTENANCE PROCEDURES. 146 ELECTRIC SYSTEM SCHEMATIC. 45. TRANSLIFTER SYSTEM 18.1 LOCATION OF MAIN COMPONENTS: 133 134 135 136 1331 1331 13:32 13:36 1397 13.44 13-45 13-45 13.45 13.45 13-47 13-48 13-49 13-60 163 TABLE OF CONTENTS 18.2 CONSTRUCTION AND WORKING PRINCIPLE. 162.1 OUTLINE 16.3 WORKING PRINCIPLE 183.1 RAISING THE TRANSLIFTER. 18.3.2 LOWERING THE TRANSLIFTER, 184 REMOTE CONTROL SWITCH 16. JIB HOIST SYSTEM 16.1 APPARATUS AND LOCATION OF COMPONENTS. 16.2 CONSTRUCTION AND FUNCTION 16.2.1 HYDRAULIC SCHEMATIC. 1622 RAISING THE JIB 162.3 NEUTRAL (MAINTAINING THE JIB POSITION) 16.24 LOWERING THE JIB, 16.3 JIB DRUM LOCK. 16.3.1 ASSEMBLY DRAWING. 16.3.2 ADJUSTING THE JIB DRUM Lock 166 166 158 158 16-10 1512 163 164 16-4 166 168 16-10 16-12 16-12 16-13 SAFETY ot (©K2500:1, CKE2500-I1 SAFETY (€K2500.1, CKE2500-I1 02 SAFETY ‘This section explains "Explanation of Waring Descriptor, “Warning Labels’ and "General safety" EXPLANATION OF WARNING DESCRIPTION ‘This manual ical the contents of warnings concerned in salet with the following twee stags according tothe ree of personal harm and material damage Since the very important raters or safety are describod, understand the contents sufcienty and observe them tout a PRISER] erring to avoid dangerous condition resulting in instantaneous death or serious personal injury. (BRWARRING) v2 10 void dangerous conton whi has post of death or serous personal jy. \Virring to avoid dangerous codon which has possibly to cause sight or medium nur or damage ofthe machine and equipments ‘This manual describes safety wamings suficinty but dangerous conitons whic are impossible tobe anticipated sate consideres “Therefore, take measures fo safety not only eparing he machin, but als including the working environment [EXPLANATION OF WARNING LABELS ‘Since the waming labels instal in the machine and inca with the toe stages in the sare way 8 the warning description, confm he postions and contents a waning libel rst. Pt them tthe practical ute to secre safety when operating checking and performing maintnance, + HANDLING OF WARNING LABELS ‘nen the warning labels damaged o stained, order ito the designated sence shop. 2, Donat remove the warning labels 3. When the surface of he warning abe soed and felt o be een, wipe clean os (¢k2500-11, CKE250041 ccK2s00-1 —_ ro Aiew 4 DANGER iri ete, eae eta (©k2500.11, CKE2500-H1 og SAFETY ‘ex2s0041 | a L_] DETAIL Y oa DETAIL OF ACCUMLATOR os (€K2500.1, CKE250041 SAFETY ‘ex250001 1 Fe ct amr f SECTION 2-2 (€k2500.11, CKE2500.1 0s SAFETY ‘eK250041 A DANGER ‘STAY anh FO WeHME | Tae reuse TpOwR ties, | cine LOAD woo BECOKE ELECTRIFIED ND END o7 (€K250041, CKE2S0041 SAFETY eK260041 VIEW R Ay DANGER. re gra eon mors 0 cues A BANGER Wo = pes SECTION N= SECTION x (€k250041, CKE2500-H1 os SAFETY ‘exzs00u1 FUEL TANK) voeaicie Tw (A cuTION DETAIL.D SECTION Eve ery DETAIL DETAIL F. CEL pera @ 09 ‘CK250011, CKE2500«1 SAFETY ‘eK250041 o oa 4 DANGER 5 SECTION H-H (© 2500-11, CKE250041 0-10 SAFETY ‘oK250041 4 DANGER Ay DANGER ‘STAY AM FROK CHIE UIE TO POFER LIMES. CME LO ak otnd BECOME ELECTRIFIED 40 DEADLY. on (€K2500-11, CKE25004 SAFETY ‘ex250041 800M BASE Boom Tip QS DANGER AL CAUTION. (€ 2500-11, CKE250041 042 .eK2500.1 043 (€k2500-11, CKE26004 SAFETY ‘ex2800.1 INSIDE view TFR, STRUT > AN DANGER]| AGAUTION INSI0E view (€k2500-11, CKE250041 ona ‘eK2500.1, dy DANGER DETAIL A DANGER —& ee eros, THE coor aaave lo evcinoen stn iNGt 048, (©K250011, CKE2S00-1 SAFETY ‘cKE2s0051 ov-T (€2500411, CKE25004 4 DANGER 4 DANGER STAY A FO cA TPeoae 10 oveh Les, Mca LOAD 0 Gm one LECTED EADY ‘eKE2500.1 SAFETY A WARNING CetinG DETAIL OF ACCUMLATOR or (Ck2500-H, CKE25004I1 SAFETY ‘eKE2s004 SECTION 2-2 ‘©K2500-11, CKE2500-1 os ‘CKE2500:1 At Not ovine arte a ter 4 DANGER ‘TAA FON RINE Tr euts 10 OnE LINES. cis 0 GND iy aecveeterairied 019 (©k250041, CKEZ50041 ‘SAFETY ‘eKE2s00-1 Soaar cena view @ ‘A BANGER wx 2 ~ poe Obl SECTION N-W SECTION SECTION x-x (€k2500.11, CKE250041 020 SAFETY (cKE2s0041 FUEL TANK) [ivoeavcic raw] LF) [aceumon) [a como q Fev ott] [botwor tog | fas DETAIL. SECTION E-E DETAIL G. DETAIL F. SeTAlA S DETAIL 021 (€K2500.11, CKE250041 SAFETY ‘eKE2s00:1 4A DANGER SECTION (€K 250041, CKE2500411 022 ‘cKE2s0041 4 DANGER 4 DANGER | ‘STAY AU FRON WCRI | COE ELECTHIFIED INO DENY. A cANGEA INSIDE VIEW (R/#D A Gao 023 (6250041, CKE2500411 (©K2500-H1, CKE2500-I1 SAFETY ‘eKE2500.1 “DONOE ENTER 2 GUY CABLE LINK PIN A, DANGER | “serrine positiON FSU INS URN? | sow er Ute 028, (€K250041, CKE2S0041 SAFETY ‘oKE2s0041 (©K2500-11, CKE2500-1 028 SAFETY ‘CKE2500:1 Exteel | | a Tenis DETAIL A ADANGER Ay WARNING awe SURELY. TF THE lack is PEW 17 18 FReslinarae feo Sst at ine Ooi tr TW OaNGeR OF Ji ie her Sa loveRwo rst kG Because [oF CYLINDER SHRINGING 027 (© 2500-11, CKE250041 SAFETY PRECAUTIONS FOR INSPECTION AND MAINTENANCE. 1. Senice and maintenance must be performed only by authorized personnel who are quails in compliance wth ‘a rlovant ao equation, 2. Regular maintenance or inspection shouldbe quciy performed afer shuting down the machine and ensuring safety o personne! and equipment Post an"INSPECTION IN PROGRESS, DO NOT START: warning ign ona eodiy vst locaton (GENERAL SAFETY PRECAUTIONS 1. Wear safety shoes, helmets and clothing suitable forthe ob. Also use protective goggles, mask loves, ee 2s requires 2. To ensure safe and correct mainienance,carefly stoy ths SHOP MANUAL and get fy fair wth he stuetons init 3. Place tie machine in a safe place. Always maintain ste clearance around the machine. 4 Btore starting crane operation, hod a safety meeting, Also, make agreement on standardized hand signals, '5. When inspecting orhanding the bata ool, donot use exposed fame nearby. “To avai Fre accident only use explosion poo! ighting equipment 1. Satan inspection or maintenance work any ar shutting down the engine 7. Certain machine components remain hot immediately ater the engines shut down. De not touch them. 8. Beloreremeving the rasatr cap, wat unt the coolant water gets sufcent cool, Next, caretly loosen the ‘ap and release radar pressure, and them emeve the cap 9. Betore inspecting or maintaining aneletical sytem onthe machine, ower of the machine by, for example, dtsconnecing he batery cables. 10. When working at high it area, always wear a safety bl, "1. When ving the operators cab fc an nspecton or maintenance work, postan “INSPECTIONIIN PROGRESS, DO NOT START." warning sign ona readily visbelocatin. Also lok he cab for secu, 12, Bere starting a cleaning or ubreston work onthe machine, always shut down the engine, 13, While adjusting the pressure, be absolutely careful shout uptureofa te, yng of wheel pa. "14, Use genuine KOBELCO replacement parts and ots only 15, ways keep the cl containers clean. Protect them against ingress of dst or moisture, Also, ilean, fresh ison. 18. Oncoa maintenance work is complete clean the machine. Protect grease nipples, breathers, and ollavel gages againat ingress of du, 17 Aways keep the subjects of regular inspection clean tow problems such a leakage, crack, looseness, 0, tobe realy detected 18, Ouing car washing, donot allow high pressure steam tobe directly applied to elecical components and con- 18, Aer removing Ovngs, ol sea, gaskets, ez clan the mounting seats. Then, install rsh O-ings cl seals, (gaskets, ec. Also, rememéer to thinly apply oto the sal faces ofthese parts boo instaation 20, Before asconnectng pressurized piping release the inside pressure 21. CAUTIONS fot epair work wth welding: Tur OFF the Key swich, disconnect the negative termina on batty to power of he eecical cut provide grounding wihin 1 meter rom a weld area; advance, remove elec: tronic components for exampie, controle) o prevent possible mage 22. Dispose indus wastes acordng ta eovant iw or regulation 23. Extely cael dung an inspection or aintenance work under ie carer Rerpamber the possbity of be ing crashed ‘when ackng up the machine for an inspection or msintenance werk place blocks below ito prevent acedentl tating 24, Provide postive ventilaton when refling oso el, sng parts, or tating the engine (€K2500.11, CKE250041 028 SAFETY 25, Toremave aheavy component (20 ky or heavier), use a crane, ee. Aways Keep safely in mid 26. legal or unauthorized, or otterwise nonconforming mosecaton is sity inhibited 27. De no allow ol or dust ta depos around the engine. Other, fre accident can result 28, Store removed atschments and comgonents safely so the! they do nat drop fl down. 29, Aways use correct ols tha have been well maintained 420, Te prevent personne rom being caught by inning fan, el, shaf or he ke, shut down the engin Beare ‘tating an inspect or maintenance work 231, Batley quid and ots ae harmtalto human heath ttouching any ofthese materials, immediatly wash away. 22. Make sure to use the igh ol for uel. 029 (€K2600.11, CKE2500-11 SAFETY (C2500, CKE250041 030 1. SPECIFICATION ory (¢K2500.1, CKE250041 1. SPECIFICATION ‘©K2500.11, CKE2500-I1 12 4. SPECIFICATION 4.4 CK2500-II SPECIFICATION 444 PERFORMANCE Fre ‘Gawler mound, ly ovoing Ia. itng capacity with 1.2m (0) boom) aoe (500,000 bs x16) [ax boon engi 91.4 m (00) [Max boom 8 lngth 762m boom + 30.5 mj (250 boom + 100) [asic boorinath 15:2m(60R) \irking weight (nctuding upper and ower machin, counterweight, carbody weighs, 18.2 m 60) boom, hook bock) ‘Approx. 216 ton (476,20 Ibs) [average ground pressure Fopiox 101 Wa TA6 pe (Gradeabaty an 0) 20% engine Fine PHTC-UN Dies engine 247 2000 min" (31 N20) Main fing owing ope peed “101 3 min (360 fo 10 Urn) [Ania iting lowering rope speed 7101 3 min (360 to f0 Min) {Bcom ring rope speed 2x22 102 mimo pane 2x72 106.8 AImin) 2x22 10 2mimn 'Bcom lowering rope speed ee ‘Swing speed "22 mim (22 om) [Propel speed] THO Hh (60 to 0.44 ros) (4) Tee main ting towering rope sped, the aula iting ower rope speed, and te prope speed vary depending onthe load. (2) The rope speed i ofthe fst ayer onthe drum, 442 PERFORMANCE OF LUFFING JIB [Max iting capacity [saatx 137m (O00 we x ASA [Max. boom length + Jb longth[6.0™m boom + 1.6 mj (200 Rboom + TTOATB) [approx 228 (602600 los) |working weight [incucing upper are ower machine, counteweighis [21.8 m boom + 21.3 mj (70 boom + 70 jy), hook lock] TAporox 106 KP (154 ps) [average ground pressure [inducing upper a lower machin, counterweight, [21.3 mboom + 21.3 mjib 70 boom + 70), hook Week) Lb aig owonng ope speed [40 to 2mm. (120106 Nin). 13 (€K2500.11, CKE2500411 4. SPECIFICATION 4.42 OUTSIDE DMENSIONS [Height above ground of cae Barommrze) ‘Wath of upper machine wi operaors eb [400 mm (1129) Rus of rear end (vit counerwegh) [3.000 mm (108°) (Courtrweight ground deararco so mm 09) (Center of rotation to boom fot pa i400 mm 7") [Height aboveground of boom fot a [230 mm 62% Height op of gan (working poston) [5530 mm a2) (Overt engi of caulers [5.985 mm (29 6 Distance between centre oF umblow 7.895 mm 254) (Overall with of rowers 7.730 mn (254) whan of rawr shoe 1.30 men (52) (Ground dearance of earbody 38 mm (172) (¢ 2500-11, CKE250041 14 LUN mm ine) 4. SPECIFICATION. Taaneorr Tras (€K25001, CKE250041 4. SPECIFICATION 444 DIMENSIONS AND WEIGHT OF EACH PARTS For your reference, he chart below shows the dimensions and weight of each pans. 4441 BASE MACHINE 3) = Oren a — ee, tn 3000") amore) ase \orawier (51,400) dé os — i em ae soc [ant (6,860) os enn = (€k2500-11, CKE250041 16 4. SPECIFICATION. 4442. COUNTERWEIGHT ‘ame mension rman (f-n} Weight c oe ny ni :| enone eaunereit 6 2 row < . (24,343) 108 1 mae) 8 562511 Piece countrwoion | (12400 q ‘eee i (O Oo} counter eooeereer a a counterwescri 17 (625004, CKE2500411 41. SPECIFICATION aa Nowe meson an a 3 ne [soy ao wee Paes eS vo ey | a TL ‘COUNTER WEIGHT BASE) (€k25001, CKE250041 18 1. SPECIFICATION 4443 ATTACHMENT “The weight ofthe guy lines isntincluded int the tachment weight ve Oi = 00 [Pom pase (10,288) ane Fa fenton ier ey mcm 190 ncn |(with guy fine) ie fezmon ao feeb a ‘aon SEXAXAXAXAXAX | ARIMA i 19 (©K2500.1, CKE250041 1. SPECIFICATION — omen om) ar ak Kou a: KOK E Li one orca es bo tx crane) ro) somcon - no - ss) lzzmom KXXXXXXXXM 71 | [eter by Fron tut 4.160 [ting y2) (2560) Rear sit 1.190 (utng i) 280) 100 ating backstop a (©K250041, CKE2500-1 142 4. 8PECIFICATION We ve mension nn tn) ea 5 leat saston tg ‘0 feo 699 2 Joe steve er Jax save 0 [Fort ea eee pew nase z) sing sem te ooo sey (32% 4 ie 5 e |Boom Base “ 6.810 wa cy «sor (Ck 25004H, CKE2500-11 41. SPECIFICATION 44.5 CK2500U STABILITY IN SWINGING AND TRAVELING ‘Abound swing Propaling ‘tachmet counter | carboay when jak (ast) wont) | weight @) | wit erawer | winouteraw| Fonwaraing | Backwarsng [Westanaie a0 (Gackvard svage) | _ N°? Ne | 9 | ° ° Mast ange esa e | None None ° ° ° ° ast angle: 185° me (@ackward stage) |S me ° ° ° ° ast ange ro a Loss than 71" 3 ° ° ° ° ast angle: 180° ioe (Backnard sage) | N x x x x Mast angie Fi Ai free wr None x x ast angie 18" | a9, a x x x x (Bacar sage) Mast angle . ri ; 7 Fae 0 26 o x o o Mast ange: 160 degrees Most ange: Less nan Epc hw {ess roe Weems a) Aegon Tides. 1 acetup wo coer wrmmocwecormoc = wnourrwo EOI Do not remove erbody weight when Jack up wi crave Otherwise te machine fl Faire to observe thi precaution may ‘eatin serious nur or det, O x 60 degree Sing porte Not possbie (¢k 250041, CKE25004I1 144 1. SPECIFICATION 4.2. CKE2500-II SPECIFICATION 4.24 PERFORMANCE courteruighs, carbody weighs, 152m beam. hok Heck) [Tse ‘Crawler mounted, ty revving Max. hing capaci (ith 18:2 m boom) i 250 1x46 Max. beer ing o14m Max. boom & Jb era FE2mboom + 30Smib [Bas boom length 152m [ering weight (indoding upper and ower machine, vere 2is PAverage ground pressure ‘ppion 108.4 Wa [Gradeabity an 0) 30% engine Tine PHTC-UN Diesel ngine 247 2000 min Mai ing owerng rope speed 101 3 mimi [away iting owerng rope speed "10 f23 min [Boom raising rope spe0d 2x22 2 nmin [Boom towering rope speed 2x 22102 mime Sing epee Famine [Prope peed 7.00.7 am (1) The maining lowering rope speed, the aula ling! owering rope speed, andthe propel speed vary depending onthe load (2) The rope speed i of he st ayer onthe drum, 4.22 PERFORMANCE OF LUFFING JIB ia ia capac moeam [Max boom length + Jb leigh 61 0m boom +61 0m) (appx 2221 ening weight {Intuing upper an lower machine, counterweight, [24m boom + 243 mB, nok block) Tappiox 113 Pa |average ground pressure {tnelusing upper and lower racine, counterweight, [24.8 m boom + 21.8 mj, hook blac) (ibang Towering rope speed |40t02 min (€K2500.1, CKE2S0041 4. SPECIFICATION 4.23 OUTSIDE DIMENSIONS [Height above ground fea [800mm [wth of upper machine wih operators cab {3400 mm [Radius of ear end (wih counsreigh) '5.000"mm [Countrweight ground cearance 1.490 ne (Center of rotation t boom fot pla 1400 mm [Height sbove ground of boom foot ia [2.528 mm Heit op of gantry (working poston 's.520mm (Overal ingth of rawlers [3.970 mm (istence between centre ofmblow [7.995 mm (Overal with of eaulers F620 mm With of erawler shoe [220 mm, (Ground Gearon of ebay [25 men (62500411, CKE250041 4. SPECIFICATION. oor ® Py Doe oer “RS ‘oese L| \ OR mi} lg \ \ SX ; \ SNF \Y % Ned a! thse a 147 (625004, CKE250041 41. SPECIFICATION 4.24 DIMENSIONS AND WEIGHT OF EACH PARTS Foryour reference, the char below shows the dimensions and weight ofeach pats 1.241 BASE MACHINE = —— |Crawler : 20,700 [Gantry , 3,020 Mest 410220 2,870 (€K2500-11, CKE2500411 4. SPECIFICATION r —- Dimension [wea] Neve (om 1g 4 it hanger |counterweoht a) ; = evr \counemain (8) zl 526 Pie lo, ® 1419 (6250011, CKE250041 4. SPECIFICATION Siena wake ene a is lata wea vn fowe) eo! Pre a commen we @) ——S Beery 3 =, (Ss | TL) coUNTER EIT BASE (€2500411, CKE26004 1.20 4. SPECIFICATION 4.243 ATTACHMENT “The weight of he guy ines snot includ into te Name on boom base 4005 boom te a0 50 minsen 8 : Bava ae \o.1 minset 00m ows guy tne) a0 1:22 minsert 00m a INI - 42 4. SPECIFICATION 3 = ss a 8 re TX . | 8] TIX (62500411, CKE2500-1 12 41. SPECIFICATION cme Weight g luwsme 00 luting Boom Tp 2088, lating {ape nset Boom ad luting Jo Base “7 {ting so Tp 1.400 cao (€k2500.1, CKE250041 4. SPECIFICATION Nane ‘inanson Weight 30m neers |» [in| ors |Front Strut t a {a (to) 1410 SEIVWAAR A= | a | 1200 Rear Sut (ating) 7 were Luting sip backstop 280 Isom spect 313 (€k2500.11, CKE250041 124 1. SPECIFICATION —— we Nene min) ‘eg (bs) Jan easstn ts wo [eso aE say's) S % a EN : es sine 3 aso [ror 0) lstea toon arm | json boom Base so [wer ncn (6250041, CKE2500411 4 SPECIFICATION Name Dimension Weaht | a (bs) al Hook 450 35 Hook 900 [roHook ql 1.200 (©k2500-11, CKE250041 4. SPECIFICATION. Name ‘Dimension (nm) a (bs) loot Heoke 1900 150 Hook 2.30 l2s0 Hook 4200 127 (€k250041, CKE250041 41. SPECIFICATION 4.25 CKE2S00.1 STABILITY IN SWINGING AND TRAVELING — rem a cag mcm | comer | carosy in ‘nest | woart) | wom) | vaticowe etct| Fewer | Bckwarseg| age 5 wee | vee | we | 0 |e ° eee None None ° ° ° ° (Backward strage) Ne 4 ° ° ° ° Maat ents None 28h | Less than 71° al = eg co 9 (Backward strage) S08 None x x -o (Backward strage) so 2 x * x x tesstran7 | a ° x 2 ce vet: cere Eereee tear eee posers vir o cansooe ECHT worms EXE [CAREOOY EIGHT Do not remove carbody weights when Jack up with raw ‘Otherwise the machine falls Failure to observe this precaution may result n serous injury or death oO (©K2500-11, CKE2500-I1 2. MAINTENANCE STANDARDS TEST PROCEDURES 24 (¢k2500.11, CKE250041 2. MAINTENANCE STANDARDS TEST PROCEDURES (€k2500.11, CKE250041 22 2: MAINTENANCE STANDARDS TEST PROCEDURES. 24 MAINTENANCE STANDARD. 2.1.4 PIN, BUSHING, SPRING, LINING AND SHEAVE 4. Pi, Busting « 6 Busting Lt: men re) ‘3a dinerion Unni Name] tocaton | tam] Partnumber | Se-serension [“Ussto Et Tpmeay se gue rr an Fant Fra Reonm| 1 | sueawororses | Me, Ae oe ~ai| Boonbum | 2 |soowenowm| 8 a Faz eu] soomonum| 2 | soorwororses | 2 ee _ rena F928 ‘ina oep, | to ae Fos a rum _|_° | Se82woro0s (788) Revise! (p27) * ’ aamrl 8 Faz? Boom Foot Jor2noto04 wee] |pensce) F827 LLuffing Jib Foot | 5 | Ju13A01016P1 ee Replace) "9247 fing fre 28) eaFeok 7 Font Srareot | | sorzaoteoser | _ rence 82 cee Onn) 7 | 2uostiss as foal es Repace Paul] Boom Orum W084 ee em ea a |" Boom Or 8 | sorwortesy 20 ora (P26) Taina won “sotm] 50 Prepac] F025 Bush. num _| & | 2snsvrorDéss0 om ree [RE] e271 bd Boom Foot 10 | sD0sA01013P1 eet 18522 | Replace] F927 ‘se, 27) ‘a v8 Fez uti > Foat_| 11 | JooworooaPt wo 15S [rece 82 = a8 me Fea sintFoo(Fem) | 12 | Joowaoroourt vam Ee [rece] F82 23 (€k2500.11, CKE25004 2. MAINTENANCE STANDARDS TEST PROCEDURES a «>| <> | Ta Fest Unt nt Usable anit at T weoion | ten | _Pannomr_ [reer] TASTES [Ron Seta ae Om rz e026 cea 29 ranaounpen | 20 | worm: | 2285 | na caemy mz ae [aera | BCE, | wacom raze fom rm ad enor repce 0282 aw | aaa | ghee, | nase reas a) res _ au pe (Compression) es (222) (€k2500-11, CKE25004 24 2. MAINTENANCE STANDARDS TEST PROCEDURES Nps A aise [tem] Pennants | S25] vssimn [neneay| SO | congue a mw [| ome | oe | Leis | Te [e[aerwr [atid oe] Le | FREE] [aor [ott att] Let ee vowrspnate [ot | woroarr | a2 |S, ies, | eae wm [af amwoe Lal aty | Len Ee S| = | mow am a) Pe wom atsare we [emonems | am [ty | [a | BR te [o|aewor ite ee] eS sero [| comonm | es [amy | ath wow [efor [as Lay) [leis owivem [0 | amwroer ttl ay | [ey SS Fixed Jib point sheave| 44 | 2407P812 aS feta haa) eat Fixed Jib stutsheave | 45 | 2407612 feta fete ney loan 25 (625004, CKE2500411 2. MAINTENANCE STANDARDS TEST PROCEDURES Fig.2:2 Front and Rear Drum Lock Fig2.3 Boom Drum Lock arn 822 y OTe} Fig2-4 Boom Drum Lock Paw! ‘©k2500-H1, CKE2500-H1 28 :L MAINTENANCE STANDARDS TEST PROCEDURES 5 jest ry f =

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