Kobelco CK2000 CKE1800 Crawler Crane Operation & Maintenance Manual Parts Catalog PDF - MKOBCK2000.zip
Full Operation and Maintenance Manual, including a Parts Catalog, covering the KOBELCO CK2000 and CKE1800 Crawler Cranes.
KOBELCO CK2000, CKE1800 Electrical Wiring Diagram.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