Kobelco CRANE CK2500-11 OPERATION & MAINTENANCE MANUAL S2JD10016ZE10 – PDF DOWNLOAD

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Kobelco CRANE CK2500-11 OPERATION & MAINTENANCE MANUAL S2JD10016ZE10 – PDF DOWNLOAD

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Kobelco CRANE CK2500-11 OPERATION & MAINTENANCE MANUAL S2JD10016ZE10 – PDF DOWNLOAD

Language : English
Pages :461
Downloadable : Yes
File Type : PDF

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Kobelco CRANE CK2500-11 OPERATION & MAINTENANCE MANUAL S2JD10016ZE10 – PDF DOWNLOAD

IMPORTANT INFORMATION
Thank you for your purchasing KOBELCO crawler crane. Our CK series full-hydraulically operated crawler crane, is manufactured based on our many years of experience and expertise. This manual describes important information about Model CK2500-II. Before operating the machine, be sure to thoroughly read this manual in order to use the machine safely and efficiently.

SAFETY INFORMATION

• Most accidents, that occur during operation are due to neglect of precautionary measures and safety rules. Sufficient care should be taken to avoid these accidents. Erroneous operation, lubrication or maintenance services are very dangerous and may cause injury to, or death of, personnel.
• Precautionary measures or notes provided in this manual should be read and understood by personnel before starting each task. Operation, inspection, and maintenance should be carefully carried out, and safety must be given first priority. Safety labels are indicated with A marks.
• The safety information contained in this manual is intended only general safety information. Safety labels appear both in this manual and on the machine. All safety labels are identified by the words “DANGER”, “WARNING” and “CAUTION”. These words mean the following:

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TABLE OF CONTENTS:

Kobelco CRANE CK2500-11 OPERATION & MAINTENANCE MANUAL S2JD10016ZE10 – PDF DOWNLOAD

COVER..............................................................................................  1
TABLE OF CONTENTS..................................................................................  3
IMPORTANT INFORMATION..............................................................................  9
1. SAFE OPERATING PRACTICES FOR MOBILE CRANES...................................................... 23
2. OPERATION....................................................................................... 43
	2.1 TERMINOLOGY OF MACHINE PARTS............................................................... 43
		2.1.1 CRANE ATTACHMENT..................................................................... 43
		2.1.2 LUFFING JIB ATTACHMENT............................................................... 44
	2.2 LOCATIONS AND TERMS OF OPERATING CONTROLS.................................................. 45
		2.2.1 OPERATING SWITCHES................................................................... 49
		2.2.2 GAUGE CLUSTER CONFIGURATION.......................................................... 58
		2.2.3 OPERATING THE AIR CONDITIONER........................................................ 70
		2.2.4 AM/FM RADIO (OPTION)................................................................. 72
	2.3 CRANE OPERATION............................................................................ 74
		2.3.1 ADJUSTING THE OPERATOR'S SEAT........................................................ 74
		2.3.2 ADJUSTING THE CONTROL LEVER DIRECTION................................................ 74
		2.3.3 STARTING AND STOPPING THE ENGINE..................................................... 75
		2.3.4 FUNCTION LOCK LEVER.................................................................. 79
		2.3.5 PROPELLING OPERATION................................................................. 79
		2.3.6 SWINGING OPERATION................................................................... 81
		2.3.7 BOOM RAISING/LOWERING OPERATION...................................................... 83
		2.3.8 HOOK RAISING/LOWERING OPERATION...................................................... 85
		2.3.9 JIB RAISING/LOWERING OPERATION....................................................... 87
	2.4 FREE FALL OPERATION (OPTION)............................................................... 88
	2.5 CLAMSHELL OPERATION........................................................................ 90
	2.6 HANDLING OF HYDRAULIC TAGLINE (OPTIONAL)................................................... 92
	2.7 HANDLING OF REEVING WINCH (OPTION)......................................................... 93
3. LOAD SAFETY DEVICE.............................................................................. 95
	3.1 ARRANGEMENT OF EQUIPMENT................................................................... 95
	3.2 TYPE AND FUNCTIONS OF DEVICES..............................................................100
	3.3 CONNECTING PROCEDURE FOR WIRING............................................................106
		3.3.1 CRANE ATTACHMENT AND FIXED JIB ATTACHMENT............................................106
		3.3.2 LUFFING ATTACHMENT...................................................................110
		3.3.3 MAST.................................................................................114
	3.4 NECESSARY ACTIONS FOR ALTERATION OF LUFFING AND CRANE......................................115
		3.4.1 CHANGE OF CABLE FOR CRANE HOOK OVERHOIST OF LUFFING HOOK OVERHOIST LIMIT SWITCHES....115
	3.5 FUNCTION OF CONTROLLER/MONITOR.............................................................116
		3.5.1 OPERATING PROCEDURE OF CONTROLLER....................................................120
		3.5.2 SETTING SCREEN.......................................................................121
		3.5.3 SETTING OF THE CRANE CONFIGURATION...................................................126
		3.5.4 SELECTION OF MAIN/JIB/AUX. LIFTING...................................................131
		3.5.5 SETTING OF WORKING AREA LIMIT VALUE..................................................132
		3.5.6 SETTING OF THE TIME..................................................................135
	3.6 WARNING ALARMS AND AUTOMATIC STOPS.........................................................137
		3.6.1 WARNING ALARMS AND AUTOMATIC STOP INDICATORS.........................................137
		3.6.2 CONTENTS FOR AUTOMATIC STOP..........................................................139
		3.6.3 RELEASE OF AUTOMATIC STOP............................................................142
	3.7 INSPECTION.................................................................................149
		3.7.1 INSPECTION BEFORE RAISING THE BOOM AFTER ASSEMBLY OF ATTACHMENT IS COMPLETED.........149
		3.7.2 INSPECTION AFTER ERECTING THE ATTACHMENT.............................................154
	3.8 CAUTIONS FOR HANDLING THE LOAD SAFETY DEVICE...............................................154
	3.9 ERROR MESSAGES AND CORRECTIONS.............................................................155
	3.10 TABLE OF ERROR MESSAGES AND ALARMS........................................................156
	3.11 CONFIRMATION OF FUNCTIONING FOR LOAD SAFETY DEVICE........................................157
4. ASSEMBLY OF THE MACHINE.........................................................................159
	4.1 STABILITY IN SWINGING AND TRAVELING........................................................159
	4.2 TRANSLIFTER................................................................................161
		4.2.1 COMPOSITION OF TRANSLIFTER...........................................................161
		4.2.2 HANDLING TRANSLIFTERS (1)-(4)........................................................162
	4.3 UNLOADING BASE MACHINE.....................................................................164
		4.3.1 SETTING TRANSLIFTERS.................................................................165
		4.3.2 UNLOADING BASE MACHINE FROM TRAILER..................................................168
		4.3.3 RAISING MAST.........................................................................169
		4.3.4 INSTALLATION OF THE HOOK BLOCK TO THE MAST...........................................173
	4.4 INSTALLATION OF CARBODY WEIGHT.............................................................175
	4.5 INSTALLATION OF CRAWLER....................................................................177
		4.5.1 SETTING OF LMI.......................................................................177
		4.5.2 INSTALLATION OF THE FIRST CRAWLER....................................................179
		4.5.3 INSTALLATION OF THE SECOND CRAWLER...................................................183
	4.6 ASSEMBLING CRANE ATTACHMENTS...............................................................185
		4.6.1 ARRANGEMENT OF BOOM / GUY LINE.......................................................185
		4.6.2 ASSEMBLY OF JIB......................................................................200
		4.6.3 INSTALLATION OF AUXILIARY SHEAVE.....................................................205
	4.7 ASSEMBLING THE LUFFING ATTACHMENT..........................................................206
		4.7.1 ARRANGEMENT OF BOOM / LUFFING JIB / GUY LINE.........................................208
		4.7.2 INSTALLING INSERT TAPER BOOM.........................................................219
		4.7.3 CONNECTING LUFFING BOOM TIP ASSEMBLY.................................................219
		4.7.4 INSTALLING THE AUXILIARY SHEAVE FOR LUFFING..........................................221
		4.7.5 ASSEMBLING THE LUFFING JIB...........................................................221
		4.7.6 INSTALLING STRUT GUY LINE............................................................222
	4.8 INSTALLATION OF THE BOOM BASE..............................................................223
		4.8.1 SETTING THE BACKSTOP AND GUIDE ROLLER................................................223
		4.8.2 CONNECTING THE BOOM BASE TO THE INSERT BOOM..........................................224
		4.8.3 INSTALLATION OF THE BOOM GUY LINE....................................................225
	4.9 INSTALLATION OF THE THIN TYPE COUNTERWEIGHT................................................226
		4.9.1 ASSEMBLING THE COUNTERWEIGHTS........................................................226
		4.9.2 INSTALLATION OF COUNTERWEIGHTS TO MACHINE............................................228
	4.10 CONNECTING THE ATTACHMENT TO THE BASE MACHINE.............................................231
		4.10.1 REMOVE THE HOOK BLOCK FROM THE MAST.................................................231
		4.10.2 CONNECTING THE BOOM BASE TO THE BASE MACHINE........................................232
	4.11 ASSEMBLING THE LUFFING JIB ATTACHMENT.....................................................238
		4.11.1 INSTALLING LUFFING JIB HOIST WIRE ROPE..............................................238
		4.11.2 CONNECTING STRUT GUY LINE...........................................................238
		4.11.3 INSTALLING STRUT BACKSTOP...........................................................239
		4.11.4 INSTALLING JIB GUY LINE.............................................................242
	4.12 REEVING THE WIRE ROPE.....................................................................243
		4.12.1 REEVING THE FRONT DRUM WIRE ROPE FOR CRANE WITHOUT LUFFING JIB......................243
		4.12.2 REEVING THE REAR DRUM WIRE ROPE FOR JIB.............................................247
		4.12.3 REEVING THE REAR DRUM WIRE ROPE FOR AUXILIARY SHEAVE................................249
		4.12.4 REEVING THE WIRE ROPE FOR LUFFING ATTACHMENT........................................250
	4.13 ERECTING ATTACHMENT.......................................................................253
		4.13.1 CONNECTING SAFETY DEVICE (Refer to Chapter 3.)......................................253
		4.13.2 CONFIRMATION BEFORE ERECTING THE ATTACHMENT.........................................253
		4.13.3 ERECTING ATTACHMENT.................................................................254
		4.13.4 CHECK BEFORE STARTING WORK..........................................................255
	4.14 ERECTING LUFFING ATTACHMENT...............................................................256
		4.14.1 CONNECTING SAFETY DEVICE............................................................256
		4.14.2 CONFIRMATION BEFORE ERECTING LUFFING ATTACHMENT.....................................259
		4.14.3 ERECTING LUFFING ATTACHMENT.........................................................260
		4.14.4 CHECK BEFORE STARTING THE WORK......................................................263
5. DISASSEMBLY OF THE MACHINE......................................................................265
	5.1 LOWERING ATTACHMENT........................................................................267
		5.1.1 LOWERING ATTACHMENT..................................................................267
	5.2 LOWERING LUFFING ATTACHMENT................................................................269
		5.2.1 LOWERING THE ATTACHMENT..............................................................270
		5.2.2 REMOVING THE GUY LINE................................................................279
	5.3 REMOVE THE ATTACHMENT FROM THE BASE MACHINE................................................281
	5.4 INSTALLATION OF THE HOOK BLOCK TO THE MAST.................................................287
	5.5 REMOVING THE COUNTERWEIGHTS................................................................290
		5.5.1 REMOVAL OF COUNTERWEIGHTS............................................................290
		5.5.2 DISASSEMBLING OF COUNTERWEIGHTS......................................................293
	5.6 DISASSEMBLING THE ATTACHMENT...............................................................294
		5.6.1 REMOVE THE BOOM BASE TO THE INSERT BOOM..............................................294
		5.6.2 REMOVE THE GUY LINE..................................................................296
		5.6.3 DISASSEMBLING THE JIB................................................................297
		5.6.4 REMOVING THE AUXILIARY SHEAVE........................................................299
		5.6.5 DISASSEMBLING THE BOOM TIP AND INSERT BOOM...........................................299
	5.7 DISASSEMBLY OF LUFFING ATTACHMENT..........................................................300
		5.7.1 DISASSEMBLING THE LUFFING JIB........................................................301
		5.7.2 DISASSEMBLING THE LUFFING BOOM.......................................................302
		5.7.3 CAUTION WHEN TRANSPORTING LUFFING BOOM TIP ASSEMBLY..................................303
		5.7.4 HANDLING BOOM NESTING (OPTION).......................................................303
	5.8 REMOVAL OF THE CRAWLERS....................................................................304
		5.8.1 SETTING THE TRANSLIFTER (REFER TO 4.2.)..............................................304
		5.8.2 REMOVING CRAWLERS....................................................................304
	5.9 REMOVAL OF THE CARBODY WEIGHT..............................................................314
	5.10 LOADING THE MACHINE.......................................................................318
		5.10.1 LOWERING THE MAST AND GANTRY........................................................318
		5.10.2 LOADING THE BASE MACHINE ON THE TRAILER.............................................320
		5.10.3 FOLDING THE TRANSLIFTER.............................................................321
6. WIRE ROPE.......................................................................................323
	6.1 HANDLING WIRE ROPE.........................................................................323
		6.1.1 UNREELING WIRE ROPE..................................................................323
		6.1.2. WINDING WIRE ROPE ONTO DRUM.........................................................323
		6.1.3 INSTALLING THE ROPES.................................................................325
		6.1.4 SPECIFICATION OF WIRE ROPE...........................................................325
		6.1.5 WIRE ROPE LENGTH.....................................................................326
7. MAINTENANCE.....................................................................................331
	7.1 INSPECTIONS................................................................................336
		7.1.1 UPPER STRUCTURE PARTS AND DEVICES TO BE INSPECTED....................................336
		7.1.2 LOWER STRUCTURE PARTS AND DEVICE TO BE INSPECTED.....................................348
		7.1.3 ATTACHMENT PARTS AND DEVICES TO BE INSPECTED.........................................354
		7.1.4 REPLACEMENT STANDARDS FOR WIRE ROPE..................................................359
	7.2 OIL / GREASE SUPPLY AND WATER SERVICE......................................................363
		7.2.1 UPPER STRUCTURE LUBRICATION (INCLUDING WATER SUPPLY).................................366
		7.2.2 LOWER STRUCTURE LUBRICATION..........................................................368
		7.2.3 ATTACHMENT STRUCTURE LUBRICATION.....................................................370
		7.2.4 GREASE...............................................................................372
		7.2.5 ENGINE OIL...........................................................................380
		7.2.6 FUEL.................................................................................381
		7.2.7 COOLANT..............................................................................382
		7.2.8 HYDRAULIC OIL........................................................................384
		7.2.9 GEAR OIL.............................................................................386
	7.3 CLEANING / WASHING / CHANGING FILTER ELEMENT AND STRAINER..................................391
	7.4 BATTERY INSPECTION.........................................................................400
	7.5 LOCATION AND USE OF FUSE...................................................................402
	7.6 OPERATION UNDER UNUSUAL CONDITIONS.........................................................404
	7.7 MACHINE STORAGE............................................................................405
	7.8 TIGHTENING TORQUE VALUES...................................................................406
	7.9 SECURITY PARTS TO BE REPLACED PERIODICALLY.................................................408
	7.10 ADJUSTMENT................................................................................409
		7.10.1 ADJUSTMENT OF FRONT AND REAR DRUM LOCKS.............................................409
		7.10.2 ADJUSTMENT OF BOOM DRUM LOCK........................................................409
		7.10.3 ADJUSTMENT OF LUFFING JIB DRUM LOCK.................................................410
		7.10.4 CRAWLER SHOES ADJUSTMENT............................................................411
	7.11 CONSUMABLE PARTS LIST.....................................................................412
8. REFERENCE MATERIALS.............................................................................417
	8.1 SPECIFICATION..............................................................................417
		8.1.1 PERFORMANCE..........................................................................417
		8.1.2 PERFORMANCE OF LUFFING JIB...........................................................417
		8.1.3 OUTSIDE DIMENSIONS...................................................................418
	8.2 DIMENSIONS AND WEIGHT OF EACH PARTS........................................................420
		8.2.1 BASE MACHINE.........................................................................420
		8.2.2 COUNTERWEIGHT........................................................................421
		8.2.3 ATTACHMENT...........................................................................423
	8.3 SYSTEM SCHEMATIC...........................................................................428
		8.3.1 HYDRAULIC SYSTEM SCHEMATIC...........................................................428
		8.3.2 ELECTRICAL WIRING SCHEMATIC..........................................................431
9. INITIAL ASSEMBLY OF THE MACHINE.................................................................445
	9.1 INSTALLATION OF THE MAST...................................................................445
	9.2 REEVING OF THE BOOM HOIST WIRE ROPE........................................................448
		9.2.1 REEVING THE GUIDE WIRE ROPE..........................................................449
		9.2.2 CONNECT THE REEVING ROPE AND BOOM HOIST WIRE.........................................449
		9.2.3 INSTALLATION OF THE BOOM HOIST WIRE ROPE.............................................450
		9.2.4 RAISE THE GANTRY AND MAST............................................................451
		9.2.5 LOWERING THE MAST FORWARD............................................................453
		9.2.6 INSTALLATION OF THE 2ND DEAD END OF BOOM HOIST WIRE ROPE.............................454
		9.2.7 LOWERING THE MAST AND GANTRY.........................................................455
	9.3 UPPER STRUCTURE (WITH CARBODY) LIFTING PROCEDURES..........................................457
		9.3.1 INSTALLATION OF BOOM FOOT LIFTING BRACKET............................................457

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