Maintenance Standards Test Procedures

2.
MAINTENANCE STANDARDS TEST PROCEDURES
2.1 MAINTENANCE STANDARD

2.1.1 PIN, BUSHING, SPRING, LINING AND SHEAVE
1. Pin, Bushing
d d’
D D’
Pin Bushing
Unit : mm (inch)
Std. dimension Usable limit
Name Location Item Part number Remedy See figure
D d D' d'
44.0 43.82 Fig.2-1
Fr.& Re.Drum 1 JJ82W01013P1 Replace
(1.732) (1.725) (P.2-6)
50.8 50.60 Fig.2-3
Pawl Boom Drum 2 JD01W01019P1 Replace
(2.0) (1.992) (P.2-6)
Luffing Jib 45.0 44.84 Fig.2-5
3 GB82W01008P1 Replace
Drum (1.772) (1.765) (P.2-7)
Pin
165 164.36 Fig.2-7
Boom Foot 4 JD02A01004P1 Replace
(6.496) (6.471) (P.2-7)
110 109.47 Fig.2-11
Luffing Jib Foot 5 JJ13A01016P1 Replace
(4.330) (4.310) (P.2-8)
Strut Foot 80 79.77 Fig.2-11
6 JD12A01003P1 Replace
(Fr. & Re.) (3.150) (3.140) (P.2-8)
44.0 44.26 Fig.2-1
Fr. & Re. Drum 7 2405T1151
(1.732) (1.743) (P.2-6)
Replace
50.8 51.10 Fig.2-3
Pawl Boom Drum 8 JL01W01199P1
(2.0) (2.012) (P.2-6)
Luffing Jib 45.0 45.11 Fig.2-5
9 2405U101D4540 Replace
Bush- Drum (1.772) (1.776) (P.2-7)
ing 165 165.80 Fig.2-7
Boom Foot 10 JD03A01013P1 Replace
(6.500) (6.528) (P.2-7)
110 110.6 Fig.2-11
Luffing Jib Foot 11 JD04A01003P1 Replace
(4.330) (4.354) (P.2-8)
80 80.54 Fig.2-11
Strut Foot (Front) 12 JD04A01004P1 Replace
(3.150) (3.171) (P.2-8)
2-3 CK2500-II, CKE2500-II

Copyright © 2018 Kobelco Construction Machinery Co.,Ltd. All right reserved.
2. MAINTENANCE STANDARDS TEST PROCEDURES
2. Spring
Free Length Free Length
Unit : mm (inch)
Usable limit of
Location Item Part number Std. Free length Remedy See figure
free length
72 (2.835) Fig.2-1
Fr.& Re.Drum pawl 20 HP26C15002G1 68.4 (2.693)
(Compression) (P.2-6)
42 (1.654) Fig.2-3
21a 2417T335 39.9 (1.571)
Boom drum pawl Replace
75 (2.953) Fig.2-3
21b 2417T373 71.25 (2.805)
72 (2.835) Fig.2-5
Jib drum pawl 22 GB82W01004P1 68.4 (2.693)
CK2500-II, CKE2500-II 2-4

3.Sheave
Standard root diameter
40 to 45 deg.
Groove
Radius
Unit : mm (inch)
Std. root Groove
Equipment Item Part number Use limit Remedy See figure
diameter radius
494 ± 1.5 491 14.0 Fig.2-7
Boom point 30 JL06A01004P1
(19.45 ± 0.059) (19.33) (0.55) (P.2-7)
549 546 14.0 Fig.2-7
Idler 31 2407P812
(21.61) (21.50) (0.55) (P.2-7)
for Main 494 ± 1.5 491 14.0 Fig.2-9
32 JL06A01004P1
Auxiliary Boom (19.45 ± 0.059) (19.33) (0.55) (P.2-8)
sheave for Luffing Jib 494 ± 1.5 491 14.0 Fig.2-10
33 JL06A01004P1
or Long Boom (19.45 ± 0.059) (19.33) (0.55) (P.2-8)
428 425 14.5 Fig.2-12
Lower spreader 34 JD61F01028P1
(16.85) (16.73) (0.57) (P.2-9)
494 ± 1.5 491 14.0 Fig.2-13
Mast 35 JL06A01004P1
(19.45 ± 0.059) (19.33) (0.55) (P.2-9)
Luffing boom 494 ± 1.5 491 14.0
36 JL06A01004P1 Replace
point sheave (19.45 ± 0.059) (19.33) (0.55)
or
Luffing boom 494 ± 1.5 491 14.0
37 JL06A01004P1 Build-up
idler sheave (19.45 ± 0.059) (19.33) (0.55)
Taper boom 418 415 12.5
38 JJ06A01010P1
guide sheave (16.46) (16.34) (0.49)
Fr. & Re. strut 418 415 12.5 Fig.2-11
Luffing 39 JD63A01021P1
point sheave (16.46) (16.34) (0.49) (P.2-8)
Fr. strut 494 ± 1.5 491 14.0
40 JL06A01004P1
sheave (19.45 ± 0.059) (19.33) (0.55)
495.6 492.6 14.0
Jib point 41 GG63A01051P1
(19.51) (19.39) (0.55)
495.6 492.6 14.0
Jib idler 42 GG63A01051P1
(19.51) (19.39) (0.55)
494 ± 1.5 491 14.0 Fig.2-12
Gantry peak 43 JL06A01004P1
(19.45 ± 0.059) (19.33) (0.55) (P.2-9)
549 546 14.0 Fig.2-8
Fixed Jib point sheave 44 2407P812
(21.61) (21.50) (0.55) (P.2-7)
549 546 14.0 Fig.2-8
Fixed Jib strut sheave 45 2407P812
(21.61) (21.50) (0.55) (P.2-7)
2-5 CK2500-II, CKE2500-II

7 119 m
m (4,6
85 inc
h)
Wear Limit : 3 mm
(0.118 inch)
20
Fig.2-1 Front and Rear Drum Lock Fig.2-2 Front and Rear Drum Lock
21a
21b
Fig.2-3 Boom Drum Lock
inch)
m (6,969
177m
Wear Limit : 3 mm
(0.118 inch)
Fig.2-4 Boom Drum Lock Pawl
CK2500-II, CKE2500-II 2-6

125 mm (4.921
inch)
9
Wear Limit : 3 mm
(0.118 inch)
3
Fig.2-6 Luffing Jib Drum Lock Pawl
22
Fig.2-5 Luffing Jib Drum Lock
4 31
10
30
Fig.2-7 Main Boom
44
45
Fig.2-8 Fixed Jib
2-7 CK2500-II, CKE2500-II

33
32
Fig.2-10 Aux. Sheave (For Luffing or Long Boom)
Fig.2-9 Aux. Sheave (For Main Boom)
42
41
39
6, 12
40
39 6 5, 11
36
37
38
Fig.2-11 Luffing Boom and Jib
CK2500-II, CKE2500-II 2-8

43
34
Fig.2-12 Gantry
35
Fig.2-13 Mast
2-9 CK2500-II, CKE2500-II

2.1.2 PROPEL DEVICE

1. Crawler shoe
88 (3.465)
72 (2.835)
(3.973)
(4.370)
111
100
P
R16
(R0.630)
D
16 4)
R2 8.50
(R
178 (7.008)
Wear limit : 2 mm (0.079 inch)

Remedy : Build-up or Replace
Unit : mm (inch)
Std. Dimension Usable limit Remedy
Pin hole (D) 45 (1.772) 47.0 (1.850)
Build-up
Pin 44.45 (1.75) 42.5 (1.673) or
279 Replace
Pitch (P) -
(10.984)
When 6 pcs. shoes are connected by shoe pin and

hanged vertically, distance between pins should be
1671 -6 mm (65.787 inch)
CK2500-II, CKE2500-II 2-10

2. Drive tumbler
476.6 (18.764)
472 R13
(18.583) (R0.512)
R51
(R2.009)
48
(1.890)
R13
(R0.512)
Wear limit : 2 mm (0.079 inch)

55 R16
(2.165) (R0.63)
86.5 (3.406)
R13
R6 (R0.512)
R16
(R0.63)
5 1)
R1 .59
0 R16 (R0.63)
(R
R476.6 (R18.764)
197 (7.756)
Unit : mm (inch)
2-11 CK2500-II, CKE2500-II

3. Idler
A
B
R13
(R0.512)
R19
(R0.748)
110
(4.331) Wear limit : 2 mm (0.079 inch)
184
(7.244)
Unit : mm (inch)
Symbol Item Std. Dimension Usable limit Remedy
A Outer diameter 772 (30.394) 764 (30.079) Build-up or Replace
Std.
Tolerance Standard Allowable
Dimension
-0.043
-0.106
Shaft
Gap between of (-0.0017) Gap Replacement of
B 135
shaft and bushing (-0.0042) 0.273-0.386 Bushing
Gap 1.0 (0.0394)
( 5.315) +0.28 (0.0093-
+0.23 0.0152)
Hole
(+0.0110)
(+0.0090)
CK2500-II, CKE2500-II 2-12

4. Track roller
242 (9.528)
109 (4.291)
B
A
R15 (R0.591)
R10 (R0.394)
Unit : mm (inch)
380
A Outer diameter 372 (14.646) Build-up or Replace
( 14.961)
Std.
Tolerance Standard Allowable Build-up or Replace
Dimension
-0.043
-0.106
Shaft
Gap between of (-0.0017) Gap
B
shaft and bushing 125 (-0.106) 0.273-0.336 Gap Replacement of
(4.921) +0.28 (0.0093- 1.0(0.0394) Bushing
+0.23 0.0152)
Hole
(+0.0110)
(+0.0090)
2-13 CK2500-II, CKE2500-II

5. Guide roller
242 (9.528)
130 (5.118)
A
R10 (R0.394) R10 (R0.394)
Unit : mm (inch)
265.4
A Outer diameter 257.3 (10.130)
( 10.445) Build-up or Replace
Std.
Tolerance Standard Allowable
Dimension
-0.030
-0.076
Shaft
Gap between of (-0.0012) Gap
B
shaft and bushing 65 (-0.0030) 0.26-0.36 Gap Replacement of
(2.559) +0.28 (0.0102- 0.8 (0.0315) Bushing
+0.23 0.0142)
Hole
(+0.0110)
(+0.0090)
CK2500-II, CKE2500-II 2-14

6. Guide bar
A
B
60 (2.362) 60 (2.362)
7 deg.
7 deg.
(5.315)
(3.819)
135
97
A B
Unit : mm (inch)
A Height of Guide Bar 135 (5.315) 115 (4.528)
Build-up or Replace
B Height of Guide Bar 97 (3.819) 77 (3.032)
2-15 CK2500-II, CKE2500-II

2.2 PERFORMANCE STANDARD AND TEST PROCEDURE

1. TERMINOLOGY
Standard value : Standard of assembling new machine.
When the value exceeds the standard, repair or replace the part as required to maintain ma-
chine performance and or safety.
Temperature of oil : It means temperature of hydraulic oil.
2. As to the items of which limit of use is not shown, referring to standard value as the guidance, repair or replace
the part as required.
2.2.1 OPERATING SPEED
No. Item Test Condision Test Procedure Standard Value

Boom • Engine min : High idling
-1
Measure the time taken to rotate drum 10
Hoisting • Temperature of Hyd. oil : times.
and 45 to 55°C (113 to 131°F) (Start measuring when the rotation of the
1 41 to 49 sec
Lowering • Boom Length : Std. Boom drum becomes stable)
wire rope • Speed adjusting knob :
Speed High Take average of 3 times measuring
• Engine min-1 : High idling Measure the time taken to rotate drum 10
times.
• Temperature of Hyd. oil : Low speed
Main and (Start measuring after the preparation ro-
45 to 55°C (113 to 131°F) 40 to 48 sec
2 Aux. hoisting tates of 10 seconds. Take average of 3 times
• Loading : No load High speed
wire rope measuring.)
• Speed adjusting knob : 9 to 12 sec
High Take average of 3 times measuring
• Engine min : High idling
-1
Measure the time taken to rotate machine

• Temperature of Hyd. oil :
one time.
Swing 45 to 55°C (113 to 131°F)
3 Measure the time for 2nd rotation after 1st 25 to 30 sec
Speed • Boom Length : Standard
preliminary rotation.
Boom
Take average of 3 times measuring.
• Loading : No load
• Engine min-1 : High idling Measure the time taken to propel machine
L=
• Temperature of Hyd. oil : the distance of 20 m (66 ft).
Propel 101 to 119 sec
4 45 to 55°C (113 to 131°F) Propel machine first preliminary more than 2
Speed H=
• Boom Length : m (6.6 ft) before starting the measuring.
60 to 71 sec
Standard Boom Take average of 3 times measuring.
• Engine min-1 : High idling Measure the discrepancy volume resulted
• Temperature of Hyd. oil : from propelling the distance of 20 m (66 ft).
45 to 55°C (113 to 131°F) Propel machine first preliminary more than 2
m (6.6 ft) before starting the measuring.
• Boom Length : Standard
Boom
Discrepancy
Propelling Within 600 mm

5
Discrepancy (23.6 inch)
volume
20m (66ft)
CK2500-II, CKE2500-II 2-16

2.2.2 POINT AND METHOD OF MEASURING PRESSURE

Use a pressure gauge which has a surplus of more than 10 MPa (1450 psi) for pressures to be measured and which
has passed the inspection.
Prior to pressure measurement, clean the port for pressure measurement so as to be free from oil and dust.
Connector and hose for measuring pressure.

Connector : GB03H01085P1
Hose : GG03H01068D1 (KPM004000001-20)
No. Item Test Condition Test Procedure Standard Value
Main • Engine revolution (min-1) : 1. Lower the rear drum hook onto the
• Propel High idling ground.
Left • Temperature of oil : 2. Lock the rear winch drum with the drum
• Rear 45 to 55°C lock.
Drum (113 to 131°F) 3. Make the valve relieve by rear drum winch
lowering operation.
PRESSURE GAUGE RELIEF

PORT (PF 1/4) VALVE 31.9 MPa
1
(4626 psi)
PROPEL
LEFT SIDE
B1 A1
B2 A2
REAR
DRUM
2-17 CK2500-II, CKE2500-II

Main • Engine revolution (min-1) : 1. Lower the front drum hook onto the
• Propel High idling ground.
Right • Temperature of oil : 2. Lock the front winch drum with the drum
• Front 45 to 55°C lock.
Drum (113 to 131°F) 3. Make the valve relieve by front drum
• Load safety device : winch lowering operation.
Setting of the crane con-
figuration
(Select of attachment :
Crane) PRESSURE GAUGE
PORT (PF 1/4) RELIEF
VALVE
31.9 MPa
2
PROPEL (4626 psi)
LEFT SIDE
B1 A1
B3
B4 A4
FRONT
DRUM
CK2500-II, CKE2500-II 2-18


• Engine revolution (min ) : -1
1. Lower the boom onto the ground.
High idling
2. Lock the boom drum. 32.0 MPa
• Temperature of Hydraulic
3. Make the valve relieve by boom lowering (4640 psi)
oil : 45 to 55°C
operation.
(113 to 131°F)
PRESSURE GAUGE PORT

(PF1/4)
3 Boom
RELIEF VALVE
• Engine revolution (min-1) :

High idling 1. Lock the upper not to turn with the swing
• Temperature of Hydraulic lock pin and parking brake. 27.5 MPa
oil : 45 to 55°C 2. Make the valve relieve by swing opera- (3988 psi)
(113 to 131°F) tion.
• Swing mode : Free high
RELIEF VALVE
4 Swing
PRESSURE
GAUGE PORT (PF 1/4)
2-19 CK2500-II, CKE2500-II


Relief Valve
6.6 MPa
(957 psi)
• Temperature of Hydraulic [Low idling]
Remove the cap of plug installed in valve
oil : 45 to 55°C Pressure Reducing
block and install the pressure gauge.
(113 to 131°F) Valve
5.4 MPa
(783 psi)
[Low idling]
Control Circuit
5 (Primary
pressure)
PRESSURE RELIEF VALVE

REDUCING
PRESSURE REDUCING VALVE RELIEF VALVE PRESSURE

PRESSURE GAUGE PORT GAUGE PORT
1. Operate the control lever for the sec-

tion to be measured.
(Operate the speed adjusting knod to
the Max. position)
Take pressure out from the quick cou-
pler of the control valve spool end.
• Engine revolution (min-1) :

Control
Low idling Standard value
Circuit
6 • Temperature of Hydraulic 2.65 to 2.94 MPa
(Secondary Front & Rear Drum
(363 to 405 psi)
oil : 45 to 55°C
pressure)
(113 to 131°F) Propel 1.42 to 1.62 MPa
(206 to 235 psi)
Swing 1.62 to 1.81 MPa

(235 to 262 psi)
Third (Jib) [Option] 2.75 to 3.24 MPa

(384 to 426 psi)
Boom 2.50 to 2.79 MPa

(399 to 470 psi)
CK2500-II, CKE2500-II 2-20


Raise :
20.6 MPa
• Engine revolution (min-1) : (2987 psi)
1. Relief by raising the mast cylinder.
High idling Lower :
2. Relief by lowering the gantry cylinder.
• Temperature of Hydraulic 4.9 MPa
3. Relief by operating crawler fixing pin (711 psi)
oil : 45 to 55°C
cylinder.
(113 to 131°F) Lower Circuit :
20.6 MPa
(2987 psi)
• Mast raising/
7 lowering
• Lower circuit
GAUGE
PORT (PF 1/4) PORT RELIEF VALVE
(MAST RAISING)
20.6 MPa (2987 psi)
PORT RELIEF VALVE

(MAST LOWERING)
4.9 MPa (711 psi)
MAIN RELIEF VALVE

(MAST RAISING & LOWER CIRCUIT)
20.6MPa (2987 psi)
2-21 CK2500-II, CKE2500-II


• Engine revolution (min ) : -1
High idling
1. Relief by raising the counterweight re- 21.0 MPa
• Temperature of Hydraulic
moval / installation cylinder. (3045 psi)
oil : 45 to 55°C
(113 to 131°F)
Counterweight
and
8
Gantry raising/
lowering
PRESSURE GAUGE
PORT (PF 1/4)
RELIEF VALVE
CK2500-II, CKE2500-II 2-22

2.2.3 SLEWING RING
WITHIN
100 mm (3.94 inch)
REVOLVING FRAME
DIAL
GAUGE
LOWER FRAME
COUNTERWEIGHT : Upper : 8 pcs. (97 t), Lower : 2 pcs. (20 t), 117 t in total
Condition of measurement Amount of play
Boom length (Standard boom) : 18.4 m (60.4 ft)
Radius : 10.0 m (32.9 ft) Less than 3 mm (0.118 inch)
Load : 116.3 t
2-23 CK2500-II, CKE2500-II

2.2 PERFORMANCE STANDARD AND TEST PROCEDURE

1. TERMINOLOGY
Standard value : Standard of assembling new machine.
When the value exceeds the standard, repair or replace the part as required to maintain ma-
chine performance and or safety.
Temperature of oil : It means temperature of hydraulic oil.
2. As to the items of which limit of use is not shown, referring to standard value as the guidance, repair or replace
the part as required.
2.2.1 OPERATING SPEED
No. Item Test Condision Test Procedure Standard Value

Boom • Engine min : High idling
-1
Measure the time taken to rotate drum 10
Hoisting • Temperature of Hyd. oil : times.
and 45 to 55°C (113 to 131°F) (Start measuring when the rotation of the
1 41 to 49 sec
Lowering • Boom Length : Std. Boom drum becomes stable)
wire rope • Speed adjusting knob :
Speed High Take average of 3 times measuring
• Engine min-1 : High idling Measure the time taken to rotate drum 10
times.
• Temperature of Hyd. oil : Low speed
Main and (Start measuring after the preparation ro-
45 to 55°C (113 to 131°F) 40 to 48 sec
2 Aux. hoisting tates of 10 seconds. Take average of 3 times
• Loading : No load High speed
wire rope measuring.)
• Speed adjusting knob : 9 to 12 sec
High Take average of 3 times measuring
• Engine min : High idling
-1
Measure the time taken to rotate machine

• Temperature of Hyd. oil :
one time.
Swing 45 to 55°C (113 to 131°F)
3 Measure the time for 2nd rotation after 1st 25 to 30 sec
Speed • Boom Length : Standard
preliminary rotation.
Boom
• Loading : No load
• Engine min-1 : High idling Measure the time taken to propel machine
L=
• Temperature of Hyd. oil : the distance of 20 m (66 ft).
Propel 101 to 119 sec
4 45 to 55°C (113 to 131°F) Propel machine first preliminary more than 2
Speed H=
• Boom Length : m (6.6 ft) before starting the measuring.
60 to 71 sec
Standard Boom Take average of 3 times measuring.
• Engine min-1 : High idling Measure the discrepancy volume resulted
• Temperature of Hyd. oil : from propelling the distance of 20 m (66 ft).
45 to 55°C (113 to 131°F) Propel machine first preliminary more than 2
m (6.6 ft) before starting the measuring.
• Boom Length : Standard
Boom
Discrepancy
Propelling Within 600 mm

5
Discrepancy (23.6 inch)
volume
20m (66ft)
CK2500-II, CKE2500-II 2-16


Maintenance Standards Test Procedures

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2.

MAINTENANCE STANDARDS TEST PROCEDURES

2.1 MAINTENANCE STANDARD

2-3 CK2500-II, CKE2500-II

Free Length Free Length

CK2500-II, CKE2500-II 2-4

Standard root diameter

2-5 CK2500-II, CKE2500-II

Fig.2-3 Boom Drum Lock

Fig.2-4 Boom Drum Lock Pawl

CK2500-II, CKE2500-II 2-6

Fig.2-5 Luffing Jib Drum Lock

Fig.2-7 Main Boom

Fig.2-8 Fixed Jib

2-7 CK2500-II, CKE2500-II

Fig.2-10 Aux. Sheave (For Luffing or Long Boom)

Fig.2-9 Aux. Sheave (For Main Boom)

Fig.2-11 Luffing Boom and Jib

CK2500-II, CKE2500-II 2-8

2-9 CK2500-II, CKE2500-II

2.1.2 PROPEL DEVICE

Wear limit : 2 mm (0.079 inch)

When 6 pcs. shoes are connected by shoe pin and

CK2500-II, CKE2500-II 2-10

Wear limit : 2 mm (0.079 inch)

2-11 CK2500-II, CKE2500-II

CK2500-II, CKE2500-II 2-12

2-13 CK2500-II, CKE2500-II

R10 (R0.394) R10 (R0.394)

CK2500-II, CKE2500-II 2-14

2-15 CK2500-II, CKE2500-II

2.2 PERFORMANCE STANDARD AND TEST PROCEDURE

2.2.1 OPERATING SPEED

No. Item Test Condision Test Procedure Standard Value

Measure the time taken to rotate machine

Propelling Within 600 mm

CK2500-II, CKE2500-II 2-16

2.2.2 POINT AND METHOD OF MEASURING PRESSURE

Connector and hose for measuring pressure.

PRESSURE GAUGE RELIEF

2-17 CK2500-II, CKE2500-II

CK2500-II, CKE2500-II 2-18

No. Item Test Condition Test Procedure Standard Value

PRESSURE GAUGE PORT

• Engine revolution (min-1) :

2-19 CK2500-II, CKE2500-II

No. Item Test Condition Test Procedure Standard Value

PRESSURE RELIEF VALVE

PRESSURE REDUCING VALVE RELIEF VALVE PRESSURE

1. Operate the control lever for the sec-

• Engine revolution (min-1) :

Swing 1.62 to 1.81 MPa

Third (Jib) [Option] 2.75 to 3.24 MPa

Boom 2.50 to 2.79 MPa

CK2500-II, CKE2500-II 2-20

No. Item Test Condition Test Procedure Standard Value

PORT RELIEF VALVE

MAIN RELIEF VALVE

2-21 CK2500-II, CKE2500-II

No. Item Test Condition Test Procedure Standard Value

CK2500-II, CKE2500-II 2-22

2.2.3 SLEWING RING

2-23 CK2500-II, CKE2500-II