Kobelco CK2500-II & CKE2500-II Crawler Crane Workshop Repair Manual PDF - MKOBCK2500CKE2500.zip
This is the full workshop service and repair guide for the KOBELCO CK2500-II and CKE2500-II Crawler Cranes, complete with Electrical Wiring Diagrams and every technical detail needed to service, troubleshoot, fix, and overhaul the machines the way professional technicians do.
Contained within the KOBELCO CK2500-II, CKE2500-II Crawler Cranes workshop service repair manual are:
* 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