Kobelco CKE 1800 CK 2000 Crawler Crane Shop Manual S5JC00002ZE05 – PDF DOWNLOAD

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Kobelco CKE 1800 CK 2000 Crawler Crane Shop Manual S5JC00002ZE05 – PDF DOWNLOAD

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Kobelco CKE 1800 CK 2000 Crawler Crane Shop Manual S5JC00002ZE05 – PDF DOWNLOAD

Language : English
Pages : 596
Downloadable : Yes
File Type : PDF

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Kobelco CKE 1800 CK 2000 Crawler Crane Shop Manual S5JC00002ZE05 – PDF DOWNLOAD

SAFETY:
PRECAUTIONS FOR INSPECTION AND MAINTENANCE:

1. Service and maintenance must be performed only by authorized personnel who are qualified in compliance with
a relevant law or regulation.
2. Regular maintenance or inspection should be quickly performed after shutting down the machine and ensuring
safety to personnel and equipment.
Post an “INSPECTION IN PROGRESS. DO NOT START.” warning sign on a readily visible location.

GENERAL SAFETY PRECAUTIONS:

1. Wear safety shoes, helmets and clothing suitable for the job. Also use protective goggles, mask, gloves, etc.,
as required.
2. To ensure safe and correct maintenance, carefully study this SHOP MANUAL and get fully familiar with the instructions
in it.
3. Place the machine in a safe place. Always maintain safe clearance around the machine.
4. Before starting crane operation, hold a safety meeting. Also, make agreement on standardized hand signals.
5. When inspecting or handling the battery or oil, do not use exposed flame nearby.
To avoid fire accident, only use explosion-proof lighting equipment.
6. Start an inspection or maintenance work only after shutting down the engine.
7. Certain machine components remain hot immediately after the engine is shut down. Do not touch them.
8. Before removing the radiator cap, wait until the coolant water gets sufficiently cool. Next, carefully loosen the
cap and release radiator pressure, and them remove the cap.
9. Before inspecting or maintaining an electrical system on the machine, power off the machine by, for example,
disconnecting the battery cables.
10. When working at a high lift area, always wear a safety belt.
11. When leaving the operator’s cab for an inspection or maintenance work, post an “INSPECTION IN PROGRESS.
DO NOT START.” warning sign on a readily visible location. Also, lock the cab for security.
12. Before starting a cleaning or lubrication work on the machine, always shut down the engine.
13. While adjusting tire pressure, be absolutely careful about rupture of a tire, flying of wheel part.
14. Use genuine KOBELCO replacement parts and oils only.
15. Always keep the oil containers clean. Protect them against ingress of dust or moisture. Also, fill clean, fresh
oils only.
16. Once a maintenance work is complete, clean the machine.
Protect grease nipples, breathers, and oil level gages against ingress of dust.
17. Always keep the subjects of regular inspection clean to allow problems such as oil leakage, crack, looseness,
etc., to be readily detected.
18. During car washing, do not allow high pressure steam to be directly applied to electrical components and connectors.
19. After removing O-rings, oil seals, gaskets, etc., clean the mounting seats. Then, install fresh O-rings, oil seals,
gaskets, etc. Also, remember to thinly apply oil to the seal faces of these parts before installation.
20. Before disconnecting pressurized piping, release the inside pressure.

TABLE OF CONTENTS:

Kobelco CKE 1800 CK 2000 Crawler Crane Shop Manual S5JC00002ZE05 – PDF DOWNLOAD

COVER.................................................................................................................................................  1
TABLE OF CONTENTS.....................................................................................................................................  3
SAFETY................................................................................................................................................ 11
1. SPECIFICATION...................................................................................................................................... 23
	1.1 CK2000 SPECIFICATION.......................................................................................................................... 25
		1.1.1 PERFORMANCE............................................................................................................................. 25
		1.1.2 PERFORMANCE OF LUFFING JIB.............................................................................................................. 25
		1.1.3 OUTSIDE DIMENSIONS...................................................................................................................... 26
		1.1.4 DIMENSIONS AND WEIGHT OF EACH PARTS..................................................................................................... 28
		1.1.5 WITHOUT BOOM BASE....................................................................................................................... 36
		1.1.6 WITH BOOM BASE.......................................................................................................................... 38
	1.2 CKE1800 SPECIFICATION......................................................................................................................... 39
		1.2.1 PERFORMANCE............................................................................................................................. 39
		1.2.2 PERFORMANCE OF LUFFING JIB.............................................................................................................. 39
		1.2.3 OUTSIDE DIMENSIONS...................................................................................................................... 40
		1.2.4 DIMENSIONS AND WEIGHT OF EACH PARTS..................................................................................................... 45
		1.2.5 WITHOUT BOOM BASE....................................................................................................................... 54
		1.2.6 WITH BOOM BASE.......................................................................................................................... 56
2. MAINTENANCE STANDARDSTEST PROCEDURES............................................................................................................... 57
	2.1 MAINTENANCE STANDARD.......................................................................................................................... 59
		2.1.1 PIN, BUSHING, SPRING, LINING AND SHEAVE................................................................................................. 59
		2.1.2 PROPEL DEVICE........................................................................................................................... 70
	2.2 PERFORMANCE STANDARD AND TEST PROCEDURE....................................................................................................... 77
		2.2.1 OPERATING SPEED......................................................................................................................... 77
		2.2.2 POINT AND METHOD OF MEASURING PRESSURE.................................................................................................. 78
		2.2.3 SLEWING RING............................................................................................................................ 82
3. GENERAL WORK STANDARD.............................................................................................................................. 83
	3.1 TIGHTENING TORQUE OF CAPSCREWS AND NUTS....................................................................................................... 85
		3.1.1 METRIC COARSE THREADS................................................................................................................... 85
		3.1.2 METRIC FINE THREADS..................................................................................................................... 85
		3.1.3 COARSE THREDS UNC....................................................................................................................... 86
		3.1.4 FINE THREADS UNF........................................................................................................................ 86
		3.1.5 TIGHTENING TORQUE OF HYDRAULIC FITTINGS................................................................................................. 87
	3.2 STANDARD PARTS................................................................................................................................ 89
		3.2.2 O-RING.................................................................................................................................. 90
		3.2.3 BACK-UP RING............................................................................................................................ 91
		3.2.4 BITE FITTING............................................................................................................................ 92
	3.3 CONVERSION TABLE.............................................................................................................................. 94
		3.3.1 UNIT CONVERSION......................................................................................................................... 94
		3.3.2 MILLIMETER : INCH CONVERSION TABLE...................................................................................................... 95
		3.3.3 METER-FOOT CONVERSION TABLE............................................................................................................. 97
		3.3.4 GRADIENT CONVERSION TABLE............................................................................................................... 98
	3.4 TABLE OF UNIT WEIGHT.......................................................................................................................... 99
4. POWER TRAIN........................................................................................................................................101
	4.1 INTRODUCTION..................................................................................................................................103
	4.2 ENGINE........................................................................................................................................105
		4.2.1 INTRODUCTION............................................................................................................................105
		4.2.2 REMOVAL.................................................................................................................................105
		4.2.3 REPAIR AND MAINTENANCE..................................................................................................................106
		4.2.4 RE-INSTALLATION.........................................................................................................................107
	4.3 PUMP DRIVE ASSEMBLY...........................................................................................................................110
		4.3.1 INTRODUCTION............................................................................................................................110
		4.3.2 REMOVAL.................................................................................................................................110
		4.3.3 DISASSEMBLING THE POWER DIVIDER.........................................................................................................112
		4.3.4 CHECK AND REPAIR OF THE POWER DIVIDER...................................................................................................113
		4.3.5 ASSEMBLING THE POWER DIVIDER............................................................................................................114
		4.3.6 RE-INSTALLATION.........................................................................................................................115
5. HYDRAULIC SYSTEM...................................................................................................................................121
	5.1 HYDRAULIC CIRCUITS AND COMPONENTS.............................................................................................................123
	5.2 HYDRAULIC CIRCUIT.............................................................................................................................124
	5.3 COMPONENT SPECIFICATION.......................................................................................................................128
		5.3.1 LOCATION OF HYDRAULIC COMPONENTS........................................................................................................132
	5.4 HYDRAULIC SYSTEM..............................................................................................................................140
		5.4.1 PREFACE.................................................................................................................................140
		5.4.2 OUTLINE.................................................................................................................................140
		5.4.3 OIL FLOW FROM No.1 and No. 2 PUMPS......................................................................................................142
		5.4.4 OIL FLOW FROM No.3 AND No.4 PUMPS.......................................................................................................144
		5.4.5 OIL FLOW FROM No.5 PUMP (CONTROL PUMPS).................................................................................................145
		5.4.6 OIL FLOW FROM No.6 PUMP (FOR AUXILIARY ACTUATOR CIRCUIT)................................................................................148
	5.5 VALVES........................................................................................................................................151
6. HOIST SYSTEM.......................................................................................................................................159
	6.1 APPARATUS AND LOCATION OF COMPONENTS..........................................................................................................161
	6.2 CONSTRUCTION AND FUNCTION.....................................................................................................................162
		6.2.1 HYDRAULIC SCHEMATIC.....................................................................................................................162
		6.2.2 LIFTING A LOAD..........................................................................................................................164
		6.2.3 HOLDING A RAISED LOAD...................................................................................................................166
		6.2.4 LOWERING A LOAD (POWERED LOWERING)......................................................................................................168
		6.2.5 FREE FALL OPERATION.....................................................................................................................171
		6.2.6 FREE FALL ACCELERATION..................................................................................................................174
	6.3 DRUM LOCK.....................................................................................................................................176
		6.3.1 ASEEMBLY DRAWING........................................................................................................................176
		6.3.2 ADJUSTMENT OF DRUM LOCK.................................................................................................................177
	6.4 WINCH ASSEMBLY................................................................................................................................178
		6.4.1 WINCH INSTAL............................................................................................................................178
		6.4.2 WINCH ASSEMBLY / REDUCTION UNIT WITHOUT FREE FALL (STD.)................................................................................179
		6.4.3 WINCH ASSEMBLY WITH FREE FALL (OPT.)....................................................................................................181
	6.5 BRAKE PEDAL...................................................................................................................................182
		6.5.1 ASSEMBLY DRAWING........................................................................................................................182
		6.5.2 ADJUSTING THE BRAKE PEDAL...............................................................................................................184
	6.6 BLEEDING AIR FROM BRAKE CIRCUIT...............................................................................................................185
7. BOOM HOIST SYSTEM..................................................................................................................................187
	7.1 APPARATUS AND LOCATION OF COMPONENTS..........................................................................................................189
	7.2 CONSTRUCTION AND FUNCTION.....................................................................................................................191
		7.2.1 HYDRAULIC SCHEMATIC.....................................................................................................................191
		7.2.2 RAISING THE BOOM........................................................................................................................192
		7.2.3 NEUTRAL(MAINTAINING THE BOOM POSITION)..................................................................................................194
		7.2.4 LOWERING THE BOOM.......................................................................................................................196
	7.3 BOOM DRUM LOCK................................................................................................................................198
		7.3.1 ASSEMBLY DRAWING........................................................................................................................198
		7.3.2 ADJUSTING THE BOOM DRUM LOCK............................................................................................................199
	7.4 DRUM AND REDUCTION UNIT.......................................................................................................................200
		7.4.1 BOOM WINCH ASSEMBLY.....................................................................................................................200
		7.4.2 BOOM DRUM AND REDUCTION UNIT ASSEMBLY...................................................................................................202
8. SWING SYSTEM.......................................................................................................................................205
	8.1 APPARATUS AND LOCATION OF COMPONENTS..........................................................................................................207
	8.2 CONSTRUCTION AND FUNCTION.....................................................................................................................209
		8.2.1 HYDRAULIC SCHEMATIC.....................................................................................................................209
		8.2.2 SWING...................................................................................................................................210
		8.2.3 STOPPING................................................................................................................................214
	8.3 SWING REDUCTION UNIT..........................................................................................................................218
	8.4 SWING BEARING.................................................................................................................................220
	8.5 SWING LOCK....................................................................................................................................222
9. PROPEL SYSTEM......................................................................................................................................223
	9.1 LOCATION OF THE MAJOR COMPONENTS..............................................................................................................225
	9.2 CONSTRUCTION AND FUNCTION.....................................................................................................................226
		9.2.1 HYDRAULIC SCHEMATIC.....................................................................................................................226
		9.2.2 PROPELLING (RIGHT SIDE FORWARD).........................................................................................................228
		9.2.3 STOPPING................................................................................................................................230
	9.3 PROPEL REDUCTION UNIT.........................................................................................................................232
		9.3.1 REDUCTION UNIT..........................................................................................................................234
		9.3.2 MOTOR...................................................................................................................................236
	9.4 ADJUSTMENT....................................................................................................................................238
10. ELECTRIC SYSTEM...................................................................................................................................239
	10.1 ELECTRICAL WIRING SCHEMATIC..................................................................................................................241
	10.2 CONNECTOR LIST...............................................................................................................................255
	10.3 ARRANGEMENT OF ELECTRICAL PART...............................................................................................................307
		10.3.1 ELECTRICAL PART OF CAB.................................................................................................................307
		10.3.2 ELECTRICAL PART OF RIGHT DECK..........................................................................................................311
		10.3.3 ELECTRICAL PART OF FLOOR PLATE & LEFT SIDE STAND PANEL.................................................................................315
		10.3.4 ELECTRICAL PART OF REVOLVING FRAME.....................................................................................................320
		10.3.5 ELECTRICAL PART OF LEFT DECK...........................................................................................................322
		10.3.6 ELECTRICAL PART OF LEFT GUARD..........................................................................................................328
		10.3.7 HARNESS PART NUMBER LIST (ALL MODELS)..................................................................................................329
	10.4 ELECTRICAL PART..............................................................................................................................331
		10.4.1 LOCATION AND USE OF FUSE...............................................................................................................331
		10.4.2 FUSE BOX (GG73E00004F1)................................................................................................................333
		10.4.3 WIPER CONTROL RELAY(2480U1366).........................................................................................................335
		10.4.4 SWING FLASHER UNIT (2480U306)..........................................................................................................336
	10.5 PRESSURE SWITCH(CONTROL PRESSURE CUT & FREE FALL)............................................................................................337
	10.6 PRESSURE SENSOR..............................................................................................................................339
	10.7 RELAY BOX (GG24E00024F1).....................................................................................................................341
		10.7.1 ARRANGEMENT OF CONNECTOR...............................................................................................................341
		10.7.2 RELAY BOX SCHEMATIC....................................................................................................................343
	10.8 LEFT SIDE STAND PANEL (WITH FREE FALL).......................................................................................................346
	10.9 BYPASS SWITCH PANEL..........................................................................................................................350
	10.10 TROUBLESHOOTING OF EXHAUST GAS THIRD REGULATION ENGINE......................................................................................351
		10.10.1 FAILURE DIAGNOSIS FUNCTION............................................................................................................351
		10.10.2 HOW TO CHECK THE FAILURE CONTENTS.....................................................................................................352
		10.10.3 CHECKING OF DIAGNOSIS LAMP FUNCTION...................................................................................................357
		10.10.4 ENGINE ECU............................................................................................................................358
11. LOAD SAFETY DEVICE................................................................................................................................361
	11.1 PART NAMES AND FUNCTIONS.....................................................................................................................363
		11.1.1 FRONT VIEW.............................................................................................................................363
		11.1.2 CONFIGURATION OF SCREENS...............................................................................................................368
		11.1.3 DATA TRANSMISSION BETWEEN CONTROLLER AND CARDS.........................................................................................373
		11.1.4 DETAILS OF INDICATORS ON MAIN DISPLAY SCREEN...........................................................................................375
		11.1.5 REAR VIEW..............................................................................................................................379
		11.1.6 ITEMS REQUIRED TO BE EXECUTED FOR REPLACEMENT OF CONTROLLER OR DATA CARDAND INSTRUCTIONS(IN A SIMILAR MANNER TO UPGRADE OF PROGRAM)....384
	11.2 PREPARATION FOR USE..........................................................................................................................385
	11.3 TURN THE POWER ON............................................................................................................................386
	11.4 UPGRADING PROGRAMS...........................................................................................................................387
		11.4.1 PROCEDURES.............................................................................................................................387
		11.4.2 UPGRADING OF INDICATION PROGRAMS.......................................................................................................389
		11.4.3 UPGRADING OF CONTROL PROGRAMS..........................................................................................................392
	11.5 STATUS CHECK.................................................................................................................................394
		11.5.1 SIGNAL CHECK...........................................................................................................................395
		11.5.2 OPERATION PROGRESS.....................................................................................................................397
		11.5.3 COMMUNICATION DATA.....................................................................................................................400
		11.5.4 INDICATION OF ADJUSTMENT VALUE.........................................................................................................401
		11.5.5 TROUBLE RECORD.........................................................................................................................410
		11.5.6 CHOICE OF LANGUAGE(CKE series only)....................................................................................................412
		11.5.7 LOAD RECORD (LOAD RECORD IN THE MAIN MENU).............................................................................................413
	11.6 ADJUSTMENTS..................................................................................................................................414
		11.6.1 REMOVING THE INNER PANEL...............................................................................................................414
		11.6.2 ADJUSTMENT.............................................................................................................................415
		11.6.3 LOAD ADJUSTMENT........................................................................................................................436
		11.6.4 ADJUSTMENT DATA COPY (INITIALIZATION)..................................................................................................438
		11.6.5 VERSION CHECK..........................................................................................................................444
	11.7 ERROR CODE (ABNORMALITY DETECTION) AND COUNTERMEASURES.......................................................................................445
	11.8 CONTROL OUTPUT...............................................................................................................................449
	11.9 RELEASES.....................................................................................................................................461
		11.9.1 RELEASE FUNCTION.......................................................................................................................461
	11.10 MECHANICAL SPECIFICATION....................................................................................................................469
		11.10.1 ENVIRONMENTAL PERFORMANCE PARAMETERS..................................................................................................469
		11.10.2 LOAD CELL (CRANE).....................................................................................................................470
		11.10.3 ANGLE SENSOR..........................................................................................................................471
		11.10.4 CONTROLLER............................................................................................................................473
	11.11 EXTERNAL DIMENSIONS.........................................................................................................................477
	11.12 ELECTRIC SCHEMATIC DIAGRAM..................................................................................................................478
		11.12.1 CRANE TYPE............................................................................................................................478
		11.12.2 LUFFING TYPE..........................................................................................................................479
	11.13 CONTROLLER MALFUNCTION EMERGENCY MEASURES...................................................................................................480
	11.14 LOAD SAFETY DEVICE CHECK PROCEDURES.........................................................................................................481
12. GAUGE CLUSTER.....................................................................................................................................483
	12.1 CONFIGURATION OF DISPLAY.....................................................................................................................485
	12.2 PRIORITY.....................................................................................................................................486
	12.3 STATUS DISPLAY...............................................................................................................................488
	12.4 FAULT LOG DISPLAY............................................................................................................................498
13. TOTAL CONTROLLER..................................................................................................................................503
	13.1 ARRANGEMENT OF TOTAL CONTROLLER..............................................................................................................505
	13.2 COMPOSITION OF SYSTEM........................................................................................................................506
		13.2.1 OUTPUT RELATION TO CONTROLLER..........................................................................................................507
	13.3 FUNCTION OF TOTAL CONTROLLER.................................................................................................................508
	13.4 TOTAL CONTROLLER (HARDWARE)..................................................................................................................534
		13.4.1 OUTLINE................................................................................................................................534
		13.4.2 SPECIFICATIONS OF TOTAL CONTROLLER OUTPUT..............................................................................................535
		13.4.3 DETAILS OF TOTAL CONTROLLER CONNECTOR..................................................................................................540
		13.4.4 ARRANGEMENT OF TOTAL CONTROLLER CONNECTOR PIN..........................................................................................541
		13.4.5 PROPORTIONAL SOLENOID VALVE MEASURING POSITION.........................................................................................548
	13.5 ADJUSTMENT OF TOTAL CONTROLLER...............................................................................................................550
		13.5.1 NECESSITY OF ADJUSTMENT................................................................................................................550
		13.5.2 ADJUSTMENT PROCEDURES OF TOTAL CONTROLLER..............................................................................................550
	13.6 CONTROLLER MALFUNCTION EMERGENCY MEASURES....................................................................................................558
14. AIR CONDITIONER...................................................................................................................................559
	14.1 OPERATION ITEMS..............................................................................................................................561
	14.2 SAFETY MONITOR FUNCTIONS.....................................................................................................................562
	14.3 DISASSEMBLY AND ASSEMBLY PROCEDURE...........................................................................................................565
		14.3.1 SPECIAL CONSIDERATIONS DURING REPLACEMENT..............................................................................................565
		14.3.2 INTERIOR UNIT..........................................................................................................................567
	14.4 OPERATIONAL PRECAUTIONS......................................................................................................................576
	14.5 INSPECTION AND MAINTENANCE...................................................................................................................577
		14.5.1 INSPECTION/MAINTENANCE LIST............................................................................................................577
		14.5.2 INSPECTION/MAINTENANCE PROCEDURES......................................................................................................577
	14.6 ELECTRIC SYSTEM SCHEMATIC....................................................................................................................581
15. TRANSLIFTER SYSTEM................................................................................................................................583
	15.1 LOCATION OF MAIN COMPONENTS..................................................................................................................585
	15.2 CONSTRUCTION AND WORKING PRINCIPLE...........................................................................................................588
		15.2.1 OUTLINE................................................................................................................................588
	15.3 WORKING PRINCIPLE............................................................................................................................590
		15.3.1 RAISING THE TRANSLIFTER................................................................................................................590
		15.3.2 LOWERING THE TRANSLIFTER...............................................................................................................592
	15.4 REMOTE CONTROL SWITCH........................................................................................................................594

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