Kobelco CRAWLER CRANE CKE1800 CK2000 SHOP MANUAL S5JC00002ZE05 – PDF DOWNLOAD

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Kobelco CRAWLER CRANE CKE1800 CK2000 SHOP MANUAL S5JC00002ZE05 – PDF DOWNLOAD

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Kobelco CRAWLER CRANE CKE1800 CK2000 SHOP MANUAL S5JC00002ZE05 – PDF DOWNLOAD

Language : English
Pages : 596
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TABLE OF CONTENTS:

Kobelco CRAWLER CRANE CKE1800 CK2000 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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