Cke2500-2f (S5jd00002ze03)

CRAWLER CRANE SHOP MANUAL CK2500-11 model ¢KE2500-Il KOBELCO BOOK CODE —_: $60000022E03Aagicae | Appa Mating | —_Oate of ksve ean exasoou | Fem sooxoaona | moons | ssuoooazeoi cxEZ001,| From JOD402001 | 200608 | aiboo0022602 00508 | s5iooou2ze03TABLE OF CONTENTS SAFETY 4. SPECIFICATION 1.1 CK2500-II SPECIFICATION. 11 PERFORMANCE, 1.1.2. PERFORMANCE OF LUFFING JIB 1.13. OUTSIDE DIMENSIONS. 414 DIMENSIONS AND WEIGHT OF EACH PARTS. 1.4.4.1 BASE MACHINE 4142 COUNTERWEIGHT. 41.43 ATTACHMENT 11.5 CK25001II STABILITY IN SWINGING AND TRAVELING. 1.2. CKE2500-II SPECIFICATION 1.21 PERFORMANCE. 1.22 PERFORMANCE OF LUFFING JIB 1.23. OUTSIDE DIMENSIONS. 1.2.4 DIMENSIONS AND WEIGHT OF EACH PARTS. 1.2.4.1 BASE MACHINE. 12.42 COUNTERWEIGHT. 1.2.43 ATTACHMENT 4.25 CKE2500-II STABILITY IN SWINGING AND TRAVELING. 2. MAINTENANCE STANDARDS TEST PROCEDURES 24. MAINTENANCE STANDARD. 2.11 PIN, BUSHING, SPRING, LINING AND SHEAVE. 2.4.2 PROPEL DEVICE, 2.2. PERFORMANCE STANDARD AND TEST PROCEDURE. 22.1 OPERATING SPEED 22.2 POINT AND METHOD OF MEASURING PRESSURE. 22.3. SLEWING RING 3. GENERAL WORK STANDARD 3.1. TIGHTENING TORQUE OF CAPSCREWS AND NUTS: 3.1.1 METRIC COARSE THREADS. 3.12 METRIC FINE THREADS, 3.1.3 COARSE THREDS UNC. 3.1.6 FINE THREADS UNF. 3.15 TIGHTENING TORQUE OF HYDRAULIC FITTINGS. 32. STANDARD PARTS. 321 BOLT 322 O-RING. 13 13 13. 14 16 16 17 19 114 118 1.18 118 116 118 118 +19 121 1.28 23 23 240 246 246 247 223 33 33 a3 35 37 a7 38323 324 ‘TABLE OF CONTENTS BACK-UP RING. BITE FITTING. 3.3. CONVERSION TABLE. 33.1 332 333 334 UNIT CONVERSION MILLIMETER : INCH CONVERSION TABLE. METER-FOOT CONVERSION TABLE GRADIENT CONVERSION TABLE 3.4 TABLE OF UNIT WEIGHT 4, POWER TRAIN 4.4. INTRODUCTION, 42. ENGINE 424 422 423 424 INTRODUCTION REMOVAL REPAIR AND MAINTENANCE RE-INSTALLATION, 43 PUMP DRIVE ASSEMBLY. 434 432 433 434 435 438 INTRODUCTION. REMOVAL DISASSEMBLING THE POWER DIVIDER. (CHECK AND REPAIR OF THE POWER DIVIDER, ASSEMBLING THE POWER DIVIDER, RE-INSTALLATION. 5. HYDRAULIC SYSTEM 5.1 LOCATION OF MAIN HYDRAULIC COMPONENTS 52 HYDRAULIC CIRCUITS AND COMPONENTS. 524 522 523 HYDRAULIC CIRCUIT. COMPONENT SPECIFICATIONS. LOCATION OF HYDRAULIC COMPONENTS. 53 HYDRAULIC SYSTEM 53.1 532 533 534 535 536 PREFACE, OUTLINE: CL FLOW FROM No.1 and No. 2 PUMPS. CL. FLOW FROM No.3 AND No.4 PUMPS IL FLOW FROM No.5 PUMP (Control Purp) IL FLOW FROM No.6 PUMP (For Auxiliary Actuator Circuit). 54 VALVES 340 342 312 343 345 346 37 410 410 410 ana 413 44 45 63 54 54 58 B12 519 519 519 521 523 525 5.29 532‘TABLE OF CONTENTS. 6. HOIST SYSTEM 6.1 APPARATUS AND LOCATION OF COMPONENTS. 62 CONSTRUCTION AND FUNCTION 624 622 623 624 625 626 HYDRAULIC SCHEMATIC. LIFTING A LOAD. HOLDING A RAISED LOAD. LOWERING A LOAD (POWERED LOWERING) FREE FALL OPERATION FREE FALL ACCELERATION, 63 DRUMLOCK. eat 632 ASEEMBLY DRAWING. ADJUSTMENT OF DRUM LOCK. 64 WINCH ASSEMBLY 644 642 643 WINCH INSTAL. WINCH ASSEMBLY / REDUCTION UNIT WITHOUT FREE FALL (STD)). WINCH ASSEMBLY WITH FREE FALL (OPT) 65. BRAKE PEDAL, 6st 652 ASSEMBLY DRAWING. ADJUSTING THE BRAKE PEDAL 66. BLEEDING AIR FROM BRAKE CIRCUIT. 7. BOOM HOIST SYSTEM 7.1. APPARATUS AND LOCATION OF COMPONENTS: 7.2 CONSTRUCTION AND FUNCTION 724 722 723 724 HYDRAULIC SCHEMATIC. RAISING THE BOOM. NEUTRAL (MAINTAINING THE BOOM POSITION). LOWERING THE BOOM. 7.3. BOOM DRUM LOCK, 734 732 ASSEMBLY DRAWING. ADJUSTING THE BOOM DRUM LOCK. 7.4 DRUM AND REDUCTION UNIT 744 742 BOOM WINCH ASSEMBLY ‘BOOM DRUM AND REDUCTION UNIT ASSEMBLY 8, SWING SYSTEM 8.1 APPARATUS AND LOCATION OF COMPONENTS. 82 CONSTRUCTION AND FUNCTION 24 HYDRAULIC SCHEMATIC. 63 ea ea 66 cy 6-10 13 616 eg 618 19 620 620 621 623 624 624 628 627 73 75 75 78 78 740 Taz 742 743 744 744 745 a3 85TABLE OF CONTENTS 822 SWING 823. STOPPING. 83 SWING REDUCTION UNIT 8.4 SWING BEARING. 88 SWING LOCK 9, PROPEL SYSTEM 9.1 LOCATION OF THE MAJOR COMPONENTS 9.2. CONSTRUCTION AND FUNCTION 9.2.1 HYDRAULIC SCHEMATIC. 822 PROPELLING (RIGHT SIDE FORWARD). 92.3 STOPPING. 93 PROPEL REDUCTION UNIT. 9.3.1 REDUCTION UNIT. 932 MOTOR 9.4 ADJUSTMENT. 10. ELECTRIC SYSTEM 10.1 ELECTRICAL WIRING SCHEMATIC. 10.2 CONNECTOR LIST. 10.3 ARRANGEMENT OF ELECTRICAL PART. 10.3.1 ELECTRICAL PART OF CAB 410.32 ELECTRICAL PART OF RIGHT DECK, 40.3.3 ELECTRICAL PART OF FLOOR PLATE & LEFT SIDE STAND PANEL 10.3.4 ELECTRICAL PART OF REVOLVING FRAME. 10.3.6 ELECTRICAL PART OF LEFT DECK. 10.3.6 ELECTRICAL PART OF LEFT GUARD. 10.4 ELECTRICAL PART. 10.4.1 FUSE BOX (GG73E00004F1) 10.42 WIPER CONTROL RELAY(2480U 1366) 40.4.3 SWING FLASHER UNIT (24800308) 10.5 PRESSURE SWITCH (CONTROL PRESSURE CUT & FREE FALL). 10.6 PRESSURE SENSOR 10,7 RELAY BOX (GG24E00024F1) 10.7.1 ARRANGEMENT OF CONNECTOR 10.7.2 RELAY BOX SCHEMATIC. 10.8 LEFT SIDE STAND PANEL (WITH FREE FALL) 10.9 BYPASS SWITCH PANEL 10,10 ROUBLESHOOTING OF EXHAUST GAS THIRD REGULATION ENGINE. 4 36 810 a4 346 18 eere 08 910 oz ona 016 103 10-47 10.68 10-68 10-72 10-76 1081 10-83 10-89 10-90 10-90 10-92 10-93 10.04 10.96 10-98 10-98 10-100 10-103 10-107 10-108‘TABLE OF CONTENTS 10.10.1 FAILURE DIAGNOSIS FUNCTION 10.10.2HOW TO CHECK THE FAILURE CONTENTS 10.10.3CHECKING BLOWN-OFF DIAGNOSIS LAMPS. 10.10.4ENGINE ECU 14. LOAD SAFETY DEVICE 11.1 PART NAMES AND FUNCTIONS. 11.4.4 FRONT VIEW. 11.4.2 CONFIGURATION OF SCREENS [CKE SERIES] 11.4.3 DATA TRANSMISSION BETWEEN CONTROLLER AND CARDS. 11.4.4 DETAILS OF INDICATORS ON MAIN DISPLAY SCREEN. 11.1.5 REAR VIEW. 11.1.6 ITEMS REQUIRED TO BE EXECUTED FOR REPLACEMENT OF CONTROLLER OR DATA CARD AND INSTRUCTIONS. (In. similar manner to upgrade of program) 11.2 PREPARATION FOR USE. 11.3 TURN THE POWER ON 11.4 UPGRADING PROGRAMS. 11.4.1 PROCEDURES 11.42 UPGRADING OF INDICATION PROGRAMS. 11.4.3 UPGRADING OF CONTROL PROGRAMS 411.8 STATUS CHECK, 11.5.1 SIGNAL CHECK. 11.52 OPERATION PROGRESS 11.5.3 COMMUNICATION DATA. 11.5.4 INDICATION OF ADJUSTMENT VALUE. 1.54.1. ANGLE SENSOR ADJUSTMENT VALUE. 115.42 LOAD CELL ZERO POINT ADJUSTMENT VALUE 11.543 ADJUSTMENT VALUE OF LOAD CELL FOR LINE-PULL 11.544 RESULT OF MANUFACTURE ADJUSTMENTS "NO LOAD" AND "SOME LOAD’ 11.548 RESULT OF LOAD ADJUSTMENTS "NO LOAD" AND "SOME LOAD" 11.548 ADJUSTMENT VALUE OF WORKING RADIUS. 1115.47 ALTERATION OF ADJUSTED VALUE 11.548 DELETION OF ADJUSTED VALUE. 11.5.5 LOAD RECORD 41.5.8 TROUBLE RECORD 11.5.7 CHOICE OF LANGUAGE (CKE SERIES ONLY). 11.8.8 LOAD RECORD (LOAD RECORD IN THE MAIN MENU) 11.6 ADJUSTMENTS. 11.6.1 REMOVING THE INNER PANEL. 41.8.2 ADJUSTMENT. 10-108 40-109 10-114 10-118 113 113 18 11413 11415 11-19 11-24 11.28 1126 1427 1127 1129 41-32 1134 11.38 11.7 11-40 1141 11-42 11-43 11-44 11-45 11-48 11-47 11-48 11-49 11-60 11-53 1155 11-58 11-87 1187 11-58TABLE OF CONTENTS 11.62.1 ANGLE SENSOR ADJUSTMENT 11.622 LOAD CELL ZERO POINT ADJUSTMENT. 14.6.23 LOAD-LESS ADJUSTMENT & SOME LOAD ADJUSTMENT 1116.24 LVLADJUSTMENT (LVL SETTING) 1162.5 RADIUS ADJUSTMENT. 11.83 LOAD ADJUSTMENT. 11.64 ADJUSTMENT DATA COPY (INITIALIZATION), 11.6.4.1 READING OF THE ADJUSTMENT DATA 14.6.42 WRITING OF ADJUSTMENT DATA, 11.843 INITIALIZATION OF ADJUSTMENT DATA, 11.65 VERSION CHECK, 11.7 ERROR CODE (ABNORMALITY DETECTION) AND COUNTERMEASURES: 11.8 CONTROL OUTPUT. 11.9 RELEASES 11.9.1 RELEASE FUNCTION 17.91.1 CRANE RELEASE CHART 419.12 ALARM SOUND 419.13 EXTERNAL INDICATOR LAMPS IN RELEASE CONDITION 11-10MECHANICAL SPECIFICATION. 11.10.1ENVIRONMENTAL PERFORMANCE PARAMETERS, 411.10.2LOAD CELL (CRANE). 11.10.3ANGLE SENSOR 44.10. 4CONTROLLER, 1.10.4. MODEL NAME, 1.10.4 2SYSTEM INPUTIOUTPUT 1.10.4. 3MONITOR DISPLAY. 11.10.4.40PERATION SWITCH 11.10.4.5INTERNAL PROCESSING SYSTEM 1110.4. 6MEMORY. 11.10.4,7 EXTERNAL STORAGE ELEMENT 11.10.46 8OTHERS. {11.1EXTERNAL DIMENSIONS. {11.]2ELECTRIC SCHEMATIC DIAGRAM 11.12, RANE TYPE 11.12,2LUFFING TYPE, 1.ASCONTROLLER MALFUNCTION EMERGENCY MEASURES. .ASLOAD SAFETY DEVICE CHECK PROCEDURES. 12. GAUGE CLUSTER 12.1 CONFIGURATION OF DISPLAY. 12.2 PRIORITY 423 STATUS DISPLAY. 412.4 FAULT LOG DISPLAY. 1161 11-65 1187 1173 1176 11:78 1181 11.83 11-85 11-86 1187 11-88 11-90 4402 4-102 14-402 14-108 14-108 14110 snt0 att sae 11413 11413 114113 1415 11115 11115 11115 114116 11416 wa4t7 11418 1418 11419 11-120 1121 23 124 126 1246‘TABLE OF CONTENTS 13. TOTAL CONTROLLER 18.1 ARRANGEMENT OF TOTAL CONTROLLER 18.2 COMPOSITION OF SYSTEM. 18.2.1 OUTPUT RELATION TO CONTROLLER 18.3 FUNCTION OF TOTAL CONTROLLER. 19.4 TOTAL CONTROLLER (HARDWARE) 13.41 OUTLINE 18.4.2 SPECIFICATIONS OF TOTAL CONTROLLER OUTPUT. 13.43 DETAILS OF TOTAL CONTROLLER CONNECTOR 18.4.4 ARRANGEMENT OF TOTAL CONTROLLER CONNECTOR PIN 18.4.8 PROPORTIONAL SOLENOID VALVE MEASURING POSITION. 18.5 ADJUSTMENT OF TOTAL CONTROLLER 18.5.1 NECESSITY OF ADJUSTMENT. 18.5.2 ADJUSTMENT PROCEDURES OF TOTAL CONTROLLER, 1352.1 OPTION SETTING 13.522 ADJUSTMENT OF HAND THROTTLE AND FOOT THROTTLE. 13.523 ENGINE SPEED ADJUSTMENT. 1352.4 WHEN ADJUSTMENT OF TOTAL CONTROLLER IS IMPOSSIBLE 43.525 INITIAL ADJUSTMENT OF LIFTING HEIGHT GAUGE 14, AIR CONDITIONER 14.4 OPERATION ITEMS. 142 SAFETY MONITOR FUNCTIONS 143 DISASSEMBLY AND ASSEMBLY PROCEDURE. 14.3.1 SPECIAL CONSIDERATIONS DURING REPLACEMENT. 1432 INTERIOR UNIT 1432.1 CASE DISASSEMBLY. 14322 THERMOSTAT REPLACEMENT. 14323 EVAPORATOR OR EXPANSION VALVE REPLACEMENT. 1432.4 HEATER CORE REPLACEMENT. 14325 INTAKE DUMPER ACTUATOR REPLACEMENT. 14326 WATER VALVE ACTUATOR OR WATER VALVE REPLACEMENT. 14327 MODE ACTUATOR REPLACEMENT 14328 BLOWER MOTOR ASSEMBLY REPLACEMENT 14.4 OPERATIONAL PRECAUTIONS. 145 INSPECTION AND MAINTENANCE. 44.5.1 INSPECTIONIMAINTENANCE LIST. 14.52 INSPECTIONIMAINTENANCE PROCEDURES. 146 ELECTRIC SYSTEM SCHEMATIC. 45. TRANSLIFTER SYSTEM 18.1 LOCATION OF MAIN COMPONENTS: 133 134 135 136 1331 1331 13:32 13:36 1397 13.44 13-45 13-45 13.45 13.45 13-47 13-48 13-49 13-60 163TABLE OF CONTENTS 18.2 CONSTRUCTION AND WORKING PRINCIPLE. 162.1 OUTLINE 16.3 WORKING PRINCIPLE 183.1 RAISING THE TRANSLIFTER. 18.3.2 LOWERING THE TRANSLIFTER, 184 REMOTE CONTROL SWITCH 16. JIB HOIST SYSTEM 16.1 APPARATUS AND LOCATION OF COMPONENTS. 16.2 CONSTRUCTION AND FUNCTION 16.2.1 HYDRAULIC SCHEMATIC. 1622 RAISING THE JIB 162.3 NEUTRAL (MAINTAINING THE JIB POSITION) 16.24 LOWERING THE JIB, 16.3 JIB DRUM LOCK. 16.3.1 ASSEMBLY DRAWING. 16.3.2 ADJUSTING THE JIB DRUM Lock 166 166 158 158 16-10 1512 163 164 16-4 166 168 16-10 16-12 16-12 16-13SAFETY ot (©K2500:1, CKE2500-I1SAFETY (€K2500.1, CKE2500-I1 02SAFETY ‘This section explains "Explanation of Waring Descriptor, “Warning Labels’ and "General safety" EXPLANATION OF WARNING DESCRIPTION ‘This manual ical the contents of warnings concerned in salet with the following twee stags according tothe ree of personal harm and material damage Since the very important raters or safety are describod, understand the contents sufcienty and observe them tout a PRISER] erring to avoid dangerous condition resulting in instantaneous death or serious personal injury. (BRWARRING) v2 10 void dangerous conton whi has post of death or serous personal jy. \Virring to avoid dangerous codon which has possibly to cause sight or medium nur or damage ofthe machine and equipments ‘This manual describes safety wamings suficinty but dangerous conitons whic are impossible tobe anticipated sate consideres “Therefore, take measures fo safety not only eparing he machin, but als including the working environment [EXPLANATION OF WARNING LABELS ‘Since the waming labels instal in the machine and inca with the toe stages in the sare way 8 the warning description, confm he postions and contents a waning libel rst. Pt them tthe practical ute to secre safety when operating checking and performing maintnance, + HANDLING OF WARNING LABELS ‘nen the warning labels damaged o stained, order ito the designated sence shop. 2, Donat remove the warning labels 3. When the surface of he warning abe soed and felt o be een, wipe clean os (¢k2500-11, CKE250041ccK2s00-1 —_ ro Aiew 4 DANGER iri ete, eae eta (©k2500.11, CKE2500-H1 ogSAFETY ‘ex2s0041 | a L_] DETAIL Y oa DETAIL OF ACCUMLATOR os (€K2500.1, CKE250041SAFETY ‘ex250001 1 Fe ct amr f SECTION 2-2 (€k2500.11, CKE2500.1 0sSAFETY ‘eK250041 A DANGER ‘STAY anh FO WeHME | Tae reuse TpOwR ties, | cine LOAD woo BECOKE ELECTRIFIED ND END o7 (€K250041, CKE2S0041SAFETY eK260041 VIEW R Ay DANGER. re gra eon mors 0 cues A BANGER Wo = pes SECTION N= SECTION x (€k250041, CKE2500-H1 osSAFETY ‘exzs00u1 FUEL TANK) voeaicie Tw (A cuTION DETAIL.D SECTION Eve ery DETAIL DETAIL F. CEL pera @ 09 ‘CK250011, CKE2500«1SAFETY ‘eK250041 o oa 4 DANGER 5 SECTION H-H (© 2500-11, CKE250041 0-10SAFETY ‘oK250041 4 DANGER Ay DANGER ‘STAY AM FROK CHIE UIE TO POFER LIMES. CME LO ak otnd BECOME ELECTRIFIED 40 DEADLY. on (€K2500-11, CKE25004SAFETY ‘ex250041 800M BASE Boom Tip QS DANGER AL CAUTION. (€ 2500-11, CKE250041 042.eK2500.1 043 (€k2500-11, CKE26004SAFETY ‘ex2800.1 INSIDE view TFR, STRUT > AN DANGER]| AGAUTION INSI0E view (€k2500-11, CKE250041 ona‘eK2500.1, dy DANGER DETAIL A DANGER —& ee eros, THE coor aaave lo evcinoen stn iNGt 048, (©K250011, CKE2S00-1SAFETY ‘cKE2s0051 ov-T (€2500411, CKE25004 4 DANGER 4 DANGER STAY A FO cA TPeoae 10 oveh Les, Mca LOAD 0 Gm one LECTED EADY‘eKE2500.1 SAFETY A WARNING CetinG DETAIL OF ACCUMLATOR or (Ck2500-H, CKE25004I1SAFETY ‘eKE2s004 SECTION 2-2 ‘©K2500-11, CKE2500-1 os‘CKE2500:1 At Not ovine arte a ter 4 DANGER ‘TAA FON RINE Tr euts 10 OnE LINES. cis 0 GND iy aecveeterairied 019 (©k250041, CKEZ50041‘SAFETY ‘eKE2s00-1 Soaar cena view @ ‘A BANGER wx 2 ~ poe Obl SECTION N-W SECTION SECTION x-x (€k2500.11, CKE250041 020SAFETY (cKE2s0041 FUEL TANK) [ivoeavcic raw] LF) [aceumon) [a como q Fev ott] [botwor tog | fas DETAIL. SECTION E-E DETAIL G. DETAIL F. SeTAlA S DETAIL 021 (€K2500.11, CKE250041SAFETY ‘eKE2s00:1 4A DANGER SECTION (€K 250041, CKE2500411 022‘cKE2s0041 4 DANGER 4 DANGER | ‘STAY AU FRON WCRI | COE ELECTHIFIED INO DENY. A cANGEA INSIDE VIEW (R/#D A Gao 023 (6250041, CKE2500411(©K2500-H1, CKE2500-I1SAFETY ‘eKE2500.1 “DONOE ENTER 2 GUY CABLE LINK PIN A, DANGER | “serrine positiON FSU INS URN? | sow er Ute 028, (€K250041, CKE2S0041SAFETY ‘oKE2s0041 (©K2500-11, CKE2500-1 028SAFETY ‘CKE2500:1 Exteel | | a Tenis DETAIL A ADANGER Ay WARNING awe SURELY. TF THE lack is PEW 17 18 FReslinarae feo Sst at ine Ooi tr TW OaNGeR OF Ji ie her Sa loveRwo rst kG Because [oF CYLINDER SHRINGING 027 (© 2500-11, CKE250041SAFETY PRECAUTIONS FOR INSPECTION AND MAINTENANCE. 1. Senice and maintenance must be performed only by authorized personnel who are quails in compliance wth ‘a rlovant ao equation, 2. Regular maintenance or inspection shouldbe quciy performed afer shuting down the machine and ensuring safety o personne! and equipment Post an"INSPECTION IN PROGRESS, DO NOT START: warning ign ona eodiy vst locaton (GENERAL SAFETY PRECAUTIONS 1. Wear safety shoes, helmets and clothing suitable forthe ob. Also use protective goggles, mask loves, ee 2s requires 2. To ensure safe and correct mainienance,carefly stoy ths SHOP MANUAL and get fy fair wth he stuetons init 3. Place tie machine in a safe place. Always maintain ste clearance around the machine. 4 Btore starting crane operation, hod a safety meeting, Also, make agreement on standardized hand signals, '5. When inspecting orhanding the bata ool, donot use exposed fame nearby. “To avai Fre accident only use explosion poo! ighting equipment 1. Satan inspection or maintenance work any ar shutting down the engine 7. Certain machine components remain hot immediately ater the engines shut down. De not touch them. 8. Beloreremeving the rasatr cap, wat unt the coolant water gets sufcent cool, Next, caretly loosen the ‘ap and release radar pressure, and them emeve the cap 9. Betore inspecting or maintaining aneletical sytem onthe machine, ower of the machine by, for example, dtsconnecing he batery cables. 10. When working at high it area, always wear a safety bl, "1. When ving the operators cab fc an nspecton or maintenance work, postan “INSPECTIONIIN PROGRESS, DO NOT START." warning sign ona readily visbelocatin. Also lok he cab for secu, 12, Bere starting a cleaning or ubreston work onthe machine, always shut down the engine, 13, While adjusting the pressure, be absolutely careful shout uptureofa te, yng of wheel pa. "14, Use genuine KOBELCO replacement parts and ots only 15, ways keep the cl containers clean. Protect them against ingress of dst or moisture, Also, ilean, fresh ison. 18. Oncoa maintenance work is complete clean the machine. Protect grease nipples, breathers, and ollavel gages againat ingress of du, 17 Aways keep the subjects of regular inspection clean tow problems such a leakage, crack, looseness, 0, tobe realy detected 18, Ouing car washing, donot allow high pressure steam tobe directly applied to elecical components and con- 18, Aer removing Ovngs, ol sea, gaskets, ez clan the mounting seats. Then, install rsh O-ings cl seals, (gaskets, ec. Also, rememéer to thinly apply oto the sal faces ofthese parts boo instaation 20, Before asconnectng pressurized piping release the inside pressure 21. CAUTIONS fot epair work wth welding: Tur OFF the Key swich, disconnect the negative termina on batty to power of he eecical cut provide grounding wihin 1 meter rom a weld area; advance, remove elec: tronic components for exampie, controle) o prevent possible mage 22. Dispose indus wastes acordng ta eovant iw or regulation 23. Extely cael dung an inspection or aintenance work under ie carer Rerpamber the possbity of be ing crashed ‘when ackng up the machine for an inspection or msintenance werk place blocks below ito prevent acedentl tating 24, Provide postive ventilaton when refling oso el, sng parts, or tating the engine (€K2500.11, CKE250041 028SAFETY 25, Toremave aheavy component (20 ky or heavier), use a crane, ee. Aways Keep safely in mid 26. legal or unauthorized, or otterwise nonconforming mosecaton is sity inhibited 27. De no allow ol or dust ta depos around the engine. Other, fre accident can result 28, Store removed atschments and comgonents safely so the! they do nat drop fl down. 29, Aways use correct ols tha have been well maintained 420, Te prevent personne rom being caught by inning fan, el, shaf or he ke, shut down the engin Beare ‘tating an inspect or maintenance work 231, Batley quid and ots ae harmtalto human heath ttouching any ofthese materials, immediatly wash away. 22. Make sure to use the igh ol for uel. 029 (€K2600.11, CKE2500-11SAFETY (C2500, CKE250041 0301. SPECIFICATION ory (¢K2500.1, CKE2500411. SPECIFICATION ‘©K2500.11, CKE2500-I1 124. SPECIFICATION 4.4 CK2500-II SPECIFICATION 444 PERFORMANCE Fre ‘Gawler mound, ly ovoing Ia. itng capacity with 1.2m (0) boom) aoe (500,000 bs x16) [ax boon engi 91.4 m (00) [Max boom 8 lngth 762m boom + 30.5 mj (250 boom + 100) [asic boorinath 15:2m(60R) \irking weight (nctuding upper and ower machin, counterweight, carbody weighs, 18.2 m 60) boom, hook bock) ‘Approx. 216 ton (476,20 Ibs) [average ground pressure Fopiox 101 Wa TA6 pe (Gradeabaty an 0) 20% engine Fine PHTC-UN Dies engine 247 2000 min" (31 N20) Main fing owing ope peed “101 3 min (360 fo 10 Urn) [Ania iting lowering rope speed 7101 3 min (360 to f0 Min) {Bcom ring rope speed 2x22 102 mimo pane 2x72 106.8 AImin) 2x22 10 2mimn 'Bcom lowering rope speed ee ‘Swing speed "22 mim (22 om) [Propel speed] THO Hh (60 to 0.44 ros) (4) Tee main ting towering rope sped, the aula iting ower rope speed, and te prope speed vary depending onthe load. (2) The rope speed i ofthe fst ayer onthe drum, 442 PERFORMANCE OF LUFFING JIB [Max iting capacity [saatx 137m (O00 we x ASA [Max. boom length + Jb longth[6.0™m boom + 1.6 mj (200 Rboom + TTOATB) [approx 228 (602600 los) |working weight [incucing upper are ower machine, counteweighis [21.8 m boom + 21.3 mj (70 boom + 70 jy), hook lock] TAporox 106 KP (154 ps) [average ground pressure [inducing upper a lower machin, counterweight, [21.3 mboom + 21.3 mjib 70 boom + 70), hook Week) Lb aig owonng ope speed [40 to 2mm. (120106 Nin). 13 (€K2500.11, CKE25004114. SPECIFICATION 4.42 OUTSIDE DMENSIONS [Height above ground of cae Barommrze) ‘Wath of upper machine wi operaors eb [400 mm (1129) Rus of rear end (vit counerwegh) [3.000 mm (108°) (Courtrweight ground deararco so mm 09) (Center of rotation to boom fot pa i400 mm 7") [Height aboveground of boom fot a [230 mm 62% Height op of gan (working poston) [5530 mm a2) (Overt engi of caulers [5.985 mm (29 6 Distance between centre oF umblow 7.895 mm 254) (Overall with of rowers 7.730 mn (254) whan of rawr shoe 1.30 men (52) (Ground dearance of earbody 38 mm (172) (¢ 2500-11, CKE250041 14LUN mm ine) 4. SPECIFICATION. Taaneorr Tras (€K25001, CKE2500414. SPECIFICATION 444 DIMENSIONS AND WEIGHT OF EACH PARTS For your reference, he chart below shows the dimensions and weight of each pans. 4441 BASE MACHINE 3) = Oren a — ee, tn 3000") amore) ase \orawier (51,400) dé os — i em ae soc [ant (6,860) os enn = (€k2500-11, CKE250041 164. SPECIFICATION. 4442. COUNTERWEIGHT ‘ame mension rman (f-n} Weight c oe ny ni :| enone eaunereit 6 2 row < . (24,343) 108 1 mae) 8 562511 Piece countrwoion | (12400 q ‘eee i (O Oo} counter eooeereer a a counterwescri 17 (625004, CKE250041141. SPECIFICATION aa Nowe meson an a 3 ne [soy ao wee Paes eS vo ey | a TL ‘COUNTER WEIGHT BASE) (€k25001, CKE250041 181. SPECIFICATION 4443 ATTACHMENT “The weight ofthe guy lines isntincluded int the tachment weight ve Oi = 00 [Pom pase (10,288) ane Fa fenton ier ey mcm 190 ncn |(with guy fine) ie fezmon ao feeb a ‘aon SEXAXAXAXAXAX | ARIMA i 19 (©K2500.1, CKE2500411. SPECIFICATION — omen om) ar ak Kou a: KOK E Li one orca es bo tx crane) ro) somcon - no - ss) lzzmom KXXXXXXXXM 71 | [eter by Fron tut 4.160 [ting y2) (2560) Rear sit 1.190 (utng i) 280) 100 ating backstop a (©K250041, CKE2500-1 1424. 8PECIFICATION We ve mension nn tn) ea 5 leat saston tg ‘0 feo 699 2 Joe steve er Jax save 0 [Fort ea eee pew nase z) sing sem te ooo sey (32% 4 ie 5 e |Boom Base “ 6.810 wa cy «sor (Ck 25004H, CKE2500-1141. SPECIFICATION 44.5 CK2500U STABILITY IN SWINGING AND TRAVELING ‘Abound swing Propaling ‘tachmet counter | carboay when jak (ast) wont) | weight @) | wit erawer | winouteraw| Fonwaraing | Backwarsng [Westanaie a0 (Gackvard svage) | _ N°? Ne | 9 | ° ° Mast ange esa e | None None ° ° ° ° ast angle: 185° me (@ackward stage) |S me ° ° ° ° ast ange ro a Loss than 71" 3 ° ° ° ° ast angle: 180° ioe (Backnard sage) | N x x x x Mast angie Fi Ai free wr None x x ast angie 18" | a9, a x x x x (Bacar sage) Mast angle . ri ; 7 Fae 0 26 o x o o Mast ange: 160 degrees Most ange: Less nan Epc hw {ess roe Weems a) Aegon Tides. 1 acetup wo coer wrmmocwecormoc = wnourrwo EOI Do not remove erbody weight when Jack up wi crave Otherwise te machine fl Faire to observe thi precaution may ‘eatin serious nur or det, O x 60 degree Sing porte Not possbie (¢k 250041, CKE25004I1 1441. SPECIFICATION 4.2. CKE2500-II SPECIFICATION 4.24 PERFORMANCE courteruighs, carbody weighs, 152m beam. hok Heck) [Tse ‘Crawler mounted, ty revving Max. hing capaci (ith 18:2 m boom) i 250 1x46 Max. beer ing o14m Max. boom & Jb era FE2mboom + 30Smib [Bas boom length 152m [ering weight (indoding upper and ower machine, vere 2is PAverage ground pressure ‘ppion 108.4 Wa [Gradeabity an 0) 30% engine Tine PHTC-UN Diesel ngine 247 2000 min Mai ing owerng rope speed 101 3 mimi [away iting owerng rope speed "10 f23 min [Boom raising rope spe0d 2x22 2 nmin [Boom towering rope speed 2x 22102 mime Sing epee Famine [Prope peed 7.00.7 am (1) The maining lowering rope speed, the aula ling! owering rope speed, andthe propel speed vary depending onthe load (2) The rope speed i of he st ayer onthe drum, 4.22 PERFORMANCE OF LUFFING JIB ia ia capac moeam [Max boom length + Jb leigh 61 0m boom +61 0m) (appx 2221 ening weight {Intuing upper an lower machine, counterweight, [24m boom + 243 mB, nok block) Tappiox 113 Pa |average ground pressure {tnelusing upper and lower racine, counterweight, [24.8 m boom + 21.8 mj, hook blac) (ibang Towering rope speed |40t02 min (€K2500.1, CKE2S00414. SPECIFICATION 4.23 OUTSIDE DIMENSIONS [Height above ground fea [800mm [wth of upper machine wih operators cab {3400 mm [Radius of ear end (wih counsreigh) '5.000"mm [Countrweight ground cearance 1.490 ne (Center of rotation t boom fot pla 1400 mm [Height sbove ground of boom foot ia [2.528 mm Heit op of gantry (working poston 's.520mm (Overal ingth of rawlers [3.970 mm (istence between centre ofmblow [7.995 mm (Overal with of eaulers F620 mm With of erawler shoe [220 mm, (Ground Gearon of ebay [25 men (62500411, CKE2500414. SPECIFICATION. oor ® Py Doe oer “RS ‘oese L| \ OR mi} lg \ \ SX ; \ SNF \Y % Ned a! thse a 147 (625004, CKE25004141. SPECIFICATION 4.24 DIMENSIONS AND WEIGHT OF EACH PARTS Foryour reference, the char below shows the dimensions and weight ofeach pats 1.241 BASE MACHINE = —— |Crawler : 20,700 [Gantry , 3,020 Mest 410220 2,870 (€K2500-11, CKE25004114. SPECIFICATION r —- Dimension [wea] Neve (om 1g 4 it hanger |counterweoht a) ; = evr \counemain (8) zl 526 Pie lo, ® 1419 (6250011, CKE2500414. SPECIFICATION Siena wake ene a is lata wea vn fowe) eo! Pre a commen we @) ——S Beery 3 =, (Ss | TL) coUNTER EIT BASE (€2500411, CKE26004 1.204. SPECIFICATION 4.243 ATTACHMENT “The weight of he guy ines snot includ into te Name on boom base 4005 boom te a0 50 minsen 8 : Bava ae \o.1 minset 00m ows guy tne) a0 1:22 minsert 00m a INI - 424. SPECIFICATION 3 = ss a 8 re TX . | 8] TIX (62500411, CKE2500-1 1241. SPECIFICATION cme Weight g luwsme 00 luting Boom Tp 2088, lating {ape nset Boom ad luting Jo Base “7 {ting so Tp 1.400 cao (€k2500.1, CKE2500414. SPECIFICATION Nane ‘inanson Weight 30m neers |» [in| ors |Front Strut t a {a (to) 1410 SEIVWAAR A= | a | 1200 Rear Sut (ating) 7 were Luting sip backstop 280 Isom spect 313 (€k2500.11, CKE250041 1241. SPECIFICATION —— we Nene min) ‘eg (bs) Jan easstn ts wo [eso aE say's) S % a EN : es sine 3 aso [ror 0) lstea toon arm | json boom Base so [wer ncn (6250041, CKE25004114 SPECIFICATION Name Dimension Weaht | a (bs) al Hook 450 35 Hook 900 [roHook ql 1.200 (©k2500-11, CKE2500414. SPECIFICATION. Name ‘Dimension (nm) a (bs) loot Heoke 1900 150 Hook 2.30 l2s0 Hook 4200 127 (€k250041, CKE25004141. SPECIFICATION 4.25 CKE2S00.1 STABILITY IN SWINGING AND TRAVELING — rem a cag mcm | comer | carosy in ‘nest | woart) | wom) | vaticowe etct| Fewer | Bckwarseg| age 5 wee | vee | we | 0 |e ° eee None None ° ° ° ° (Backward strage) Ne 4 ° ° ° ° Maat ents None 28h | Less than 71° al = eg co 9 (Backward strage) S08 None x x -o (Backward strage) so 2 x * x x tesstran7 | a ° x 2 ce vet: cere Eereee tear eee posers vir o cansooe ECHT worms EXE [CAREOOY EIGHT Do not remove carbody weights when Jack up with raw ‘Otherwise the machine falls Failure to observe this precaution may result n serous injury or death oO (©K2500-11, CKE2500-I12. MAINTENANCE STANDARDS TEST PROCEDURES 24 (¢k2500.11, CKE2500412. MAINTENANCE STANDARDS TEST PROCEDURES (€k2500.11, CKE250041 222: MAINTENANCE STANDARDS TEST PROCEDURES. 24 MAINTENANCE STANDARD. 2.1.4 PIN, BUSHING, SPRING, LINING AND SHEAVE 4. Pi, Busting « 6 Busting Lt: men re) ‘3a dinerion Unni Name] tocaton | tam] Partnumber | Se-serension [“Ussto Et Tpmeay se gue rr an Fant Fra Reonm| 1 | sueawororses | Me, Ae oe ~ai| Boonbum | 2 |soowenowm| 8 a Faz eu] soomonum| 2 | soorwororses | 2 ee _ rena F928 ‘ina oep, | to ae Fos a rum _|_° | Se82woro0s (788) Revise! (p27) * ’ aamrl 8 Faz? Boom Foot Jor2noto04 wee] |pensce) F827 LLuffing Jib Foot | 5 | Ju13A01016P1 ee Replace) "9247 fing fre 28) eaFeok 7 Font Srareot | | sorzaoteoser | _ rence 82 cee Onn) 7 | 2uostiss as foal es Repace Paul] Boom Orum W084 ee em ea a |" Boom Or 8 | sorwortesy 20 ora (P26) Taina won “sotm] 50 Prepac] F025 Bush. num _| & | 2snsvrorDéss0 om ree [RE] e271 bd Boom Foot 10 | sD0sA01013P1 eet 18522 | Replace] F927 ‘se, 27) ‘a v8 Fez uti > Foat_| 11 | JooworooaPt wo 15S [rece 82 = a8 me Fea sintFoo(Fem) | 12 | Joowaoroourt vam Ee [rece] F82 23 (€k2500.11, CKE250042. MAINTENANCE STANDARDS TEST PROCEDURES a «>| <> | Ta Fest Unt nt Usable anit at T weoion | ten | _Pannomr_ [reer] TASTES [Ron Seta ae Om rz e026 cea 29 ranaounpen | 20 | worm: | 2285 | na caemy mz ae [aera | BCE, | wacom raze fom rm ad enor repce 0282 aw | aaa | ghee, | nase reas a) res _ au pe (Compression) es (222) (€k2500-11, CKE25004 242. MAINTENANCE STANDARDS TEST PROCEDURES Nps A aise [tem] Pennants | S25] vssimn [neneay| SO | congue a mw [| ome | oe | Leis | Te [e[aerwr [atid oe] Le | FREE] [aor [ott att] Let ee vowrspnate [ot | woroarr | a2 |S, ies, | eae wm [af amwoe Lal aty | Len Ee S| = | mow am a) Pe wom atsare we [emonems | am [ty | [a | BR te [o|aewor ite ee] eS sero [| comonm | es [amy | ath wow [efor [as Lay) [leis owivem [0 | amwroer ttl ay | [ey SS Fixed Jib point sheave| 44 | 2407P812 aS feta haa) eat Fixed Jib stutsheave | 45 | 2407612 feta fete ney loan 25 (625004, CKE25004112. MAINTENANCE STANDARDS TEST PROCEDURES Fig.2:2 Front and Rear Drum Lock Fig2.3 Boom Drum Lock arn 822 y OTe} Fig2-4 Boom Drum Lock Paw! ‘©k2500-H1, CKE2500-H1 28:L MAINTENANCE STANDARDS TEST PROCEDURES 5 jest ry f =
I an ai ot sol-a9 soL-ag 3 R ‘-Section Valve Hydraule Schematic (Ck 2500-11, CKE2500411 5.365. HYDRAULIC SYSTEM ‘2-Section Valve (YN3So00027F1) {ing el iat oproosimatrHitowssket (5 )Al D. ‘Tofnesoncat {py ~__esinngoig ete - Toewgputing vate __(SPB)*2 ——Tetunetonsut__ | 2-Section Valve Hydraute Schematic 537 (©k2500-11, CKE250015. HYDRAULIC SYSTEM Toboomatumioce agony re ee bom ook 2-Section Valve Hydraulic Schematic ‘Seton Valve (YN35V00001F1) “osving rare cont vane (50g rection) (¢ 250041, CKE2500411 5386. HOIST SYSTEM 4 (€K 250041, CKE2500-116. HOIST system (€k2500-11, CKE2500416.HOIST SYSTEM 6.1 APPARATUS AND LOCATION OF COMPONENTS: “The hoist system consis of the man pumps, te con trl vale, andthe front and ear erum assembles Both a he drum assembles consist ofa heist motor ‘wt a bultin mechanical brake) an eduction unt as wll 9 a lth and drum lock ‘The No.1 and No2 main pumps supply the pressurized clforthe not system by way of conto valves. oo J} exer 63 (€K250041, CKE2500416. HOIST SYSTEM 6.2 CONSTRUCTION AND FUNCTION 624 HYDRAULIC SCHEMATIC Ladi] iis! B SOS SOS oo a ! ct ie spi is is fe} H 3] aE 1. FS Fig.6-1 Hoist System Hy draule shomatic (€k2500.11, CKE2500.1 oa a‘The front and rar drums are macharicaly ical 20 {he following explanation uses he font rum foils traon purposes. 65 ‘©K250011, CKE2500-16. HOIST SYSTEM 622. UFTINGALOAD Pressurized ai fom the main pump (No2) flows trough the main contol valve fo pme the front drum hoist system Whe the function nk ever isin tne"Op- erate’ pasion (Sl On poston), pressure from ‘he contol ystom purp flows past the accumulator And ino the brake valve Beck, the ctch valve Bock, {and it fows trough the valve block secon solenoid ‘ales) and into the remote contol vate. ‘The pressurized ols feat teeth sides ol chambers cof he clutch eynaer (CLM, ESM) via tho vale block (d-sectonsclonci vas). Since the cyinder trust force ty the pressurized ols not generated, the ctch is connected win he sping. ‘hen the Heist Conta iver is operated inthe "ost lose eto, dets conte pressure al teugh ne ‘emote con valve and into the pot (PUM) of tre main conto valve where it moves the spooks. ‘Ate same tine, the contol pressurized al fows into the prt (PBM) ofthe bake cinder but inthe winch motor via the vale block 4-section pit operate ‘aves, and he moto rakes released, ‘As decid ty the pasion ofthe spool, the main pur (No.2 owing int the con vale is set to thetiRsde of he hastmetort civethe host drum and ‘hereby hoist the ead (€K2500-11, CKE25004 656. HOIST SYSTEM 67 (€K250041, CKE25004116. HOIST SYSTEM 623 HOLDING ARAISEDLOAD th he Het Conta leverbackn its neta poston, ‘he conto pressure coming rom the rerrote control valeis cut and then the spool inthe main contrlvave ‘returns to ts neutral postion, ‘When the spool returns to neutral, the pressurized oto ‘he motets cut ff and the moter stops. Nw, though the weight ofthe suspended fad contin. eso pullon he rum, further rotation of he kum is prevented by motor counterbalance valve that sal ows any motor rotation by tockng the return of oto the reser, ‘Ane same tine, the contol ot pressure nthe motor bake eyinderis decd backs the reser and the motor brake resets so ‘Thepressurizedolisfeatothe both sides ol chambers oft cute cylinder (CLA, ESM, andthe cynder thrust ore bythe pressurized ol not generated ‘Theceor, te eth main connected wth the sng. ‘The ais now eldin suspension by the combined et fecs ofthe motor counterbalance vate, and the tor brake andthe cen (6250041, CKE250041 6a6. HOIST SYSTEM 69 (©K250011, CKE2500-16.HoIsT SYSTEM, 624 LOWERING ALOAD (POWERED LOWERING) Pressurized ol rom the main pur (No2) fows through he main contl valve to power the front um hoist stom ‘when tie function eck ever isin the "Operation posi ton (So. 3:0n poston, pressure fom the contol ur flows past he accumulator and into the brake ‘lve Beck the cut ale biock and tows though the vate block 2-secon solenoid valves) and ino the remote contl valve, ‘The pressurized olisfedto the both sides cilchambers ofthe cutchcyiner (CLM, ESM) via the vave block (@-secton solenoid valves), Since the cyinde thrust fore by the pressurized os not generate, the Sich is connocted with te spring, \Wnen the Holst Conta lever is operat inthe “lower load” cection this contol ol pressure i rected by the emote contol vale to ow et the port (POM) of ‘he malncontl vale where moves he spool Atthe same time, contol presses also drecte to ‘he pont (POM) of the motor bake cyners where ‘causes the motor brake to deengoge, "Now the main pup (No.2 ol fovng ito te conta ‘valve, a dieced by the poston ofthe spo act ‘ates th lat motor ev the drum an thereby iw ferthoload. The counterbalance va is opened by plot pressure fom the"Tuning side to alow theme. (€k2500-11, CKE2500s1 6-406.HoIsT sysTEM ent (€k2500.1, CKE2500416. MoIsT SYSTEM This page is blank for editing convenience. (€k2500.1, CKE250041 426. HoIsT SYSTEM 625 FREE FALL OPERATION when the brake selector sch i et tothe "FREE FALL” mode, the solenoid valve (Sl 22) in Ne vahe Dock (section sland valves) i itched. ‘When the solenoid valve stched and he foot brake Is release, the pressurized alin the CLM side ol chamber of the th onder retuns to te tank, an the oyner trust forces generated agains the spring toreleaee the catch, ‘As ares the oad fls ety (reef), and he brake can be app with he foot rako. en the brake pedals operated the contol press ‘zed ol fows ito the CLM sie ol chamber ofthe clutch elder trough the brake valve, and the cyin- decthrust force ie deereased to actte the brake ork Ing wi re cute, 43 (©K2500-11, CKE250046. Hoist sysTem ig. 65 Feo Fal (2500-11, CKE250041 cory6. HoIsT system — i uF Fig Free Fall Control (Brake) 645 (€K250011, CKE2500416. HOIST SYSTEM 626 FREE FALL ACCELERATION Fre fal vith the "FREE FALL SPEED ACCELERA- TION SELECTOR SWITCH" on he side panel set the HIGH" pestton + Whon tho brake podalis released the slenod ‘ave (S0L-10)s swtehed, and pressurize ol ‘tows tothe [POM] poate main cone valve through the steno valve (SOL-10 inthe 3s80- ton solenoid valve Bock ad shut vale and so leno proportona ave (SOLS) to ve the spool Simuitanecusy the ol also goes into the ‘brake cy PBM } porto the winch motor ‘tvough te valve back (¢-secton plot operated valve) to release the metor brake. Then, te motor ‘ofates tothe lowering ection “Though the ctch is released while the "FREE FALL made i seectod the rotation of the winch moors transmit othe drum, andthe fe fa ‘speeds increased by the power lowering, because ‘he rotation resistance ofthe uci ager than that fhe drum. nts status, the drum ea ote ‘out any oad “+ Wnen the bake pedals dapcessed pressurzedl Is fea tothe [CLM sid fhe clutch cy through the brake vale. Then the eying rust fore is decreased to slow down te ee fl, and the conto pressure rom tho solenoid vate | SOL 1)jinthe Section vae blocks iso decreased byte proportional ave (S58) and ho solenoid ‘ave 0-10) toretur the main cont valve spo! to the newtal peston. \inen the eps retured tthe newtal poston, pressurized oto the motors shit of, an the > tor slops rotating (€k2500-11, CKE2500-1 6466. HOIST SYSTEM a le Le Fig6-7 Free Fall Speed Acceleration 647 (¢k2500:1, CKE2600-116.HoIsT sysTeM 63 DRUMLOCK 63.4 ASEEMBLY DRAWING Tattenng eee SHS 109025310 96.1 te) Tete true 2wzoNmtsio21 bet) atte ore Tohorng ave BoD N48 177 6A) Bidioad.s Nmgn016 918 Be ‘op COTTE az stewzia nn Rony were tae (€K2500-11, CKE2500411 6186. HoIsT sysTEM 632 ADJUSTMENT OF DRUM LOCK orm ess2) Do not adjust the drum locks unt the boom, hook block, and toad have eon lowored to the ground. Failure to observe tis precaution may result se- ous injury or oss of life. esa aaa (1) Pu the acum lock knob nthe LOCK poston and checkto soe thatthe pawl is engaged inthe boom ofthe drum atenet ftv pawtisnet engaged in tho bottom ofthe rach ‘ot ajst the spring length allow the pa to be ‘engaged in the bottom, (2) whine condition of step, aust the especive d ‘mansion as shown the Sue, (9) Push me dram ack kod inthe RELEASE postion and checktosoethal the paulis ear oftaratchet by atleast 20 mn 25/52"). (Operate tha kna tothe LOCK postion and tothe RELEASE positon ad confirm hat the pawl moves smoot (6250041, CKE2500-116. HOIST sysTeM 64 WINCH ASSEMBLY 644 WINCH INSTAL (€k2500411, CKE25004I1 6206.MOIST SYSTEM ‘WINCH ASSEMBLY / REDUCTION UNIT WITHOUT FREE FALL (STD), 642 winch Assy Ue an waugea2R) ono Btn zrerauus0vtety Zz onl in us 3190146 iesaasar) EF} Shen eowagr aww ED ‘©K250011, CKE2500-1 6216. HOIST SYSTEM REDUCTION UNIT ASSY Tptrna ae eee Nn (eStores Teteriginge Neroone sir ore rte fes'oar she ‘epy COOTER opi LOCTITE W515 [rescore wis eee. fissiosraben opi LOTTE wa © atone of ceectonin Sracconty Suanvaseemelel ‘eaNn {reste 2306 ‘py LOTTE ra ‘oy LOCTTE #515 FBiedN m6 107.2 m6) TOCTTE AST applet ‘Sow anata sol te of pact, tesa (itorretee Sea peo Sop COTTE 77 (€K2500-11, CKE2500-1 6226. HOIST SYSTEM G43. WINCH ASSEMBLY WITH FREE FALL (OPT) 623 ‘©K2500.11, CKE2S00416.HoIsT SYSTEM 6.5 BRAKE PEDAL 65.1 ASSEMBLY DRAWING . SECTION AA SECTION E-E SECTION 0-9 SECTION F-F (€ 2500-11, CKE25004 6.246.HOIST SYSTEM 1 Becht 20. Spacer 7 Waser 2: Lever esey 21. Bot 28. Wachee 3. unk 22 Spacer 28, Pet 4 Pel 28, shim (04) 40. Brtevate 5 Pau 24, shim 08) 42 Capscrew 6 tink 25, shim(09) 12. Locate 7 ink 28 cote pn 4 Eon a. unk 27. coterpin 45. 90" Ebow 12 2. coterpn 46 90" Ebow 13. Pn 280k 4 Copsrew 14 10. 48. 90" Ebow 15. Pm 24. Sem 48. Comecor 16 Bex 22. 59. Phin 17 23.1 2 yet 18.00 3. Waster 52. Seng 19. Spacer 95. Look washer 59, Pressure sich 26 Pie 54, Somsbot Toten oe tem Name sae cheng a ak aKa His 302 50329 2 Capes MiOX 70 34928397 25313) = Press Sih PFS pei Z04(21722) Prior to he instalation ofthe bearing (No 16), suienty pack ease ‘Apply Maly cota the cating Sections (ck 2500:1, CKE26004116. HOIST SYSTEM 652 ADJUSTING THE BRAKE PEDAL EVESOLT [52] SPRING wos Gauve (iS) ae nh a [am Bee ney ‘Adjustment (1) just the eye bok nt he cimension Ss 53 mm (ease) (2) Depress the brake pedal unl the valve spot reaches the soke end imension $= 37.5mm(- 182". (3) Bring the bot [47] nto contact with he lve (2) in the satus desertedin the 2 above, andieosen 34 ‘umn (protrude upward) o agus the dimension S ntti 38.0 mm to 38:3 mm (1.4965 to 1.508", ‘Then, tighten he nut (@) Raise the ever (2) up, and retu the vale spool to the neural postion (smenson $= 53 mem (2:31 52), Bing the cap sere [30] to contact wih the ‘ever (2), and eosen 3/4 tumor let). Then, tighten the nt {Gimension §» 52:3mmto 2.5mm (206% 207%) (6) Aajst the spring [52] unt the dimension Lis 70 fmm 2.31) n te status described ine 4 above (©) Ensure that he eectve svoke of the valve 20] from the time when the pedals depressed othe ‘ime ti leased is 18 mm (916) ‘¢k2500-11, CKE2500-1 6266. HOIST system 66 BLEEDING AIR FROM BRAKE CIRCUIT fair rminsin te piping fom the brake valve to the a Pe Pier [I eae free [@a-S) | * |e] Juve Fe ea ose Plea ae | a) ae aa ee ae ee el itl pm Pe ee ree | la el > eee aa rel st | El ioe ERE TM aul + = a eal — : oe | laut = oe 5 (2500-11, CKE2500-I1 10-14Penne ener 1045 (€K2500.1, CKE25004140. ELECTRIC SYSTEM eT E ——— eee z P| eee gel revere fame for [EET loses seats nol [OO [an [ED a tfeenet oa fae fT (6250041, CKE2500411 10-16CONNECTOR LIST a vse. 05 (Gen 2 cone suieioEs @1 o a (€K2500.11, CKE2500-140. ELECTRIC SYSTEM eeiahelel ire Pepe Ts + avss0.78 CN=18F nvss0.78 cn-178 io. Sa0 2 cone suieLDeD ©» cNn-18F (oan 3 cone suietnen ©) (@.5e0 2 cone suietnes ©? Voges cone swietoes @1 on-2F ON-3IF (€K2500-11, CKE25004 10-1810. ELECTRIC SYSTEM | (ON=32F (AVSSO. 78) (ON-33F (AVSSO. 75) f. 2 q ‘ON-36F (AVSSO. 75) A. c q ‘ON-37F (AVSSO. 78) 10-19 (¢2500:1, CKE25004I110. eLecTRIC SYSTEM sass af an_ 77 39] 19] 30 30] = i Le ia awa on-438F on-atF [falas =) = CN-46M on-42m am Ee CN-46F sat a 10] : iB on-44m cn-a5m ON-42BF ee : | lk a |e cn-a7e en-a7m vee (CN-43M (C2500, CKE25004I1 102040. ELECTRIC SYSTEM 10-21 (€K250041, CKE25004110, cLecTRIC SYSTEM cn-96F B:, Be cN-100F cNn-95m oNn-101F 0. 75s0 2 cone shieLoe @) oNn-102F ‘©K2500.11, CKE2500-1 10-2210. eLEcTRIC SYSTEM ON-104F nikeo, 75 N= 106F (ASSO. 75) fo. te0 3 cone swiewse ©) soctan 5 cont sussisee eetencterrrnnte'l/ al SZ (@. sue 3 cone shiewoes @) cn-107R | SS 10-23 ‘©K2500.1, CKE2500-140. ELECTRIC SYSTEM — (ON-109F ~ CN-110F cN-115F sexe nent cd en-113m seats cnt 14am cua et eN-113AM (6250041, CKE2500411 10-24wife) 40. ELECTRIC SYSTEM on: OF oNn-120m ON-121F on-121m en-122m eN-122F 10-25 (€k2500:, CKE250041140. ELECTRIC SYSTEM oNn-135M oN-136F cleat oN-134F oNn-137F cN=135AM (€K2500-11, CKE2500-1 10-2810, ELECTRIC SYSTEM ne cn=140F oN" 1 56F cN-140M . cn-187F cn-1436 ao cN- 158 Peal avss0.75/ eyayggp 4799075 (€k2500-11, CKE2500411 10.2710, cLecTRIC SYSTEM see onan n- 150m allie De fit PF] on-reox on 160 = oN 183F ra sas tavsee. 75) on-iaie sa oN 184F (avss0. 75) or cN-161M re) enci73F a. SEALING 7? on-1e2 a on 1736 on-1854 (©K2500.11, CKE2500-H1 10-2810, ELECTRIC SYSTEM. SEALING SEALING r= our CN-179F [e) cial oet ON-186F 10-29 (¢k 2500411, CKE260041110, ELECTRIC SYSTEM ON-193F ON-194F ONn-213F cn-202M cn-202F cNn-214m ON-2 14am EW) stains ‘oN-208m ON-216F cNn-217F o (€k2500-11, CKE26004 10:3040. ELECTRIC SYSTEM, : su gf seus beh AS CN~224M CN ane ma 1 CT on-295 en-237™ en-237F \, ofecsne CN-239M © CN-239F = CN-2.40M CN-240F rye ebelebdTe CN-241F CN-243M ON-244M —CN-244F (ASSO. 75) 10.31 (€K2500:1, CKE2500410, ELECTRIC SYSTEM avsso.73 GN-246M on-2494 on-260m WL STED PAIR 0. A552 @ \ nye | 738 [a we lo |e |e oNn-260F caste pas cese@s/ | eN-248F rz. 4 a ON-251M ON-251F cn-2sor" CN-261M CN-261F CN-294M oNn-298F ba = oa ra oa ON-205M CN~285F (6250011, CKE25004 10-32 cN-296M CN-296F10, ELECTRIC SYSTEM cN-263M UWF one ts) 22€ 00 CwsTe ue eas! 37 CaN ue 5) 338-MO TWh one tx) en-311M = o.25e01 ve W 73710 (aise Fu 8546) Liat PAR o.05400) 0 PAIR oNn-315F 10.33 (€K2500-11, CKE2500440. ELECTRIC SYSTEM cn-a22F cN-316F tthe SEAN senkina ON-323F cn-316M cn-323M cN-317F ee on-324F Sea [aise 2580 cn-317 cN-325F oa se on-321F cee en-325m (©K2500:1, CKE2500-110. ELECTRIC SYSTEM oNn-327F ON-331F Onsen ose, ome on-328F AP u oN-332F cN-328M wos ma erau oNn-330F cN-330M on-332M 10.95 (©K2500-11, CKE25004110, ELECTRIC SYSTEM cN-341F cN-341m ON-335F cNn-336M (¢k 250041, CKE250041 10-36 oN-361F TH STED PAIR 0. 852 @) on-362F iTmiaTED Pain 0.8594 @40. €LEcTRIC SYSTEM 1 cN-351F oncese estan I esr | gee | ase | gee ce | gee | op | are | oe! | ae | ste | ae Ea i oN-383m nest —— FAN SW cN-378F ONn-389F cn-379F Te cn-379M ON-370F oN-a71F 10.37 (C2500, CKE250041140. ELECTRIC SYSTEM on-a61F CNS BAF CN-387F , pa l wl e-a04m oe on-300F ¥ om Pa Te e wis ‘CN-383F 2 cr | Re on-a65F Ta on-309F ai SL cn-3aay | LOL cN-seer CN-389M cx25004,cKE25004 103840. ELECTRIC SYSTEM Ba = oNn-390F en-392F eN-392M oNn-304F cN-404F ON-401F cN-s04m ON-405F oNn-403F oN-405m on-403M 1039 (©K250041, CKE25004140, ELECTRIC SYSTEM CN-407F (Av850. 5) 450F ON=448M — CN-450M CN-487F cN-408M eN-410F cN-410M _ (€2500-11, CKE250041 10-40‘10.ELECTRIC SYSTEM al cn-502F payitsse a | t CN-5O5F # | tol seme sew cn-503F cNn-505M cNn-504F 0. 7880 2 CORE SHIELDED O cN-508M 10-41 (©K2600-11, CKE250041410, ELECTRIC SYSTEM, a =a = 10 ON-509F —CN-509M —CN-510F cN-510m cN-s11F cN-50aM (€K2500.11, CKE250041 10-4210, ELECTRIC SYSTEM, cn-514M cNn-514F cn-515¢ = cN-515F a ee ste90) a on) ae ey en-51aF 10-43 (€K2500-11, CKE2500410, ELECTRIC SYSTEM, cN-519F cN-520F oNn-s20" ves ss2u cN-522F ‘ON-523F N-520F (avsso. 75) Kavsso. 75) (©2500, CKE25004 10-4440, ELECTRIC SYSTEM, aren, f cN-530M cN-531M ON-536F CN-533F (avsso. 75) (avsso. 75) ON-537F cN-536M (avsso. 75) 10-45 (6250041, CKE250041110, ELECTRIC SYSTEM ON-539F ON-840F oNn-530m (avsso. 75) CN-541F CN-542F cN=542M (avsso. 75) cN=544M ‘ON-544F (avsso. 75) oN-543M (6 2500-11, CKE2500.1 10-4810, €LECTRIC SYSTEM, O ON-S47F cN-546F (avsso. 78) cN-546M ON-548F CN-B49M iswiNe L=J Tr CN-S50M want sce 8) CN-55OF (FLo08 ci 10.47 (©K2500.11, CKE2500-110, ELECTRIC SYSTEM, ON-B52F «L008 «0 (€2500-11, CKE250041 10-4840, ELECTRIC SYSTEM. 258.8, os. ON-B54M (ovine 1) ON-S54F (swine » 10-49 (¢K250041, CKE2500.1140, ELECTRIC SYSTEM Oman cN-S50F, (AVS80. 78) ieicit oecK 6) CN=555M (L008 4) (Avss0o. 75) CN=556M swine 0 SY EN-BBIM (seine 2) CN-BBIF conine 0) (6250041, CKE2500-11 10-5040. eLEcTRIC SYSTEM 248) ON-SSTF tFt008 w a. SL, CN-558F crt | er [ew | o at [te [ae et) ea fol BLY Rol ueluele') [rere] atest te] or sese cN-560M cn-ssor — reol W' | eo en-so1m ennsear woos 1 En CN-562M hvsso. 75 cN-56aM cNn-563F 10.51 (©K2500-11, CKE2500-1140. eLecTRIC SYSTEM cN-567F CN-S74F ON-575F cN-578m ON-876F CN-577M ON-577F (CK2500-1, CKE2500+1 10-5210. ELECTRIC SYSTEM cNn-578M oNn-578F cn-579¢ cN-580m SEALING SEALING oNn-579F cn-sa1M ON-S81F cn-sa2m oNn-580F cn-se9F cn-580F 10-53 (€k2500.11, CKE260041140. eLECTRIC SYSTEM cNn-595M cN-595F oNn-595M cN-597 oNn-597F ON-S98M —cN-S96F oNn-601F, cNn-802F cNn-605F cn-652F (Ck2500%11, CKE2500411 10-5410, ELECTRIC SYSTEM, e io a oNn-671F N-673M CN-873F i850. 88! CN=777F CN-751F CN=801M CN-BO1F cN-802M CN-802F eALING 241 tow 20) a cn-804M ON=804F cN-805" cN-805F cNn-807 cNn-807F = on-808F a seauing seauing ON-8 12M oNn-812F cNn-815F err) (CN-815M ‘F1002 © (CN-815M towine &) 10-55 (C2500, CKE2500-1140. ELECTRIC SYSTEM CN-B16M CN-BI6F on-817H on-817H seat saci CNSBETFiae 5 et s990> cn-a 16m Peat fia paivso 8s \ ve] ge sou SN-8NF oN=851M (€k2500-11, CKE250041 15190 ON-B51F (asso. 75) EN-853M_ swine 0) 10-5610. ELECTRIC SYSTEM se fn a SS cn-a50r cn-8556 cN-e56H cN-a80H TPE CN-BB 1M FLOOR » = aoe ON-BBOF IFiooR #) yap TET) seatine seauing ON-B80M wins «) Zee ON-BB IM Is¥iNE 81 ON-880F Is" H0 © cn-sa2m s109@ 2065 soon, cn-8836 sexing | seating cn-803F cNn-884M 10.57 (©K2600-11, CKE2S00410, ELECTRIC SYSTEM cN-925m cues or 2 ut ox. 209 cn-e20F n-027F S cy cne8a2F 1 re 480) se su) ED) howe? stag) 3628 tee ee SEO) ER) (€K2500-H1, CKE2500-I1 10-58410, ELECTRIC SYSTEM, cN-937M (AvSs0. 5) cNn-938F (AvSS0. 5) inte ate soto) 426 tive ome gue) E00 (a Cosette sneer gee 8 sieHe0@) o.ive ke seu) A280 ON-939M ae 090) at et) 1 ee ssue9> see! fet inn 10-59 (ck2500-N1, CKE25004140. ELECTRIC SYSTEM orn 2 ome suing £0088) 0 rea) no HUE ie # ee siEI B28 FcR SE! bee ane sReNB2 i 62 tee SHEE) ie eo e0 1825 1) cN-940M (et et REID eeo we) cN-940F atone # ome SHEUEI! encore ae aeoOW Yeaun Ke ‘Yes om ie esi HeDD| e280) sea cN-941M Vise TAVSS0, 5) Wh ua sce is) ee cNn-941F (AVSS0. 5) cN-943m (avss0. 5) oNn-943F (avsso. 5) ON-944F (€k2500.11, CKE250041 10-6010, ELECTRIC SYSTEM CN-945M (CN-945F Corre Iv CN-953F (Aza (nv380. 5) 4 A Iw Ws 74988 We? | on-asar (av880. 8) we] [eq_fe ps | [eq fh DR I ou aser nvs80.5 10-64 (625004, CKE2500-1110. ELECTRIC SYSTEM f.r9e 2 coe sueLED@! (ten 2 ake at) wg e/g ns (aysso. 08) 1 BP] [PE] weal Fras [75 fore oa te se lye haa lye’ Wis Mis Iwi Wir [yew oN-956F, (AVSSO. 8) Taine 2 ene oeue@! erent a ranger Wo eee 8) a] [eed Re] [ee] [ee] Be , ie e [yr cN-967F_ ON-O7IF (AVSSO. 8) cN-957F (avsso. 5) 29 aes] ae Lapin mn Teel #5 oT 252 Te aA ane sae a [te te sc! iy Sy 2 “ : en ws [era Saaaeen tea ne cate SUED! (AVS80. 6) wae o Dee EE ELD) ote # Ce sheen) HPS nee SHEL? on-a77e hele Wee sn . Fe gan eu] ees en-967F Sher ere nmum@) — ON-9B5F cn-978F (AVSSO. 5) (¢k2600-11, CKE2500411 10-6210, ELECTRIC SYSTEM, 1] ” [al] 4 oNn-998F on-995F cN-s1M oNn-s1F 10-63 (©K2500-11, CKE250041140. ELECTRIC SYSTEM oNn-s7F, Seung isso. 78111 O57 A56GrO ey ase wow a sss oNn-s9F, (avsso. 75) cN-J 10M CN=J10F. (Avg50. 78) vo uaa i Pics mori oN-J11M cN-JTTF iP BR aa1 wo ose N-s12M (€K2500-N1, CKE2500-I1 10-64ON-J14M cN-J22m 40. ELECTRIC SYSTEM cN-s13F cNn-s15F oNn-s16F cN-122F 10-65 (6250041, CKE25004110, ELECTRIC SYSTEM ON-J23F on-s99) Ne eNn-102F CN-J 102m (avast. 25) (€k2500-11, CKE25004 10-6810, ELECTRIC SYSTEM, se 2 ae ss! fe cos aze. [E YAR Ea inate ©! hacen (ON-J105F seauing Vero cxenn ae veh sep co eam sealing | senting Wie ws “ey ens 108 owestese FAVESO. 5 see cnt ua) tor fe ocue ) oe wH f.tne 2 tant itt) Bae bm 2am snes senor] yee tg 68.88 c meee eN-stogF TH eneayi2e ONn-s112F 10-87 (€K2500.1, CKE25004140. ELECTRIC SYSTEM 40.3. ARRANGEMENT OF ELECTRICAL PART 403.1 ELECTRICAL PART OF CAB “DeTTORAL OFTEN owent gumiten IY renzo ewrias cicarerre |O O| meat’ | (gat “= | J ag toes x jo sy en Sule a a aa view 8 DETAIL F view A (€K 250041, CKE25004I 10-6810. ELECTRIC SYSTEM tat Hakowsee atta Ypfen-se7 aos Sitar a ‘bhuw Ten sececr sw Yptow-saa 10-69 (€K2500.1, CKE2S004110. ELECTRIC SYSTEM % ck ch I TA a (250041, CKE250041 10-7010, ELECTRIC SYSTEM, (wor USER) Pre Te tay |FAN (oP ONAL VIEW D 10-71 (C2500, CKE2500411410, ELECTRIC SYSTEM 4032 ELECTRICAL PART OF RIGHT DECK. V4 ii ee F en (€K2500.11, CKE2600-I1 10-7210, ELECTRIC SYSTEM —) 10-73 (©K2500.1, CKE2500-140. €LECTRIC SYSTEM 28 Lo; ‘CK2500-1, CKE2500-I1 SECTION 10-7410, ELECTRIC SYSTEM eee oa a a a DETAIL 8 Haan SECTION FoF SECTION H-H 10.75 (CK250041, CKE2500-1110. ELECTRIC SYSTEM 103.3 ELECTRICAL PART OF FLOOR PLATE & LEFT SIDE STAND PANEL. (Ck 2500-1, CKE2500-11 10-7610, ELECTRIC SYSTEM, us 10-7 (©K2500-11, CKE250041140. ELECTRIC SYSTEM (€2500-11, CKE2500-I1 10-7840. €LEcTRIC SYSTEM =} DETAIL OF SEAT STAND irswet9h PROPEL STAND 10.79 ‘©K2500.11, CKE2500+110, ELECTRIC SYSTEM (©K2500.1, CKE250041 10-8010, ELECTRIC SYSTEM, 403.4 ELECTRICAL PART OF REVOLVING FRAME 10-81 (©k2500-11, CKE250041140.€LEcTRIC SYSTEM SECTION 8-8 10-82 ‘¢k2500-11, CKE25004110. ELECTRIC SYSTEM 4035 ELECTRICAL PART OF LEFT DECK i 10-83 (C2500, CKE250041110, ELECTRIC SYSTEM SECTION SECTION c-¢ SECTION E-E (€k2500.11, CKE2500-H1 10-84410. ELECTRIC SYSTEM, ‘WossTwangs WIV TIVIaG SoivNwaT TivisG (€K250041, CKE25004 10.8510, LECTRIC SYSTEM (€k2500-11, CKE2S004 10-8840. ELEcTRIC SYSTEM enrso3 (900-71) 10.87 (Ck 25004H1, CKEZ50041140. ELECTRIC SYSTEM oaths oO) 7 so Soo AGUS WATER LEVEL an . stGeSGE Se" | g Sanne aa (Ck 25004H, CKE2500411 SECTION ACA 10-8810, ELECTRIC SYSTEM. 4036 ELECTRICAL PART OF LEFT GUARD - ed Gy SL ott Leet cuaeo 10-89 (€k2500:1, CKE25004410, ELECTRIC SYSTEM 104 ELECTRICAL PART 10441 FUSEBOX (GG7SE00004F1) 4 Inthe case that a same fuse i frequently burnt out itis considered that burning out ofthe fuse may be due to some fault inthe elect irult and tls not yet repalred. in such case, absolutely do not replace tho burt fuse simply with a fuse over the specified capacity. This could eause damage tothe wirlng and electvieal appa- tu 2. Inthe above case, oF when instaling 2 new op tional apparatus, be sure to consultthe service shop of our representative. They will make a proper treatment or give a proper Instruction. 3. When replacing the fuse with anew one, be sure to tur the key switch of Tae T2]2 (sofas |ia[i7 fis[ielis [raf zlets [ael2s[oela1 se [sa] J2ali ‘ue oear ones comsctar ctor Wn 12 rn WALA Ware is bor connector .7123-2037 ‘ane wae (Ck2500-H, CKE2500-11 10-90410, ELECTRIC SYSTEM, {terete —e 2s |__Fis isi} —# 26 >is} —© 27 | {Fis ix} —o | {Fis ix} —o |__fr0"ii}—e 30 D--cN-4im o--cN-42F O--0N-43F © - -cN-44F On -cn-45F An-Terminal F An-Terminal ™ (€2500-11, CKE25004140. ELECTRIC SYSTEM 1042 WIPER CONTROL RELAY(2490U1366) iar aig oe i a]. Pa Fe Bt ce POAT, B a TR yyy RO a oe ee = (¢ 2500-11, CKE250041 10-92410. ELECTRIC SYSTEM 4043 SWING FLASHER UNIT (24800206) swing FLASHER SW rage yan TASER ON Mhont tae thas —Q Pressure 6 @|@|o @|® ® 10-93 (€ 2500-11, CKE2500410, ELECTRIC SYSTEM 10.5 PRESSURE SWITCH (CONTROL PRESSURE CUT & FREE FALL) —wte — ono — Red — POWER) Ne 4 Green — opencotetr() es Y = e Sa et (rng Pre zottPor4o0) PFI TaNning rue 26h 2 oN] OFF) Use Partnumber | Pressure | Pressure NMpa(Ps) | _MPa(Psi) ‘anv! Pressure Foot Pedal [sesosoo00srt} 44,640) | 36,622) (€K2500.1, CKE2500-I1 10-94PRESSURE SWITCH (PROPEL, SWING) 10. €LECTRIC SYSTEM | Ee (ecsosoneo7Ft) ‘osena Prn@ostPotse0) ASAE Bt NOSMPaE 10.95 (Ck 2500-1, CKE2500-1140. ELECTRIC SYSTEM 10.6 PRESSURE SENSOR (esasooo1sPs - Les2so0012P4) Terminal, Losasooores Pris esesoootaet : Pr Location of connector terminal COMMON eo OUT-PUT (4) 3--POWER (+) texz19 Hex (Gsasoootap1 : 2exas's HO Use Part number [Passo arse Power (V) ‘Output (¥) Remote conirol pressure mrt | coset Contheorsntseem | ‘eszsooanpt | 0301435 5 oste4s ‘Swing pump pressure | Lge2S000%207 | OTe 50 Ot 722), z Osteas NOTE TeeaSGOOIPT TeRSOOOTOPT Pressure range 010 30 MPa + Votage Vee: 5020800 + Output: 110 Veoto a0 Ver = 05 Vt04 SY “aghteing torque 35.3 Nem max (25.7 bs) (©k2500-11, CKE250041 |» Pressure ange Oo 50 Pa (019 7252 pay | Votage Ver: 50205 V0C | ouput: 110 ecto 90 Ver=05VI045V “Tightening orue 73.5 N-m max (54.2 fs) 10-9640. €LEcTRIC SYSTEM ‘@Ns2s00002P1 2 1 2-our-rur (+) A sonPOWER (+) Press aanoe i Pet umber z u Paes “ Gach pases | enszstooces Jove wwecorozeen| 10.97 (C2500, CKE2500-1110. eLecTRIC system 10.7 RELAY BOX (GG24E00024F1) 107.4 ARRANGEMENT OF CONNECTOR (Ck 2500111, CKE2500411 10-9840, ELECTRIC SYSTEM one Co ovens ons 10.99 ‘©K250011, CKE2500-H110, ELECTRIC SYSTEM 107.2 RELAY BOX SCHEMATIC Fig 10-4 shoot (19) (C2500, CKE2500-I1 10-10010. ELECTRIC SYSTEM 10-401 (€k2500.11, CKE2500410. ELECTRIC SYSTEM, wo eevee Bh} 8h, 8h PRERRRRRERER ig. 10° sheet (9) (250041, CKE250041 10-10240. ELECTRIC SYSTEM 10.8 LEFT SIDE STAND PANEL (WITH FREE FALL) ‘ex280041 . 0,078 @/8 @.6.0| oO @xe|S o7e7e| ie vel NL tata ol rea el evea ets OT 8, ia fern" 5, outro pee” OE rn eomana noe angen, ° 2 pac oa {om | ssehHEHS How > nu a oa AgcEtERAT ON de, BRU oo _ . Ce: LP SWITCH PANEL CIRCUIT i 10-103 (625001, CKE250041110, ELECTRIC SYSTEM ‘oK2s00.1 134 f E or cn-251 ri ay (Ko oo° 44 16 = alice (6 2500.1, CKE25004 oor10.ELEcTRIC SYSTEM ‘eKE2500:1 eof ‘tw > oa rae eee.» Ea Lo SWITCH PANEL CIRCUIT 10-105 (€K2600.11, CKE2500-110, ELECTRIC SYSTEM coxezso0 134 "Eb cn-251 5 5 ey vo 112) 114 ey lo ° 00° rae/ 13/134 gai tee 2a jo Es Es 16 o 18 238 245 ack a) Tia] ve a[a]s cn-aeiF en-24r0 liza ZL xo 208 a 10-106 (Ck250011, CKE250041110, ELECTRIC SYSTEM 10.9 BYPASS SWITCH PANEL cn-248F 10-107 ‘©K2500-11, CKE2500-1140. €LEcTRIC SYSTEM 10.10 TROUBLESHOOTING OF EXHAUST GAS THIRD REGULATION ENGINE 40.401 FAILURE DIAGNOSIS FUNCTION ECUalays diagnoses whether ornotthe sensors mae ‘uncon whl the key suite (Mis ured ON, and t lights on th diagnosis amp when the sensors judged ‘as being malinctoned and restores the place of alure atthe same ime to inform te operator of noel. ‘and ECU rests the inecton amount of ful depend Ing on he failure content Is possible to check he pace of ore by using he <éagnosis lamp or he diagnosis tel via the DST con- necte + Diagnosis lamp status while the ky is tuned ON “ne lam ight on when te ay is ON (M) and engine i stopped as shown nthe fotoning chart, ‘nen help doesnot go of even ifthe engine hasbeen stared, romp sep the engine ater avlding dan gor Because the sytem may have abnormality. Fert oh rouble deo STATER SWITCH ON Lock ENGINE oe start —— on i Berea Tani OFF ‘©K2600-11, CKE2500-1 40-10810, ELECTRIC SYSTEM. 4010.2 HOWTO CHECK THE FAILURE CONTENTS hon the abnormality is detected bythe dlagnoss lamp the alagnsis code can be checked by connoct- Ing the dagnosis sich (1) Postion of he equipment elated tothe agnosis + Postion of ECU + Postion of he diagnosis lamp + Postion of he diagnosis switch + Postion ofthe DST connector DAGNOSSS ANP 1 ReD) enraaer 10-108 (©K2500-11, CKE2500+1i i | ! i wanes] aoe oo ra 7 = a EI i i ill (2) Table of Diagnosis codes (P11C-1) 10. eLecTRIC SYSTEM = =| aan a Se Pewee see ast ae 10-110 (©K2500.11, CKE2500-I110, ELECTRIC SYSTEM = = Te ame [ore | eon |e Oo coor) ‘oan [wae eo ° teentamna] | eatin [wae ace | oma | aman ° se ma Genre [rvenno| am e Tiemwernerss| cI Tem [ sonny | aoe o (ieee a0 Sar To co [ren | — oman © manoani| on poe femiee | wemaner_| sare = [ean | a a Gee | wamaner_| avai =| soonest oar) a ai ae cd a ferme | emery | aor =| erbroetmonna| a i eemice [ear | aor | seatonei mein] a a ence | ener | aor ee oe Zeme[ eee | an © csomewremont| wo Ta oe a comer] au ema | woe | en a Taian | fem | won| wo 3 ‘are ioomenear| — emer | wt o_[menrwemmmem| | ame | aaa | ae | wanoweaicreiamacemm| a meg [aman | aa O [ioroaniernacenam | a jem [ame | ana 0 [sermon erent | a cw [ania | anioeen | vmware latBaa| rH ig] oe (€ 250041, CKE250041 t0-t1440. ELECTRIC SYSTEM un a ge yon co ns om ea apn en No pr "Sto ino soup, Uomo sud dae outs a Bual ODe rehome jaan | ane | ame | mom a a aon [ame ‘sam awn | eemanee | em | a o Ronen] wate jaom| een | eemaney | om o Sea wooo [ama wom eee | eemenor | oman | 3 Seng men [om roams |S | otieauney [abtaag | Gontmoms | _omrenea [an ee =e |S s0-112 (€K2500.11, CKE2S004410, ELECTRIC SYSTEM. (3) Indestion of agnosis codes (0) For example, te following chart shows the case when tna lagnosis codes 32 21 are islayed ‘The csplay method is based onthe inking ier vals of ie lam. Fst the rst code makes he lamp ight onthe igure" at the 10 plac or 0.5 seconds 3 tines and ight on 2 nes ater 1.5 sc (nds, Next code alspiay makes the lamp ght on 2 +1 times having 43 seconds intervals nthe same ay as he et code, and aterward ns sequence vil be repeated (©) Uscaty,thelamp does ntigntonor lnk when the ‘system nas no abnormaiy. Lis tie, te dg ross indication connector is connected the lam repeats linking wih 0:3 seconds oighi-on dura [Example] Display of dlagnosis codes example 1) When codes 32 and 21 are aaplayed IU] example 2} Normal dsplayed 0-113 B= (€k2500.11, CKE25004140. ELECTRIC SYSTEM, 40103 CHECKING BLOWN.OFF DIAGNOSIS LAMPS “The dagnoss lamp is t up when ll he conditions shown boiw ar satied, [Requrements for checking bown-of diagnosis lames} + Engine speed :Omin" + tater ston: ON + Dignsis nication connector (CN-440): Open + There shoud be no faut causing ether of th age nosis lamps tobe it up. (6250041, CKE2500411 ro-11410, ELECTRIC SYSTEM. 10404 ENGINE ECU 10-115 (Ck 2500-11, CKE25004114 ELECTE system ECU TERMINAL NUMBER ® © o © (€2500411, CKE25004 10-11610.ELECTRIC SYSTEM INPUT AND OUTPUT TABLE. (€K2500.1, CKE2500-1 s0-417(¢k250041, CKE2500- 10-11811. LOAD SAFETY DEVICE “4 (€K2500-11, CKE25004111, LOAD SAFETY DEVICE (©K2500-11, CKE2500-111.LOAD SAFETY DEVICE ‘1.1 PART NAMES AND FUNCTIONS 4444 FRONTVIEW 2 ouzZER Boo.) oeerscmre eu (|Fa8 os seo secu ‘All numeric values and unis inthe payin this manual are jst exaes Unis onthe isla canbe changes. For deals of change procedures, refer to "115.7 (CHOICE OF LANGUAGE (CKE SERIES ONLY)" 13 (©K2500-11, CKE2600411‘1. LOAD SAFETY DEVICE 4. DISPLAY (Current status ofthe crane is dsplayed (cre ws) 2, BUZZER (veep) Worning buzzers mainly related to ovrcad (includ Ing load bt warring) ae sued. When te mo ‘ment rato $0% or mor, intrmitant buzzer re ‘stued, and continuous buzzes ae issued when it ‘3 100% Intervals of intermittent buzzes are dive into three types. As the moment rato otater, the n= tervals of buzzers become shore Buzzer pes Bae Intermittent | beep. beep, beep Continuous — 3. SPEAKER (peep peep.pe6p-) ‘Overholt and working area it warning buzzes ‘reissued. Whon the boom exceeds the working ‘team prenatee pol, ntermitent buzzer a issued ‘when the boom reaches the working aea it stop point rhe hook backs or boom Is overeisted, ‘continuous buzzers are sued, Intra finer ritnt burzere ae dived nto tree types, As the boom lser tothe stop point, he ntvals of buzzere become shorter Buazer ype Bases Tnterritent | peep peep. peep Continous — (€ 250041, CKE25004 1411. LOAD SAFETY DEVICE Ce 1. Buzzers warning overtost Buzzers waning boom overoist ae sued when ‘he it switch is actuate. Buzzers waning hook ‘overnelst are sued when the iit ste is ctut- 0 stop he hook block, andthe winch levers set othe "WINCH" poston ortheboomleveris set to the LOWER* poston {No warning buzzer issued whe the lovers are sotto the NEUTRAL” potions.) 2. Buzzers waming working area it Untess te penotes pont set, warring burzers ‘arsed when the boom reaches th posiion 5 ogre before o 1 fet or 1 mbeforethe stop pont 15 (€K2500.1, CKE2500411‘1. LOAD SAFETY DEVICE 4, SHEET SwaTCH [Use ihc ewich a change the display colors or Goreabe Figures "To enange te colors, depress and hld he ewtch for thee seconds or ong. Use his swich aerate Bewween the WAIN and AUX modes orinarease gus. To change the curent made, depress and hod this suite fr tee seconds or longer. [Users ewich to pay the sevon io darker) selec any tended Tem [To dust the conrast, depress and old this swich for three second orlnger. Then th | ‘bigness ofthe scren s changed ite every tree seconds. To change thebrighess extremly, depress and hold ier several ens of seconds. (Use his cwich io pay the screen (io brghten or eeloc any Wfended fom "To adjust the contrast, depress and hold his sh forthe seconds or longer. Thea, the ‘bigness ofthe seren s changed ate ever tree seconds. To change thebrightness cettomly, depress and hold iter several ens of seconds 0/8 |8/0|a [uso this wich to esplay or cancel the it of slected tes. Use ths awit to decide or execute the eoectd tem. Us is evi aorta batwaan Te assonblleascoryo” operation modes, to change he curent mode, depress and hld his swich for three seconds or longer. Use his ewicn when Ws nacessary to ower the Boom nia the ground a out a angle | ston (ower it angleino rated load) without a load ‘Depress and hod tis switch for ree seconds or longer fer cancelation, (625001, CKE250041 168‘1. LOAD SAFETY DEVICE 5. COVER 'DONOT open unless youneeto oad the memory card or operate the seting and adjusting sweches 6, MEMORY CARD SLOT Insert he data memory card here. 7, MEMORY CARD ‘This card contain the data lated tthe erane oa pact Insert hie card ino the data card slot unless ther: wise specie. 8, SETTING AND ADJUSTING SWITCHES This eves are used for upgrading of programs er adusiment ony. 100 NOT tose them unless otherwise absolutely necessary, ‘The dip switches are uted to make asstments, The folowing cnet explains the ap suteh unetons Dip switches LOAD SAFETY DEVICE ens ee CC EE ‘emission ol upareig ndeson Brearan Permission of upgrading contol program Permission of wing adustment vale Display of mantonancescrean Making UL tuneton avalabe Nene Tniaizaton of ond and voubie records (€k2500-11, CKE250041[ok SERIES] ‘W42_ CONFIGURATION OF SCREENS 11, LOAD SAFETY DEVICE ns (€K2500:1, CKE25004{1.LOAD SAFETY DEVICE (Procedures and condition requited for change of seers) 1. When he conationsrequied forthe setup mode are satisfied, press and hold he setup swith for tee seconds orlonger Cree) 1 The boom anal 15 deo, orless nthe crane rode, 2. Theboom angles 30 deg oss (in he ing crane mode) ‘The boom angle detectors not conecte, andthe 94 ne tension ssn epution value (about 64 (13.228 5, 4. Neither the boom angle detector nr load detector isconnectes, 2, Pressandhold th setup switch forthe seconds or lenges, or shut dow the power supply, fat 0 satay any of th condone requires forthe satin mode, 3. When the I switch is pressed, the items are displayed, When any of them is selected with the EE ‘wen, sereensin the lower category appear ‘when the 29 switch is presse! agin, hose nthe Upper estegor appesr. ‘4 When any ofthe tems is selected withthe ‘seh, sreens in the lower estgory appear, and ‘those inthe upper category appear when the ‘wich s pressed 5. When the ap sniton Noi tuned on. they ar de layed 65. When the ap switch No.1 i tuned on they ae di layed 1. When the ip switch No 2 tuned on, they ae is payed 8. When he ap sch No tyme on, they are ds played 9, Press he Eland WJowiches ata tine, and hold ‘them fr tres seconds or longer. 10. Inthe stats (6) above, release te switches 19 (CK2500:1, CKE2600.1‘1.LOAD SAFETY DEVICE +14 When the B2 ewith is pressed, the next screen sppears 12, When the ©8 mark onthe soreen s selected and ‘he Bl tenis pressed, the next screen appears 13. Oniy while the BE switch is pressed and hel, the ext sereen appears 14, When tne swt i elessed the nest screen spears 15, When the ES mark on the seen is selected and the BE euten pressed, the net sereen appears. 16. When the seting is completed the next Sreen ap: peas (€k2500-11, CKE250041 144041, LOAD SAFETY DEVICE. [ek series) ‘CK250011, CKEZ500« “Ht‘41. LOAD SAFETY DEVICE [Procedures and condtons required fr change of screens] 41. When he conations required forth setup made are 2, Press ano the setup switch for tree seconds or longer, or shut down the power supply Or fifo satay any ofthe conditions required forthe setup ‘mode. 3. When the ewtchs pressed. th items are dis- ‘played. When any ofthom is selected wih tho EE} ‘leh, sereensin the ower category appear. _mnen the [29 switch is pressed again, those in the upper category sppest 4. When any ofthe ors selected wih the sh, seeens inthe lower estagry spear, and those in the upper eatepory appear when the 4 sch is presses 5. When help swich Nos timed on thy ae s- played 6. When help wich No.1 is tuned on thy are s- played 7. When the ipswich Nos tued on they are s- played 18, When the lp seh Nos tuned on they ae s- Played 2, Press the [2] and (switches at atime, and hold them fo theee second oenges, 10. Inthe stats (0) above, release tho swiches 4. Tho boom angles 15 dog. ores (nthe crane mode 2. Tho boom angle is 30 deg. oles in the iting crane mode) 3. Theboom angle detetoris nat connected, andthe uy lne tension ess han regulation valu (about $594(13 0001s). 4 Neer the boom angle detector norload detector is comecea (¢k2500-11, CKE250041 11.4211. LOAD SAFETY DEVICE ‘1.43. DATA TRANSMISSION BETWEEN CONTROLLER AND CARDS Data card SR Guam 1 Progam inden nd ota a Aguamentae [a] Benen) | Poza einen) 5 Pog toto) “The data cardi loaded inthe lad safely deve nor mally, and data are vansmited as shown below 1 Copying crane data Crane data for he instale attachment are copied Int the fash merry fom te data card by cary ing ot the “crane contguration setup" ater the at tachment changed (strat emoval ofthe card wil ot giv ay n= uence onthe mation of the machi, since data copied inthe fash memery are use fer operation) 2 Copying ajusment vale automate backup) Whenever sjusmentis cared ou, ejusment ‘values ae stored into the Fach memory, and used for operation. However, the convo malune- tioned and replaced wih anew one, the conven tional adusiment values become uravaiabe, ‘since the fash merry is fed onthe PCB by sol ering. Thus, whenever adustmentisperfoome, ata ae automaticaly copied int the data car. If ‘he data cards not oaded,no datas copied, and no play warning wil be provided 143 (€K2500.11, CKE2500-1‘1. LOAD SAFETY DEVICE 3. Copying adjustment value an history data Adjustrent values coped uring adjustment ‘hoon te step (2) above can be writen into the contol by executing outthe command. Conver tonal austen values canbe used by tanster- fing the copy data hat are stored inthe ta card used int the contol. Aber copying of asjust- ‘ment values of he connote data cad and ‘etunofadustment values nthe conta tothe Inia statuses are ao avaiable 11.8.5 VERSION CHECK} 4 Upgrading rogram for sepiy rogram for pay can be upgraded by tuning on the dip such No.1 and exeeutng the command 5. Upgrading rogram for onto} Program for control canbe upgraded by tuning on the dip switch No.2 and executing the command (¢k 250041, CKE25004 1.44{1.LOAD SAFETY DEVICE {1.414 DETAILS OF INDICATORS ON MAIN DISPLAY SCREEN INCASE OF CK series) [CRANE TPE: __LUFFING TYPE ” 2 Ne. Tndiesior Deas ‘Moment ratio indicator (bar intieaton, Moment rato is indicated from 60 to 126% by the 25%, a |when moment rato is less than 90%, tis indicated in green color. [CTT en ts 0% crmere antes than 100% is eaten yetow [When tis 100% r move, ti indeated In res. ‘Mode indicator 2 jater the ED sith is presse and the "MAIN" or the "AUX." mode ise com lected, the selected mode is indicate, ~ Boom angle indiator [current boom angles inccate. a hens erage tom 198550509989 et Geek] \Wnenitisin te ange fom 150-10 deg, tis inseated by the dog, Poin height nator Fl [Boom pont elevation orb pal elvaion scaled ‘When isin the ange from-090 99.9 mts indested by the 01 feet. ‘meni inthe range tom 100 to 989 feet rin the range em-09 0 10, ts indeated by the 1.0 est [you can choose whether his tem should be dspayed or rot |Refero"2 6 # SETTING SCREEN’ of he operation mana) ment rat indicator (otal indicator Moment ratio is inated rom 0 to 200% by he 1% 11.48 (©K2500-11, CKE2500+1‘1. LOAD SAFETY DEVICE te ina as a alana We iota wating aa a eualeatintewr | nent pounds x 16,0 cated ‘ Vinten be tange fom 109 pune 100 dtd na pour X00) | finont sine rage om 1010550 pounds 16 fiIndeateain {Opens 100 aaa nora Ftd at este | When itis out of the working area, "0.0" is indicated, ; Vente abe range om tpn 00 isndeatdnat cared} poo x 1000 finonts ne ng or 1010550 oun x 10, isndcatedin Dgounds X10 Tarn a ace ong rusia 8 Vines rng fo 01 10 et sina. fet Vent sinte ange ton 100 96 fet ts ese a 19 et Tessge a essges nz or ty ses rina ‘ Tertne pean ct te estage frt92 11 NOICATION OF estab ant tamer opr mans ar tao wT dete stirs eave conkguabn are Sayed 0 Forte etnonoeto"962 SeTIMGOF Te CRANE CONFGURA Tow tte operon mani agi aio luting ages indcate " ‘tren tse ange fon 2.1 9g. tsincatedby he ep, Sd ‘enti te range Hom 10 10d tlc the 10. Roe ae TET — i tet ang inane. Vinents he ge fon 2.169 de, tisincatedby he 0. de. ft a iene nie ege tom 290g, ised ye ge, + Tsincatcamatbe displayed peer wih he pat hag nd (€k2500-11, CKE250041 11-4641. LOAD SAFETY DEVICE a INCASE OF KE series) (CRANE TYPE: LUFFING TYPE = Ts ns Mt ol | A. 2 epee 7 7 | dL | gu =e vo ; =| |e Fae {el * The indicating units depend on the choice done inthe steps described In “115.7 CHOICE OF LANGUAGE (CKE SERIES ONLY)" Ne Tndisior Data ment ratio nde (barinaestn) ie Moment ratio is inicated rom 60 to 126% by the 2% nen momen rat ses than 90%, ts ndestea in green cole. nents 0% or more and les than 100%, tis incited in yelow nents 100% or more, tis inated in re ‘when the E] switch is pressed, the mode changes, The actual load and ‘rated oad ofthe ook athe selected nds are delayed. ‘Boom angie indicat = or (Curent boom anges incicatd ‘nen itis nthe range fom 0 t29.9t098.9deg, tis nda bythe 0.1 og \inenitisin the ange fom 1501010 deg, tis inca by he deg, Poin height nia aa lacom point etevatin orb pint elevation is inccated Wen tisin the rango from-to 93.8, itis indicate by the 0.1 m ‘nen itsin the range tom 100 o 899 m or inthe range rom 99 10 1 is indicate bythe 1.0m, ‘Boom engi ndeator [The selects boom length is displayed 11-47 (Ck2500-11, CKE2500411‘1, LOAD SAFETY DEVICE Ne. indestor eta etal oad inate = [actual load is icicated. When tis out ofthe working area, "inca es nents 0,20" ndestes ‘When's the range from Oo 1001, itis indicated in 0.1 nen tn the range rom 1001 999, is indested in 0 Fated oad ndeior Ga Rated iad is indicates ‘When ts out the working area, "0 0"Is incest ‘When tis inthe range fom Oo 100, itis indcated in Ot ‘when is inthe range rom 100 fo 999, sindeated in 1.0¢ Wiering ads nda [Working acs i inicatod. ‘hen itis in the range rom 00 100 mits inca in 0.1 m. ‘when tis in he range fom 100 to 099 m itis inated in 1.0m Took, mumbo of pa ines © XD [Messages for hazardous or faulty statuses ae indicated For tho typos and deals ofthe messages, refer to"3.11 INDICATION OF [MESSAGE AND ALARM" ofthe operaton manual ected type and number of part lines ofthe hook ae displayed “bangle nator ‘Ae Luting jb angle is inca ‘When tis the range rom 990 99 deg, itis nto bythe 0.1 dog neni inthe ange rm-180 0-10 deg, isindeaedby te 1.009 “Tb oft ang nds of] exh [nb ofset ange i naicapes ‘When tein he range rom 0.9109 de, tis indctes bythe 0.1 dog. \Whenitisin the range rom 990-10 dep is indicated bythe 1.0 deg. * Tris insicatr cannot be payed together wth the point hela ind ctor at tine, Tena a a he slete lengths dslayed (625001, CKE25004 14811, LOAD SAFETY DEVICE 4145 REARVIEW +. Contllerinstaation les Use 050 inch (15 mm) serows (ME) for mounting, 2. CNIIM: Power input connector CCNZAM: Load Detector (104) input connector Load Detect output is between 1 and 5 vs. (CN28M Load Detector (S07) input connector CCN: Angle Detector (110 3) input connector CCN aM: Angle Detector (105) put connector CCN1EM: Dita input connect CCN1eM: Dita output connector CCNYTM: Analogue ouput connector 10, CNI6M : Communion connector 11-48 (€K2500.11, CKE2S00-1‘1, LOAD SAFETY DEVICE Chart, System Input/Output, Connector Designations Sans ter sea leet (©K2500.1, CKE2500-I141, LOAD SAFETY DEVICE ‘Chart. System InpuOutput, Connector Designations Toners [Se girceea —— [Ter vgn tnt ‘ange |___ursg_ Teens Sd Bien ato Seo eg ted 21 (625004, CKE2500411‘1. LOAD SAFETY DEVICE ‘Charts. System InpwwOutput (Digital Input) SS smn ane uname toate one tno cosa Oe (6250041, CKE2500411 Cpr ouametoaes 11-22‘1, LOAD SAFETY DEVICE (Chara. System InputiOutput Digital Output) rT “Sevens oo temo wean 2 oon #_Misewmer ce seven Bint oe _temmgoo estrone Oo ens ae ih tae ee oeae crores = ore gree Caament = one 7 tees aR Toners? om icoaieeal ‘chants. Output Spares Gane ne oer oae , 11.23 (€K2500.11, CKE25001‘1, LOAD SAFETY DEVICE ‘WA TEMS REQUIRED TO BE EXECUTED FOR REPLACEMENT OF CONTROLLER OR DATA CARD [AND INSTRUCTIONS Ireatnaranerwparade ot parm) | —— feel] sakes eae oe oe 2 ~ [se ceasoo, exe2s0041 12441, LOAD SAFETY DEVICE 11.2. PREPARATION FOR USE Proto isaiston, be sue to cores identity and vr yal the connecting Ines, hen connect them tthe CCNTIM to CNTBM connectors, onthe back fhe ut (The CN-12BM and CN- 14M reno connected 11.25 (€K250041, CKE2500-I‘1, LOAD SAFETY DEVICE 11.3. TURN THE POWER ON ‘Ate checking all connections fr accuracy. Then tn the power on, ‘Aline risconnecon may cause rrrsandor cause an ‘tam to sound, Inths ease, hut the power off andre checking and the detectors (oad detactr, angle de tector). Fer fhe information on handing emers, see "1.7 ERROR CODE (ABNORMALITY DETECTION) [AND COUNTERMEASURES” (€ 2500-11, CKE2500411 11.2841. LOAD SAFETY DEVICE. 11.4 UPGRADING PROGRAMS ‘when upgrading the programsin the controler, us the program meron era “Two ypes of programs, comprising “indlestion xo- grams" and "contol programs’ re sored inthe con- ‘roler. Tho program memory card for upgrading aways contains these wo types of programs. 1144 PROCEDURES ‘Open he cover, and press he pushbutton ected on thee side ofthe lading porto paral eject the data memory ear. Then, remove the carom he osdng port win your gers ‘Check te version onthe abe attached othe program memory ear, and fly inset he card ino the losing por. Use he ipswich acted onthe ose ofthe card loading por to enable the upgracing of programs. “Tum he ap sweh No.1 ON to upgrade incon pro- jams, andtur he ipswich No 2 ON to upgrade contol programs, When upgrading both of ply programs and contol programs, be sur to upgrade the dspay programs frat, and then, upgrade the conta programs. Insertion and removal of car “Tha cardcanbe removed o inserted oven when power conor is tumed a, excepto the tne cluding "Reacing’ or "Transfering" appear aing he ‘access, In suena stats, 00 NOT remove he car 127 ‘©K2500-H1, CKE2500-1‘1. LOAD SAFETY DEVICE 4. Tum ON the ap switch Not or 2 ected in the cov- or Then, is splayed onthe menu serean, Move th cursor > onto the and press the El switch aye TTT “THE UPDATE OF THE INDICATION CPUT is die- played te dip suite No.1 hasbeen tumed ON, fand "THE UPDATE OF THE CONTROL CPU" ie onto “THE UPDATE OF THE IN- DICATION CPU:, and press the EE switch. Then, ‘he indication programs canbe upgraded. To up {1340 the contol programs, move the cursor <> ‘onlo"THE UPDATE OF THE CONTROL CPU, and press the EE swt eg. rae] Ser ee “CKSERIES. (¢k 250041, CKE2500411 11.28 ‘CK SERIES‘42 UPGRADING OF INDICATION PROGRAMS 1, Select THE UPDATE OF THE INDICATION CPU Than, the screen shown below is played DISPLAY PROGRAM UPDATE OK? YES: DOWN CANCEL: MENU nen uparating the program, pressthel) switch When canoeing, press the 2 switch ‘The previous sreen appears when tho switch ispressed \Wnen enor messages appear on he seven stat torte [0] switch is pressed the data memory card ‘may eletinserted In such case, chocktne data rmerery card DISPLAY PROGRAM UPDATE OK? YES: DOWN. CANCEL :MENU PROGRAM DATA OPEN DATA OPEN PUSH ANY KEY TO RESET 11.29 41. LOAD SAFETY DEVICE. = CTT > UOT (€k2500-11, CKE2500411{1.LOAD SAFETY DEVICE 53. tthe data memory cards not inserted the err ‘message of'INSERT PROGRAM CARD & PUSH [ANY KEY" appears onthe screen ist ter “THE LUPOATE OF THE INDICATION CPU" is selected INSERT PROGRAM CARD & PUSH ANY KEY Ite err message above appears even though the data memory card isinserted, imperfect contact may occur In such a cas, remove the data mem oy ars, and ener “wen neering o removing he carditis unnee- ‘essary to shut he power coun. Ate einsering I press any suite. tne error stillcannot be cor rectd, the controler othe cardmay be aly. In fuch ase, t must be epaced (€K2600-11, CKE2500-I1 11.30‘1. LOAD SAFETY DEVICE 4. Ater the programs in he contol ar eased (t takes approx 30 sec), new propramsin the card ae wren ont the contale, ‘When the indicated 0 KB is nressedto 1023 KE, Uupgradingiscomplet. upgrading issuccecsuly compete, the sereen shown below appears a GTO DISPLAY PROGRAM UPDATE OK? YES: DOWN CANCEL :MENU =n PROGRAM DATA OPEN PROGRAM DATA OPEN DETECTED ERASE EEPROM (about 30sec) a TRANSFER PROGRAM DATA 1023KB COMPLETE. PUSH ANY KEY TO RESET ‘nen ether suite is pressed, the power supay is reset and ne controle reotes ‘Then, upgrading ofthe indeatongrograms is com pleted (AcauTION] [DONOT remove orsert the data memory card while programs inthe card are writen onto the conte. Cerise, malunction wil cut 31 (€K250041, CKE2500-11“1, LOAD SAFETY DEVICE 1143 UPGRADING OF CONTROL PROGRAMS 4. Select"THE UPDATE OF THE CONTROL CPU” “Then, the sereen shown below is epayed, ae rere] oe oronran oft control EP nat ve ssn cea cenati cee al When upgrading the program, press tne] seit ‘when canceling, press the 29 switch, ‘The previous sereen appears when the FH switcn spressee, 2. When err messages appear on he screen usta tertne ]ewich is pressed, the data memory card may not be inserted a ho maybe nerd p= fall orleRingertes. in such case checktne data memory ead Pn ei a te Cancel tation Tete bu HEM, eee (62500411, CKE25004 11-32‘1. LOAD SAFETY DEVICE Other errs + Memory elimination error Program area in he fash memo in the contr ‘cannot be deleted » Replace the conve. + Memory card ea error Program cannot be rea out fom the card “+ Recheck the card insertion status or repiacethe cae + Whiting enor Program cannot be ween into he flash memaryn the contol “+ Replace the contoter, 3. Ithetended programs ae feundin the conor ater the [Ol switch is pressed they are erased rst (ites several seconds for erase). The, nea programs inthe cad are writen ono he contol. Wen te indicted 0 KB is inereased to 1023 KB, upgrading iecomplete, i upgrading i suczassuly complete, the seen shown below appear, We a0 men eter state is pressed the power supay is reset, and the contol sreoted “Then parading ofthe conto programs i com pets (Acaurion] [DO NOT remove onset the data memory card while programs inthe car are writen onto the conte. Carve, mattunction wil cut 11.33 (€k2500:1, CKE25004141, LOAD SAFETY DEVICE 14.5 STATUS CHECK ‘This controler features various sats check untions {or easier agnosis of maltnctons, “Tum ON the sip swich No inthe cover. Then tbe itomstobe checked are dsplayed in tetowe al pat ‘of he screen as show boon RATIO o one 0 Items to be checked (Ce. ELEV] [JE te) Cem RATIO Waren ut bet Goths choles screen 7900. (©2500, CKE250041 1134{41.LOAD SAFETY DEVICE. 4151 SIGNAL CHECK ‘Statutes o signals input om he sensors an it stones or those of autmatic top signal ouput can be chacked Ontha ‘STATUS CHECK” sreen, move the cursor > ‘ontothe"INPUT AND OUTPUT SIGNAL CONDITION, ‘and press the EV switch, Then, the screen shown be- tow appears, ‘Statuses of analogue signals fom the oad cols and angle detectors ae displayed on tis fst splayed Upto soven ea cots and up to fve angle detectors can be connected to this entrar. eferto ‘Chat. Systom InputOutput, Connector Dos ignatione” page-20 for deat of conection Forthe oats and sensors hat are not connected tothe controler vals cose to 0 are dslayed ow cet 2.37 AME SeOR 21.18 low ce 378 ane see sa. low ce 4 a7 ante sene 6a ow ce $0.7 Me Seno SE low ces at ow ce 61 ® Shi 8Sms 1138 (6250041, CKE2500-1111, LOAD SAFETY DEVICE ress the [or switch once. ‘Ten, the sreen shown below appears ‘Statuses of nput and output of dtl signals can be splayed on ts scren. Forthe designations and funcons of ina, fer to ‘Chart, System InpuOutput (Dal Input. “Char, ‘stem InputOuput (Digit Output page 1-22.11- 2 For apt ligta signals, 9°" mark eats the (grounded statue, and aX" marknccats the open sa ‘us For ouput dtl signals, 70" mak india the out putstate, and 2°" markindeatos te nonoutut a ‘us, * Dispayed output signal statuses are decided as are- suit of sotware processing ony te hardware saul the ouput may note 25 shown below input ovreur rood ooiney Bo ik Bo ink So ik Ho 1:6 Bo wk Bo ty S00 ts: i so 18k Se tek go tek Be ink 8 Ino ax tek go tax ax tek $0 tek roi at rik 2:0 (€K2500.11, CKE2500-11 11.38‘1. LOAD SAFETY DEVICE. 452 OPERATION PROGRESS 'STATUS CHECK” arsen, mova the cursor > conto tho"OPERATION PROGRESS", and press the EE switen. Thon, te sereen shown below appears Fm ne ia 0.00, A i fm teat fac een mm te mate iG ete Tae ie atte re ance! As mot meet ite te tet He eae ah te u : Pouce 20 i ii i Syrbak — Daa = FON Tare wight ponent ding nan wh og win conan adie FOR Tre wei congorent ding auc winch ing wi cen rad FOR are weit consonent dung hi wich fing wh cont rdus 3h [led coef rng man wine fing wih cure ce 2A [Led coon ding aux wh fing wit cent ads {aR [led coeflen rng whe Hg wi urea sao” waht omponent terra weight of ok Bock wh Gaara (crn smtansss ing on (Nt es) Fair gre terion hi ]sn wren we ope tri fw rn wich ado) Wt) FA [A wine ire ope fers a wine dell (Not ed) FR [Tard wnch wie op lesion wir winch od ca) Nosed TWHOUERL Wo red nd ated ond ding sled moder hn eons ig B=) WHOLE AL [ites seul ndorualca dng sete made cer an smulaoaus ng malo). WHOLE RAT —[Wfols roment ato (vous nate nb 9h) THAN Ran woh rated os win cure radio bai AUX. [A winch reed bad wih cretion bai ola THIRD RL |Thied woch atid dwn comet adi on he bot Rattles rn wnch esting aus bere covecton ya ahainen RA [Esse a wine open rad Before een by adi aire [Css hr winch opersing as before covecton by rads adie VOLTAGE Contr voage igi ryt TBs nonber [Dats genoa 1.97 (CK250011, CKEZ500-1‘1. LOAD SAFETY DEVICE Example of using operation screen “Te actual load W can be ndested bythe formula shown below Host guy ne tension Dead welt component 4A) Leotibs agnor valve (Spon) ——Usaaiee acuriment value(S) etna wa = (FO2K1 12) (eee seme nad agusment ve (ht) | See acre ae pe) ead cote MAR) ‘Suppose the values above ae indeated shown below and he ndestes actual losis 2 when alead weigh- ng tis te with he main winch Feao7 FoM=228 33 tfneitner loads ajusiment nor some oad adjust- ‘enti cated out and actos fom kt tk ae i> nod, he theoretical F required forthe actual lad of '5tcan be found bythe using the formula above, 2 ‘shown below F25x199+220=099 ner, the actual Fis cbvousy sme than the theoretical "Nest, the Fan be fund by he formula shown below [7 tose capaty peng en te maine med) Moist quy tine tension F = 5% istment valve) : wa ee | L comtmeense mS sesepegntiny —| emia eee aces seat Comet cout owen (Gepantng on the machine mod) (©k2500.1, CKE2500-1 1.38+1, LOAD SAFETY DEVICE Ifthe oad col zoo point adjustment has not been car ‘ed ou adjustment vuoi 1, andthe coeticentis 1102 flowering stopped. In sucha statis, reload col votage i caleulates with sing the formula above ‘andthe vaties when ha Fis 4.7, the presentload cal votage is 134, Inasimiarmannertheloadcellvotage's 1.61 V, when the theoretal tension Fis &8. “Thon, check tho load cel votage onthe signal check screen (age 11.35) Wie cote to 1.24 V above, the detected ood caval age is emale than he theoretical value, Ia bis eat the lo ce may be fay, 11.38 ‘©K2500.11, CKE2500-111. LOAD SAFETY DEVICE 49.53 COMMUNICATION DATA, Dota of datatansmited tomesher controterscanbe dopiyed Meanings ofthe nubs in communication data re shown boow (On he “STATUS CHECK" screen, move the cursor > onto the “COMMUNICATION DATA’ and press he fitch, Then, te screen shown below appears Control signals of control evers are used othe output ofbuzzer sounds orcoectonofload, Thus, checkhe ‘ommunicaton status ny felts ound in them. rtat 1 o1en0 cna 2 aot crit 3 onto ca. 4 onto DIGITAL 1 9900000 DIGITAL 2 1000000 Both gta 3 and digtal 4 ae spare, and ues to 200 11 appears inthe indeator coresponding othe op- ‘erated iver, the stat is normal. The responce may be delayed by approxmatoly a sacon, dopending on the conmuneaten tats, Ifonl one operation faut and he others are nerma,chack he signal be "ween the pressure sensors and the ttl con. soopean ieee Nooperaton meet FE hana (C2500, CKE2500411 11-40 1 Maio winch up Ain wren down ‘Aux winch op ‘Ak ch dm ‘Third wh Sun Boom rising Boom ower Spacing UBlowerhg Reciever error

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