CKE2500 Service Manual

KOBELCO
SHOP MANUAL CK2500

CKE2500
MAINTENANCE STANDARDS
TEST PROCEDURES
TABLE OF CONTENTS
1. MAINTENANCE STANDARD 1- 1
1. 1 Pin, Bushing, Spring, and Seave · · .. · · · · · · · · · · · · · · · · · · · · · · · · · · · · 1- 1
1.1.1 Pin, Bushing · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 1- 1
1.1.2 Spring · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 1- 2
1.1.3 Sheave · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 1- 3
1. 2 Propel Device · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 1- 8
1.2.1 Crawler shoe · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 1- 8
1.2.2 Drive tumbler · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 1- 9
1.2.3 Idler · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 1- 10
1.2.4 Track roller · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 1- 11
1.2.5 Guide roller · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 1- 12
1.2.6 Guide bar · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 1- 13
2. PERFORMANCE STANDARD AND TEST PROCEDURE · · · · · · · · · · · · · · · · · · 2 - 1
2. 1 Operating Speed · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2- 1
2. 2 Point and Method of Measuring Pressure · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2- 2
2. 3 Slewing Ring · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2- 7
PREFACE
Performance standards are a measure of whether the machine is in normal or abnormal condition.
Under some operating conditions, the machine runs outside performance standards.
For example, in extremely cold places where machine operation is not under strict test conditions (oil
temperature low), the machine itself might be normal butthe operating speed could be slowed down.
Keep such possibilities in mind when using this manual.
Model Applicable Machine Note Model Applicable Machine Note

CK2500
CKE2500 JD-00001 ~
Revision Date of Issue Book Code
lst. Edition 2000.03 S5JD0401E
2nd. Edition 2002.08 S5JD0401E(l)

1. MAINTENANCE STANDARD
1.1' PIN, BUSHING, SPRING, AND SHEAVE
1.1.1 Pin, Bushing
b---··1···-·r·---~ I d'
..... ~------~·-----
Pin
l::===-~-=====-=-====:::::1----...L
Bushing
[Unit: inch (mm)]
Std. dimension Usable limit See

Name Location Item Part number Remedy fig.
D d D' d'
Fr.& 1 JJ82W01024Pl 1.732 1.725 Replace Fig.

Re.Drum (44.0) (43.82) 1-1
Pawl Boom Drum 2 JJ82W01007Pl 1.732 1.725 Replace Fig.

(44.0) (43.82) 1-3
Luffing 3 GB82W01008Pl 1.772 1.765 Replace Fig.

Jib Drum (45.o_io2s ) (44.84) 1-5
Pin
Boom Foot 4 JJ02A01003Pl 6.496 6.471 Replace Fig.
(165i.~!i) (164.36) 1-7
Luffing Jib Foot 5 JJ13A01016Pl 4.330 4.310 Replace Fig.

c110~:D (109.47) 1-11
Strut Foot 6 JJ12A01018Pl 3.150 3.140 Replace Fig.

(Fr. & Re.) (80 :8.tf ) (79.77) 1-11
Fr.& 7 2405T1151 1.732 1.743 Fig.

Re.Drum (44.0) (44.26) 1-1
Replace -
Pawl Boom Drum 8 JJ82W01010Pl 1.732 1.743 Fig.
(44.0) (44.26) 1-3
Luffing 9 2405U101D4540 1.772 1.776 Replace Fig.

Jib Drum (45.0?0.025 ) . (45.11) 1-5
Bushing
Boom Foot 10 JJ03A01010Pl . 6.500 6.528 Replace Fig.
(165::lrn;) (165.80) 1-7
Luffing Jib Foot 11 2405R41D21 4.330 4.354 Replace Fig.

(llOj:~ri) (110.6) 1-11
Strut Foot (Front) 12 2405R41Dl3 3.150 3.171 Replace Fig.

(80 :8_]5 ) (80.54) 1-11
1-1
1.1.2 Spring
i---- Free Length
[Unit: inch (mm)]

Std. Free Usable limit See
Location Item Part number Remedy
length of free ·length figure
Fr. & Re. Drum pawl 20 HP26C15002Gl 2.835 (72) 2.693 (68.4) Fig. 1-1
(Compression)
Boom drum pawl 21 HP26C15002Gl 2.835 (72) 2.693 (68.4) Fig. 1-3
(Compression)
Replace
Jib drum pawl 22 GB82W01004Pl 2.835 (72) 2.693 (68.4) Fig. 1-5
(Compression)
Gantry stopper 23 JJ61F01042Pl 16.063 (408) 15.260 (387.6) Fig. 1-12

(Compression)
1-2
1.1.3. Sheave
Standard root diameter
[Unit: inch (mm)]

Std. root Use Groove See
Equipment Item Part number Remedy
diameter limit radius figure
Boom point 30 JL06A01004Pl 494±1.5 491 14.0

-
Fig. 1-7
Idler 31 2407P812 549 +03 546 14.0
for Main 32 2407U140 587.4 584 15.5 Fig. 1-9

Auxiliary sheave
for Luffing 33 JL06A01004Pl 494±1.5 491 14.0 Fig. 1-10
Lower spreader 34 JJ06A01010Pl 418 +3 415 12.5 Fig. 1-12

0
35-1 JJ06A01010Pl 418 ~3 415 12.5

Mast Fig. 1-13
35-2 JJ06A01007Pl 494 ~3 491 14.0
Luffing boom point sheave 36 JL06A01004Pl 494±1.5 491 Replace 14.0

or
Luffing boom idler sheave 37 JL06A01004Pl 494±1.5 491 Build-up 14.0
Taper boom guide sheave 38 JJ06A01010Pl 418 +3 415 12.5

0
Luffing Fr. & Re. strut point sheave 39 JJ06A01010Pl 418 +3 415 12.5 Fig. 1-13
0
Fr. strut sheave 40 JL06A01004Pl 494±1.5 491 14.0

'
Jib point 41 GG63A01051Pl 495.6 14.0
Jib idler 42 GG63A01051Pl 495.6 14.0
Gantry peak 43 JJ61F01031Pl 550 0+3 547 12.5 Fig. 1-12
Jib point sheave 44 2407P812 549 +03 546 14.0 Fig. 1-8
Jib strut sheave 45 2407P812 549 +()3 546 14.0 Fig. 1-8
1-3
\
7
Wear Limit:0.118inch
(3mm)
20 Figl-2 Front & Rear Drum Lock

Figl-1 Front & Rear Drum Lock
(3mm)
Figl-3 Boom Drum Lock

Figl-4 Boom Drum Lock Pawl
4.921(125)
22
(3mm)
I I
___ II
----~ Figl-6 Luffmg Jib Drum Lock Pawl
Figl-5 Luffing Jib Drum Lock
1-4
4
31
10
30
Figl-7 Crane Boom
Figl-8 Crane Jib
32
Cl
Figl -9 Aux. Sheave(For Main) Figl-10 Aux. Sheave(For Luffing)
1-5
42
39
Figl -11 Luffing Crane
1-6
34
43
23
Figl-12 Gantry
35-1
~35-2
.....____35-1
Figl-13 Mast
1-7
1.2 PROPEL DEVICE
1.2.1 Crawler shoe
3.465(88)
.835
(72)
R0.630
Rl6
Wea:r limit:0.079inch(2mm)
Remedy:Build-up or Replace
[Unit: inch (mm)]
Std. Dimension Usable limit Remedy
Pin hole (D) 1.772 (45 +:;5) 1.850 (47.0)
Pin 1.75 (44.45 '.li.2) 1.673 (42.5) Build-up or Replace
Pitch (P) 10.984 (279 ~i:;)

When 6 pcs. shoes are connected by shoe pin and hung vertically, distance between pins should be
65.787 _g 33 inch (1671 _~. 4 -6 mm).
1-8
1.2.2 Drive tumbler
18.583
(472)
Wear limit:0.0791nch(2mm)
Remedy:Build-up or Replace
2.165
55
R0.236 R0.591
(R6) (R15)
R0.630
(R16)
R0.630
(R16)
7.756(197)
SECTION A-A SECTIONB-B
[Unit:inch(mm)]
1-9
1.2.3 Idler
,Fr _____ITTI I I I
1_1 1_1
LJ LJ
~--
--
I I
--11
- -
n n -<
I I I I
CJ R0.512
(R13)
R0.748(R19)
7.244
(184) Wear limit:0.079inch(2mm)
Remed :Build-u or Re lace
[Unit: inch (mm)]
Symbol Item Std. Dimension Usable limit Remedy
030.079 Build-up or
A Outer dimater 030.394 (0772)
(0764) Replace
Std.
Tolerance Standard Allowable
Dimension·
-0.0017
Gap between
B -0.0042 Replacement
of shaft and Shaft
( -0.043) Gap Gap of Bushing
bushing 5.315
-0.106 0.0093 - 0.0152 0.0394
(0135) (1.0)
(0.273 - 0.386)
+0.0110
+0.0090
Hole
( +0.28)
+0.23
1-10
1.2.4 Track roller
9.528(242)
4.291(109)
R0.394
(RlO)
R0.591
(R15)
[Unit: inch (mm)]
!ZS14.646 Build-up or
A Outer dimater !ZS14.961(!1S380) (!ZS372) Replace
Std.
Dimension
-0.0017
Gap between
B Shaft
-0.0042 Replacement
of shaft and , ( -0.043) Gap Gap of Bushing
bushing !ZS4.921 -0.106 0.0093 - 0.0152 0.0394
( </J 125)
(0.273 - 0.336) (1.0)
+0.0110
Hole
+0.0090
( +0.28)
+0.23
1-11
1.2.5 Guide roller
9.528(242)
5.118(130)
R0.394(R10)
[Unit: inch (mm)]
!1!10.130 Build-up or
A Outer dimater !1!10.445 (!1!265.3) (!1!257.3) Replace
Std.
Dimension
-0.0012
Gap between
B Shaft
-0.0030 Replacement
of shaft and
( -0.030) Gap Gap of Bushing
bushing !1!2.559 -0.076 0.0102 - 0.0142 0.0315
(!1!65) (0.26 - 0.36) (0.8)
+0.0110
Hole
+0.0090
( +0.28)
+0.23
1-12
1.2.6 Guide bar
< i:Q
<
,...- -... ' ~ ~
r,
~ ,....,
~
I=
'
c::::)
_Q)
"'I IE. 2.362(60)
A B
[Unit: inch (mm)]
A Height of Guide Bar 5.315 (135) 4.528 (115)

Build-up or Replace
B Height of Guide Bar 3.819 (97) 3.032 (77)
1-13
2. PERFORMANCE STANDARD AND TEST PROCEDURE
CD TERMINOLOGY
Standard value: Standard of assembling new machine.
When the value exceeds the standard, repair or replace the part as required to maintain machine
performance and or safety.
Temperature of oil: It means temperature of hydraulic oil.
@ 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.
2.1 OPERATING SPEED

No. Item Test Condision Test Procedure Standard Value
Boom · Engine R.P.M.: Measure the time taken to rotate drum 32 to 35 sec
Hoisting High idling 10 times.
and · Temperature of Hyd. (Start measuring when the rotation of the
1
Lowering oil: 122°F (50°C ±5°) drum becomes stable)
wire rope · Boom Length:
speed Std. Boom
Main and · Engine R.P.M.: Measure the time taken to rotate drum lst. speed
High idling 20 to 22 sec
Aux. 10 times.
· Temperature of Hyd. 2nd. speed
2 hoisting (Start measuring when the rotation of the
oil: 122°F (50°C±5°) 9 to 12 sec
wire rope drum becomes stable)
• Loading: No load
· Speed adjusting
knob:HIGH
Swing • Engine R.P.M.: Measure the time taken to rotate machine
Speed High idling one time
· Temperature of Hyd. Measure the time for 2nd rotation after lst
3 oil:122°F (50°C±5°) preliminary rotation. 27 to 30 sec
· Boom Length: Take average of 3 times measuring.
Standard Boom
· Loading: No load
Propel · Engine R.P.M.: Measure the time taken to propel machine L=lOO to 115 sec
Speed High idling the distance of 65'-7" (20m). H=60 to 67 sec
· Temperature ofHyd. Propel machine first preliminary more than
4 oil: 122°F (50°C±5°) 2m before starting the measuring.
· Boom Length: Take average of 3 times measuring.
Standard Boom
Propelling · Engine R.P.M.: Measure the discrepancy volume resulted Within 23.6 inch
Discrepancy High idling from propelling the distance of 65'-7" (20m). (600mm)
· Temperature of Hyd. Propel machine first preliminary more than
oil: 122°F (50°C ±5°) 6'-7" (2m) before 'starting the measuring.
· Boom Length: Take average of 3 times measuring. !
5 Standard Boom g. Cl)
..
~i
I
·--·-----·· IIIIIIVllR!D1Dmrft
8·
BlllllDDlli[liiDUmlll. ... - ... - - ...•..
H-
2-1
2.2 POINT AND METHOD OF MEASURING PRESSURE
Use a pressure gauge which has a surplus of more than 14.22 psi (9.8 MPa) 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: GB03H01085Pl
Hose : KPM004000001-20
Main · Engine revolution ( 1) Lower the hook onto the ground.

· Propel (rpm) : High idling (2) Lock the rear drum.
Left · Temperature of (3) Make the valve relieve by rear drum
··Rear Hydraulic oil: lowering operation.
Drum 113 to 122°F
(45 to 55"C)
PRESSURE GAUGE RELIEF

PORT(PFl/4) VALVE
4479 psi
(30.9MPa)
Main · Engine revolution ( 1) Lower the main hook onto the ground.
· Propel (rpm) : High idling (2) Lock the main drum.
Right · Temperature of (3) Make the valve relieve by front drum
· Front Hydraulic oil: lowering I-speed operation.
Drum 113 to 122°F
(45 to 55"C)
PRESSURE GAUGE RELIEF
PORT(PFl/4) VALVE
2
I 4479 psi
(30.9MPa)
2-2
Boom · Engine revolution ( 1) Lower the boom onto the ground. 4479 psi
(rpm) : High idling (2) Lock the boom drum. (30.9 MPa)
· Temperature of (3) Make the valve relieve by boom
Hydraulic oil: lowering operation.
113 to 122°F
(45 to 55°C)
PRESSURE
GAUGE PORT
(PFl/4)
Swing · Engine revolution (1) Lock the upper not to turn with the 3982 psi
(rpm) : High idling swing lock pin and parking brake. (27.4 MPa)
· Temperature of (2) Make the valve relieve by swing
Hydraulic oil: operation.
113 to 122°F
(45 to 55°C)
RELIEF VALVE _L
PRESSURE
GAUGE PORT
(PFl/4)
VIEW A
2-3
Control · Temperature of (1) Lower the hook onto the ground, and 782 psi
Circuit Hydraulic oil: set the drum lock. (5.4 MPa)
(Primary 113 to 122°F (2) Remove the plug from valve block, (Low idling)
pressure) (45 to 55"C) and instal the pressure gauge.
ACCUMULATOR
RELIEF VALVE
PRESSURE GAUGE PORT
Control · Engine revolution ( 1) Operate the control lever for the

Circuit (rpm) : Low idling section to be measured.
(Secondary · Temperature of (Operate the speed adjusting knod
pressure) Hydraulic oil: to the Max. position)
113 to 122°F .Take pressure out from the quick
(45 to 55"C) coupler of the control valve spool
end.
~~
Standard Value
lst. speed 2nd speed
Front& 384- 427 psi
206 - 235 psi (l.42 - l.62MPa)
Rear Drum (2.65 - 2.94 MPa)
Propel 206 - 235 psi (l.42 - l.62MPa) ---
Swing 235 - 263 psi (1.62 - l.81MPa) ---
Third 398 - 469 psi (2.75 - 3.24MPa) ---
Boom 384 - 427 psi (2.65 - 2.94MPa) ---
2-4
· Mast · Engine revolution (I) Relief by raising the mast cylinder. 2986 psi
raising/ (rpm): High idling (20.6 MPa)
lowering • Temperature of
· Trans Hydraulic oil :
Lifter 113 to 122°F
(45 to 55'C)
RELIEF VALVE(MAST RAISE)

2986psi(20.6MPa)
RELIEF VALVE
2986psi(20.6MPa)
PRESSURE GAUGE
PORT PFl/4
RELIEF VALVE(MAST LOWER)

711psi(4.9MPa)
2-5
· Counter- · Engine revolution (1) Relief by raising the counterweight Raise: 3555 psi
weight (rpm): High idling removal/installation cylinder. (24.5 MPa)
and · Temperature of
Gantry Hydraulic oil : Lower: 711 psi
raising/ 113 to 122°F (4.9MPa)
lowering (45 to 55°C)
1--~~~~~~--'-~~~~~~~~~~~~~~~-'-~~~~~~-1
MAIN CONTROL VALVE
RELIEF VALVE
(COUNTERWEIGHT LOWER)
711psi(4.9MPa)
PRESSURE GAUGE
PORT(PFl/4)
RELIEF VALVE
(COUNTERWEIGHT RAISE)
3555psi(24.5MPa)
2-6
2.3 SLEWING RING
WITHIN 3.937inch(100mm)
REVOLVING FRAME
DIAL GAUGE
COUNTER WEIGHT: FULL

Condition of meadsurement Amount of play
Radius: 34.1 ft (10.4 m)

Less than 0.118 inch (3 mm)
Load: 216,090 lbs (98.0 t)
2-7
Book c o ; ; ~ D 11 01 E(D
KOBELCO
SHOP MANUAL CK2500
CKE2500
POWER TRAIN
TABLE OF CONTENTS
1. INTRODUCTION · · · · · · · · · · · · · .. · · · · .. · · · · · · · · · · · .. · · · · · · · · · · · · · · · · · · · · · · · · · 1- 1
2. ENGINE · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2 - 1
2.1 Introduction · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2- 1
2.2 Removal · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2- 1
2.3 Repair and Maintenance · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2- 1
2.4 Re-installation · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2- 2
3. PUMP DRIVE ASSEMBLY · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3- 1
3.1 Introduction 3- 1
3.2 Removal · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3- 1
3.3 Disassembling the Power Divider · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3- 3
3.4 Check and Repair of the Power Divider · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3- 3
3.5 Assembling the Power Divider · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3- 4
3.6 Re-installation · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3- 4
CK2500
CKE2500 JD-00001 ~
1st. Edition 2000.03 S5JD1101E
2nd. Edition 2002.08 SSJD l lOlEW

1. INTRODUCTION
This is a fully hydraulic crawler crane.
The crane's engine drives two pairs of tandem-plunger-type pumps and tandem-mounted gear pumps through the power
divider.
Both of the tandem-plunger-type pumps are variable. The main pump powers the front and rear drum motors and the right
and left drive motors through the two control valves.
For another pair of the plunger pumps, the inner pump powers the boom drum motor, and the outer pump powers the swing
motor, respectively.
The oil flow from the inner side gear pump of the tandem-mounted gear pumps is directed to the translifter and crawler
removal/installation cylinder through the gantry raising/lowering cylinder, boom foot pin removal/installation cylinder,
and the swivel, while the outer gear pump feeds pressurized oil to the control line.
1-1
PUMP
POWER
DIVIDER
REAR DRUM
SWING MOTOR &

REDUCTION UNIT
BOOM DRUM MOTOR &

REDUCTION UNIT CONTROL VALVE
REDUCTION UNIT
TRANSLIFTER CYLINDER
CRAWLER FIXING PIN
Fig. 1-1 Component Locations
1-2
2. ENGINE
8. Lavel and then remove the control cable, fuel line
2.1 INTRODUCTION
and electric harness from engine.
This chapter explains how to remove and re-install the
Cap all the fuel lines to prevent soil from getting
engine. Refer to the manual provided by the engine
into them.
manufacturer for maintenance and repair details.
9. Recheck to be sure that no electrical lines,

2.2 REMOVAL mechanical connections and fuel pipes are
Proceed as follows when removing the engine from the remaining to interfer with the removal of the
machine. engine.
NOTE 10. Use a sufficiently strong engine lift. (The engine/

power divider combined weight is approximately
Remove the pump drive assembly with the
1500 kg.) Note the three designated lifting points
engine.
on the engine assembly.
1. Remove the grounding cable of the battery.

11. Remove the nuts, washers and bolts from the
rubber mounts of the engine and power divider.
2. Remove the muffler.
12. Slowly lift to remove as a single unit the engine and

3. Remove the air inlet hose from the engine and air
pump drive assembly.
cleaner.
13. Check the rubber mounts and replace them if

4. When removing the engine and pump drive
necessary.
assembly, it is necessary to first remove the guard.
5. Drain the engine oil, hydraulic oil and coolant

2.3 REPAIR AND MAINTENANCE
water. Regarding the repair and maintenance of the engine,
refer to the manual provided by the manufacturer.
A WARNING The engine manufacturer : Mitsubishi Motors, Inc.

The engine model : 6024-TCEC
Do not drain the oil and water when it is hot.
The hot oil and water may spout out which could
result in personal injury. After the oil and water
has cooled, drain the oil and water.
Failure to observe this precaution may result in
serious injury or loss of life.
6. Remove the cap screws that hold thy fanguard to

the radiator and take off the radiator assembly.
7. Label and then remove the hydraulic hoses from

the hydraulic pumps.
All the ports and hoses should then.be plugged to
prevent soil from getting into them.
2-1
2.4 RE-INSTALLATION
9. Install the air inlet hose and muffler.
Proceed as follows when re-installing the engine.
(See figure 2-1)
10. Install hydraulic hoses to the hydraulic pumps.
1. Check to make sure that no cables, fuel lines,
coolant water hoses, mechanical connection parts
11. Refill the engine with coolant water and engine oil
or other items are left to interfer with the re-
to the required levels.
installation.
12. Remove the air from the fuel lines.

2. If the rubber mounts were removed, replace them.
13. Start the engine and set it to low idle. Check for
3. Using a sufficiently strong engine lift, lift the
water and fuel leaks, and any strange noises.
engine and place it onto the mount pads.
4. Use Loctite #271 on the rubber mount holding A CAUTION

bolts and tighten them to 368 to 455 ft-lbs (500 to Before starting the engine, re-check all
618 N·m) torque. electrical, fuel, water and hydraulic connections
as well as mechanical connections.
5. Install the radiator assembly and fan guard. The Be prepared to stop the engine immediately if
space between the fan shroud and the fan should something unusual develops.
be even all around.
Use Loctite #271 on the bolts of the radiator
assembly and tighten them with 210 to 253 ft-lbs
(285 to 343 N · m) torque.
6. Connect all the electric lines that were

disconnected when the engine was removed.
7. Install all the fuel lines and control cables that

were removed when the engine was removed.
8. Install the guard, and connect the battery cable.
A WARNING
• Do not bring a flame or spark close to the
batteries.
•Since the battery electrolyte is dilute
sulfuricacid, avoid battery acid contact with the
skin, eyes, or clothing. If accidentally
contacted, immediately flush the area with
water and consult a doctor immediately.
• Wear eye glasses to protect eyes when
working with electrolyte.
Failure to observe this precaution may result
in serious injury or loss of life.
2-2
RUBBER MOUNT
POSITION
RUBBER MOUNT
POSITION
THERMO SWITCH
THERMO METER
HOIST POSITION
HOT WATER OUTLET
b---
II
II r-A
ll
TURN SENSOR
STEPPING MOTOR
Tightening torque,:231ft-lbs(314N-m)
(Apply coat LOCTITE#271) OIL FILTER ALARM
Fig. 2-1 Engine Removal and Reinstallation (1/2)
2-3
Tightening torque:412ft-lbs(559N -m)
(Apply coat LOCTITE#271)
VIEW A Tightening torque:89ft-lbs(121N -m)

Tightening torque: 14lft-lbs(191N -m)

(Apply coat LOCTITE#271) Tightening torque:141ft- lbs(191N-m)
Tightening torque:412ft-lbs(559N -m)

Tightening torque:412ft-lbs(559N-m)
VIEWB
Fig. 2-1 Engine Removal and Reinstallation (2/2)
2-4
3. PUMP DRIVE ASSE~MBLY
3.1 INTRODUCTION 4. The main part of this coupling will be removed
with the power divider connected to its core.
This chapter explains how to remove, inspect, repair
and re-install the pump drive assembly.
The pump drive assembly is mounted directly onto the
back of the engine. It consists of a coupling, a power
divider, tandem-mounted main pumps (hoist,
propel) , swing/boom hoist pumps and a double-
mounted pump set (control and aux-actuator) .
The power of the engine is transfered from a flywheel
through the coupling to the center core of the power
divider. Three pairs of gears divide this power between
the main pump shaft and the swing/boom pump shaft
and gear pump shaft. (See figure 3-1)
3.2 REMOVAL
Proceed as follows when removing the pump drive
assembly. (See figure 3-1)
A CAUTION
Pump drive assembly should be removed from
the engine according to the following procedure
,<::mly after the engine has been removed from
the machine as described in Chapter 2.
1. Drain the oil in the power divider through the port

on the lower part of the power divider.
2. Remove the main pump, swing/boom pump and

gear pump.
Main pump 356 lbs (175 kg)
Swing/Boom pump 356 lbs (175 kg)
Double gear pump 20 lbs (9 kg)
3. Using a sufficiently strong lift device (the

approximate weight of the power divider is
130kg) , attach the lift riggings to suspension
screws provided on the power divider. (screw
holes: M16)
Remove the cap screws set in the fly wheel housing
of the engine and move the power divider slowly
toward the back of the engine.
Remove the coupling and disconnect the power
divider.
3-1
Swing pump
AUXILIARY PUMP
(BOOM FOOT PIN, REEVING WINCH, Boom pump
TRANSLIFTER)
Control pump
Suspension screw
Main pump
Flange
Insert
Element Coupling
Bushing
Fig. 3-1 Pump Drive Assembly
3-2
3.3 DISASSEMBLING THE 3.4 CHECK AND REPAIR OF
POWER DIVIDER THE POWER DIVIDER
Proceed as follows when disassembling the power Check all parts prior to reassembling the power divider.
divider. (See figure 3-2) All questionable parts should be replaced to maximize
the re-assembled power divider's service life and to
I. Set the power divider on a block with the pump side avoid further break downs.
facing up. Checking should proceed in the following order.
2. Use the screw holes (M8) provided when I. Clean all the parts with fresh cleaning oil and blow
removing support "X" (3) with a puller. Remove them dry.
the 0-ring ( 15) .
2. Check bearing balls, rollers, inner and outer races
(
3. Remove the gear "X" (6) and remove the bearings to see that they are free of pitching and scratches.
"X" (11, 12) on both sides if necessary. Replace any defective ones.
4. Use the screw holes (M8) provided when 3. Bearings with no pitching or scratches should be
removing support "Y" (3) with a puller. Remove lightly lubricated, but replace any bearings that
the 0-ring ( 15) . develop rattles due to excessive clearances toward
the shaft or toward the external side should be
5. Remove gear "Y" (6) and remove the bearings replaced.
"Y" (11, 12) on both sides ifnecessary.
4. Check the bearings' outer and inner races. Replace
6. Remove the capscrew ( 19) and remove the any that show indications of slipping and/or
support "Z" (4) . rolling.
7. Detach the gear "Z" (7) , and remove the both 5. Check the teeth of all the gears and replace any that
sides bearings (13, 14) , if necessary. show pitching, scratch, signs of friction wear,
peeling or cracking.
8. Now, turn the assembly over and set the power
divider on a block with the fly wheel side facing up. 6. Check the shafts and replace any with signs of
cracking, deformation, wear at contact surfaces or
9. Remove the capscrews (18) , insert the capscrew bearing slippage.
(MIO) into the screw hole for removing the
support (2) and remove support (2) 7. Check the splines of the shafts and gears. Replace
or fix any that show cracking, signs of wear or
10. Remove the shaft (8) and gear (5) . impact damage.
11. Remove the oil seal (17) , 0-ring (16) and 8. Check the bearing casings and replace any that
outer race of the bearing ( 10) from the support show slip wear or other deformations.
(2) .
Remove the outer race of the bearing ( 10) from 9. Check the gear casings and replace or fix any that
the housing ( 1) . show cracks, deformation or scratches.
Retain and keep all the shims (20, 21, 22)
together. 10. All the 0-rings and oil seals should be replaced
with new ones.
12. If necessary, remove the inner race of the tapered
roller bearing ( 10) from the shaft (8) . 11. Check cap screw threadings and screw hole
threadings and replace or repair any that show signs
of cross-threading and or strippage.
3-3
3.5 ASSEMBLING THE POWER 3. Torque the cap screws (7) to 310 to 354 ft-lbs
DIVIDER (421 to480N·m).
Assembling the power divider takes place in the reverse
order for disassembly. Be particularly cautions with the 4. On the side of the fly wheel (8) , install flange
following factors. (See figure 3-2) (9) and push ( 10) and then torque the cap
screws ( 11) to 310 to 354 ft-lbs (421 to 480
1. Apply clean oil to each part before assembling. N·m).
2. When assembling the shaft (8) , drive gear (5) 5. Fit the hook of a hoisting device with suitable
, tapered roller bearing ( 10) and support (2) , capacity to the eyebolt of the power divider ; insert
adjust with the shims (20, 21, 22) to Omm to the element at the coupling side of the power
0.15mm clearance at point "S" as shown in Figure divider into the bushing at the flywheel and thus set
3-2. the power divider assembly to the flywheel
housing.
3. Install the bearings (12 and 13) as shown in the
figure, ensuring that the seal of the bearing (13) and 6. Apply Loctite #271 to the capscrews (12) and
the inner race shoulder of the bearing (12) face the tighten to 47 to 57 ft-lbs (63 to 78 N · m).
correct directions.
7. Apply Loktite #271 to the respective cap screws,
4. Install the support (2) to the housing (1) so that the and tighten them to the two tandem-type pumps
oil hole is positioned as shown in the Figure 3-2. (main and swing/boom) with a tightening torque
from 209 to 253 ft-lbs (285 to 343 N·m) and the
5. Apply Loctite #271 to the assembling bolts (18) tandem-type gear pumps from 47 to 57 ft-lbs (63 to
for the support (2) before tightening them to 47 78N·m).
to 57 ft-lbs (63 to 78 N · m) torque. Ensure that the installation positions of the main
pump and swing/boom pump are correct (refer to
6. Apply Loctite #271 to assembling bolts (19) for Fig.3-1).
the support (4) before tightening them to 209 to
253 ft-lbs (285 to 343 N · m) torque. 8. Supply the specified #90 gear oil to the power
divider to the specified level [about 0.66 gals (2.5
7. After assembly is completed, make sure the input Q) is needed].
shaft can be turned easily by hand , and no noise is
emitted. 9. Attach power devider to the engine, and install the
engine assembly to base machine.
3.6 RE-INSTALLATION
10. Start the engine, and check that there is no
Assemble the pump drive as follows. (See Figure
abnormal noise, oil leakage, etc.
3-3)
1. Grease the spline of the input shaft ( 1) and insert NOTE

the coupling hub (2) to the untii it comes in
If the pump is not installed to the power divider,
contact with the shaft shoulder section, as shown in
the support (3) may come off.
the Figure 3-3.
Torque the set screws to 144 to 159 ft-lbs (196 to
216 N·m).
2. Assemble the coupling in the following order; first

put spring pins (4) into the coupling hub (2) ,
then the elements (5) and then inserts (6) .
3-4
2 5 Tightening torque
48ft-lbs(64. 7N · m)
4
2 4 Tightening torque 1
[72ft-lbs(98N·m)] (Seal tape)
Shim adjust
2 3 Tightening torque 0.004 to 0.043ft-lbs(O.l ~Llmm)
[72ft-lbs(98N ·m)](Seal tape)
1 9 Tightening torque : 231ft-lbs(314N ·m)

(LOCTITE#271)
13
14
A
!
9
Tightening torque
4.0 to 7.2ft-lbs(4.9~9.8N ·m)
(LOCTITE#515) 27 Tightening torque : 72ft-lbs(98N · m) SECTIONB-B
28 Tightening torque : 4 7 to 51ft-lbs(63. 7 to 68.6N · m) 1. Housing 11. Bearing 21. Shim (t=0.4)
2. Support 12. Bearing 22. Shim (t=0.5)
3. Support 13. Bearing 23. Elbow
3 12 5 10 3 12
4. Support 14. Bearing 24. Tube
5. Gear 15. 0-Ring (G170) 25. Cap
20,21,22 6. Gear 16. 0-Ring (G160) 26. PLug
7. GEar 17. Oil seal 27. Connector
Insert the oil seal 8. Shaft 18. Cap screw (MlO) (PT3/49)
until it is flush
with this face 9. Level gauge 19. Cap screw (M20) 28. Drain cock
6
/ 10. Bearing 20. Shim (t=0.3) (M8X 1. 5)
Gap" S"
Shim adjust : 0 to 0.006inch(0~0.15mm)
16
2 20. 21.22 8 1 7 (LOCTITE#515)

18
Tightening torque : 52ft-lbs(70.6N · m)
(LOCTITE# 271) 17
SECTION A-A
Fig.3-2 Power Divider
3-5
~ffl®~~5L~®~-V~~StTQo
THIS PAGE INTENTIONALLY LEFT BLANK.
3-6
5
3 12
SECTION A-A
1. Shaft 7. Capscrew
2. Coupling hub 8. Fly wheel
3. Setscrew 9. Flange
4. Spring pin 10. Insert A
5. Element 11. Capscrew
6. Insert R 12. Capscrew
Fig. 3-3 Coupling
3-7
KOBELCO
SHOP MANUAL CK2500
CKE2500
HYDRAULIC SYSTEM
TABLE OF CONTENTS
1. LOCATION OF MAIN HYDRAULIC COMPONENTS · · · · · · · · · · · · · · · · · · · · · · 1- 1
2. HYDRAULIC CIRCUITS AND COMPONENTS · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2 - 1
2.1 Hydraulic Circuit · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2 - 1
2.2 Component Specifications · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2 - 3
2.3 Location of Hydraulic Components · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2 - 6
3. HYDRAULIC SYSTEM · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3- 1
3.1 Preface··································································· 3- 1
3.2 Outline · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3- 1
3.3 Oil Flow from No.I and No.2 Pumps · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3- 2
3.4 Oil Flow from No.3 and No.4 Pumps · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3- 3
3.5 Oil Flow from No.5 Pump · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3- 4
3.6 Oil Flow from No.6 Pump (Secondary Pump) · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3- 7
4. VALVES · ·· · · · · ·· · · · · · · · · · · · · · ·· ··· · · · · ·· · · · · · · ·· · · · · · ·· · · · · · · · · · · · · · · · ·· · · · 4 - 1
4.1 5 - Section Valve · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 4 - 1
4.2 4 - Section Valve························································ 4 - 2
4.3 3 - Section Valve · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 4 - 3
CK2500
CKE2500 JD-00001 ~
Revision Date oflssue Book Code

2nd. Edition 2000.05 S5JD 120 lEW
3rd. Edition 2002.08 S5JD1201E@
1. LOCATION OF MAIN HYDRAULIC COMPONENTS
HYDRAULIC OIL TANK
PUMP,
POWER
DIVIDER
BOOM DRUM
SWING MOTOR &

REDUCTION UNIT
BOOM DRUM MOTOR &

REDUCTION UNIT CONTROL VALVE
REDUCTION UNIT
CRAWLER FIXING PIN
Fig. 1-1 Location of Main Component
1-1
2. HYDRAULIC CIRCUITS AND COMPONENTS
Fr. DRUM
2.1 HYDRAULIC CIRCUIT MC,
BOOM 8/P
SIP
b, (Up)
dv
SWING 17
2000 .. 111 ..
220k•
27
-----~
2-1
BOOM FOOT PIN CYLINDER MAST
(L. H.)
57 PROPEL (R.H.)
D,
f°·
I
I
I
I P,
I
. EETl
5/P J/P [OPT)
TI!
-~
I
PBJ
@k PS
24
LOWER HYDRAULIC LINE
COUNTERWEIGHT REMOVAL CYLINDER
b 4 (UPl
LUFFING
"
2-2
2.2 COMPONENT SPECIFICATIONS
Item Name of Component Specification

Swash Plate Type, Variable Capacity
1 Pump (Front & Rear Drum, Propel) Max. Delivery: 66 gals/minX2 (250Q/minX2)
Set Pressure : 4479 psi (30.9 MPa)
Swash Plate Tvoe, Variable Caoacity

Swing Boom
2 Pump (Swing/Boom) Max. Delivery 79 gals/min 85 gal/min
(300Q/min (320..Q/min)
Set Pressure 3982 psi 4479 psi
(27.5 MPa) (30.9 MPa)
Auxiliary Actuator Max Delivery : 9.2 gals (35 Q/min)

Set Pressure: 2986 psi (18.6 MPa)
3 Gear Pump
Control Max. Delivery: 14.5 gal/min (55 Q/min)
5 Control Valve Max Delivery : 66 gals/min (250 Q/min)

6 Control Valve Max Delivery : 66 gasl/min (250 Q/min)


7 Motor (Front & Rear Drum) Max. Oil Flow : 132 gals/min (500Q /min)
Swash Plate Type, Fixed Capacity

8 Motor (Boom) Max. Oil Flow : 85 gals/ min (320 Q/min)
9 Motor (Swing) Swash Plate Type, Fixed Capacity

Max. Oil Flow : 40 gals/min (150 Q/min)

10 Motor (Propel) Max. Oil Flow : 66 gals/min (250 Q/min)
11 Swivel Joint 8 Port A,B,C,D: Propel E : Propel Speed Select

F, G :Translifter H: Drain
12 Control Valve (Swing) Pressure : 3982 psi (27.5 MPa)
13 Control Valve (Translifter) Pressure : 2986 psi (20.6 MPa)
14 Remote Control Valve Pressure: 5.7 to 37.0 psi (0.4 to 2.6 MPa)
(Front, Rear and Boom)
15 Remote Control Valve (Propel) Pressure: 5.7 to 20.0 psi (0.4 to 1.4 MPa)
16 Remote Control Valve (Swing · OPT.) Pressure: Swing 7.1 to 24.2 psi (0.5 to 1.7 MPa)
OPT. 5.7 to 37.0 psi (0.4 to 2.6 MPa)
18 Solenoid Valve Block (5-Section) · Swing Parking Brake · Propel Speed Select
· Press. Relief Shift · Swing Reaction · Function Lock
2-3
19 Valve Block (4-Section) Fr. Drum, Re. Drum, Boom Drum Parking Brake
20 Relief Valve 76.8 psi (5.4 MPa)
22 Control Valve (Gantry) Pressure: 2986 psi (20.6 MPa)
23 Accumulator 122 cu¥m (2000cc)
24 Cylinder (Crawler Removal) Pressure: 2986 psi (20.6 MPa)
2986 psi (20.6 MPa)

25 Cylidner (Mast) Pressure
711 psi (4.9 MPa)
26 Line Filter lOOMesh 380 cm2
27 Drain Filter 10 7230 cm2
28 Filter 200 Mesh 280 cm 2
29 Suction Filter 80 Mesh 5300 cm2
30 Return Filter 10 38300 cm2
31 Bypass Valve (For Return Filter) 15 psi (0.1 MPa)
32 Bypass Check Valve (For Oil Cooler) 42.6 psi (0.3 MPa)
34 Slow Return Check Valve (j>0.8 _
36 Hyd. Oil Temperature Switch (Hyd. Oil Tank) 185° F (85° C)
38 Pressure Sensor (For Hoist) 30K
39 Pressure Sensor (For Swing) 500K
42 Pressure Switch For Pump Control
43 Pressure Switch For Control
2-4
Max. Delivery: 85 gals/min (320 Q/min)

45 Control Valve (Boom)
46 Cylinder (Translifter) Pressure: 2986 psi (20.6 MPa)
47 Flow Regulator Swing
48 Solenoid Valve Jib Drum Lock
49
Control Valve Max. Delivery: 10.6 gals/min (40Q/min)

55
(Boom Foot Pin, Reeving Winch) Set Pressure: 1849 psi (12.8 MPa)
57 Cylinder (Boom Foot Pin) Pressure: 1849 psi (12.8 MPa)
59 Shuttle Valve
Fr. Drum Hoist Stop, Re. Drum Hoist Stop,

62 Solenoid Valve Block (3-section)
Boom Drum Hoist Stop
63 Solenoid Valve Boom Pump Power Control
Max. Delivery: 74 gals/min (280 Q/min)

64 Motor (Luffing Jib Hoist)
65 Cylinder (Counterweight Removal) For Counterweight Removal
· R.H Cylinder Ext. · L.H Cylinder Ext.

66 Control Valve (Counterweight Removal)
· R.H Cylinder Ret. · L.H cylinder Ret.
67 Cylinder For Jib Drum Lock
For Mast Control

68 Relief Valve Pressure: Ext.=1564MPa (110 kgf/cm2)
Ret=2318psi (163 kgf/cm 2)
70 Slow Return Check Valve For Counterweight Removal
2-5
2.3 LOCATION OF HYDRAULIC COMPONENTS
-
The item numbers in figure are linked with the item number in the hydraulic circuit diagrams and "2.2
28 LINE FILTER 27 DRAIN FILTER COMPONENT SPECIFICATION".
26 LINE FILTER 1 MAIN PUMP (HOIST, PROPEL)

11 SWIVEL JOINT
30 RETURN FILTER 39 PRESSURE SENSOR
MAIN PUMP (BOOM, SWING)
31 BYPASS CHECK VALVE
47 VALVE BLOCK
3 GEARPUMP
. 29 SUCTION STRAINOR
22 MASTVALVE
ENGINE·
57 BOOM FOOT PIN CYLINDER
12 CONTROL VALVE
0 55 CONTROL VALVE
(BOOM FOOT PIN, REEVING WINCH)
57 BOOM FOOT PIN CYLINDER
16 REMOTE CONTROL VALVE

(SWING, LUFFING JIB)
18 SOLENOID VALVE BLOCK

66 CONTROL VALVE (5-BLOCK)
(COUNTERWEIGHT REMOVAL) 14 REMOTE CONTROL VALVE
(FRONT, REAR, BOOM)
7 FRONT DRUM MOTOR
8 BOOM DRUM MOTOR 6 MAIN CONTROL VALVE 19 SOLENOID VALVE BLOCK
(4-BLOCK) 15 REMOTE CONTROL VALVE
(PROPEL)
23 ACCUMULATOR
5 MAIN CONTROL VALVE 7 REAR DRUM MOTOR
62 SOLENOID VALVE BLOCK
(3-BLOCK)
2-6
7 REAR DRUM MOTOR 34 SLOW RETURN CHECK VALVE
7 FRONT DRUM MOTOR
57 CYLINDER 8 BOOM DRUM MOTOR

(COUNTERWEIGHT REMOVAL&GANTRY)
34 SLOW RETURN CHECK VALVE
c:> FRONT
\ 32 BYPASS CHECK VALVE
38 PRESSURE SWITCH 38 PRESSURE SWITCH 57 CYLINDER

(COUNTERWEIGHT
REMOVAL&GANTRY)
FRONT~
36 HYD. OIL TEMP. SWITCH
2-7
MAST
24 CYLINDER (CRAWLER)
25 MAST CYLINDER
46 CYLINDER
(TRANSLIFTER) 46 CYLINDER
REEVING WINCH
(TRANS LIFTER)
13 CONTROL VALVE
(TRANSLIFTER)
i:=> FRONT
46 CYLINDER
(TRANS LIFTER) 46 CYLINDER
(TRANS LIFTER)
LUFFING JIB DRUM .
64 LUFFING JIB DRUM
24 CYLINDER (CRAWLER)
1 67 !CYLINDER (DRUM LOCK) I
2-8
3. HYDRAULIC SYSTEM
3.1 PREFACE
This chapter provides a general outline of the overall hydraulic system. For more detailed explanations of each circuit,
please refer to the specific sections relating to each systems.
3.2 OUTLINE
The pressurized hydraulic oil flowing through these circuits is supplied by seven pumps (four variable displacement, two
fixed gear) installed on the power divider mounted directly on the engine. The two tandem-mounted variable
displacement pumps power the front and rear drums, and the propel system. The other variable displacement pump,
powers the swing system and the boom drum.
The gear pump directly connected to the power divider is provided for control and auxiliary actuator.
PROPEL(R.H.),Re.DRUM(2),Fr.DRUM(l)
PROPEL(L.H.),Re.DRUM(l),Fr.DRUM(2)
No.1 -----------------
COUNTERWEIGHT REMOVAL CYLINDER
I No.5j CONTROL j
No.6 AUXILIARY
3-1
.3.3 OIL FLOW FROM No.1 and No. 2 PUMPS
REAR DRUM FRONT DRUM
These are tandem mounted, variable capacity pumps.
The pressurized oil from the No. I pump flows through the 3-sectioned control valve PROPEL(R.H.) PROPEL(L.H.)
for the L. H. propel, rear drum (I st speed) and front drum (2nd speed) circuits, while
the oil from the No.2 pump flows through the 4-sectioned control R. H. propel,
OPTION, rear drum (2nd speed) and front drum (lst speed) circuits. In neutral, the
flow from each pump passes through its respective control valve and returns freely to I~ I~
the oil reservoir. COUNTER , - - - - - - - - - , COUNTER
BALANCE BALANCE
However, when one of the control valve spools is moved by oil pressure from its VALVE VALVE
remote control valve, then the oil flow from the pump is directed toward the targetted
actuator.
When the "Slow-Speed" switch in the operator's cab is used, this activates the
slow-speed solenoid on the pump's regulator which minimizes the discharge rate of
oil from that pump.
Pressurized oil in the No. I pump is fed to the counterweight removal/installation
cylinder (PCW) by switching the solenoid valve (A).
BACKWARD
FORWARD
SOLENOID
VALVE(A)
OIL COOLER
- RETURN FILTER
Oil Flow From No. 1 and No. 2 Pumps
3-2
3.4 OIL FLOW FROM No.3 AND No. 4 PUMPS
This is also a variable capacity pump. BOOM
The oil flow from the No.3 pump flows through the control valve for the swing system.
In neutral, the flow from No.3 pump passes through the control valve and return freely to the oil reservoir.
When tl;ie swing valve spool is moved by oil pressure directed from the swing remote control valve, the oil flow
from the No.3 pump powers the swing motor to rotate the crane's upper body. BOOM MOTOR
On the other hand, the pressurized oil from the No.4 pump flows into the boom control valve, and returns to the tank
with no load.
When the control valve spool is moved by the pressurized oil from the remote control valve, the main pressurized
oil is led to the boom motor to actuate the boom.
SWING
SWING SWING
MOTOR MOTOR
MAIN CONTROL VALVE
CONTROL
OIL COOLER
- RE11JRN FILTER
Oil Flow From No. 3 and No. 4 Pumps
3-3
3.5 OIL FLOW FROM No.5 PUMP
( Control Pump)
The pressurized oil discharged from this fixed capacity gear pump flows through a line filter, by an accumulator, and
as
through a relief valve that reduces line pressure to 55kg/cm2• The pressurized oil is now available to it flows toward the
5-section valve and to the 4-section valves.
When the Function Lock lever is in the "Shut Down" position, the solenoid valve (Sol 3) that is part of the 5-section valve
disallows delivery of oil to the main control valves. As there is no control pressure, the machine will not move even if the
its· control levers are operated.
When the Function Lock lever is in the "Operation'' position, however, then solenoid valve (Sol 3) allows pressurized oil
to be directed from the remote control valves to the main control valves. Thus operating the control levers will cause the
machine to move.
3-4
LUFFING REAR FRONT BOOM PROPEL PROPEL
SWING JIB DRUM DRUM DRUM DRUM (LH.) (R.H.)
SWING SWING FUNC-

FREE REAC- TION
BRAKE TION LOCK
To Fr.Drum motor regurator
BOOM LUFFING
Re.DRUM DRUM IlB DRUM Fr.DRUM
To Re.Drum motor regurator PARKING PARKING PARKING PARKING
BRAKE BRAKE BRAKE BRAKE
To solenoid valve for I

swing brake mode select w
SWING
ACCUMULATOR
AUX.ACTUATOR
UNEFILTER
REUEFVALVE
... ---------
N0.6
PUMP
Oil Flow From No. 5 Pump

(when the function lock lever is "lock" position)
3-5
LUFFING REAR FRONT BOOM PROPEL PROPEL
JIB DRUM DRUM DRUM DRUM (L.H.) (R.H.)
SWING SWING FUNC-

r FREE REAC- TION
BRAKE TION LOCK
I
To Fr.Drum motor regurator
BOOM LUFFING
Re.DRUM DRUM JIB DRUM Fr.DRUM
To Re.Drum motor regurator L - .... - PARKING PARKING PARKING PARKING
I BRAKE BRAKE BRAKE BRAKE
I
To solenoid valve for I
swing brake mode select
w
ACCUMULATOR
(AUX.ACTUATOR)
LINE FILTER
....--~.....------------~-----------<·"' ~---1-----..----------................______________.,.____________.....
RELIEF VALVE
r---------
N0.6
PUMP
Oil Flow From No. 5 Pump

(when the function lock lever is "work" position)
3-6
3.6 OIL FLOW FROM No.6 PUMP (Secondary Pump) BOOM FOOT PIN
REEVING WINCH
The No. 6 pump is fixed capacity gear pump. It is used to the mast cylinder, reeving winch, boom foot pin cylinder and
translifter.
MAST
The pressurized oil flow from pump No. 6 flows through the mast cylinder control valve. If the mast control valve and
hydraulic selector switch is in its neutral position, the oil flow returns freely to the reservoir.
Pressurized oil can be supplied to the reeving winch, boom foot pin, and translifter with the hydraulic selector switch (sol.
45).
Lo - - - ~
MAST
CONTROL VALVE
r------------
1
---------,
i.lJ SWIVEL JOINT
r-------------------
MAIN CONTROL VALVE
TRANSLIFTER
c::::::J
BOOM
CRAWLER REMOVAL DEVICE
CONTROL
TRANSLIFTER
-------------------------~
3-7
REEVING WINCH
BOOM FOOT PIN
MAST
~ - - - .J
MAST
CONTROL VALVE
LI.J SWIVEL JOINT
MAIN CONTROL VALVE
TRANSLIFTER
(BOOM)
CRAWLER REMOVAL DEVICE
FRONT
(L.H.)
I
L- - -
___I
TRANSLIFTER
Oil flow from N0.6 pump

(When the gantry control valve and hydraulic selector switch is shifted)
3-8
4. VALVES
4.1 5-SECTION VALVE
~ - - - - - - - RELIEFPRESSURESHIFT
PROPELSPEEDSELEC~ ~ SWINGREACTION
I 1L REMOTE CONTROL CUT
..--! - JIB DRUM LOCK

LO (Y)
0 0 0 0 0
CJ) CJ) CJ) CJ) CJ)
To Tank
From Accumulator
SOL-42
SOL-3
To Tank From Accumulator
5-Section Valve Hydraulic Schematic (Solenoid Valve Block)
4-1
4.2 4-SECTION VALVE
From Accumulator
Ai 81 C1 01
02
To Tank
From Accumulator
To Re.Drum Brake Master To Boom Drum Brake Master To Fr.Drum Brake Master
4-Section Valve Hydraulic Schematic (Solenoid Valve Block)
4-2
4.3 3-SECTION VALVE
To.Tank
p T
REEVING WINCH
811
I BOOM FOOT PIN(R.H.) .
A2 1
82
BOOM FOOT PIN(L.H.)
83 --------~
3-Section Valve Hydraulic Schematic (Control Valve)
4-3
KOBELCO
SHOP MANUAL CK2500
CKE2500
HOIST SYSTEM
TABLE OF CONTENTS
1. APPARATUS AND LOCATION OF COMPONENTS · · · · .. · · · · · · · · · · · · · · · · 1 - 1
2. CONSTRUCTION AND FUNCTION · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2 - 1
2.1 Hydraulic Schematic · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2 - 1
2.2 Lifting a Load · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2 - 2
2.3 Holding a Raised Load · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2 - 4
2.4 Lowering a Load (Powered Lowering) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2 - 6
3. ADJUSTMENT OF DRUM LOCK · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3 - 1
CK2500 JD-00001 ~
CKE2500

2nd. Edition 2002.08 S5JD1301E(D
1. APPARATUS AND LOCATION OF COMPONENTS
The hoist system consists of the front and rear drum assemblies.
Both of the drum assemblies consist of a hoist motor and reduction unit and drum lock.
The No. I and No.2 main pumps supply the pressurized oil, which is controlled by the control valves, to the respective
motors.
PUMP
POWER
DMDER
CONTROL VALVE
.----REAR DRUM LOCK KNOB ~ \

\
FRONT DRUM LOCK KNOB
I- I
2. CONSTRUCTION AND FUNCTION
2.1 HYDRAULIC
SCHEMATIC
-! To Gantry Cylinder
1 1Cfe I ~
]6[
)le I )jc
1-r -~r. ,. , ._ _ _
Fr.DRUM Re.DRUM
To swing I To boom!
To
Mast
RE*1ving winch
Boom foot pin cylinder
--·Translifter
--------, P51
~--, ' - - + - - - - - ! PI S
L:~~ ~
~
FIG. 2-1 HOIST SYSTEM HYDRAULIC SCHEMATIC 2-1

The front and rear drums are mechanically identical so the following explanation uses the front drum for illustration
purposes.
2.2 LIFTING A LOAD

Pressurized oil from the No.I and No.2 pumps flows through their respective main control valves to power the hoist
system.
While the function lock lever is in the "Operation" position, oil pressure from the control system pump flows past the
accumulator and through the 4-section valve and 5-section valve and the remote control valve.
In this status, since the release pressure is not provided for the negative brake of the motor, the brake of the motor shaft
remains actuated.
When the Hoist Control lever is operated in the "hoist load" direction, it directs control pressure oil through the remote
control valve and into the (Mg) and (Mu I) ports of the main control valve where it moves the spools.
At the same time, the control pressurized oil flows into the brake cylinder built in the winch motor, and the motor brake is
released via the valve block (4-series solenoid hydraulic selector valves).
As directed by the position of the spools, the main pump oil flowing into the control valve is sent to the lift side of the hoist
motor to drive the hoist drum and thereby hoist the load.
2-2
!j To Gantry Cylinder j
]6[
I To swing I ! To boom!
PC
To
Mast
Reeving winch
Boom foot pi,n cylinder
~ - - 1 - < '>-+--- Translifter
r---,
"--1--...-..IP/S
L __ ~ L'._j
FIG. 2-2 HYDRAULIC SCHEMATIC (HOISTING) 2-3

2.3 HOLDING A RAISED LOAD
With the Hoist Control lever back in its neutral position, the control pressure coming from the remote control valve is cut
allowing the spool in the main control valve spool to return to its neutral position.
When the spool returns to neutral, the pressurized oil to the motor is cut off and the motor stops.
Now, although the weight of the suspended load continues to pull on the drum, further rotation of the drum is prevented by
a motor counterbalance valve that disallows any motor rotation by blocking the return of oil to the reservoir.
At the same time, the control oil pressure in the motor brake cylinder is directed back to the reservoir and the motor brake
resets itself.
The load is now held in suspension by the combined effects of the motor counterbalance valve and the motor brake clutch.
2-4
_jTo Gantry Cylinder I

, 1Cfe
~
]6[
J L J
1-r
To swing J Tobooml
@
L..J
To
Mast
Reeving winch L.!..J
Boom foot pin cylinder
>-+---•Translifter
PSI
T!-T13
FIG. 2-3 HYDRAULIC SCHEMATIC (HOLDING) 2-5

2.4 LOWERING A LOAD (POWERED LOWERING)
Pressurized oil from the No. I and No.2 Pumps flows through the main control valves to power the hoist system.
When the function lock lever is in the "Operation" position, oil pressure from the control pump flows past the accumulator,
valve block and the remote control valve.
In this status, since the release pressure is not provided for the negative brake of the motor, the brake of the motor shaft
remains actuated.
When the Hoist Control lever is operated in the "lower load" direction, this control oil pressure is directed by the remote
control valve to flow through into ports (M!D and (MD 1) of the main control valve where it moves the spools.
At the same time, control pressure is also directed to the motor brake cylinders where it causes the motor brake to
disengage.
Now the main pump oil flowing into the control valve, as directed by the position of the spools, activates the hoist motor
to drive the drum and thereby lower the load. The counterbalance valve is opened by pilot pressure from the "running in"
side to allow the motor to rotate.
2-6
ITo Gantry. Cylinder

]6[
,--, ~
J
I
I
I I
I
I
I
I
L -1--ii:-,--r--
.----,-,·--~
-~I
I
L! __________ __J
I I
)( LU w ~ I
Jv ! Jv MU
To swing I To boom I
@
L..:..J
MPC
To
Mast
Reeving winch L'..J
------1---< >--1--_.Boom foot pin cylinder
Trauslifter
......_-+-1.._P /5
FIG. 2-4 HYDRAULIC SCHEMATIC (LOWERING) 2-7

3. ADJUSTMENT OF DRUM LOCK
A WARNING
Do not adjust the drum locks until the boom,
hook block, and load have been lowered to the
ground.
serious injury or loss of life. 0.87 inch
(22mm)
CD Pull the drum lock knob in the LOCK position and
check to see that the pawl is engaged in the bottom
of the drum ratchet.
If the pawl is not engaged in the bottom of the
ratchet, adjust the spring length to allow the pawl to
be engaged in the bottom.
® With the condition of step CD, adjust the respective
dimension as shown in the figure.
® Push the drum lock knob in the RELEASE position 2.48 inch 63mm 2.09 inch(53mm)
and check to see that the pawl is clear of the ratchet
by at least 0.87 inch (22mm). 4.96 inch
(126mm)
Operate the knob to the LOCK position and to the
RELEASE position and confirm that the pawl
Main/awr. winch drum lock
moves smoothly.
3-1
KOBELCO
SHOP MANUAL CK2500
CKE2500
- - - - B O O M HOIST SYSTEM----
TABLE OF CONTENTS
1. APPARATUS AND LOCATION OF COMPONENTS ·· ···················· 1- 1
2. CONSTRUCTION AND FUNCTION · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2 - 1
2.1 Hydraulic Schematic · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2- 1
2.2 Raising the Boom · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2 - 2
2.3 Neutral (Maintaining the Boom Position) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2 - 4
2.4 Lowering the Boom · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2 - 6
3. BOOM DRUM LOCK · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3- 1
3.1 Assembly Drawing · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3- 1
3.2 Adjusting the Boom Drum Lock · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3- 2
CK2500 JD-00001 ~
CKE2500
2nd. Edition 2000.05 S5JD1401ECD

The boom hoist system consists of the boom drum motor, a reduction unit, the boom drum itself and the drum lock
mechanism.
The pressurized oil for the boom hoist system is supplied by the No. I pump installed on the engine's power divider. From
this pump, the oil flows through the control valve to power the motor for the boom drum.
HYDRAULIC OIL TANK

PUMP
BOOM DRUM
BOOM DRUM MOTOR &

REDUCTION UNIT
BOOM DRUM
LOCK KNOB
( DRUMLOCK \
1-1
2. CONSTRUCTION AND FUNCTION
2.1 Hydraulic Schematic
I BOOMI I BOOMI
~ap
\"..Y1
PBB
L!J
To Swing
@iv MPC Jv To
Mast
Reeving winch
Boom foot pin
Trans lifter
P/5
T/S
,---i
I Tl~T13
L __ ~ L..'..J
Fig. 2-1 Hydraulic Schematic
2 -1
2.2 Raising the Boom
Pressurized hydraulic oil from the No.I pump flows continuously through the control valve.
While the Function lock lever is in the "Operation" position, pressurized oil is also flowing from the control pump, past the
accumulator and then through the valve block and the remote control valve.
Shifting the Boom Hoist control lever to "Raise" directs control system oil through the remote control valve and valve
block and into thednDport of the control valve. This pressure shifts the spool.
Control pressure is simultaneously applied to release the negative brake mechanisms.
This allows the oil pressure from the No.I pump to activate the boom hoist motor and drive the drum to raise the boom.
2-2
IBOOM!
L..'..J
To Control Valve [ To Swingl
To
Mast
winch
pin
I
I
I
I I
I I
@}) @)
L __ :__J L..'..J
~-~- - -------- I
1
1I --- II L T1"-'T13
, l_kas• __ __ - --
1
~-- -- --- -~~,:;:]- r=---~~- --- -__J Fig. 2-2 Raising the Boom
2-3
2.3 Neutral (Maintaining the Boom Position)
With the Boom Hoist control lever returned to its neutral position, the control pressure is cut off, and the oil flow from the
No.1 pump is again allowed to pass through the control valve and flow freely back to the oil reservoir.
At the same time, the oil pressure to the boom drum motor negative brake is also released back to the reservoir. Both
braking mechanisms then re-engage to hold the boom hoist drum in position.
2-4
I BOOM!
I BOOM!
I
l I
I I I
L: _~r--'..--=---lJ
I
-l
~J
I
I
I
I
__ ____,
f
I
@
To Control j To Swing!
To
Mast
Reeving winch
Boom foot pin
I
I
I
I I
I I
(QB) ~
L __ :_J L'.J
DR1"'DRB
-------~~--~~ Fig. 2-3 Neutral (Maintaining the Boom Position)
2-5
2.4 Lowering the Boom
Pressurized hydraulic oil from the No. I pump flows through the control valve while oil from the control pump oil flows
past the accumulator and into the valve block and the remote control valve. (The function Jock lever remains in the
"Operation" position.)
Shifting the Boom Hoist control lever to "Lower" directs control system oil through the remote control valve and through
the valve block and into the Cill2) port of the control valve to shift the spool.
At the same time, control pressure is applied to the boom drum motor negative brake to release.
Oil pressure from the No. I pump is applied to the lowering side of the boom hoist motor. This line pressure opens the
counterbalance valve and drives the boom hoist motor so that the boom drum lowers the boom.
2-6
I BOOMI
!BOOM!
To Control Valve
To
Mast
Reeving winch
Boom foot pin
Translifter
I
I.
I
I I
I I
@}) (DR2)
L __ ~ ~
L_
Fig. 2-4 Lowering the Boom
2-7
3. BOOM DRUM LOCK
3.1 Assembly Drawing
Tighteningtorque:29ft · lbs(39.2N · m)
Tightening torque: 16ft •lbs(21.6N · m)
Tightening torque:
16.6ft · lbs(22.6N · m)
( \
I
, Tightening torque: ,
~to 2.2ft· lbs(2.0 /90N ·m)
.,
Tightening torque:
25 to 36ft · lbs(34.3 to 49.0N · m)
• When the assembly is complete, fill grease until it is squeezed out from the clearances of the pawl.
3-1
3.2 Adjusting the Boom Drum Lock
A WARNING
Do not adjust the boom hoist drum locks until
the boom has been lowered to the ground.
CD Pull the drum lock knob in the LOCK position and

check to see that the pawl is engaged in the bottom
of the drum ratchet with the drum lock condition.
ratchet, adjust the spring dimension to allow the
pawl to be engaged in the bottom.
@ With the condition of step CD, adjust the respective
® Push the drum lock knob in the RELEASE position
by at least 26mm.
Operate the knob to the LOCK position and to the
RELEASE position and confirm that the pawl
moves smoothly.
A WARNING
Keep hands and clothing clear of the rotating
drum.
3-2
KOBELCO
SHOP MANUAL CK2500
CKE2500
SWING SYSTEM
TABLE OF CONTENTS
1. APPARATUS AND LOCATION OF COMPONENTS · · · · · · · · · · · · · .. · · · .. 1- 1
2. CONSTRUCTION AND FUNCTION · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2- 1
2. 1 Hydraulic Schematic · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2- 1
2. 2 Swing · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2- 2
2. 3 Stopping · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2- 5
3. SWING REDUCTION UNIT · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3- 1
4. SWING BEARING · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 4- I
5. SWING LOCK · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 5- 1
Model Applicable Machine 401 Note Model Applicable Machine Note
CK2500
CKE2500 JD-00001 ~
2nd. Edition 2002.08 S5JD150IE(D

The swing system consists of the swing motor which includes an internal brake, the swing control valve, the reduction unit,
the swing bearing ring, the swivel joint, the swing gear and the swing lock.
To swing the machine's upper body, pressurized oil from the swing pump mounted on the power divider is sent to the
swing motor by way of the control valve which is directly mounted on the swing motor.
HYDRAULIC OIL TANK

SWING PUMP
SWING
~~~~~~iC~O~N~TROLVALVE
REDUCTION UNIT
SWING BE.ARING
SWIVEL JOINT
Fig. 1-1 Main Component Locations
1-1
2. CONSTRUCTION AND
FUNCTION
I
2.1 Hydraulic Schematic r---

I SWING!
To Main Control Valve
~-------1 To Boom
To
Mast
I
I
Reeving winch
I I Boom foot pin
I I
I I Translifter
@}) @1)
~~~1
I I I
L..'..J
L __ :J L..'..J
L_ T1-vT13
Fig. 2-1 Swing Hydraulic Schematic
.2-1
2.2 Swing
The working principle of the rightward swing, identical to that of the leftward swing, is shown below. [The swing brake is
released (SPB SOL5 is actuated).]
The pressurized oil from the swing pump is led to the swing control valve. On the other hand, the control pressurized oil
from the control pump flows into the valve block, swing remote control valve, and brake mode select solenoid valve
(SOL43A, 43B) through the accumulator.
[The function lock lever is at the "working position" (SOL3 is actuated).]
1. Neutral free mode

When the swing mode selector switch on the side stand panel in the operator's cab is set to the "free" side, the control
pressurized oil flows through the solenoid valves (SOL 43A, 43B) to move the spool "B" of the swing control valve to
the full stroke.
In this status, when the swing control lever is swung down to the right swing side (forward), the control oil flows
through the remote control valve, and is led to the "bl 1" port of the control valve to move the spool "A".
The main pressurized oil controlled by the control valve is fed to the swing motor to run the motor.
2. Neutral brake mode

When the swing mode selector switch on the side stand panel in the operator's cab is set to the "brake" side, the solenoid
valves (SOL 43B) are actuated to connect the both pilot ports, the swing control valve spool "A" and "B".
In this status, when the swing control lever is swung down to the right swing side (forward), the control oil flows is led
to the "b 11" port of the remote control valve to move the spools "A" and "B" at the same time.
The main pressurized oil controlled by the control valve is fed to the swing motor to run the motor.
2-2
Brake Mode Select
Solenoid Valve I SWING!
(SOL43B)
Right
.
1.6-1.BkPa
{16.5-18.Skgf/cnl}
b 11 M~~M/.In\J.L.ubl
To Main Control Valve !

---------< To Boom
Swing Brake
(SOL5)
To
Mast
I
I
Reeving winch
I I
I
Boom foot pin
I
I I Translifter
~ (DR2)
L __ ~ ~
L_
Fig. 2-2 Swing (Neutral Free Mode)
2-3
Brake Mode Select
*------- Solenoid Valve I SWING!
(SOL43B)
Right
.
'
To Main Control Valve I

~-----< To Boom
L.'..J
Swing Brake
(SOL5)
Function Lock
To (SOL3)
Mast
I Reeving winch
I
I I Boom foot pin
I I
I I Translifter
(Qill (OR2)
L __ ~ L.'..J
L_
Fig. 2-3 Swing (Neutral Brake Mode)
2-4
2.3 Stopping
When the swing control lever is returned from the swing mode to the neutral mode, the control pressure from the remote
control valve is lost, and the control valve spool "A" returns to neutral. Thus, the main pressurized oil returns to the tank
with no load.
I. Neutral free mode

Although the pressurized oil flow to the swing motor is shut down, the returned oil circulates in the motor and valves,
since the spool "B" has been moved to. the full stroke by the pilot pressure. Thus, the motor continues rotating by
inertia. (The swing brake is released.)
To stop the swing motion, carefully swing down the swing control lever to the opposite side.
2. Neutral brake mode

The brake mode select solenoid valves (SOL 43A, 43B) are actuated, and the spool "B" returns to neutral.
The brake pressure is generated at the exit port of the swing motor by the oil returned from the swing motor passing the
restrictor section of the control valve spool "B".
The swing motor is decelerated by the brake pressure until the motor is stopped smoothly. (The swing brake is
released.)
However, remember that the motor will not be stopped completely when external forces are always applied, including
the operation on a slope or on windy days.
2-5
Brake Mode Select
Solenoid Valve
(SOL43B) I SWING!
To Main Control Valve I

~--------' To Boom
To
Mast
I Reeving winch
I
I I Boom foot pin
I I
I I Translifter
@]) @I)
L.'...J
L __ ~ L.'...J
L_ T1"-'T13
Fig. 2-4 Stop (Neutral Free Mode)
2-6
Brake Mode Select
Solenoid Valve
(SOL43B) I SWING!
_ _ _ ____, To Boom
To
Mast
I
I
Reeving winch
I I
I
Boom foot pin
I
I I Translifter
(Q[D (DR2)
L __ ~ ~
Fig. 2-5 Stop (Neutral Brake Mode)
2-7
3. SWING REDUCTION UNIT
36. 35
Apply coat
lO
,-I
Loctite#515
lO
'II:
...,
Cl)
.....
130 30
~
3
16
25
37
34
5 7
6
17
34
lO
,-I
lO
'II:
...,
Cl)
.....
13
0
~
~
0
t.)
~ 1
p.
~ 23
lO
,-I
lO
'II:
Cl) 13
...,
;1:l
t.)
0
~ 14
~
0
t.)
~
p.
~
40. 39. 38
42. 41
Shim adjust
0.002 to 0.006inch 0.05 to 0.15mm
Fig. 3-1 Swing Reduction Unit
3-1
I. Retainer 17. Pin 30. Plug
2. Housing 18. Pin 31. Plug
3, Housing 19. Bearing 32. Plug
4. Housing 20. Bearing 33. Snap ring
5. Spindle 21. Bearing 34. Thrust washer
6. Ring gear 22. Bearing 35. Shim (0.2)
7. Pinion 23. Caps crew 36. Shim (0.5)
8. Sun gear 24. Caps crew 37. Spring pin
10. Gear 25. Capscrew 38. Shim (0.05)
12. Pinion 26. Capscrew 39. Shim (0.1)
13. Pinion 27. Capscrew 40. Shim (0.2)
14. Plate 28. Oil seal 41. Shim (0.5)
16. Shaft 42. Shim (1.0)
Tightening Torque Table
Tightening Torque
Item Name of Part Size
ft·lbs (N·m)
23 Bolt M8Xl6 24.5 ft·lbs (33.3 N·m)
24 Bolt Ml6X45 206 ft·lbs (279 N·m)
25 Bolt M20X 120 412 ft·lbs (559 N·m)
26 Caps crew M20X130 412ft·lbs (559 N·m)
27 Capscrew Ml2X35 85 ft·lbs (115 N·m)
31 Plug PT3/8 33 ft· lbs (44N·m)
· Apply coat Loctite #242 to bolt and capscrew.

· Assembly weight: Approx. 882 lbs (400 kg)
3-2
4. SWING BEARING
SCREW HOLE FOR LIFTING(M30)
B
Inside circle zone
("S" Mark Position)
Outside circle zone

(Stop plug)
Tightening torque: 2058 ft· lbs (2.8 kN · m)

(Apply coat Loctite #242)
Tightening torque: 2058 ft· lbs (2.8 kN · m)

LOCK PIN
SECTION A-A SECTION B-B
Fig. 4-1 Swing Bearing
4-1
1. Method of bolt tightening
(I) Temporarily tighten two axisymmetrically bolts positioned in the lower frame with a tightening torque of I 08
ft·lbs (147 N·m).
(2) Temporarily tighten two bolts, which are positioned 90° apart from the bolts tightened in step (1), with a
tightening torque of 108 ft·lbs (147 N·m).
(3) Similarly, tighten all the bolts, in pairs of axisymmetrically located two, with a tightening torque of 108 ft· lbs
(147 N·m).
(4) Fully tighten all the bolts with a tightening torque of 1430 ft· lbs (1.9 kN ·m).
(5) After all the bolts are tighten to the car body, fully apply molybdenum disulfide grease to the gear tooth faces.
(6) Place the upper unit with the roll pins inserted in the front and rear sides fitting to the bearing.
(7) Tighten the four bolts which are located on the front both ends and rear both ends of the swing frame side with a
tightening torque of 108 ft· lbs (147 N · m).
(8) Tighten the bolts axisymetrically one after another with a tightening torque of 108 ft· lbs (147 N · m).
(9) Tighten all the bolts with a tightening torque of 1430 ft· lbs (1.9 kN · m).
(10) The soft zone of the bearing inner ring (S-marked area) against the lower unit must be positioned as shown in the
figure.
4-2
5. SWING LOCK
\
D
1
0
O')
i
......
1.0
i.q
,:,-:, RELEASE
LOCK
Fig. 5-1 SWING LOCK
5-1
KOBELCO
SHOP MANUAL CK2500
CKE2500
PROPEL SYSTEM
TABLE OF CONTENTS
1. LOCATION OF THE MAJOR COMPONENTS · ·· ·· ·· · · · · · · ··· ··· ··· ·· · ·· 1- 1
2. CONSTRUCTION AND FUNCTION · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2- 1
2.1 Hydraulic Schematic · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2- 1
2.2 Propelling (Left Side Forward)" · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2- 2
2.3 Stopping · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2- 4
3. PROPEL REDUCTION UNIT · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3- 1
3.1 Reduction Unit · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3- 2
3.2 Motor · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3- 4
4. ADJUSTMENT · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 4- 1
CK2500
CKE2500 JD-00001 ~
2nd. Edition 2000.05 S5JDl801ECD

1. LOCATION OF THE MAJOR COMPONENTS
The Propel system consists of the propel motors, the propel reduction units, the upper/lower rollers, the drive tumblers,
idlers and shoes.
Pressurized oil from the main pumps (No. l and No.2 installed on the power divider) is controlled through the main
control valve. This stream of pressurized oil flows through the swivel joint and then on to the left and right propel motors
to run their respective motors.
A spring set/hydraulic release disk brake is installed on each of the two propel motors (built-in type).
REDUCTION UNIT
UPPER ROLLER
IDLER
LOWER ROLLER
1-1
2
. CONSTR UCTIO~N~A~N-=-D_F_U_N_C_Tl==O==N==========================~
11lB
)le
1-r
I
I
l_J_
J To Swing ~- To Boom
MPC
To
Mast
Reeving winch
Boom foot pin
Trans lifter
-,
: _I_ L - --_]
i:c : : ;;:i i:c : : ;;:i
L__________________________ .
Fig. 2_1 Propel Hydraulic Schematic 2-1
2.2 Propelling (Left Side Forward)
Propeling the right and/or left sides and to the forward and reverse are basically the same operation.
We will use a rightside forward operation as the example here.
Pressurised oil from the No. l pump is directed into the control valve.
The oil from the control pump, however, goes through the accumulator and into the propelcircuit's remote control valve,
(The machine's function lock lever remains in the "Operation" position.)
When the propel control lever is shifted to "forward" the control oil runs through the remote control valve to the control
valve's (PRF) port to shift the spool on the propel section.
The pressurized oil directed by the control valve then goes through the swivel joint and run into the propel motor. At the
same time, this oil runs into the pilot of the brake valve and the brake cylinder.
The oil in this cylinder releases the brake, and the oil in the brake valve pilot moves the spool, so that the oil in the brake
cylinder releases the brake.
The pressurized oil that activated in the propel motor then is free to return to the reservoir.
2-2
, 1°Fe
)le
1-r
I
I
L!_
To Swing To Boom
I PROPEL!
MPC
To
Mast
Reeving winch
Boom foot pin
Translifter
L..'.J
T/5
PS1
L_ L __ :J L..'.J
Fig. 2-2 Propelling (Right side forward)

Hydraulic Schematic
2-3
2.3 Stopping
When the propel control lever is shifted back to neutral from propel, the flow from the remote control valve is cut and the
spool on the control valve repositions itself. At the same time, the pilot pressure on the propel brake valve is discontinued,
and the spool on the brake valve also repositions itself.
Inertia may continue momentarily to rotate the propel motor. This creates negative pressure on the supply side and high
pressure on the return side which engages the brake valve. Therefore, the supply side is connected to the reservoir
inneutral. If extreme pressure developes on the return side, an overflow relief valve will open to protect the circuit.
At the same time, the pressurized oil in the brake cylinder is returned to the reservoir, and the parking brake engages.
2-4
i 'Cf8
PIT
r 1
Tlu
,-,
- PIT
)le I
To Gantry
T ( --0
1-r -r
~-------1.---::+-1-L---J-+---4~---+--+-'II
L __d_j
-,!, tfI ~ I -=-~;J- • I
J,, J,, Ji,~ I
I
L __ _
To Swing To Boom
I PROPEL!
MPC
To
Mast
Reeving winch
Boom foot pin
Trans lifter
T/5
PS1
L __ ~ ~
Fig. 2-3 Stopping Hydraulic Schematic
2-5 .
3. PROPEL REDUCTION UNIT
Tightening torque:1921 ft· lbs(2.6kN ·m)
--7
--
I
I
/
/
Tightening torque:1921 ft· lbs(2.6kN ·m)
Tightening tor ue:318 ft· lbs(431N ·m)

d
II
LJ==::
II J Tightening torque:318 ft· lbs(431N · m)
I Assembly Weight:About 4410 lbs(2000kg) I
3-1
Apply coat Loctite #515 Apply coat Loctite #515 w
.........
JJ
CD
a.
c
g
0
:::,
c:::::,
;::::;:
Shim adjust
-0. 047 to O. 063inch
(-1. 2 to 1. 6mm)
....-------<!'
Shim adjust !
' fi
!i
ii !i I
!.>)
-0. 002 to O. Ob4inch
(-0. 06 to 0. l!nm) ~
.------j j
il
-rr--r
li i
52
~~E~=r~iiii--lH--
I
N
.I l I!
L---~I
!11I !I
i 1, -++---
I
i
I i
\L
I;!I !!
~/.;:,.7.7':;v.....,,,,..,.>-7-77~7-7:;~7~7~77.-l.:;--,-;,7,-.,7.-,-7-r./7.-,7'7:;,/T,;7'7'>.>>-
Apply coat Loctite #515
20
1. Cover 18. Shaft 35. Shim
2. Ring gear 19. Shaft 36. Shim
3. Ring gear 20. Pin 37. Shim
4. Housing 21. Keeper plate 38. Shim
5. Support 22. Keeper plate 39. Shim
6. Spider 23. Thrust Washer 40. Shim
7. Spider 24. Spacer 41. Snap ring
8. Spider assy 25. Thrust button 42. Snap ring
9. Sun gear 26. Spacer 43. Snap ring
10. Sun gear 27. Thrust washer 44. Thrust washer
11. Sun gear 28. Floating seal 45. Plug
12. Pinion 29. Bearing 46. Capscrew
15. Coupling 32. Bearing 49. Capscrew
16. Retainer 33. Shim 50. Capscrew
17. Retainer 34.·Shim 51. Capscrew
52. 0-Ring (G-250)
Tightening Torque
Item Name Size
ft·lbs (N·m)
45 Plug - 72 (98.1)
46 Capscrew M8X20 26 (35.3)
' 47 Capscrew M10X25 48 (65.7)
48 Capscrew M10X35 48 (65.7)
49 Capscrew M12X35 84 (114.8)
50 Caps crew M16X40 206 (279.6)
51 Capscrew M24X150 686 (932)
• Apply Coat Loctite #242 to capscrew
• Wrap a seal tape or apply coat loctite #242 to the plug.
I Assembly weight about 1170 lbs (530 kg) I
3-3
3.2 Motor
3-4
022. Spool sub 361. Washer 541. Sheet-2A
101. Shaft 362. Spring 542. Stopper
102. Bearing 364. Cover 543. Steel ball
103. Bearing 365. 0-Ring (G-45) 545. Taper bolt
107. Snap ring 366. Capscrew 546. Taper bolt
111. Cylinder 401. Capscrew 547. 0-Ring (P-IO)
113. Bushing 435. Snap ring 564. Plug
114. Spring 451. Pin 567. Plug
121. Piston 461. Plug 568. 0-Ring (P-11)
122. Shoe 462. Plug 569. Plug
123. Plate 464. Plug 570. 0-Ring (P-11)
131. Valve plate 472. 0-Ring (WG-47) 571. Plug
161. 0-Ring (G-30) 485. 0-Ring (P-18) 572. 0-Ring (P-14)
162. Back-up ring 491. Oil seal 702. Piston
201. Plate 502. Piston-B 703. Lock bolt
301. Casing-A 503. Shoe 704. Lock bolt
303. Casing-A 504. Steel ball 705. Spring
350. Relief valve 509. 0-Ring (P-16) 707. 0-Ring (WG-44)
351. Reduction valve 531. Spool 708. 0-Ring (WG-49)
352. Cover 533. Spring 741. Separator plate
742. Friction plate
Tightening Torque
Item Name Size
ft·lbs (N·m)
350 Relief valve M33 130 (180.0)
351 Reduction valve M20 33 (44.0)
366 Capscrew M12 72 (98.0)
401 Caps crew M20 318 (430.0)
461 Plug NPTF 1/16 6.5 (8.8)
462 Plug PT 1/8 7.2 (9.8)
464 Plug PF 1/2 79 (110.0)
545 Taper bolt NPTF 1/16 5.1 (6.9)
546 Taper bolt NPTF 1/16 5.1 (6.9)
564 Plug PT 1/4 16 (22.0)
567 Plug PF 1/4 27 (36.0)
569 Plug PF 1/4 27 (36.0)
571 Plug M22 101 (137.0)
703 Lock bolt M4 2.5 (3.4)
704 Lock bolt MS 5.1 (6.9)
3-5
4. ADJUSTMENT
If the crawler shoes are too tight, the shoes wear quickly
and a connection between two shoes could break. On
the other hand, if the shoes are too loose, the shoes may
ride off the drive sprocket and idler wheel during the
SHIM PACK(B) SHIM PACK(A)
travel operation. To prevent these occurrence from
happening, it is required to adjust shoe tension.
To adjust shoe tension, proceed as follows: 0
(1) Move the machine forward about the crawler

length so that the slackening of the crawler shoes
appear on the upper side of the crawler. 0
(2) Remove all the shims from shim pack (A) .

(3) Set the hydraulic jack in the position between the
bracket and block of the side frame.
Operate the jack to push the idler wheel, and
remove the slackening of the shoes.
(4) Insert the shims removed from pack (A) in step
(2) into the vacant room of pack (B) .
Insert the remaining shims into pack (A) .
(5) Remove the hydraulic jack. Store spare shims in
the shim pack (A).
NOTE
Equalize the tension in right and left crawler
tracks.
ADAPTER PORT POWER
4-1
Book code N;s J D 1 9o4E
KOBELCO
SHOP MANUAL CKE2500
ELECTRIC SYSTEM
(WITH LMI)
TABLE OF CONTENTS
I. ELECTRICAL WIRING SCHEMATIC ·· ·· · · ·· · ·· ··· ··· ······· ... · · ·· · .. ·· · 1 - 1
2. ARRANGEMENT OF ELECTRICAL PART ······························· 2 - 1
2.1 Electrical Part of Cab · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·· · · · · · · · · · · · · · · 2 - 1
2.2 Electrical Part of Right Deck · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2 - 3
2.3 Electrical Part of Floor Plate & Left Side Stand Panel · · · · · · · · · · · · · · · · · · · 2 - 6
2.4 Electrical Part of Revolving Frame · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2 - 10
2.5 Electrical Part of Left Deck · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2 - 12
3. ELECTRICAL PART ·· · · · ···· · · · · · · · · · · · · ·· · · · · · ··· ·· ·· · ·· ·· ·· · ·· ··· · · · ·· ·· · 3 - I
3.1 Fuse Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 1
3.2 Wiper Control Relay ................................................... 3 - 3
3.3 Swing Flasher Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 4
3.4 Stepping Motor (Governor Motor) ..................................... 3 - 5
3.5 Pressure Switch (Control Pressure Cut) .. ...... ............... ........ 3 - 6
3.6 Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 7
3.7 Pressure Switch (Boom, Propel, Swing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 8
3.8 Relay Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 9
3.8.1 Arrangement of Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 9
3.8.2 Relay Box Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - lO
3.9 Left Side Stand Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 11
3.10 Bypass Switch Panel 3 - 12
A CAUTION
1. Before unplugging or plugging in the connector, be sure to. shut off the power supply (set the starter
switch to the OFF position).
2. When unplugging the connector, hold it with both hands and draw it straight, while pressing down the
catch. DO NOT pull on the cable. Otherwise, the inner conductors can be damaged. NEVER twist
or pry the connector. Otherwise, its internal female terminal will be expanded, leading to
disconnection.
3. When plugging in the connector, fully insert it until the catch is engaged (clicks into position).
Otherwise, disconnection can occur later.
4. When performing a continuity test or voltage measurement on the connector, follow the procedure
below.
• Square connector
For easy measurement, place the measurement probes of the multitester onto the pins of male side
connector.
NEVER insert the probe of the multitester into the socket of the female side connector. Otherwise,
disconnection can occur later.
• Round waterproof connector
The male side connector has waterproof construction, and the measurement probe of the multitester
cannot touch its pins.
Therefore, place the measurement probes onto the terminals on the female side connector. NEVER
forcibly insert the measurement probe. Otherwise, disconnection can occur later.
Short-circuiting across terminals inside a connector can damage electronic components. Be
absolutely careful to prevent short-circuit.
CKE2500 JD02-00027 ~
lst. Edition 2002. 10 S5JD1904E

TOP. 4 TOTAL CONTROLLER
KEY SWITCH
•
HEATER RELAY
HEAT
OFF
AIR HEATER
STARTER RELAY
m
ACC
r
ON
START m
0
ST ARTER MOTOR -I
:IJ
BATTERY RELAY
ALTERNATOR DETECT RELAY (1) -0
)>
AL TERNA TOR r
R-1
-JJ~
BATTERY
-z
TO STARTER RELAY G)
TOP. 7 E/G CONTROL UNIT (J)
0
I
m
PROPEL SPEED SELECT
SW-B
INCHING SPEED SELECT
231 O. 7A
PROPEL SPEED SELECT
(ON FOR HIGH SPEED}
s::
-02:i
SW-9 TOP. 4 TOTAL CONTROLLER
232 O. BA FRONT. REAR I NCH I NG
SOL-I SPEED CONTROL
z R-19 FROM P. 6 COUNTER WEIGHT
(ON FOR I NCH I NG SPEED}
0 SELF REMOVAL DEVICE
N - -l
m ----cR- I lo--(1)------------"2"'-46"'--------+-IR-I0'-+-----4
PUMP CONTROL RELEASE
0 -l -l ..
::::, ::::,- ::::,-
- CD -·
'< CJ) TO P. 4 TOTAL
CONTROLLER
..... ::::, a.
0 CJ) -,
-·
..... a. ::;; "'
::::,- CD -·
-
CD ::::,
0 <O TOP. 4 TOTAL CONTROLLER
m-
(/) c
~
..... CJ)
m
CJ)
"O
CD
::::,-
CD
-
0
-
1-j n CT" -,
,-..,. -· -,
-o r+
__,
\0 -·
n
;,<""
CD
::::,-
CD
Q) ::::,
..... - r
:s:
0 ::::, -
::::, Cl)
CJ)
-· ::::, HYDRAULIC SELECT TRANSLIFTER SELECT

CJ) CJ) SW-52 244 O. BA
SOL-44 (TRANSLIFTER OPERATION
Q)
AT ENERGIZED}
"O "'- 245 O. BA REEVING WINCH SELECT (OPT.)
"O -
- Q) (REEVING WINCH AT ENERGIZED)
n -·
Q) 0
CT" ::::,
CD 3
0
a. SWING NEUTRAL FREE PILOT LAMP
CD
R-32 233 RELIEF PRESSURE SHIFT
0 (HI. PRESSURE AT ENERGIZED)
0
;,;: SWING MOOE SELECT 0-BA
J
N SW- I O-(i) SOL-43A
Ul 0 SW I NG BRAKE MODE SELECT
0 238 o. BA (NEUTRAL BR AKE AT EN ERG I ZED}
'*"s.:co:...:L"'-4'--3~9-
?
~ SW I NG PARK I NG
-----0 234
0 _.l£,l;il..._.C.....---_,,...- SW- I I
o---=23=5~------+' O. 7A
SOL-5 SWING PARKING BRAKE
(ON FOR RELEASE}
O. 7A
SOL-3 FUNCTION LOCK
JIB ORUM LOCK
(ON FOR LOCK}
SW-63
256 O. 7A
JIB DRUM LOCK
(ON FOR UNLOCK)
f--~~~~~4 CONTROL PRESSURE DETECT
'-----<6 TO P. 6 TRANSL I FTER CONTROL BOX
52 12 2 3 II
TO SHEET 2/9 TO SHEET 2/9

.......
I TO SHEET 1/9 TO SHEET 1/9
N
52 12 IT [I [iJ F-7 +lOV

_,~ ~ 161 "
I 2 1s2 / \ 1..r"i.
CN- i V p---------1=5=13---t-+-il~
1 1 "". BOOM
F-20 l3Q] I I - ~ ')I~/ LOAD CELL

.___.~'1'\l'---k::'.:.J....J-:; )cN- 1 1 I l
1 4
15891 ,. .
F-8 lisl 2
1
" 590 / \,I -~7-.
LJH?J/Al-...1.!...2l.-+-<j--,I j 11
4
59 1 I~ - -"". J IB
I I 60-------=iEslEs~-~') I~/ LOAD CELL
,_ m " )
==- - -I1- 1I- 1 -
I CNJ'l 14 -~p--------=183
18 2
t--~·~-;-,r-p-----,---~~E~sl~-~,r-t
BDOM
ANGLE SENSOR
1 I a1>------=rm=-1____,
1
)
I CN-1 /(p------~===---r-,, -
3
192
J Is
~ ~ \' ANGLE SENSOR
dn l>D--------~~--~
m
1C>-i-<l ,...,1------~----~ CHANGE
(.o-.t.___..__..~~-----___. (OFF
Ls-34 HOOK OVERHO I ST L/S (JIB MA IN)
FOR OVERHO I ST)
- - - - - - - - - - - - + - < , R -41 ,-...-.---·~m,0=2"-<J>-;11.---'>;-=Ls'---=-2_ _ _ _ _ _ _ HOOK OVERHO I ST L/S (MA IN)
li"97I - '---' ( OFF F0£1 OVERHO I ST)
2P-t-+-------~~------t--,
R- liosl Ls-3 HOOK OVERHO I ST L/S (AUX.)
----------+-<, 4t!r-t,-,--~"----9(.-"""'~.__.,-=-~------. (OFF FOR OVERHOIST)
CHANGE
-o-,,-L....9'f'-L=-s--=3-=-s..,_,ir,.i...,_13,.__,._L....9_'f'-L=-s--=3-=-s--, HOOK OVERHOIST L/S (JIB AUX.)
fiTol '-------I R:.!?_{D L - - J (OFF FOR OVERHO I ST)
41>-lf-+--------ITTi\1~11~9,___ _ _ _ _ _ _ _ _-o-R-SO
Jl 1i9iiJ LS-7
5~:-t:-------~~---------Ip-;9-10;-=~-------. CRANE BOOM OVERHO I ST L/S
l .._l_ _ _ _ _ _ _ _ _-+-l R_
[jgg1
7 1 > - t + - - - - - - ~ ~ - 1 > 1 - - - - - - - - 1-.~..__."'R=---'
1
1 36
,,.....___lioiil~1o~a,__,_--o~R-1a-<D
- ' - _ ® - - - - - - - + LUFF I NG JIB OVERHO I ST L/S

18 (OFF FOR OVERHOIST)
LS 8
(OFF FOR OVERHOIST)
fi09I l R:±E._-(l)
o----------
LMI -----------HIR-371--.--_,.._,10._,.9.___--0
-----------H·R-3BIJ-+----"-fisil1.._s1"----<J,__,~-lt-'R'--..:.;1B,_--=®'--------+
2 00 1 9
CN-15 61>-1c+--------=121i1i1 = ~ - - - - - - - --.,~.__.,,,L=s....,-' - - - - - - - - . LUFFING BOOM OVERHOIST L/S
l1'------------+-<•·-51 SW-13
gb-r.:---------~rfiiiil1~soa__~·o1----.__JIITiil~11L.><L__-o-'"""
~
ITTII s w_ 14
o--~~-
t
ANT I TWO BLOCK RELEASE
BOOM OVERHO I ST
(OFF FOR OVERHOIST)
J
1 Ol:>-+---------------'-'-''-'L-----D"" t RELEASE
l 1b--<C.J_ _ _ _ _ _ _ _ _ _ _ _ _ _~fi""i",11.!..'14!1..-_s:..:w:..._-.:...I50--- t LM I RE LEASE
l l
1 '.'J:>-+---------------'ffii41"--'19a.:,4...._s_w-_3_o_-®o-'""
o--~~----
BOOM FI x
o-----
I
r-0-- J
--l+-J'b--+-------------"-r,,,i1_,_,12...__ _ _ _..-iR-45,....__
J UM PER
___,fi"'isl""'11""3co o-----. SET UP MODE
(ON FOR SETTING UP)
+-- -0-0-- -1r.P-t------------~1is211s~2,__,_ _ _ _ _ _ _ _ _ _ _ _+1~; ~
~
16 LUFFING MODE
(ON FOR LUFF I NG)
I R-51
TO P. 4
TOTAL CONTROLLER
1
! -_ ~-- ~ - ITT5PJ
-+t-i>-+-~ITssl-=6=5--+-R--<>-4 lc-(j)
- R-co,-0)
- "" •c,_o_-OJ
c
""
-
,.a,,"J>
o
ffi';""J> 3 ""'1
~ MAIN HOIST STOP
L
I
-0 0-- --,,h<-<l
l 6~7 --oR-
~......+-~liT71-=
4
: [ffiJ 0--
R-36-0)
ff«! -
R-38-0>
fi"54I
l ~~;J ~)'
R-
18
-® ITT11
TO P. 4
I@}- BOOM
R-16
AUX. HOIST STOP
RA I s E s T Op
~
I CN- 1 6 SW-30-(j) r<t9>, TOTAL
CONTROLLER
I ~~1= Iel- BOOM LOWER STOP
r -0--
1
_ m
_)_TO_P_...4.... ,R-4
l-<J)>-1
- - H > - + - - - - - - ~ - = = - - - - - - R - 0 - 3 7 0 - - 0 ) - ~ ~ - - -..
,,...
m
:J I@L
JIB RAISE STOP
I Ir<iJ>
1
TOTAL
CONTROLLER
' - - - - - - - - - - - - - - - 4 - ~ ~ R - ~ 4 JIB LOWER STOP

I
r-0--
---- --0-0--
-H-'i1>-+---------~l12711~2~7'------------H-Q9 O. 5A
-IH>l>--l---------~112611~2~6'------------H-Q:9 O. 5A
OVER LOAD ALARM LAMP
(GREEN)
L -c-o-- -tH.P--t---------~112511~2~5~-----------tt-Q:9 O. 5A
(YELLOW)
- (RED) (OPT. )
'---'
LS-38
R-45-0)
LS-98 liss1 0, BA
1 SOL-9 BOOM RAISE STOP
0
0, BA
SOL-10 MAIN HOIST STOP
O. BA
SOL-11 AUX. HOIST STOP
. _ - - - - - - - - - - - - - - - - - - - , I T I I I J 1 - - - - - . H O U R METER
TO P. 4
TOTAL CONTROLLER fE1
C N - 1 1 ( 3 P - - - - - - - - - - - - - - - - ~ E . . . __ _ _ _ _ _ _ _ _~BATTERY EARTH
s2 12 IT IIJ '------~~ [

TO SHEET 2/9
TO SHEET 2/9
FROM
P. 6 F-1 7
:)cN-100
ENGINE SPEED -1
SENSOR 3 !)cN-101
0 BOOM RAISE CONTROL
Fr.DRUM MOTOR SPEED
-1
VARIABLE TRIMMER )>
I
Re. DRUM MOTOR SPEED
VARIABLE TRIMMER BOOM LOWER CONTROL
0
BOOM MOTOR SPEED CN-104 0
VARIABLE TRIMMER
z
JIB MOTOR SPEED 10 -1 Fr. DRUM HO I ST CONTROL
VARI ABLE TRIMMER 11 ::;:o
(OPT.) 12
0
I
I Fr. DRUM LOWER CONTROL
rn
::;:o
HAND ,.........,,
THROTTLE 17 Re. DRUM HO I ST CONTROL
1B -1
10
FOOT
THROTTLE (OPT. l
16
17
18
""'
0
11 393
Re. DRUM LOWER CONTROL
12
1sCN-104
CN-101 JIB DRUM HOIST CONTROL

14
O. 7SA
SOL-72 SWING CONSTANT SPEED
SWING PUMP O. 7A
PRESSURE SENSOR PT-l
SOL-SO MAIN PUMP
POWER CONTROL
CN-105
Fr. DRUM HOISTING PT-3 1--~~~-';:~c--~~-d10 r.t>.J"-"-'"-~~~--<~,.:..:,0.7A
PRESSURE SENSOR 1--~.......-~---~'--~~---q23 SOL-70 BOOM PUMP
1--~~~~~f--~~---<l16 POWER CONTROL
Fr. DRUM LOWER ING PT- 4 l--~-4-~-"'-"-"''--~~-d17
PRESSURE SENSOR
Re. DRUM HOISTING PT-S

PRESSURE SENSOR
21
Re. DRUM LOWERING PT-B
PRESSURE SENSOR
7b-'""-'.__~~~--<A.....:..:.O· 7A
SOL-SI SWING REACTION
29
30
CN - 10 8[1!211>-""""---t-t-+::.
1311>-'~"---',-I--.P 3A STEPP I NG MOTOR
3 p--""''---...J
CN- 10 3(1 s;p--..J.<.eC!!L..--f--< <>-+---

STARTING POINT LS
LS-13
TO P. 4/9
22
TO SHEET 4/8 TO SHEET 4/9 TO SHEET 4/9

TO SHEET 3/9
22 FROM P. 3/9
I - - -- - - I-DRUM SW-56-<i) - - ,
I •-•••• FRONT
=05
j 1s)cN-110
1 WINCH SELECT ,.,sw-ss osl
I I
l•DRUH
L ______
14
CN-106
;·DRUM~=--_J 15
TO P. 1
BATTERY RELAY
FREE HIGH 380 ,..~~'-'--L-"-~'-'-~... F r. DRUM MOTOR
SWING BRAKE t----o-- SW- 1 0 -{z) 5 2
MODE SELECT 302 CONTROL
BRAKE
CN-109
Fr. DRUM s~-L~~3 Re. DRUM MOTOR
TURN SELECT (OPT.)
OFF SW-33 13
CN-106 -I CONTROL
OFF 0
Re. DRUM ~o=•-s_w_-3_4_ _ _~"---~
14 A-~:..:.L...::~.:.:.~_.3rd. DRUM MOTOR
TURN SELECT (OPT.) -I 5 4
CONTROL (OPT. l
)>
4 TO P. PUMP CONTROL RELEASE
~RUM - OVER PAY -OUT
,PREVENTIVE ~-----,L...0;,..,._,,-"-'-----''-"-'L..Lc r- 9
R-19 (RELEASE +24V)
l~~~P,~UM OVER PAY OUT 9

A-°:..:....::L_.:.:.A_.BOOM INCHING SPEED
~ E N T I VE ~---.,....,.-=--=~-----""'-"'-+a 0 5 0 5
- --- - - ---
0
z
KEY-SW CON) FROM P.
-I ,..~~'-'--L-"-~'-'-\--4
5 4 Fr. DRUM NEGATIVE BRAKE I
SIGNAL (ON:+24V) SW-I ::::0
0
SWING CONTROL SIGNAL TO P. 5
(CONTROL:GNDl R-12 i)cN-110 r-
INCHING SPEED SELECT SIGNAL FROM P. 1 11 239
r-
(NORMAL: +24Vl SW-9 9)CN-106 m
M/L REDUNDANCY SIGNAL FROM ::::0
(ON:+24V) BOOM DRUM LOCK ALARM
R-25
IOJ ...---...
GENERATION OF ELECTRICITY FROM P. 2
(ON•+24Vl R-1 12CN-102 -I
ENGINE PREHEAT
(ON:+24Vl
FROM
SW-1 10cN-106
""'
0
...___,.
CN-105
:]'"-110 14
24
BOOM RAISE SIGNAL FROM P. 1 26 s~L~~ 5 Fr. DRUM MOTOR BOOST

(RAISE:+24V) SW-9
BOOM LOWER SIGNAL FROM P. 1 12
(LOWER=+24Vl PSW-10 A-~:. :.·L. .: ~.:.:.~.... Re. DRUM MOTOR BOOST
5 6
BOOM RAISE STOP
(NORMAL'+24Vl
FROM P. 2
R-18
CN-108 ~'22
BOOM LOWER STOP FROM P. 2
(NORMAL: +24V) R-18
t>-="-~---..ru-"'-_ __,, ' ~ -~"'--L-'-~::.:..0_. F r · DRUM TURN SENSOR GR I P
FROM P. 2 CN-102 5
Re.DRUM HOIST STOP (OPT.)
(NORMAL: +24 V) R-38
JIB RAISE STOP FROM P. 2 5 ~:..:.L-'~"":._.

.,,--- 1 Re. DRUM TURN SENSOR GRIP
R-37 CN-109 (OPT.)
(NORMAL.' +24V)
JIB RAISE SIGNAL FROM P. 1
(RAISE:+24V) PSW-12
Fr. DRUM HOIST STOP

(NORMAL: +24 V)
FROM P. 1
PSW-10 S~L~:9 JIB DRUM NEGATIVE BRAKE I
JIB LOWER STOP FROM P. 2
R-42
--- - - --- - - --- - -
(NORMAL:+24V)
JIB LOWER SIGNAL FROM P. 1
(LOWER:+24Vl PSW-13
21
20
1cN-108
20
17 CN-107 SERIAL.COMMUNICATE
(RECEPTION)
E/G OIL PRESSURE
TO P. 6 GAUGE SERIAL COMMUNICATE
E/G O I L F I LT ER .----o o-"""-'-"-~'-"--_,.,
CLUSTER (TRANSM I Tl
RECEPTION GND
AIR CLEANER
COOL I NG WATER TEMP.
RADIATOR WATER LEVEL t----,o.....,.."'--""'-"""""-~
i
HYD. OIL TANK OIL TEMP • .----o CN-111 [ P/C I
CONTROL PRIMARY PRESSURE~----'-"'---''-""'--~ _J
ADJUSTING CONNECTOR
STEPP I NG MOTOR I NCH I NG
Fr. DRUM TURN SENSOR
Re. DRUM TURN SENSOR

TO SHEET 4/9
TO SHEET 4/9 WIPER
SWITCH
ID [I1 IT [iJ
If I 2
' 4
WI PER (FRONT UPPER) w ~H.
.E.::._9_
liol
s~ !soil
INT >--K
"fu 34 .11 16021 l!1NTERMl161

OFF
ON
i. UN IT w
s lii1i4I r;-tl WIPER
[ffi LW~ .3/1 SA (Fr.UPPER)
WASHER@o SA L 'o
MOTOR - • IB03i I
WIPERIFRONT LOWER)
SW- 8
lii06I
,3 .'J 16071
~
I! I NTERM I 16[
I ls09I
(§]]
WASHER® O SA
- 3
UN IT
5
LW~
L
~" I R
3/1 SA
WIPER
(Fr. LOWER)
MOTOR • lsoa1 I
WI PER !TOPI
SW- 9
IITTI
- ,3
~
.'J 16121 ! INTERMI 16f
WI.PER
UNIT ·1
3 s fsi4l ~r-.'I (TOP)
IITs LW~ 3/1 SA
WASHER®o SA L R
MOTOR • IIT3I I
'6"61
662
663 -u )>
-10
'2ol 664 )>"
215A 6 651 zo
FROM HEAD LIGHT SW-21 lsTTI 6661 m
4 ,0
)> 6671
0
"-
0
668
669 z
670 -I
671
;:o
c 6 721 0
ls3' z
FROM P. 1 SW-1 5
-
6 7 31
6741 '
-l
Im liffsl Q COMPRESSOR
~
PRESSURE SI\Y
F-11
AIR CONDITIONER
'2il 0. 4 7A
to A
ONE-WAY CALL (OPT.)
FROM SWING ALARM
M~
m SELECT SW-23
1644
11
<O>
SWING BUZZER
15231
82
SPEAKER_ ii
{ lffil (+)
17391(-1 .l. .l.
(+)lffil
A1737 If
1SPEAKER
© © I -
+24V ANTENNA
+24V
RADIO
(BATTERY)
ONO
I. SA
I
ROOM LIGHT
SW-20
-1@°' 4A ON
.DOOR ffi =LS-14
HEAD LIGHT OPERATORS
SW-21 OOFF ROOM LIGHT
- , m 2. SA
FROM P. 4
TOTAL C O N T ~
4 TO A/C UNIT
2, SA
HEAD LIGHT
l 111
-® o·. 2A
SPOT LIGHT
R-fl,
- IITil H ALARM HORN
HORN
lsTII - L SW-24
ci 1241
REAR WORK LIGHT
SW-22
m
'-~
L..+il-
~ 0,2A
JOA -
- IX O. 2A REAR WORK LIGHT
~ O. 2A
(RIGHTl
SWING ALARM TO SWING BUZZER IX O. 2A REAR WORK LIGHT
SELECT
~ (LEFT)·
SW-23
<O> SWING FLASHER UNIT
15221 I;°]'> 61
~I m
rn
l2"~71
I
TO P. 4 lrnl m
TOTAL CONTROLLER 5
rn I ~ :::: SWING FLASHER
I R-12-®
~ (RIGHT)
L[Ri:J O. 2A
'<.>'
O. 2A SWING FLASHER
~ (LEFTl
F-15
l2sl 3A
,/
LIGHTER
10A
~
0
w
N
0
0
v-v:v,I
., M
FUEL PUMP
(OPT.)
0
,-......
w o-0 FAN
(OPT. )
'"'C
,-......
IT [

......
I TO SHEET 5/9 TO SHEET 5/9
0\
[I [ SERIAL COMMUNICATE
/
8 l303i < (TRANSMIT)
~TOP.3
REDUNDANCY SELECT l30<il FROM
I 41 P. 4 TOTAL SERIAL COMMUNICATE
20A SW-27, 28, 29, 38 . CONTROLLER (RECEPTION)
5 '3o1l ,j 1
RECEPTION GND
HZJ ffijJ sJcN-21 CN-21

IOA
2
ffog1
ITTol
-
'"-=
.,.
COOLING WATER TEMP SENSOR
3 r FUEL LEVEL SENSOR
GAUGE CLUSTER ,1 fel

BATTERY EARTH
REAR WORK CAMERA (OPT.)

HZ1
5A
ITT! sJcN-276 +12V
D
+9V
VIDEO
VIDEO GND
GNO
0. 3A
LCD MON I TOR (OPT.) BOOM DRUM CAMERA (OPT.)
+12V +12v
D D
VIDEO +9V
VIDEO GND VIDEO
GNO VIDEO GND
GND
I. 1A O. 3A
F-18 FRONT&REAR CAMERA (OPT. l
Kfu! +12V
D
+9V
VIDEO
SELECT S/W (OPT. ) VIDEO GND
GNO
12V/9V O. 3A
SPEAR (OPT.)
~
F-19
6 6 REGULATOR +12V
D
+9V
+SELECTER UNI T VIDEO
VIDEO GND
(OPT. ) GND
0. 3A
CN-276(4
TRANSLIFTER CONTROL BOX

POWER SW EXT.
FROM P. 1 F-6 laool
6
li6l } SOL-80 VERTICAL EXT. CF r. R. H)
t liioii1
VERTICAL RET. CF r. R. H)
RET. SOL-86
EXT. laoil
VERTICAL EXT. (Re. R. H)
- }
t '8071
SOL-81
~SOL-87 VERTICAL RE T. CR e. R. H)
RET.
EXT.
-~ l802I
SOL-82 CRAWLER FIXING PIN (Re. EXT. )
-
t liio1il
CRAWLER FIXING PIN(Re.RET.)
RET. ~SOL-88
EXT. la031
- ~ SOL-83 CRAWLER FIXING PIN (Fr. EXT. )
-t ls09l
CRAWLER FIXING PIN (Fr. RET. )
RET. SOL-89
EXT. lao41
VERTICAL EXT. (Re.L.Hl
~ SOL-84
-t lsTol
SOL-90 VERT I CAL RET. (Re. L. H)
RET.
EXT. liios1 VERTICAL EXT. (Fr.L.H)
~ SOL-85
-t liiTil
SOL-91 VERT I CAL RET. (Fr. L. Hl
RET.
~
"-"'
COUNTERWEIGHT
SELF REMOVAL DEVICE
POWER SW SW- I 2A_ R. H. UP .
~~
R-49 fisAI -
l25'i1 - ~
12511 ~-4~
- - lzsTAI -SOL-65 R. H CYLINDER EXT .
(ON FOR EXT. )
t '2521 R. H CYLINDER RET.
SOL-66
R. H. DOWN (ON FOR RET.)
L. H. UP R-48
SW-128_ 12531 ::--:: l253A1
- ~ SOL-67 L. H CYLINDER EXT.
(ON FOR EXT.)
-
t 12541 L. H CYLINDER RET.
L. H. DOWN SOL-68
(ON FOR RET.)
12581 COUNTERWEIGHT
SOL-70
REMOVAL SELECT
12321 ~
TO P. 1 SOL-I
MAST CONTOROL
SW-62
RAISE
12361 MAST RAISE
} SOL-26
(ON FOR MAST RAISING)
LOWER t '23"il MAST LOWER
SOL-27
(ON FOR MAST LOWER I NG)
[1
TO SHEE.T 7/9 [
TO SHEET 7/9
2
E
E/G CONTROL UNIT

FROM P. 1
F-3 (ST SI GNAU
MEMORY CLR bb 908

CONNECTOR .------<> o----~~......_--02 6
TIMING
DIAG LAMP SENSOR
DI AG LAMP 2 ~----1
(+) 15P---'~9~14~-------,
N-TDC SENSOR . TCV ADV

( _) 2 P---'~9~15 ~ - - - - - - - '
(+) 16P---'~9~16~-------,
TCV RTD
RACK SENSOR ( _) 3 P---'~9~17 ~ - - - - - - - - '
D I AG CON NECTOR .----------on 90 9

o - - - ~~ ~--<12 9 POWER GND 4ao-~-~
WATER T EM P -------'}111v--~~~- 5 POWER GND 4 7 P---'-E......____._ _ _ _ _ __.,

SENSOR
~-~90~7~--<13 2 CASE GND 460---~
E
~
I
.....J
SWITCH SWITCH RELAY
SW-NO. LINE NO. USE PART NO. SW-NO. LI NE NO. USE PART NO. COIL TERMINAL
R NO. PART NO.
SW- 1 ll.!J- -lli..lJ ENG. KEY E250S00016Pl SW-52 ~HYDRAULIC 7921657 LINE NO. LINE NO. TYPE USE
-!§] SWITCH Lill
SELECT
R-11 ~ [i]---fil N. 0. PUMP CONTROL JJ 24E00007F 1
-ffi]
SW-55 J J 50500004 D1
--i54I
SW- B (i]----ill ~~?~~~ 247922872
SW- 9 ~ INCHING
SPEE[
(GG50M01032Fll
SW-56 JJ50S00005P1 R-12 rn-ill m-@ N. O. SWING ALARM
SPEED
SELECT
SW-57 24792349
l1..§J--iill SWING BRAKE
~
SW-1 Q GN50S00002Pl BOOM RAISE
~MODE
R-16 rn--ill N. 0.
STOP
~
BOOM LOWER
R-17 [ill-till N. O.
STOP
234H235 ~~~~~"'"
~
(GB20E00001 F2)
SW-11
SW-12A ~ GANTRY JJ50E00008Fl
R-18 ~ N. O. ATT. SELECT
l.f252
CONT RO L m---@ N. C. ATT. SELECT
SW-126 ~ G A N T R Y
~ CONTROL
JJ50E00008Fl
~ N. C. ATT. SELECT
SW-62 JJ50E00008FI
SW-13 11 0-E, ~~~!. '!~, «« GB50S00040P I rn--D.Til N. C. ATT. SELECT
SW-14 ~~~~/~~\ ... GB50S00040Pl
~
1 l 2f--Ec N. C. ATT. SELECT
SW-63 FY50S00007Fl
SW-15 114-Ec ML RELEASE GB50S00040Pl
SW-17 R-19 ~ [i]--jillJ N. C. PUMP CONTROL
[j]]-ffi ~ CONTROL PRESSURE

R-21 N. C. DETECT
LIMIT SWITCH HO I ST STOP
SW-18 ~WIPER E250S00015Pl LS-NO. TYPE LINE NO. USE PART NO.
R-23 ~ m-lill N. O. (MAIN/AUX.)
FUSE
~ (Fr. LOWER) PRESS.
LS- 1 N. O. ~ LOCK
FUNCTION GB50S00036FI R-32 ~ [i]--ill N. C. RELIEF SHIFT F-NO. RATED LINE NO. USE PART NO.
SW-19 E250S00015PI
LS- 2 N. C. [ill]----ill HOOK OVER HOIS
IMAIN HOIST> 24100N6192F3 R-36 @:Q}----lilll ~ N. O.
BOOM OVER
HOIST
F- 1 20A [D-[II ELECTRIC
lornuCD ~OIIDCf 24100R215S2
HOOK OVER HOIS
LS- 3 N. C. ~ IAUX. HO I ST) 24100N6192F3
~ N. O.
BOOM OVER
HOIST
f.,. 2 SA [j]-fil] BACK-UP 241 OOR215S4
CRANE BOOM
LS- 7 N. C. m--[J OVER HOIST GK50S00001PI BOOM OVER F- 3 SA rn]---[j] E/G START 24100R215S4
SW-20 llJJ--,~ OPERATORS
Lso 2 ROOM
2456R315 LS- 8 N. C. rn------fil J18 OVER HOIST JJ50SOOOOIOI fil--fil N. C.
HOIST F- 4 SA lfil---{j]J CAMERAIOPT. I 24100R215S4
~w
~ LIGHT !LUFFING JIB)
LUFF I NG JIB
LS- 9A N. C. lIT1H] LUFF I NG BOOM
JJ50S0000101 R-37 [Q]--ill ILl]-ill N, D.
OVER HOIST F- 5 JOA 121---u] TRAN SL I FTER 24100R215S3
SW-21 OVER HOIST
HEAD LIGHT GB50S00007Dl BOOM OVER LUFFING JIB
lifill-{illl EACH
LS- 96 N. C. [m-[ill] HOIST JJ50SOOOOIOI N. 0.
OVER HO I ST F- 6 lOA ~ so• ncn1n 24100R215S3
STEPPING MOTOR ' LUFFING JIB
SW-22 GB50S00007D I LS-13 N. O. ~ {STARTING POINT) 12406U197F4)
fil--fil N. C.
OVER HOIST
F- 7 SA ~ SPARE 24100R21SS4
SW-23 GB50S00008DI OPERATORS LMI
LS-14 N. O. m-[J ROOM LIGHT 2479R638 F- 8 SA lm--!Im PnW<R SDIIRr~ 24100R215S4
SW-24 ~ HORN (G820EOOOO 1F2) LS-15 N. O. ill--fil E/G OIL FILTER -

@]----ill rn-ITTI N. O.
LUFFING BOOM F- 9 20A [2l-{j]J WIPER 241 OOR21 552
LS-16 N. O. m-------u AIR CLEANER (GGI IPOOOOlFll
R-38
llli}---{j]]
OVER HO I ST
LUFF I NG BOOM
F-10 20A ~
AIR
CONDITIONER 24100R215S2
SW-27 24792349 LS-17 N. O. ~ WATER TEMP. - N. O. OVER HOIST F-11 1.QA ~ RADIO (OPT. ) 24100R215S3
LUFF I NG BOOM TOTAL
LS-18 N. C. ~ WATER LEVEL (2427Ul416Fll fil--fil N. C.
OVER HOIST F-12 20A fil-----fil CONTROLLER 24100R215S2
~
N. 0. HYO. 0 I L TEMP. BOOM DRUM ig]----lLl]
LS-19 2479U285 R-40 ~ ~ N. O. LOCK ALARM
F-13 5A GOVERNOR 241 OOR215S4
JIB OVER HOIST HOOK OVER SWING
LS-24 N. C. [illl--fil IC RANE JI BI GK50SOOOOIP1 R-41 [Q)-[Q] fil-[ill N. O. HOIST (MAIN)
F-14 lOA lfil---l2] FLASHER
24100R215S3
fr. DRUM OV[R PAY OU .FUEL PUMP
LS-32 N. C. ~ PREVENTIVE JJ50S00003PI HOOK OVER F-15 lOA ~ 24100R215S3
~ N. C. HOIST {MAIN) LIGHTER
LS-33 N. C. fg]-----iill Re. DRUM OV[R PAY DU
PREVENTIVE JJ50S00003Pl HOOK OVER F-16 JOA fil----12] GAGE
CLUSTER
24100R215S3
R-42 [QJ----jill ~ N. O. HO I ST IJ I 8) REDUNDANCY
SW-28 ~Fr.DRUM 24792349
LS-34 N. C. [ill]----ill HDOK OVER HOOIST
IJIB MAIN) 24100N6192F3
HOOK OVER
F-17 20A fil---[zl CIRCUIT
24100R215S2
fil-lBYPASS LS-35 N. C. ffi----!D] !JIB) HOIST
HOO! OV[R 24100N6192F3 rn--fil N. C. HO I ST IJ I 8) F-18 20A &-- SPARE 24100R215S2
JIB RAISE
~ ~
HOD! OVER HOIST [§]1-fil
LS-36 N. C. IJIB AUX.) 24100N6192F3 R-43 ltim-ill N. 0.
STOP
F-19 lOA &-- SPARE 24100R215S3
SPREADER POSITION LMI
LS-37 N. O. ~ DETECT GK50SOOOOIP1
R-44 lli-fil ~ N. O.
JIB LOWER F-20 JOA ~ CONTROL SOURCE 24100R215S3
~
STOP
MAST ANGLE DETECT
LS-38 N. C. ~ GK50SOOOOIP1
R-45 m----ill [jJ]---fil N. O. SET UP E224S00010Pl
RELAY ~ N. O. SETUP
SW-29 ~Re.DRUM 24792349 COIL TERMINAL [iIQl---ill N. O. SETUP

fil-1BYPASS R NO.
LINE NO. LINE NO. TY PE USE
PART NO.
BOOM RA I SE
PILOT LAMP
R-46 ~ ill--liill N. O. E224S00010Pl
~
STOP PL-NO. LI NE NO. USE PART NO.
~
R- B [j)--[g] N. O. ELECTRIC E224S00027Fl
POWER SOURCE R. H. CYLINDER
~ ffi-M m----fil
r~
R-47 N. O. E224S00010Pl PL-4 SWING FREE GB80S00007F2
EXT. STOP
0
L. H. CYLINDER
R-48 ~ ~ N. O.
EXT. STOP
E224SOOOIOPI PL-7 ~ E/G CONTROL JJ80S00006D2
R- H ~ ~ N. O. AIR HEATER GG24S00003Pl
CWT SELF REMOVAL
R-49 lill1H] [i]f--{j]] N. C.
POWER OFF
E224SOOOIOPI PL-8 ILll---fil E/G CONTROL JJ80S00006DI
R- Ho []-ill !ID--ill N. O. HORN 4079222
SW-30 GB50S00045Pl
R-50 ~ ~ N. 0. LUFF ING 2 E224SOOOIOPI
R- s ~ ~ N. O. STARTER -
ANT I TWO
[§J-------u
R-51 [Qf---[J] rn-ill N. O.
BLOCK RELEASE
E224SOOOIOPI
R-SF ~ N. C. SAFETY GG24S00004Pl
IE, --!4 1 3 ~~; ~~~M I UKN
~
SW-33 247921813
R- 1 ~ N. O. GENE RAT I ON OF E224S00010P1
ELECTRIC I TY
JJ03Z00013Pl
SW-34 247921813 ~
SENSOR
SW-49 24792560 (SHEET 8/9)
1-8
SOLENOID VALVE SOLENOID VALVE PRESSURE SWITCH
SOL NO. LINE NO USE PART NO. SOL NO. LINE NO USE PART NO. PL-NO. LINE NO. USE TYPE PART NO.
INCHING SPEED CRAWLER FIXING JJ20V00004FI BOOM RAISE
SOL- I ~ CONTROi G835V00002F2 SOL-82 ~ . PIN (Re. EXT. J PSW-4 [j]J-fil DETECT N. 0 GG50S00007FI
CRAWLER FIXING BOOM LOWER
SOL- 3 rn-fil FUNCTION LOCK G835V00002F1 SOL-83 ~ PIN (Fr. EXT. J JJ20V00004F1 PSW-5 [fil---ill DETECT N. 0 GG50S00007F1
PROPEL SPEED VERTICAL EXT.
~ ~
~
SOL- 4 Sele!'T G835V00002F1 SOL-84 (Re. L. HJ JJ20V00004F1 PSW-6 CONTROL N. 0 GB50S0004BPI
VERTICAL EXT. PRESS.
SOL- 5 ~ SWING PARKING G835V00002F1 SOL-85 ~ (Fr. L. HJ JJ20V00004F1 9 DETECT
VERTICAL RET.
SOL- 6 ill-@ BOOM INCHING G835V00002F2 SOL-86 ~ IF r. R. Hl JJ20V00004F1 PSW-7 [j]]------fil PROPEL
DETECT
(RIGHT)
N. 0 GG50S00007FI
BOOM H_DIST VERTICAL RET.
SOL- 9 [illJ--fil STOP G835V00002F2 SOL-87 ~ (Re. R. HJ JJ20V00004FI PSW-8 [i]----ill PROPEL
DETECT
(LEFT)
N. 0 GG50S00007FI
MAIN HOIST CRAWLER FIXING
SOL-10 [illJ--fil STOP G835V00002F2 S.OL-88 ~ PIN !Re. RET. J JJ20V00004F1 PSW-9 [§)-ill SWING DETECT
(RIGHT)
N. 0 GG50S00007FI
AUX. HOIST CRAWLER FIXING JJ20V00004F1
SOL-I I ffi-fil STOP GB35V00002F2 SOL -8 9 ~ PIN (Fr. RET. J PSW-10 [§)-ill SW ING (LEFT)
DETECT N. 0 GG50S00007FI
Fr. DRUM MOTOR VERTICAL RET.
SOL-12 m-fil CONTROL SELECT G835V00002F2 SOL-90 ~ {Re. L. HJ JJ20V00004F1 PSW-11 [ill----fil E/G OIL
PRESSURE N. C -
Re. DRUM MOTOR VERTICAL RET. JIB RAISE
SOL-13 rn-ill CONTROL SELECT
Fr.DRUM MOTOR
GB35V00002F2 SOL-91 fil-U (Fr. L. HJ JJ20V00004F1 PSW-12 ~ DETECT N. 0 GG50SOD007F1
SOL-15 ~ BOOST GB35V00002F2 PSW-13 [i]]-ill JIB DETECT
LOWER
N. 0 GG50SOD007F1
Re. DRUM MOTOR
SOL-16 ~ BOOST G835V00002F2
SOL-26 ~ MAST RAISE JJ20V00003F1
SOL-27 ~ MAST LOWER JJ20V00003F1
Fr. DRUM TURN
SOL-40 ~ DETECT GRIP GB50M01093F1 PRESSURE TRANSMITTER
Re. DRUM TURN
SOL-41 ~ DETECT GRIP GB50M01093FI PT-NO. LINE No USE P-NO.
PRESS.
SO L-4 2 ~ RELIEF SHIFT GB35V00002F1 PT- SWING LC52.S00002P2
SWING
SOL-431 ~ BRAKE MODE GB35V00002F2
PT- 3
SWING Fr. DRUM LC52SOOOO l P3
SOL-43! ~ BRAKE MODE GB35V00002F2 HOIST
HYDRAULIC
SDL-44 ru-fil SELECT
HYDRAULIC
JJ20V00003F1 PT- 4 Fr. DRUM LC52SOOOO 1P3
SOL -4 5 ~ SELECT JJ20V00003F1 LOWER
Fr.DRUM PT- 5
SOL-46 ~ NEGATIVE BRAKE GB35V00002F1 Re. DRUM
HOIST
LC52SOOOOIP3
Re. DRUM
SOL-4 7 ~ NEGATIVE BRAKE GB35V00002F1
PT- 6 Re. DRUM LC52SOOOO I P3
BOOM DRUM
SOL -4 8 ~ NEGATIVE BRAKE GB35V00002F1 LOWER
JIB DRUM
SOL -4 9 ~ NEGATIVE BRAKE GB35V00002F1
SOL-50 l4o4H401I MAIN PUMP GB34V00002F2
POWER REDUCE
SOL-51 !332H333I SWING REACTION GB34V00001F1
SOL-52 ~ BOOM RAISE GB34V00001F4
CONTROL
SOL-53 ~ BOOM LOWER GB34V00001F4
CONTROL
SOL-54 lllil-ill Fr. ORUM HOIST G834V00001F4
CONTROL
SOL-55 132 sH33ol Fr. ORUM LOWER GB34V00001F4
CONTROL
SOL-56 !367H3osl Re. DRUM HO IST GB34V00001F4
CONTROL
SOL-57 ~ Re. DRUM LOWER G834V00001F4
CONTROL
SOL-58 14 s3H4 s41 JIB LOWER GB34V00001F4
CONTROL
JIB LOWER
SDL-59 mill CONTROL GB34V00001F4
SOL-62 142 6H421I TAGLINE GB22V00007F1
R. H CYLINDER
SOL-65 ~ EXT. JJ35V00004F1
R.H CYLINDER
SOL-66 ~ RET. JJ35V00004F1
L.H CYLINDER
SOL-67 m-fil EXT.
L. H CYLINDER
JJ35V00004F1
SOL-68 [ill-fil RET. JJ35V00004FI
SOL-69 ~ JIB ORUM LOCK G835V00002F1
SOL-70 !43oH4 331 BOOM PUMP G834V00001F4
POWER REDUCE
COUNTER WE IGHT
SOL-71 ~ REMOVAL SELECT JJ35V00003FI
SWING CONSTANT
SOL-72 film SPEED GB34V00001F4
VERTICAL EXT.
SOL-80 ~ (Fr. R. HJ JJ20V00004F1 JJ03Z00013Pl
VERTICAL EXT.
SOL -81 ~ (Re. R. HJ JJ20V00004F1
(SHEET9/9)
1-9
2. ARRANGEMENT OF ELECTRICAL PART
2.1 Electrical Part of Cab ~ SWING ALARM SELECTOR SW-23 REAR WORK LIGHT SWITCH SW-22 ¥
CN-385 CN-386
~ PROPEL ALARM SW-26 HEAD LIGHT SWITCH SW-21 ¥

CN-384 (OPTION) CN-387
SPOT LIGHT
~ VOICE ALARM SW-32 WIPER (ROOF) SWITCH SW-19 ¥
CN-379 (OPT I ON) --C2- CN-388
511
~ Fr. DRUM TURN SW-33 --g:f-- SW-18 ¥
CN-383 SELECTOR (OPT I ON) Eo CN-389
~ Re. DRUM TURN SW-34 UPP. ) SW-17 ¥

CN-382 SELECTOR (OPT I ON) CN-390
CN-370
REAR FRONT LIGKT LIGHT WIPER WIPER WIPER
DRUM DRUM IREARJ (FRONT> (RODFI IFRONT LOWER> IFRONTJ
CN-378 0 @ 0 0
0
0
0
0
AIR CONDITIONER ¥
CN-394
CONTROL PANEL
ONE-WAY CALL AMP.
(OPTl
CN-381
WI PER MOTOR (FRONT UPP.)
SWING FREE RAMP

1-- --- ---T;~ --- --- --- --- --- --- -!
HOUR METER
, CN-279F
CN-278F
I
TO SWING FREE LAMP
I CN-160F ,
LMI CONTROLLER . I
I .
i O O !
. TO LMI CN-279F
!
(R-45)
1
CN-12AF
I
CN16M '
WI PER MOTOR
0
(FRONT LOW. l CN15M I
'
ouLJ CN12M
I I
CN-352
I I I
L ___________________ _ i
' VIEW E
JJ04E00002F0(1/2)
2-1
WIPE~ MOTOR
(ROOF)
HEAD LIGHT
ROOM LIGHT
CN-371
SPEAKER (L. H.)
SPEAKER (R.H.)
CN-362
DRUM SPEED CN-361

TRIMMER BOX CN-369
-ROOM LIGHT L/S

CN-361
CN-21 WASHER TANK
CN-668
DRUM LOCK
ALARM BUZZER CN-364
CN-363
CN-150 A/C UNIT
r"'-!Jla'Fl-+--1-11-- C N - 3 3 2
~~~[J:il£1~,.-UI-- CN-3 3 1
CN-31 1
CN-325
VIEW A
JJ04E00002F0(2/2)
2-2
2.2 Electrical Part of Right Deck
E--J i---F DETAIL II 111
11 J,.nf- D
DETAIL II H DETAIL "Q"
I==:::, I
0
0
11
DETAIL G"
0
SWING ALARM LAMP

CN-214
C---iJJoJ E---i 1--m--- F DETAIL' II K"

J,.nf---0 CONTROL PRESS. SWITCH PSW-6
CN-186
CN-596F
OCNTROL PRESSURE SWITCH PSW-6 RECEPTACLE
CN-299F
(FOR C/W SELF REMOVAL DEVICE)
JJ01E00029FO(l/3)
2-3
BOOM LOWER SOL-53
PROPORTIONAL VALVE
CN-573
GANTRY (R. H. )
~-:r,--
LOWER
GANTRY (L. H. )
LOWER BOOM LOWER PSW-10
CN-565
PRESSURE S/W
CN-547
CRC SDL-73
SWING PARKING SOL-5
PROPEL SPEED HIGH/LOW SOL-4 SWING BUZZER
RELIEF PRESSURE SHIFT SOL-42
SWING REACTION PROPORTION VALVE SOL-51
GANTRY (R. H. ) FUNCTION LOCK SOL-3
RAISE
GANTRY (L. H.)
RAISE
BOOM RAISE SOL-52
PROPORTIONAL VALVE
DETAIL "J"
DETAIL "G"
DETAIL "I"
CN-577
To jib raise Proportional valve
Fr.DRUM HOIST
CN-575M PRESSURE SENSOR PT-3
To jib lower Proportional valve CN-537
Re. DRUM HOIST SOL-56 Re.DRUM HOIST
PROPORTIONAL VALVE Fr.DRUM HOIST STOP SOL-10 PRESSURE SENSOR PT-5
CN-529 Re.DRUM HOIST STOP·SOL-11
Fr. DRUM LOWER SOL-55
PROPORTIONAL VALVE BOOM RAISE HOIST STOP SOL-9
CN-579F
Re. DRUM HO I ST PT-5 Fr. DRUM LOWER PT-4

PRESSURE SENSOR
CN-528
PRESS. SENSOR
CN-533
di
Re. DRUM LOWER PT-6 Fr. DRUM HOIST PT-3
PRESSURE SENSOR PRESS. SENSOR BOOM RAISE PRESSURE SWITCH PSW-9
CN-523 CN-537 CN-163
Re. DRUM LOWER SOL-57 Fr. DRUM HO I ST SOL-54 DETAIL "K"

PROPORTIONAL VALVE PROPORTIONAL VALVE
DETAIL "H"
JJ01E00029F0(2/3)
2-4
CN-164F
-----1 - -----1
------
r
------ - -
1
CN-577F
1 I
Connect to sol. 58
CN-529F CN-524F (Luffing jib hoist)
Connect to sol. 56 Connect to sol. 57
(Re. drum hoist) (Re. drum lower)
CN-538F
Connect to sol.54
(Fr. drum hoist)
CN-115F
CN-114F
CN-523F
Connect to Press. sensor
(Re. drum I owe rl CN-578F
SECTION E-E
SECTION A-A SECTION B-B SECTION C-C SECTION D-D
Fr. DRUM MOTOR CONTROL SOL-12
CN-541
-----
r
I
------
CN575F
Connect to sol. 59
(Luffing jib lower)
Cable for swing cab
Fr. DRUM MOTOR BOOST SOL-15

CN-534F CN-540
Connect to so I. 55
(Fr. drum lowerl
CN-576F
VIEW "N"
CN-6 Re. DRUM MOTOR BOOST SOL-16

CN-531
CN-533F
Connect to Press. sensor
(Fr. drum lower)
SECTION F-F Re. DRUM MOTOR CONTROL SOL-13

CN-532
VIEW "0" JJ01E00029F0(3/3)
2-5
2.3 Electrical Part of Floor Plate & Left Side Stand Panel
Cable(A,B,C) for swing cab CN-134
CN-223
D D AIR CONDITIONER
PRESSURE SWITCH
I I
CN-551
CN-550 CN-224
CN-549 0
T
A
CN-555
CN-556
F
CN-554 CONDENSER
FAN MOTOR
[I] 0
0
0
0
0 0
[?
0 0
0 0
0 0
0 0
0 0 0
Cable(B) for swing cab WINCH SELECTOR SWITCH

CN-1 94· ·CN-193
Cable(C) for swing cab
Cable(B) for swing cab
JJ01E0003lFO(l/4)
2-6
CN-156
PROPEL (L. H.) PSW
PROPEL (R.H.) PSW
FUNCTION LOCK
Connect to foot accelerator
0 0 0
D
D D
ICN-328F. 320MlleN-312M. 327MI
le N - 3 3 4 F . 3 3 5 Ml
le N - 3 2 5 F! le N - 3 1 1 F. 3 2 1 File N - 3 4 F. 1 0 4 F. 1 0 6 F. 1 0 7 F!
le N - 3 3 1 M. 3 3 2 F! le N - 3 1 F. 3 3 F, 1 0 1 F. 1 0 9 F. 1 1 0 F!
le N - 3 2 F. 1 0 0 F. 1 0 2 F. 1 0 3 F. 1 0 5 F. 1 0 8 F. 3 2 2 F. 3 2 3 F, 3 2 4 F!
VIEW FROM UNDER OF FLOOR PLATE

JJ01E00040F0(2/4)
2-7
INCHING SPEED S/W
D
F
Jll·l"ASI
~o
~""
nOMT"
CN-155
~ ... ~ ... Connect to Re.drum turn
(OPT.)
9 riP
n IIO . . AL .. IIOlllAL
H
HU /(:
CN-154
Connect to Fr. drum turn gr i P
(OPT.)
:~i.
~-=n, CN-150
SWING(RIGHT) PRESSURE SWITCH

I 1: I
Connect to drum speed adjusting knob
I I
REMOTE CONTROL VALVE

SWING(LEFT) PRESSURE SWITCH (For swing)
SI DE STAND (R.H.)
To one-way call speaker

and air conditioner unit
JJ01E00040F0(3/4)
2-8
CN-311
CN-331
CN-.325
CN-323
CN-322
- -- ====--=-=-- -==\\=o =JJJ

\\ /--.......
e--j-::+==~\\ ( 0 )
"--- __.,,..
______lL____H 1F == == 0
11
11
CN-109 0
11
C N- 1 1 O --t1r--°+--!-~
11
11
)~o ==
O
I o
CN-31
CN-32 0
CN-33
CN-34
JJ01E00040FO(4/4)
2-9
2.4 Electrical Part of Revolving Frame
ATTACHMENT
SWING BRAKE MODE SELECT JUNCTION PANEL
(SOL-43A)
SWING BRAKE MODE SELECT CN-570

(SOL-43B)
Fr. DRUM TURN
(OPT. )
BOOM OVERHOIST LS-7
CN-570
SWING PUMP
PRESSURE SENSOR
CN-176 CN-173
0 0
-x
0
II
II 0
MAST RAISE/LOWER (SOL-26/27)
HYDRAULIC SELECT (SOL-44/45)
-----
I
Re. DRUM TURN SENSOR
011
0 CN-136 (OPT. )
II
II
SECTION B-8
BOOM DRUM LOCK SENSOR
SECTION A-A
JJ01E00041FO(l/2)
2-10
SWING BRAKE MODE SELECT
(SOL-438)
MAST ANGLE DETECT

LIMIT SWITCH
CN-532 CN-540 CN-8
CN-531 CN-541
BOOM OVERHOIST
LIMIT SWITCH
SECTION G-G
BOOM ANGLE DETECT

LIMIT SWITCH
REMOTE CONTROL BOX
JJ01E00041F0(2/2)
2-11
2.5 Electrical Part of Left Deck
BATTERY
HYDRAULIC OIL ALARM LAMP
r"II- H
LEVEL SENSOR
BATTER.Y RELAY SAFETY RELAY

CN-504 CN-512
GENERATE DETECT RELAY

HORN _...._ -
CN-500
CN-511
HORN
E/G OIL FILTER LS-15
CN-501
SECTION H-H
WATER TEMP. SENSOR SOL-1 (CN-511)

E/G TURN SENSOR
PRESSURE Fr. & Re. DRUM I NCH I NG SPEED SOL-1
TEMP. ALARM
PSW-8 MAIN PUMP POWER REDUCTION SOL-50
A/C PRESSURE
STEPPING MOTOR
B JJ01E00039FO(l/2)
2-12
CN-216
COMPRESSOR
BOOM INCHING SPEED SOL-6 ALTERNATOR CN-566
BOOM PUMP RELAY
0
DETAIL"A"
SOL-6 (CN-566)
0 0
SWING CONSTANT SPEED
SOL-70 (CN-567) SOL-72 (CN-568)
ENGINE CONTROL UNIT
AIR CLEANER CLOG SWITCH

LS-16
0 0
CN-507
0
CN-590
0
0
0 0
DIAG LAMP-1 CN-805

(RED) CONNECT TO MUT- II
(For maintenance)
CN-804 CN-805 CN-568
DAIGNOSIS INDICATOR CONNECTOR MEMORY CLEAR CONNECTOR
CN-567
I
L __ _J
DETAIL "A"
SECTION F-F
JJ01E00039F0(2/2)
2-13
3. ELECTRICAL PART
3.1 Fuse Box (JJ73E00001 F1)
A DANGER
1. In the case that a same fuse is frequently burnt out, it is considered that burning out of the fuse
may be due to some fault in the electric circuit and it is not yet repaired. In such case, absolutely
do not replace the burnt fuse simply with a fuse over the specified capacity. This could cause
damage to the wiring and electrical apparatus.
2. In the above case, or when installing a new optional apparatus, be sure to consult the service shop
of our representative. They will make a proper treatment or give a proper instruction.
3. When replacing the fuse with a new one, be sure to turn the key switch off.
&i
§§]
1
I
CN44F
I
I
CONNECTOR No. 7123-2237
(YAZAKI)
___ J
1 2 2 2 2
2 2 3 52 54
CN41M
CONNECTOR No. 7122-2107
(YAZAKD
14 11 22 21 20 19 18 CN41M
26 15 27 25 24 23
CN43F CN42F
CONNECTOR No. 7123-2186 CONNECTOR No. 7123-2107

aAZAKD (YAZAKI)
3-1
Generator
Battery Key switch Battery relay sensor relay Battery relay Battery relay
I
IF-i/20A IJI F-~/SA I I. F-'.3/SA I I F-:/SA I IF-!;10A I IF-+OA I I F-;/sA I I F-~/SA 11 F-~20AI IF-1~1103
t:
~
Ql
~
Q.
~ ai "O
·a !::! ai ai
*
Q) -
,: .s:: :,
!t ::, a. c
O
a.=
Ol I
-"' Q) "'a.
(/) <ii
cQ) "'
a.
(/)
0
Ul § ,g
0 c c 0 i;; '6
c "O at ·5, at (JJ c
·-
at at
Q) co c t= ~ 0
:::; :c UJ a. 0
:,; ~
....J
Key switch Battery relay Battery relay Battery relay
IF-1l/10AI F-12/20A F-13/SA F-14/10 F-15/10A F-20/10

~ 0 ai Q)
~ ~
<ii
ec .s::
.,
~ Ol
., ~=§ e'E
.g ·ue
0 E
>,
at
Q)
>
I))
gE" :,
(!l
c "'
a.
(/)
"'a.
(/)
,: "" Co O Q)
~[ -'-' e
0 0 Ol
(!l
-~c
0 :,
=a.,01c
~
Q)
<ii
at-
Ol Q)
·-::,
"O
Q) 0
c :::; 0
....JI))
:,
cc O ;§ (JJ (.) LL CC O
Fuse Connection Schematic
10
540
I ::~ ::
F3 SA
~::
013
F4 SA 14
2 FS 10A 15
F6 10A 16
30
20
I ::: : :
F9 20AI
~::
~19
20 I F10 20A I ~20
520 I F11 10AI ~21
20
I .:::: ::A: :::
20
L:t410A:F1S 10A
F16 10A
::: 26
Connecting connector
©
0
CN44F
CN43F
0 CN42F
F17 20A 27 D CN41M
2 F18 20A 0 28
F19 10A 0 29
F20 10A 0 30
3-2
3.2 Wiper Control Relay (2479R1366)
f Wiper intermediate relay

01
.
@I I@
Wiper intermediate @I I@
relay
(DI I®
-=. 24V Wiper motor
l
~ Wiper switch
3-3
3.3 Swing Flasher Relay (YN24S00002P1)
....--------
A12 +B
09 2Ka +B +B
2NA1 201 +c2

39V 212 22JJF
Q2
0 8791
0 YN24S00001Pl 0
0 RB
7.5K.a
A5
100K.o
Q4
01209
04
IC1 +B +B
40118 06
SW(YELLOW) -[>- = -0--

GND2 (BLOWN)
Qi
8791
05
03 R6 ---- ~L1
7.5Kn
L2(WHITE) GND2 (BLACK) Q3

01209
L1(BLUE) R4
01 02 100K.o
R1
100Kn
R2 R3 + C1
27K.o 33Ka 10JJF
SWING FLASHER LAMP
08
+24V
L-c
SWING FLASHER SWITCH R13 R10
100Ka 27Ka
GND1 I..z
GND2SW Relay Q5
C1815
R11
07 220K.o
EM-1C
GND2 SW
3-4
3.4 Stepping Motor (Governor Motor)
1 2
t
B
! 3 4
A
VIEWB VIEW A
Connector No. Harness color
1 Brown A
2 Orange A
3 Red B
4 Yellow
-B
5 White COM
6 Red NO
7 Yellow NC
3-5
3.5 Pressure Switch (Control Pressure Cut)
1 - W -COMMON
2 - R -POWER(+)
3----NC
4 - G- Open collector ( +)
1-+---r---U 4 124v
1
555psi (3.8MPa): ON
441psi (3.0MPa): OFF
roNJ roFFJ
Use Part Number Pressure Pressure
psi (MPa) psi (MPa)
Control Pressure GB50S00048Pl 555 (3.8) 441 (3.0)
~/N
SER.NO.
0-Ring P14 (ZD11P01400)
PF3/8 (Tightening rorque : 21ft-lbs (29N · m))
3-6
3.6 Pressure Sensor
(YN52S00003P1 • YN52S00004P1)
Location of connector terminal

TerminalNo.
I · .. ···POWER (+)
2······0UT-PUT (+)
3······COMMON
I I
( )
1---------01
--·2 Jsv
0.5-4.5V
r----------;u 3
Pressure range Out-put (V)

Use Part number Power (V)
psi (MPa)
Remotecotrol
pressure YN52S00003Pl O to 427 (0 to 2.9) 5 0.5 to 4.5
(Front·Rear·3rd)
Swing pump pressure YN52S00004Pl Oto 7110 (3.9 to 49.1) 5 0.5 to 4.5
(NOTE)
YN52S00003Pl YN52S00004Pl
• Pressure range : Oto 427psi (0"'2.9MPa) • Pressure range : 0 to 7110psi (0-49.lMPa)

• Voltage V c c : 5.0±0.SV DC • Voltage V c c : 5.0±0.SV DC
•Out-put: 1/10Vcc-9/10Vcc=0.5V-0.45V • Out-put : 1/10Vcc-9/10Vcc=0.5V-0.45V
• Tightening torque : 25ft· lbs (34.3N·m) • Tightening torque : 40ft · lbs (54M · m)
3-7
3.7 Pressure Switch
(Boom, Propel, Swing)
(GGSOS00003Pl)
0-Ring Pll (ZDllPOllOO)
At 85psi (0.6MPa): ON
At 57psi (0.4MPa): OFF
3-8
3.8 Relay Box
3.8.1 Arrangement of Connector
0 0
- - - - r- - . , - - -
II II
-------
11
----Ti-ii
II
0 0
II II
II II
II II
II II
- - - - r: - ii .
----11-;
-,
II I~
=:'..--~-J
____ .!J_J
.t1n. .
-,
- .J
'00
II~ I
:~--n-~ lgl
- ,I
----11-1
II I
.t,,.
I
1J
......
- .. II II z
- - - - 11 - ,1
- - - - 11 - 11
II II
II II
II tl
I
-------
-------
II II
II 11
0 0
- - - -•L- _,1_ - - J
0 0
11 11 ll 11
317 311 233
I"" 400 105 102 209 238 124 248 232 145 123 122 121 139 135 18 152
""" i~I~ ;~ 588

""
27 395 366
I"" 586 159 451 449 450 448 327 358 128 155 154 118
CN-31 CN-32
Ii
11 11 11
203 142 141 121 138 137 ;~ 151 109 108 106 104 103 101 14 220 16
"" :"" 392 468 466 246

CN-33
Eo 587 243 242 115 208 647 524 114
CN-34
i"" 148
3-9
3.8.2 Relay Box Schematic
- - - - - - - - - - - - - - - - - + - - ( r : : c N : : ' :3~2_"'1::;;--
2 TC (M/L Redundancy)
R-13-(l) ----4---o-CN...._3.u3 _....1- TC (Main hook hoisting stop)

,.._...Jffi=---o o---------l::>--cc:-'N""
33:""-_-,6-- TC (Free release)
M/L (Alarm select) -c...1N:.: -c1------~
34ll._-
2
SW-54-®
-1:_.9_._ _ _ _ _ _ _ _ _ _ _ _-J::>--:~"'"":-- Inching speed control

--,..11liL...-d----'-----T--iiR....
F-6 CN34-I 7 CN31-I SOL-1
TC
4
CN33-7 (Pump control release) M/L
(Main hook lowering stop) CN32-5
R-12~ Swing pump control
CNJl-2 SOL-2
R-32 Relief pressure shift M/L
CN31-11 SOL-42 (Boom raise stop) CN32-6
Control pressure detect
CNJl-5 PSW-6
Propel control -cN...i.3:,i.4_a.1-9-o------~.m. 1\-4--------------1

PSW-7,8 M/L (Boom lowering stop) CN32-7
Swing control -=-cN-"3"':_"-:2-:c--<l---------'till-• '\-'--------------, L------4---t>---"'....._-SW-30-®

0
PSW-4,5 R-36~@ @ R~37-@ Third hoisting stop
M/L Third hoisting stop _c.....N"'32"-_-6 -<:1-----1---o o----------+--(>-':c~~- SOL-18
Boom drum lock L/S
TC (Boom drum lock) -cN~Jm2-~1-J-ri----------------~'fq!- ~4---+---l>--"'""::-'.-LS-27
TC (Engine start)
--""'-"---<O---------'R'<l-18-(i) CN33-B
M/L (Main hook overhoist) - cN34_4 '-------------T--P----:c~'",:- Main hook overhoist L/S TC A-21
M/L{Latch lamp (Engage)} -cN.w3""4 _L-s-<I-------- cNJ1-s LS-2 (Control first pressure detect) CN33-9 --l!llg_-d---------ill-------------,
R:E.=12>
M/L (Aux. hook overhoist) -=L--o-------..:.:R.._--1e-12> Aux. hook overhoist L/S Swing flasher -cN-'3~4_s.1-5- o - - - - - - - - - - - - - o <>-------1
CN34-6 '-o-------------;r---p-;;~"-:;--
M/L{Latch lamp (Disengage)} CN34 _7 CN 31-7 LS-3
_1-0- o - - - - - - - - - '
TC (Swing control) -CN.J.3~3....
Propel alarm -....ll.!4--<i-------------oR-H-o-12)------;__-t>-~~- Earth

SW-26 CN34-16 CN34-22
M/L (Boom overhoist LIS)
L---------4----c,-C~N3~.~-8- LS-7
R-18-@
M/L (Tower jib overhoist L/S) R-23

L---------~--C>-:C~N3~4~-9c--- LS-8 ~-"'M,---"""'---o 0-----------0--,c=N~a':"1-':-1•} TC (Fr. drum redundancy S/W)
A-18-@ 22n/20W SW-28 (17.S!l /0.7A)
CN31-16
14
M/L (Tower boom overhoist LIS) A- ,;-----------P-c=N~3"."'
1_"::-24} TC (Re. drum redundancy S/W)
CN34-IO LS-8 l----'vllv-----"".,.__--OA-15"------------l:)-,C-N~31~-~25 SW-29 (17.5 QI 0.7A)
Crane jib overhoist L/S (LS-24) 2.2n/20W

4 -~1,,....aBoom angle detect US (LS-25)
'----------+---o-c,,-N""J~ - -vv,.- - -
33n/20W TC (Swing speed redundancy S/W)

1.___,Wv--~-------------(>-;:c~NJ~1~-a;-SW-38
55n/20W Fr. drum turn sensor grip
TC (Fr. drum turn sensor grip) _cJN3!1.:l1ll__
16
-d-------'Mr-----------------J:>-;c::-:N~Ji~-";-; 18;- SOL-40(12±0.3!l/0.4A)
Over load release A-33-(i) 55n/20W Re. drum turn sensor grip
SW-15 -C-N311.14.:S.-l-.-{j---<) 0------------------t TC (Re. drum turn sensor grip)-cJN3~ 1illl_1-7,...df--------w.....----------------j:>-;c::;N;'.
31~-';19
;:; - SOL-40 (12 ±0.3!l/0.4A)
3-10
3.9 Left Side Stand Panel
0 J'J-/;i;~ ;,701 111" 11r.! 11111 11111 0

LU;~_l:GoRELEASE RELEASE RELEASE RELEASE
7'1-/Ho O
REE/HIGH
FREE/LOI
1v-~IH
BRAKE/LOW
~~ANE
SETUP
~
i!llliaiM
r§J ~
:1-L.H J·,:?i!l'!,
n@~nac-,;,~-, 79·yf,;{:,,~il~ JlJ-J;t-J~~J!:.
LM I BOOM ANT I
SWING ATT. FREE FALL
NEUTRAL MODE/SPEED SELECTOR LOCK OVER HO I ST TWO BLOCK
!ibELEASE ;:::::::@)i~~:::,::: ~bORMAL 70~rNT :~HLIOGWH

0
0•:,7 LOCK
-:JjF?b.D·:i?
J I 8 ORUM
io.
LOW'l 1 f.";Ui'l!(t:HIGR
J I 8 ORUM
~5:,;{tr;,~
HYO
TRANSLI FTER
:.Emil!
Iii,!
,•J-n-,PH
FREE FALL
HIGH IJ 7 REAR
".>-1':;ril!~
WINCH
1<>1Jdl
atfii!II
PROPEL
0
LOCK SPEED SELECTOR SELECTOR SPEED
I
I
A
238
QQQo
0 0
0 0
L[!c
16
0 0
0 0
BACK
ANTI-TWO BLOCK
RELEASE SWITCH
or [Toi
BOOM OVERHOIST
RELEASE SWITCH
LMI
or ITT]
CN-241 M
RELEASE SWITCH
or [TI] CN-241M
MI C I 3P Crf-243F
7FA-M IC
13MA-MICll
rn VIEW A
FREE LOCK?
m
245 244 112 110
(i]
302 380
PROPEL SPEED
SELECT '"
ffiJ] CN-243F CN-24 IM
CN-243F
MIC 7P
HYD. SELECTOR m
m
SWING MODE
SELECT
m
[)]]
rn
22
Switch panel circuit

3-11
3.10 Bypass Switch Panel
SWITCH
BYPASS Ji:Ji BYPASS
9'7- TOWER )in;" NORMAL

~
ii~ NORMAL
M/LJi:i ±'1! 1-1.:..
M/L BYPASS FRONT BOOM
0 0
Ji:i BYPASS '.ii:i BYPASS
~
ii~ NORMAL
~
Ji~ NORMAL
iH ::;1
REAR JI 8
roove side
BACK
CN-245F Jib bypass switch.
0
0
Boom bypass switch N
CN-246F
CN-245F CN-246F CN·247F

1 IFA·HICI 21FA-MICI 17FA·HICI
Front bypass switch

491 492 493 E, 495 3 I I 3 I 2 3 I 3 E, 3 I 5
320 358 323 324
CN-246F
CN-247F
Rear bypass switch
CN-247F
Iilll m~}
,'.ii M/L bypass switch
Switch panel circuit 3-12

Book code No.
ssJD2601E
KOBELCO
SHOP MANUAL CK2500
CKE2500
- - - LOAD SAFETY DEVICE - -
•
CK2500 JD02-00026~
CKE2500

TABLE OF CONTENTS
1. PART NAMES AND FUNCTIONS ............................................................................................................... 1-1

1.1 Front View .............................................................................................................................................. 1-1
1.2 Configuration of Screens ........................................................................................................................ 1 - 5
1.3 Data Transmission between Controller and Cards ................................................................................. 1 - 6
1.4 Details oflndicators on Main Display Screen ........................................................................................ 1 - 7
1.5 Rear View ............................................................................................................................................... 1-10
1.6 Choice of Language ................................................................................................................................ 1 - 15
2. PREPARATI ON FOR USE ............................................................................................................................ 2 -1
3. TURN THE POWER ON ................................................................................................................................ 3 -1
4. UPGRADING PROGRAMS ........................................................................................................................... 4-1

4.1 Procedures .............................................................................................................................................. 4-1
4.2 Upgrading of Indication Programs ......................................................................................................... 4- 3
4.3 Upgrading of Control Programs ............................................................................................................. 4- 6
5. STATUS CHECK ........................................................................................................................................... 5-1

5.1 Signal Check ........................................................................................................................................... 5-2
5 .2 Operation Progress ................................................................................................................................. 5 -3 -1
5.3 Communication Data .............................................................................................................................. 5-4
5.4 Indication of Adjustment Value ............................................................................................................. 5-5
5.4.1 Angle Sensor Adjustment Value ................................................................................................ 5-5
5.4.2 Load Cell Zero Point Adjustment Value .................................................................................... 5 - 6
5.4.3 Adjustment Value of Load Cell for Line-Pull ........................................................................... 5-6
5.4.4 Result of Manufacture Adjustments "NO LOAD" and "SOME LOAD" .................................. 5-7
5.4.5 Result of Load Adjustments "NO LOAD" and "SOME LOAD" .............................................. 5 - 8
5.4.6 Adjustment Value of Working Radius ....................................................................................... 5-8
5 .5 Load Record ........................................................................................................................................... 5 - 9
5.6 Erasing Load Record .............................................................................................................................. 5-12
5.7 Trouble Record ....................................................................................................................................... 5-12
5.8 Load Record (Load record in the main menu) ....................................................................................... 5-14
6. ADJUSTMENTS ............................................................................................................................................. 6-1

6.1 Removing the Inner Panel ...................................................................................................................... 6- 1
6.2 Adjustment ............................................................................................................................................. 6-2
6.2.1 Angle Sensor Adjustment .......................................................................................................... 6-5
6.2.2 Load Cell Zero Point Adjustment .............................................................................................. 6 - 8
6.2.3 Load-Less Adjustment & Some Load Adjustment .................................................................... 6-11
6.2.4 L VL Adjustment (LVL Setting) ................................................................................................ 6-16
6.2.5 Radius Adjustment ..................................................................................................................... 6-18
6.3 User Adjustment ..................................................................................................................................... 6-20
6.4 Adjustment Data Copy (Initialization) ................................................................................................... 6-22
6.4.1 Reading of the Adjustment Data ................................................................................................ 6-24
6.4.2 Writing of Adjustment Data ....................................................................................................... 6-26
6.4.3 Initialization of Adjustment Data ............................................................................................... 6-27
6.5 Version Check ........................................................................................................................................ 6- 28
7. ERROR CODE (ABNORMALITY DETECTION) AND COUNTERMEASURES .................................... 7-1
8. CONTROL OUTPUT ..................................................................................................................................... 8-1
9. RELEASES ..................................................................................................................................................... 9-1

9.1 Release Function .................................................................................................................................... 9-1
9.1.1 Crane Release Chart ................................................................................................................... 9- 1
9.1.2 Alarm Sound .............................................................................................................................. 9-7
9.1.3 External Indicator Lamps in Release Condition ........................................................................ 9-7
10. MECHANICAL SPECIFICATION ................................................................................................................ 10-1

10.1 Environmental Performance Parameters ................................................................................................ 10-1
10.2 Load Cell (Crane) ................................................................................................................................... 10-1
10.3 Angle Sensor .......................................................................................................................................... 10-3
10.3.1 Type 1 ........................................................................................................................................ 10-3
10.3.2 Type 2 ........................................................................................................................................ 10-4
10.4 Controller ................................................................................................................................................ 1O- 5
10.4.1 Model Name ............................................................................................................................... 10-5
10.4.2 System Input/Output .................................................................................................................. 10-5
10.4.3 Monitor Display ......................................................................................................................... 10-6
10.4.4 Operation Switch ........................................................................................................................ 10-6
10.4.5 Internal Processing System ........................................................................................................ 10-6
10.4.6 Memory ...................................................................................................................................... 10-6
10.4.7 External Storage Element ........................................................................................................... 10-7
10.4.8 Others ......................................................................................................................................... 10-7
11. EXTERNAL DIMENSIONS .......................................................................................................................... 11 - I
12. ELECTRIC SCHEMATIC DIAGRAM .......................................................................................................... 12-1
13. CONTROLLER MALFUNCTION EMERGENCY MEASURES ................................................................ 13-1
14. LOAD SAFETY DEVICE CHECK PROCEDURES ..................................................................................... 14-1
11
1. PART NAMES AND FUNCTIONS
1.1 Front View
00000
0000000
000000000
00000000000
00000000000 @ SPEAKER (Pi·······)
ooooo------
OOO 00000000000
® BUZZER (boo·····) 00000
---oo
00000000000
000000000
00000 ..... 0000000
OOO 00000
I .
R~~:o •111111111111111111111111111111
H 71
II
10 II 100
I
.
I IIOOM
ANGLE
BOOM POi
NT ELEY.
I 6 4 . 6'·~! 9 5. Bui Q)DISPLAY

I MAIN I -
-RATIO 1~711
A~~~~L I I 7. 8 =~ms
WAEDD ! 2 6. 4 =~~~gs
RAD I US ,, 4 7, ii I t
c,... 110, aro. ••••11• ua, Hf••t I

~= :::
IOON1 •• ,
UH A••• A1a.
Jiit H•h IOI••
~"='°'----'
.,,,.~~~~.....,..==""'-="'=--~~~--
~CONTRAST
COLORl..!d..J MODE
n El
MENU~
® SHEET SWITCH
§ §
~
( )
( .(){oNT•AsT ( m J
,1-------'=-=--------1 @ COVER
LOAD SAFETY DEVICE~:~-+-~~~_;_~~~~~~~~~~
0 0
@ SEmNG AND ADJUSTING @ MEMORY CARD SLOT

SWITCHES
(J) MEMORY CARD
I I
1-1
G) DISPLAY Current status of the crane is displayed.
.............
-·-
9#•••
..,......
ll'L .. ftll
........
(2) BUZZER (boo ... ) Warning buzzers mainly related to overload (including
load limit warning) are issued.
When the moment ratio is 90% or more, intermittent
OOO buzzers are issued, and continuous buzzers are issued
00000
00000 when it is 100%.
00000
OOO Intervals of intermittent buzzers are divided into three
types. As the moment ratio is greater, the intervals of
buzzers become shorter.
Buzzer types Buzzers
Intermittent boo, boo, boo, .....
Continuous boo
@ SPEAKER (pi. .. ) Overhoist and working area limit warning buzzers are
issued. When the boom exceeds the working area limit
prenotice point, intermittent buzzers are issued. When
the boom reaches the working area limit stop point or
00000 the hook blocks or boom is overhoisted, continuous
0000000
000000000 buzzers are issued.
00000000000
00000000000 Intervals of intermittent buzzers are divided into three
00000000000
00000000000
00000000000 types. As the boom is closer to the stop point, the
000000000
0000000 intervals of buzzers become shorter.
00000
Buzzer types Buzzers
Intermittent pi, pi, pi, .....
Continuous pee
*l: Buzzers warning overhoist

Buzzers warning boom overhoist are issued when
the limit switch is actuated.
Buzzers warning hook overhoist are issued when
the limit switch is actuated to stop the hook blocks,
and the winch lever is set to the "WINCH" position
or the boom lever is set to the "LOWER" position.
(No warning buzzer is issued while the levers are
set to the "NEUTRAL" positions.)
*2: Buzzers warning working area limit
Unless the prenotice point is set, warning buzzers
are issued when the boom reaches the position 5°
or 1 feet before the stop point.
1-2
@ SHEET SWITCH
r:c;::,CONTRAST
COLOR Lill MOOE [MENU] ~
§,!}§
G:BCONTRAST El ~
COLOR
Use this switch to change the display colors or decrease figures.
§
MODE
Use this switch to switch the mode between the MAIN and AUX. modes or increase figures.
§
CONTRAST
Use this switch to adjust the brightness of the display screen (to darken) or select any intended
(TI] item.
CONTRAST
[QJ Use this switch to adjust the brightness of the display screen (to brighten) or select any intended
item.
Use this switch to display or cancel the list of selection items.

rENUJ
El Use this switch to decide or execute the selected item.
~
Use this switch to switch the mode between the assembly/disassembly and operation modes.
~
Use this switch when it is necessary to lower the boom onto the ground at out of angle (lower
limit angle/no rated load) without any load only.
1-3
® COVER
DO NOT open unless you need to load the memory
LOAD SAFETY DEVICE card or operate the setting and adjusting switches.
0
@ MEMORYCARDSLOT
Insert the data memory card here.
(J) MEMORY CARD

This card contains the data related to the crane capacity.
Insert this card into the data card slot unless otherwise
specified.
@ SETTING AND ADJUSTING SWITCHES

Use these switches for upgrading of programs or
adjustments.
LJ LJ LJ LJ LJ LJ LJ LJ DO NOT touch them unless otherwise absolutely
12345678
necessary.
The dip switches are used to make adjustments.

The following chart explains the dip switch functions.
Dip Switches
Dip switch No. Functions
1 2 3 4 5 6 7 8
ON - - - - - - - Permission of upgrading indication program
- ON - - - - - - Permission of upgrading control program
- - ON - - - - - Permission of writing adjustment value
- - - ON - - - - Display of maintenance screen
- - - - ON - - - Making L VL function available
- - - - - - ON - None
- - - - - ON - - Initialization of load and trouble records
1-4
1.2 Configuration of Screens
(1) (9)
SET UP - MAIN
VERSION
MODE CHECK
(2) (10)
I
(3)
- - - - T - - - - , (6)--, (7)
I I I I I I r ___ _J __ ,r _ _l ____ ,
RATED RATED
WORKING LOAD I I UPDATE II UPDATE I
LOAD LOAD SETIING
AREA RECORD I I (INDICATION II (CONTROL I
TABLE CURVE
I I CPU) II CPU) I
1(4) II (5)I ______ .JL
II ______ .JI
I I I I
WORKING 1---------,
CRANE AREA TIME SCREEN rJ.-----, r---1---,
POSTURE LIMIT
(8} I ADJUSTMEN~ I ADJUSTMENT I
I
__ L.J11 DATE I
.J
I
L _____
I I I
L_
r_J_--=._-=:_~ r l-----,
I/O SIGNAL OPERATION COMMUNICATIOtl ADJUSTMENT LOAD TROUBLE I LOAD 11 MANUFACTUREI
CONDITION PROGRESS DATA VALUE RECORD RECORD IADJUSTMENTIIADJUSTMENT I
L _ _ _ _ _ _J L _ T _ _ _ _ J
r-- [ -,r-
---]-----,---]----]---~]
- - , r - - - - , r - ---,r- - - , r - ---,
I ANGLE IILOAD CELL II LOAD II SOME II LVL II RADIUS I
I SENSOR IIZERO POINlfl LESS II LOAD II II I
L - - - - . J L _ _ _ _ .JL _ _ _ _ .JL _ _ _ _ .JL _ _ _ _ .JL _ _ _ _ .J
<Procedures and conditions required for change of screens>

(1) When the conditions required for the setup mode are satisfied, press and hold the setup switch for three seconds or
longer.
(2) Press and hold the setup switch for three seconds or longer, or shut down the power supply. Or, fail to satisfy any of
the conditions required for the setup mode.
(3) When the MENU switch is pressed, the items are displayed. When any of them is selected with the SET switch,
screens in the lower category appear. When the MENU switch is pressed again, those in the upper category appear.
(4) When any of the items is selected with the SET switch, screens in the lower category appear, and those in the upper
category appear when the MENU switch is pressed.
(5) When the dip switch No.3 is turned on, they are displayed.
(6) When the dip switch No.I is turned on, they are displayed.
(9) Press the " t " and " i " switches at a time, and hold them for three seconds or longer.
(lO)ln the status (9) above, release the switches.
Notes) Conditions required for setup mode

1) The boom angle is 15° or less (in the crane mode).
2) The boom angle is 20° or less (in the luffing crane mode).
3) The boom angle detector is not connected, and the hoist tension is constant.
4) Neither the boom angle detector nor load detector is coi:inected.
1-5
1 .3 Data Transmission between Controller and Cards
Data card
I (1) No.1-+No.b > Load safety device
<(2) No.2-+No.d
Contents
1. Performance data Flash memory
(all the configurations) (in the controller)
2. Adjustment data (Copy) Contents
3. History data (Copy) a. Program (display and control)
b. Performance data
(single configuration)
Program card
c. Area control value
I (4) No.4-+No.a >

Procedure (4) is available
d. Adjustment value
e. Statuses
(modes, screen colors, etc.)
f. History data
only while the dip switch g. Fault data
Contents
4. Program (for display)
5. Program (for control)
No. 1 is turned on.
I (5) No.5-+No.a >

Procedure (5) is available
only while the dip switch
.....
~~~~~~~~~~~~~~~- .....
-----------.-J No. 2 is turned on.
The data card is loaded in the load safety device normally, and data are transmitted as shown below.
( 1) Copying performance data
Performance data for the installed attachment are copied into the flash memory from the data card by carrying out the
"crane configuration setup" after the attachment is changed.
(After that, removal of the card will not give any influence on the motion of the machine, since data copied in the flash
memory are used for operation.)
(2) Copying adjustment value (automatic backup)

Whenever adjustment is carried out, adjustment values are stored into the flash memory, and used for operation.
However, if the controller is malfunctioned and is replaced with a new one, the conventional adjustment values
become unavailable, since the flash memory is fixed on the PCB by soldering. Thus, whenever adjustment is
performed, data are automatically copied into the data card. If the data card is not loaded, no data is copied, and no
display warning it will be provided.
(3) Copying adjustment value and history data

Adjustment values copied during adjustment shown in the step (2) above can be written into the controller by
executing out the command. Conventional adjustment values can be used by transferring the copy data that are stored,,
in the data card used into the controller. Arbitrary copying of adjustment values of the controller into the data card and
return of adjustment values in the controller to the initial statuses are also available (refer to 6.5).
(4) Upgrading program for display

Program for display can be upgraded by turning on the dip switch No.1 and executing the command.
(5) Upgrading program for control

Program for control can be upgraded by turning on the dip switch No.2 and executing the command.
1-6
1.4 Details of Indicators on Main Display Screen
CRANE TYPE LUFFING TYPE
•
ao · 10 eo eo
ii
11111111111 1111111111111111
I oo
1
I
.
~ATI O •
UO eo
111111111111111111111111111111
10 ao 10 100 .
~:::::::::::=====l· I BOOM POi

NT ELEV.
0
:N°o ~e U A~~~e I 18
J ANg~FiET
3 6d· 1·g 5. an! 6 4. 6d·~ d,. I

I MAIN
====== ~~II 67'"

.__A..:.~~;:;..a~=~-L_,j~ :~~~gs ~A~~~-~-~-L~j~ :~~~gs 12
'--R.:.;to::..:.TAE;;:.o__.ll 2 6. 41 :~~~gs
6
'- R-=-to;:;. aTA=~__,11 2 6 . 41 =~~~gs 11 0
.__RA_o_,_us_.j 4 7. 7 ..._RA_o_1u_s__.i I4 7 . 1I ft
9 Crane STD. Wei •ht

8 Crane STD.Weltht
BOON: 100fe•t JIB i 30htt BOOM• IOOlott JIB• 301otl
JI- an1l1 IOd11 Jib at11l1 IOd1t
~~= ! :: Utt Aux. Aux, -"U•a-•--_. ~~:.: : : U11 Aux. Aux. .--u•-•---
1
* The indicating units depend on the choice done in the steps described in "1.6 Choice of Language".
No. Indicator Details
Moment ratio indicator (bar indicator) Moment ratio is indicated from 60 to 126% by the 2%.
When moment ratio is less than 90%, it is indicated in green color.
IR~~: 0•
1
eo
111111111111111111111111111111
10 ao ID 100
When it is 90% or more and less than 100%, it is indicated in yellow.
When it is 100% or more, it is indicated in red.
MODE
Mode indicator After the @switch is pressed and the "MAIN" or the "AUX." mode is
2 selected, the selected mode is indicated.
I MAIN I
Boom angle indicator Current boom angle is indicated.

When it is in the range from Oto 99 deg., it is indicated by the 0.1 deg.
3 I BOOM
ANGLE I When it is in the range from -99 to O deg., it is indicated by the 1.0 deg.
I 64. 6d·~
Point height indicator Boom point elevation or jib point elevation is indicated.
When it is in the range from O to 100 feet, it is indicated by the 0.1 feet.
When it is in the range from 100 to 999 feet or in the range from -99 to O
I BOOM PO I I
NT ELEY. feet, it is indicated by the 1.0 feet.
4
I g 5. 8,tl You can choose whether this item should be displayed or not.
(Refer to "3.6.1 SETIING SCREEN" of the operation manual)
Moment ratio indicator (digital indicator) Moment ratio is indicated from O to 200% by the 1%.
5
I RATIO
IG"
1-7
No. Indicator Details
Actual load indicator Actual load is indicated. When it is out of the working area,"-----" is
indicated.
When it is O pounds X I OOO, "0.0" is indicated.
6 I ACTUAL
LOAD 1~:~~~gs When it is in the range from O to 100 pounds X 1000, it is indicated in
0.1 pounds X 1000.
When it is in the range from 100 to 999 pounds X 1000, it is indicated in
1.0 pounds X 1000.
Rated load indicator Rated load is indicated.

When it is out of the working area, "0.0" is indicated.
II 2 6. 41
When it is in the range from O to 100 pounds X I OOO, it is indicated in
7
I RATED
LOAD
POUNDS
*1000
0.1 pounds x 1000.
When it is in the range from 100 to 999 pounds X 1OOO, it is indicated in
1.0 pounds X 1000.
Working radius indicator Working radius is indicated.

When it is in the range from Oto 100 feet, it is indicated in 0.1 feet.
8
II 47. 1i
When it is in the range from 100 to 999 feet, it is indicated in 1.0 feet.
I RADIUS
ft
Message indicator Messages for hazardous or faulty statuses are indicated.

For the types and details of the messages, refer to "3.10 INDICATION
9 I
OF MESSAGE AND ALARM" of the operation manual.
I
Crane configuration indicator The detailed settings of the crane configuration are displayed.
For the settings, refer to "3.5.2 SETTING OF THE CRANE
10
Cra••
BOON: IOOlul
STD.W•l•ht
JIB• 30ful
Jib an,le IOda,
I CONFIGURATION" of the operation manual.
HOOK I M• I.tit Au•. U11
L./No ; Ma Au•, I
Jib angle indicator Luffing jib angle is indicated.

When it is in the range from Oto 99 deg., it is indicated by the 0.1 deg.
11 I JIB
ANGLE I When it is in the range from -99 to O deg., it is indicated by the 1.0 deg.
I d·~
Jib offset angle indicator Jib offset angle is indicaged.

When it is in the range from O to 99 deg., it is indicated by the 0.1 deg.
12 I JIB OFFSET
ANGLE
I
When it is in the range from -99 to O deg., it is indicated by the 1.0 deg.
I d·~ * This indicator cannot be displayed together with the point height
indicator at a time.
1-8
Chart 1. Display
Display item Display range Remarks

1) Rated load 0.0 to 999 pounds X 1000
In 0.1 pounds X 1OOO units up to 100 pounds X 1OOO :
2) Actual load 0.0 to 999 pounds X 1000 then 1 pound X 1000 units
3) Boom angle
Jib angle -150 to 99 deg. In 0.1 degree units for Oto 99 degrees, 1 deg. units for
Jib offset angle O to -150 degrees
4) Operating Radius 0.0 - 999 feet In 0.1 feet units up to 100 feet: then 1 feet units
In 0.1 feet units up to 100 feet: then 1 feet units when

5) Boom height 0.0 - 999 feet
exceeding 100 feet
1-9
1.5 Rear View
1
Controller installation holes
Use 0.59 inch (15 mm) screws (M6) for mounting.
2 CNl lM: Power input connector
3 CN12AM: Load Detector (1-4) input connector

Load Detector output is between 1 and 5 volts.
4 CN12BM: Load Detector (5-7) input connector
5 CN13M: Angle Detector (1-3) input connector
6 CN14M: Angle Detector (4~5) input connector

CHI IM CNIBN
2 8
7 CN15M: Digital input connector
9 :I 7
8 CN16M: Digital output connector
CNl<N
10 6
9 CNl 7M: Analogue output connector
10 CN18M: Communication connector
3 4
1-10
Chart 1. System Input/Output, Connector Designations
Connector No. Pin No. Signals Functions CK2500/CKE2500

CNllM 1 Power supply Power supply (+24 V) Power supply
2 Power supply for output signal (+24 V)
3 Grounding
CN12AM 1 Load detector 1 Power supply (+ 10 V) Boom raising
(18 poles) 2 Signal(+) Load detector
3 Power supply grounding & signal grounding
4 Shield grounding
5 Load detector 2 Power supply (+ 10 V) Spare load detector I
6 Signal(+)
8 Shield grounding
9 Load detector 3 Power supply (+10 V) Spare load detector 2
10 Signal(+)
12 Shield grounding
13 Load detector 4 Power supply (+10 V) Luffing jib
14 Signal(+) Load detector
16 Shield grounding
17 Vacant -
18 -
CN12BM 1 Load detector 5 Power supply (+10 V) Spare load detector 4

(12 poles) 2 Signal(+)
4 Shield grounding
5 Load detector 6 Power supply (+I O V) Spare load detector 5
6 Signal(+)
8 Shield grounding
9 Load detector 7 Power supply (+10 V) Spare load detector 6
10 Signal(+)
12 Shield grounding
CN13M 1 Angle detector I Power supply (+I O V) Boom angle detector
2 Signal(+)
4 Shield grounding
5 Angle detector 2 Power supply (+I O V) Spare angle detector 2
6 Signal(+)
8 Shield grounding
9 Angle detector 3 Power supply (+ 10 V) Luffing jib angle detector
10 Signal(+)
12 Shield grounding
13 Vacant - -
14 - -
CN14M 1 Angle detector 4 Power supply (+I O V) Spare angle detector 4

2 Signal(+)
4 Shield grounding
5 Angle detector 5 Power supply (+ 10 V) Spare angle detector 5
6 Signal(+)
8 Shield grounding
1-11
Chart 2. System Input/Output, Connector Designations
Connector No. Pin No. Signals Functions CK2500/CKE2500

CN15M 1 Limit switch signal Main hook overhoist
2 Aux. hook overhoist
3 Spare
4 Boom overhoist (Backstop first)
5 Boom overhoist (Crane)
6 Boom overhoist (Backstop second)
7 Luffing jib overhoist
8 Spare
9 Contact point input Release switch signal Hook overhoist stop release
10 Reset switch signal Boom and jib stop release
11 Others Overload stop release
12 Spare
13 Boom fix
14 Spare
15 Spare
16 Spare
17 Spare
18 Spare
19 Spare
20 Spare
CN16M 1 Drum stop output Front/Rear drum winch up
2 (ON: Start/OFF: Stop) Spare
3 Spare
4 Boom drum winch up
5 Boom drum winch down
6 Spare
7 Spare
8 Third (Jib) drum winch up
9 Contact point output Third (Jib) drum winch down
10 Others Spare
11 Spare
12 Spare
13 Luffing mode
14 Spare
15 Assembly and disassembly mode
16 Spare
17 External indication output External indication (Green)
18 External indication (Yellow)
19 External indication (Red)
20 CPU fault signal output CPU fault
CN17M 1 Tension Tension(+)
2 Tension(-)
3 Analogue output Boom angle Boom angle(+)
4 Boom angle (-)
5 Jib offset angle Jib offset angle (+)
6 Jib offset angle (-)
7 Vacant - -
8 - -
CN18M 1 RS232C RXD (I) Communication with total controller

2 TXD (I)
3 GND (1)
4 RXD (2) Spare

5 TXD (2)
6 GND(2)
1-12
Chart 3. System Input/Output (Digital Input)
Signals Operations
1) Main hook overhoist Grounded ___. Normal
Open ___. Hook overhoisted
2) Aux. hook overhoist Grounded ___. Normal
Open ___. Hook overhoisted
3) Spare
4) Boom overhoist (Backstop first) Grounded ___. Normal

Open ___. Boom overhoisted
5) Boom overhoist (Crane) Grounded ___. Normal
6) Boom overhoist (Backstop second) Grounded ___. Normal
7) Luffing jib overhoist Grounded ___. Normal
Open ___. Jib overhoisted
8) Spare
9) Hook overhoist stop release Grounded ___. Release of automatic stop caused by hook overhoist
Open ___. Non-release
10) Boom and jib stop release Grounded ___. Release of automatic stop caused by boom overhoist
11) Overload stop release Grounded ___. Release of automatic stop caused by overload
12) Spare
13) Boom fix Grounded ___. Fix

Open ___. Move
14) Spare
15) Spare
16) Spare
17) Spare
18) Spare
19) Spare
20) Spare
1-13
Chart 4. System Input/Output (Digital Output)
Signals Operations Remarks

1) Front/Rear drum winch up
2) Spare
Power is turned OFF ---->- Open
3) Spare Safety area ---->- Output
4) Boom drum winch up Hazardous area ---->- Open
5) Boom drum winch down
6) Spare
7) Spare
8) Jib drum winch up Power is turned OFF ---->- Open Contact capacity
Safety area ---->- Output 2.5 A30VDC
9) Jib drum winch down
Hazardous area ---->- Open (Allowable inrush current : 5 A)
10) Spare
11) Spare
12) Spare
13) Attachment identification (Luffing) Luffing attachment ---->- Output

Others ---->- Open
14) Attachment identification (tower) Tower attachment ---->- Output
(Not use) Others ---->- Open
15) Assembly and disassembly mode Assembly and disassembly mode ---->- Output
Others ---->- Open
16) Setup Setup ---->- Output
Others ---->- Open
17) External indication (green) less than 90% Power is turned OFF ---->- Open Contact capacity
18) External indication (yellow) 90% or more Conditions are not satisfied ---->- Open 2.5A 30VDC
19) External indication (red) 100% or more Conditions are satisfied ---->- Output (Allowable inrush current: 10 A)
20) CPU fault CPU is normal ---->- Output As per remarks of 1) to 16)
CPU is faulty ---->- Open
Chart 5. Output Spares
Signal Operation Remarks

Guy line tension o~FMAx;o~sv Output resistance
Boom angle output o~+90 deg f o~sv is less than 100 n .
Jib offset angle output -90~+90deg/o~sv
1-14
1.6 Choice of Language
The controller display patterns can be altered.
(1) Press the (MENU) switch while the main screen is displayed. Then, the item selection screen appears.
I R~~,·
0
•
10
111111111111111111111111111111
10 10to 100
I !! 111 !!111 !!111 !! 111 !!! 111111111111
R~~)l O
I e. ANGLE II e. P. I
I
BOOM
ANGLE
II BOOM POi
NT ELEY.
I I 56. od·JI aa. 3ul
ELEY-
I 64. 6d·~I
MAIN I
9 5. 8ttl I 3 01"
RATIO
MAIN I I 5. 5 Im~~s
Af6~~L
J8 31. *1000
I RATIO
671" I. RATED
LOAO
60. Oltt
•
POUNDS
1 7. al
j
[MENU]
RADIUS J
I ACTUAL
LOAD
POUNDS
*1000 RATED LOAD
j 26. 41
TABLE
I RATED
LOAD
POUNDS
*1000
Press
RATED LOAD
CU RYE
I 114 7. 1I
- WORKING
RADIUS ft AREA
SETTING
c, ....
BOOM: IOOhet
HOOK r Ma ...
STD. W•leht
JIB,
Aux.
so,111
JI!:. uele
U••
100•
I l t •Chol co
L./No : Ma Au•. SET :Toth• choice •creen
I MENU=To the ••In 1cr11n
Main screen Item selection screen
(2) On the item selection screen, select the "SETTING" with the (ID and @ switches, and press the (SET) switch.
IRATIO
C,I) ••
11111111111111111111111111111111111
70 ao 90 100
I B. MGLE II e. e ELh, I
I 56. od·JI 88. I 3ul !Ml!:l I
I RATIO
II 3 01"
fill c> I
I
I
Afmc
RATED
r.oAO
RADIUS
II
II
II
5. 5lm~gs
1 8. 3 I*1000
60. 0J11
POUNDS
[QJ I It.BLE
RATED LOAD
I CU BYE
RATED LOAD
I ABEt.WORKING
11
I
I
e~mo I Press
Select
->
r
......-:::: SETTING
I
l t =Choice
SET :fa the choice acr11n
I SETT I NG
I MENU:To the •aln 1cre1n
1-15
(3) Next, select the "SETTING OF THE SCREEN" among the items displayed on the screen with the (jt) and @
switches, and press the (SET) switch.
I RATIO
Ill)
11111111111111111111111111111111111
10 70 10 10 100
I RATIO
(Ill
11111111111111111111111111111111111
80 70 10 10 100
I II· 6!!!iLI: II II· e. ELE¥, I I D· 6!!!iLI: II II, e, ELE¥· I
I d·JI ttl1!611! I d·JI ttl
I i I !!All! I
I
I ~m~[ IIII
RATIO
I"
I
I
:~~~gs [ill I
I ~m~[
RATIO
II
II I:~~~~s
'"
I
I
I
RATED
LPAO II
II Ift
POUNDS
*1000
Q Q I RATED
LPA.0 II
II 11 t
POUNDS
*1000
[Q] I
RADIUS RADIUS
I SETTING I iseTT1NGI Press

1seft ING OF THE CRAN~ FETTING OF THE CRAN~
PDnl.lBE
Emma~~ m,~~m:~
ePHIIBE
Emma~~ m,~m~~~
!SETTING OF THE TIMEI
Select
lserTING OF THE T1wel
fETTINO OF THE SCREE3

.- .
,,. --".£err I NG OF THE SCREENj
:choice
' t •To the cholc• 1cre1n
SET
ISETTING OF THE SCREEN I

I , t 1tholc1
SET :to the choice 1creen
Item selection screen
(4) Then, the screen to alter display patterns appears. Select any intended item with the (jt) or@) switch, and choose any
intended choice between "ENG" or "ENG (SI UNIT)" with the §) or @ switch.
I RATIO
(I)
11111111111111111111111111111111111
10 70 IO 10 100
I II· 6!!!iLE II D· e. ELE¥- I

I d·JI ttlM!IH I
I ~m~(
RATIO
I I'":~~~gs
I RATED
LPAO I:~~~gs A. LOAD
I RADIUS I ft 1• 31.*1000
POUNOS
I SETT I NG OF HE SCREEN
I Press
R. LOAD I
CRANE SI LKO\IETTE _No •ves 6• 71.*I
POUNDS
OOO
BDDII PO I NT ELEY. No eves RADIUS I
JI I OFFSET ANGLE eNo Yeo 19 o. 5!tt
TNE CHOICE Of THE JPN •ENO
' -
LANGUAGE ENGblWlff
Choice Crue STO,W•l•M
BOOH t IOOfe•t J 18 i IIOhet
JI t, an• I• 30dee
~~~ : : : 11 Uee A1'x. 1:""· ,..=U•::..•- - - '
Examnle:Crane silhouette
THE CHOICE OF THE LANGUAGE .................... The language used can be switched. For use in the Northern
America, choose the "ENG". Choose "ENG (SI UNIT)" for use in
the Europe.
1-16
2. PREPARATION FOR USE
Prior to installation, be sure to correctly identify and verify all the connecting lines, then connect them to the CNI IM to
CN18M connectors, on the back of the unit.
(The CN-12BM is not connected.)
2-1
3. TURN THE POWER ON
After checking all connections for accuracy. Then tum the power on.
A line misconnection may cause errors and/or cause an alarm to sound. In this case, shut the power off and recheck wiring
and the detectors (load detector, angle detector). For further information on handling errors, see "6. Error Listings
(Detecting Abnormalities) and Corrections".
3-1
4. UPGRADING PROGRAMS
When upgrading the programs in the controller, use the program memory card.
Two types of programs, comprising "indication programs" and "control programs", are stored in the controller. The
program memory card for upgrading always contains these two types of programs.
4.1 Procedures
Open the cover, and press the push button located on the left side of the loading port to partially eject the data memory
card. Then, remove the card from the loading port with your fingers.
Check the version on the label attached to the program memory card, and fully insert the card into the loading port.
Use the dip switch located on the left side of the card loading port to enable the upgrading of programs.
Turn the dip switch No.I ON to upgrade indication programs, and turn the dip switch No.2 ON to upgrade control
programs.
A CAUTION
When upgrading both of display programs and control programs, be sure to upgrade the display
programs first, and then, upgrade the control programs.
Insertion and removal of card

The card can be removed or inserted even when power supply to the controller is turned on, except for the time that the
controller accesses the card. Messages including "Reading" or "Transferring" appear during the access. In such a status,
DO NOT remove the card.
4-1
(1) Tum ON the dip switch No. I or 2 located in the cover. Then, (UPDATE) is displayed on the menu screen.
i
Move the cursor "=>" onto the (UPDATE and press the (SET) switch.
I R~~)I o !!I "!! 111 !! 111 !! II lj !!I 1111111111 I

I B. ANGLE II B, P. ELEy. I
I deJI ttl
~--~' MAIN I
I A~~~~L II
I RATIO
11:======:I =~~~gs
'"
I RL~TAEoo 11 I :~~~gs
I RADIUS II jtt
RATED LOAD II LOAD
::===:=;:~I~A~B~LE~:;::=~ ~-~BE~C=P=B~P_ __.
RATED LOAD
CURVE
I
WORKING 1->J
::====:::::!:!AR~E~A-====~""1~_-u_PD_A_T_E_ __,
SETTING
I
t ! :Choice
SET :ro the choice screen
MENU:To the main screen
(2) "THE UPDATE OF THE INDICATION CPU" is displayed if the dip switch No.I has been turned ON, and "THE
UPDATE OF THE CONTROL CPU" is displayed if the dip switch No.2 has been turned ON.
* Both of the messages above are displayed in the example of the screen shown below, since both of the dip switches
No. I and 2 are turned ON in this case.
I R~~)I O !!I" !!I "l! 111 !!111! w11111111111

I e. ANGLE II e. P. ELEV. I
I d·JI ttl
MAIN I
I RATIO '"
ACTUAL ::===~1 POUNDS
I. =R:=A;::;;T;:;;E;;;:D==::======:1
;:I
LOAD . *1000
POUNDS
LOAD ::===~· *1000
I RAD I us I I f t
I UPDATE I
~I THE UPDATE OF
THE INPLCAIIPN CPU
?I===~T~H~E~U~P~D~AT~E~OF~=====:
. THE CONTROL CPU
t 1 :Choice
SET :fo the choice screen
Move the cursor "=>" onto "THE UPDATE OF THE INDICATION CPU", and press the (SET) switch. Then, the
indication programs can be upgraded. To upgrade the control programs, move the cursor"=>" onto "THE UPDATE
OF THE CONTROL CPU", and press the (SET) switch.
4-2
4.2 Upgrading of Indication Programs
(1) Select "THE UPDATE OF THE INDICATION CPU". Then, the screen shown below is displayed.
I R~~)I O !! 11 '!l Ii I!!I II !!I ''! !! 111111111111

I B. ANGLE ii B. P. ELEV. I
I deJ I ttl
MAIN
I RATIO
I Af&~~L :?~~gs
RATED ::=======: POUNDS
I =L~O~AD:::=:: :=====::::: *I O00
I
:=·
RADIUS f t
DISPLAY PROGRAM UPDATE OK?

YES:DOWN CANCEL:MENU
When upgrading the program, press the @ switch. When canceling, press the (MEN(!) switch.
The previous screen appears when the (MENU) switch is pressed.
(2) When error messages appear on the screen just after the @ switch is pressed, the data memory card may be left
inserted. In such a case, check the data memory card.
IR~~~ !! 11 q!II IHI 11 !! 11 q!!' 11111 111111

0
DISPLAY PROGRAM UPDATE OK? I e. ANGLE II e. p. ELEy. I

YES:DOWN CANCEL:MENU I deJI ul
HAIN
I RATIO "
I Af ~~~c :::::======: :?~~gs

PROGRAM DATA OPEN I ::::!L=:!!:O!:!:!!AD!:::::::::::l :::::===:::::
RATED POUNDS
::=======: *t ooo
I
::::=·
RADIUS ft
PUSH ANY KEY TO RESET
4-3
(3) After the programs in the controller are erased (it takes approx. 30 sec.), new programs in the card are written onto the
controller.
When the indicated OKB is increased to 1023 KB, upgrading is complete. If upgrading is successfully completed, the
screen shown below appears.
I R~~,
10
wI!!
I
I B. ANGLE II B.
l! HI "! w11111 11111 I
111 II I
P. ELEY. I
I deJI tt!
DISPLAY PROGRAM UPDATE OK? MAIN
YES:DOWN CANCEL:MENU RATIO %

At 6~~L ::::::==~ ~~~~gs
RATED :::======! POUNDS
PROGRAM DATA OPEN ::::~L~OA==P==::: ::====: * I O00
f t
PROGRAM DATA DETECTED RAD I US
ERASE EEPROM (about 30secl

TRANSFER PROGRAM DATA
1023KB
COMPLETE, PUSH ANY KEY TO RESET
When either switch is pressed, the power supply is reset, and the controller is rebooted.
Then, upgrading of the indication programs is completed.
A CAUTION
DO NOT remove or insert the data memory card while programs in the card are written onto the
controller. Otherwise, malfunction will occur.
4-4
(4) If the data memory card is not inserted, the error message of "INSERT PROGRAM CARD & PUSH ANY KEY"
appears on the screen just after "THE UPDATE OF THE INDICATION CPU" is selected.
I R~~)I O l!' 11 !!' 11 l! 111 !! 111 !!! 111111111 111

I e. ANGLE II B. P. ELEY. I
I d.,JI ttl
MAIN
I RATIO
ACTUAL POUNDS
I.i=I=;R;;=A;:=.T~E:;;;:D~
LOAD
::===~ *1000
POU NOS
I:::·:::!:L~OA!::!P!!::=~ i====:::::: *t ooo

RADIUS f
I
INSERT PROGRAM CARD &PUSH ANY KEY
If the error message above appears even though the data memory card is inserted, imperfect contact may occur. In
such a case, remove the data memory card, and re-insert it.
* When inserting or removing the card, it is unnecessary to shut the power down.
After re-inserting it, press any switch. If the error still cannot be corrected, the controller or the card may be faulty.
In such a case, it must be replaced.
4-5
4.3 Upgrading of Control Programs
(1) Select "THE UPDATE OF THE CONTROL CPU". Then, the screen shown below is displayed.
I e.
I
R~~)I O
e'tNQLE
!!' II H111 HI II !!111 !!! 111111 111111
II e. p. ELEy. I
I d·JI ,t!
~--~'
I II Hr'l!N I"I
RATIO
I AE~~~L l:=I==~I :?~~gs

I. RATED
LOAD
II.. I. *1000
POUNDS
I RADIUS II Ift
n, ornrn ol 111 coolral tPU 11 011111.
"l'ualt ,I, If It h 110•. Cuctl lltlH II to •u11t MENU,
The Program of the control CPU is updated.

Push .J, if it is good.Cancellation is to Push MENU.
When upgrading the program, press the @) switch. When canceling, press the (MENU) switch.
The previous screen appears when the (MENU) switch is pressed.
(2) When error messages appear on the screen just after the @ switch is pressed, the data memory card may not be
inserted at all, or may be inserted partially or left inserted. In such a case, check the data memory card.
IR~~: 0!! 111 HI 11 !! 111 !!' I lj Hi 1111111111 I

I e. ANGLE II e. e. ELEY- I
I d·JI ttl
~---.I MAIN
I RATIO Ii "
The Prooram of the cont ro I CPU is uPda ted. I AE~~~L 1::::1 ===: :n~gs
Push ,I, if it is good.Cancellation is to Push MENU.
Data are being referred to.

Proeram data reference error. Pusn any switch.
I. RATED
I RADIUS
THE
LOAD
' ~--~It
II..
UPDATE OF
THE CONTROL CPU
Tbt orotrt• ol th, control CPU It uoltled.
POUNDS
*1000
PUlh ~ lr II l1uod.Cuctlltlloo l1toH1hMENU.
4-6
Other errors
· Memory elimination error
Program area in the flash memory in the controller cannot be deleted. -+ Replace the controller.
· Memory card read error
Program cannot be read out from the card. -+ Recheck the card insertion status or replace the card.
· Writing error
Program cannot be written into the flash memory in the controller. -+ Replace the controller.
(3) If the intended programs are found in the controller after the @ switch is pressed, they are erased first (it takes several
seconds for erasure). Then, new programs in the card are written onto the controller.
When the indicated OKB is increased to 1023 KB, upgrading is complete. If upgrading is successfully completed, the
IR~~,. 0!! 111 H111 !!I II!! II q!!111111111111

I B, ANGLE Ii 8, P ELEY· I
The Proeram of the control CPU is updated. I d~I ,tl
I HAIN I
Push ~ if It is oood.Cancellation is to Push MENU.
o;;:::::l! ===ll •
l=I,:;RA.;,T;;,1 I=!
Data are beino referred to. cmE]I 1:~~~~s

Program data were detected. ~:=j====II =~~~gs
A Provram memory is being erased.
Prooram data are beins transferred.
I II
RADIUS lit
128KB
n, ,,,.,,1 11 ••• c•trat c,v tt 1H1t1•.
It was completed. h1• l If It II Ut'-CHCIIIIIIH II tl Hiii N!IIJ.
It is reset. Push any switch. Gita IU •1111 rtftrrtll te.
,, .. ,11 ll1tl 11r1 llttacltL
A H1tru HHn II hlll lflll ..
PrHtH
121KB
••ta '" ,,, •• tn11httl..
It Ill UlfllttL
II h rult. , ... lltr HI hL
When either switch is pressed, the power supply is reset, and the controller is rebooted.
Then, upgrading of the control programs is completed.
A CAUTION
DO NOT remove or insert the data memory card while programs in the card are written onto the
controller. Otherwise, malfunction will occur.
4-7
5. STATUS CHECK
This controller features various status check functions for easier diagnosis of malfunctions.
Tum ON the dip switch No.4 in the cover. Then, the items to be checked are displayed in the lower half part of the screen
as shown below.
II
.
RATIO
(%)
B. ANGLE
I I I I I I I I I I I I I I I I I I I 111111111111111
60 70
II
80
B. P. ELEV.
90
I
100
I deJI.___---=====f t::!..._I_
MAIN
RATIO %
:==A:;::C;;:;T;;:;U:;::A;:;L===! ::====::::! POUNDS
RATED
*
:==:;;:L:::::O:;;A:::;:D:::=::::! :=======! l OOO
POUNDS
::=:::::L=O=A=D==::::! :=======! >:c l OOO
RADIUS ft
- NPUT AND OUTPUT SIGNAL CONDITION

OPERATION PROGRESS
Items to be checked COMMUNICATION DATA
ADJUSTMENT VALUE
LOAD RECORD
- TROUBLE RECORD
t ~ =Choice
SET :To the choice screen
5-1
5.1 Signal Check
Statuses of signals input from the sensors and limit switches or those of automatic stop signal output can be checked.
On the "STATUS CHECK" screen, move the cursor"~" onto the "INPUT AND OUTPUT SIGNAL CONDITION", and
press the (SET) switch. Then, the screen shown below appears.
Statuses of analogue signals from the load cells and angle detectors are displayed on this first displayed screen.
Up to seven load cells and up to five angle detectors can be connected to this controller.
Refer to the input/output list of page 1-9 for details of connection.
For the cells and sensors that are not connected to the controller, values close to 0.4 are displayed.
! R~~)IO !!111!!111 !!11 IJ!I I1!!!11111111111 j

I e. ANGLE II a. P. ELEY, I
I d,JI ,ii
LOAD CELL I !. 4 7 ANGLE SENSOR I 6. 04 I !!Alrl I
LOAD CELL 2 o. 3 7 ANGLE SENSOR 2 I RATIO
II I•
o.
1. 1 0
o.
I l f~~~c II 1:m~s
LOAD CELL 3 79 ANGLE SENSOR 3 41
I RATED
\.OAQ II 1m:gs
LOAD CELL 4 o. 3 7 ANGLE SENSOR 4 o. 41 I RADIUS
II 1,t
LOAD CELL 5 o. 3 7 ANGLE SENSOR 5 4. 28 SIGNAL CHECK !u• :~~
LOAD CELL 6 o. 59 lOMI Cfll I 1. 4 7 AIIGLf lfllOI I 8. 04
WI CELL I O. 3 7 AIIGlf lfllOI I I. 10
LOAD CELL 7 5. 61 WI CELL I O. 7 8 ANGLE IEIIOI I o. 41
LIAO CELL 4 O. 3 7 AIIGlf IEIIOI 4 o. 41
WO CELL I O. 3 7 AIIGlf SEIIOI I 4.28
WO CELL I o. 59
WO Cfll J 5. &I
Press the @ or (ID switch once. Then, the screen shown below appears.
Statuses of input and output of digital signals can be displayed on this screen. For the designations and functions of
signals, refer to the input/output list of page 1-11.
For input digital signals, a "0" mark indicates the grounded status, and a "X" mark indicates the open status.
For output digital signals, a "O" mark indicates the output status, and a "X" mark indicates the non-output status.
* Displayed output signal statuses are decided as a result of software processing only.
If the hardware is faulty, the output may not be as shown below.
I <•l
RATIO 11111111111111111111111111111111111
10 70 10 10 100
I Eli 6~iiLE II II· E! ELE~. I
INPUT OUTPUT I d~I f tl
1: 0 I 1 x 1 0 11 x I !!l~ltJ I
2 :0 12: x 2: 0 12: x I RATIO
II I•
3: 0 13: x
x
3: 0 13: 0
14 : x
I llm~c II I:~~~gs
4:
5:
0
0
14:
1 5: x
4:
5:
0
0 I 5 : x I AAno 1..QAQ II 1:mgs
5: x 1 6: x 6: 0 1 6: x I RADIUS
II Ift
7: x 17: x 7: 0 17: 0 SIGNAL CHECK !u' NEXT
a= x 18: x a: 0 18: x
PAGE
9: x 1 9: x g: 0 1 9: x INPUT OUTPUT
I O: x 20: x 1 0: x 20: 0 I
2
0
·o
II
12
I
2
0
0
II
12
x
x
.
3
5
0
0
0
I5
14
15
3
•e5
0
o·
0
1S
14
15
0
x
x
e x I8 0 11 x
••x
7 I7 7 0 17 0
8 18 I 0 18 x
a I9 a 0 19 x
10
• 20 10 x 20 0
5-2
5.2 Operation Progress
On the "STATUS CHECK" screen, move the cursor"=>" onto the "OPERATION PROGRESS", and press the (SET)
switch. Then, the screen shown below appears.
IA~~: 0!! 111 !JI II!! 111 !! II'!!!' 11111111111

FOM 23. 62 FR 0.
00 I B ANGLE Ii 8 P, ELEY, I
FOA 24. 00 WHOLE R. L. 11.83 I 3 1. 4d·JI s 1. 3,tl
FOR o. 00 WHOLE A. L. 7.
47 ~-~I
I RATIO H
HAIN
64!•
I
6M
6A
4. 7 3
4. 74
WHOLE RAT.
MAIN R. L.
63.56
83
1 1.
i Am~c II 7. 5 !:?~~gs
I. RATED II. . 1 1• 8 I. *IPOUNDS
6R o:·o o AUX. R. L. 28
1 1.
!
LOAD
H89. 3!tt
OOO
FOO o. 00 TH IRD R. L. o. 00 RADIUS
F 58. 93 RM 8 9. 30 OPERATION PROGRESS I

FM o. 00 RA 9 2. 5 0 FON 23. 92 FR o. 00
FA o. 00 RR o. 00 FOA
FOR
!M
24.00
O. 00
4. 73
IIHILE LL
IIIOLE lL
IIHILE IAT.
11. 83
7. 47
83. H
C. VOLTAGE 2. 80 U
!R
4. 74
0.00
IAINLL
AUi. LL
11.U
II. 28
1101 OOO I 00110 FOO
F
0.00
58. 83
INIIO L L
IN
O. 00
U.So
FM O. 00 IA 92,50
FA O. 00 11 0, 00
C. YOLTIGE 2. ao
IIOIIOOlltllO
Symbols Details
FOM Tare weight component during main winch lifting with current radius
FOA Tare weight component during aux. winch lifting with current radius
FOR Tare weight component during third winch lifting with current radius
oM Load coefficient during main winch lifting with current radius
oA Load coefficient during aux. winch lifting with current radius
oR Load coefficient during third winch lifting with current radius
FOO Tare weight component other than weight of hook block with current radius
(during simultaneous lifting only) (Not used)
F Raising guy line tension
FM Main winch wire rope tension (w/ main winch load cell) (Not used)
FA Aux. winch wire rope tension (w/ aux. winch load cell) (Not used)
FR Third winch wire rope tension (w/ third winch load cell) (Not used)
WHOLER.L. Whole rated load (rated load during selected mode other than simultaneous lifting mode)
WHOLEA.L. Whole actual load (actual load during selected mode other than simultaneous lifting mode)
WHOLE RAT. Whole moment ratio (value indicated in bar graph)
MAINR.L. Main winch rated load with current radius on the basis of data
AUX.R.L. Aux. winch rated load with current radius on the basis of data
THIRDR.L. Third winch rated load with current radius on the basis of data
RM Calculated main winch operating radius before correction by radius adjustment
RA Calculated aux. winch operating radius before correction by radius adjustment
RR Calculated third winch operating radius before correction by radius adjustment
C. VOLTAGE Control voltage of liquid crystal
13-digits number Data judgment code
5-3-1
Example of using operation screen
The actual load W can be indicated by the formula shown below.
Hoist guy line tension

Dead weight component (M.A.R)
I Load-less adjustment value (Span)
Load-less adjustment value (Shift)
Actual load W = F - (FO x kl+ k2 )
cox k3 +k4)
I I l___ Some load adjustment value (Shift)

~ S o m e adjustment value (Span)
Load coefficient (M.A.R)
Suppose the values above are indicated shown below and the indicated actual load is 2 t, when a
load weighing 5 t is lifted with the main winch.
F=4.97
FOM=2.28
o = 1.33
If neither load-less adjustment nor some load adjustment is carried out, and factors from kl
to k4 are ignored, the theoretical F required for the actual load of 5 t can be found by the
using the formula above, as shown below.
F = 5 x 1.33 + 2.28
= 8.93
Where, the actual F is obviously smaller than the theoretical F.

Next, the F can be found by the formula shown below.
I Load cell rated capacity (depending on the machine models)
5 x (present load cell voltage - load cell zero adjustment value)

Hoist guy line tension F =
(5 - load cell zero adjustment value) x 0.08333 x (1.02 or 0.98)
Load cell rated voltage _J

I/hoist rope coefficient
_J L Correction coefficient
for raising (depending
(depending on the machine models) on the machine
models)
Correction coefficient for lowering
(depending on the machine models)
If the load cell zero point adjustment has not been carried out, adjustment value is l, and the coefficient is 1.02, if lowering
is stopped. In such a status, if the load cell voltage is calculated with using the formula above and the values when the F
is 4.97, the present load cell voltage is 1.34 V.
In a similar manner, the load cell voltage is 1.61 V, when the theoretical tension Fis 8.93.
Then, check the load cell voltage on the signal check screen (P.5-2). If it is close to 1.34 V above, the detected load cell
voltage is smaller than the theoretical value. In this case, the load cell may be faulty.
5-3-2
5.3 Communication Data
Details of data transmitted from other controllers can be displayed.
Meanings of the numbers in communication data are shown below.
On the "STATUS CHECK" screen, move the cursor "~" onto the "COMMUNICATION DATA", and press the (SET)
switch. Then, the screen shown below appears.
Control signals of control levers are used for the output of buzzer sounds or correction of load. Thus, check the
communication status if any fault is found in them.
DIGITAL 1 0000000
DIGITAL 2 1000000
DIGITAL 3 0000000
COMMUNICATION DATA
DIGITAL 4 0000000
IIIITII. I 0000000
tlllTAI. I toOOOOO
1111111. I OOOIOOO
IIIITM. 4 0000000
Digital 1 0 0 0 0 0 0 0
E
0: No operation 1: Main winch up
0: No operation 1: Main winch down
0: No operation 1: Aux. winch up
0: No operation 1: Aux. winch down
0: No operation 1: Third winch up
0: No operation 1: Third winch down
Spare: Fixed to O
Digital 2 0 0 0 0 0 0 0
E
0: No operation 1: Boom raising
0: No operation 1: Boom lowering
0: No operation 1: Jib raising
0: No operation 1: Jib lowering
Spare: Fixed to O
Spare: Fixed to O
0: Receive normal 1: Receive error
Both digital 3 and digital 4 are spare, and fixed to zero.
If" 1" appears in the indicator corresponding to the operated lever, the status is normal. The response may be delayed by
approximately a second, depending on the communication status. If only one operation is faulty and the others are normal,
check the signals between the pressure sensors and the total controller.
5-4
5.4 Indication of Adjustment Value
Results of adjustments can be checked.
On the "STATUS CHECK" screen, move the cursor"~" onto the "ADJUSTMENT VALUE", and press the(SET) switch.
Then, the screen shown below appears (menu screen).
I RATIO
,.,
11111111111111111111111111111111111
10 70 10 10 100
I 8. ANGLE II B. P. ELEY, I
I ANGLE SENSOR I d·J I
I
,t!
!!AIN I
I LOAD CELL ZERO PO I NT I Am~[ RATIO
II
1m~gs
IA LOAD CELL FOR LINE-PULL
I
I RATED
~OAO
II
II '"
1m~gs
I RADIUS
II 1,1
THE INDICATION OF THE AOJUIINENI VALUE
I FO/o (MANUFACTURER) ANGLE SENSOR I
I LOAD CELL ZERO POINT I
I FO/o WSERl IA LOAD CELL FOR LINE-PULLl
I F0/1 INAIIUFACTUAERJ I
I I
I RADIUS I
Fo/llVSEII
RADIUS I
5.4. 1 Angle Sensor Adjustment Value

On the "ADJUSTMENT VALUE" screen, move the cursor"~" onto the "ANGLE SENSOR", and press the (SET) switch.
Then, the table showing angle sensor adjustment values appears on the screen.
THE INDICATION OF THE ADJUSTMENT VALUE IR~~lo J!lll\!111!!111!!'11!!!11111111111 !

ANGLE SENSOR I B. ANGLE Ii g. p. ELEY, I
No. 1 No. 2 No. 3 No. 4 No. 5 I '·JI I
ttlHAIN I
SHIFT 0. OOO O. OOO O. OOO 0. OOO 0. OOO
II Am~L IIII
SPAN 1. OOO I. OOO I. OOO 1. OOO 1. OOO RATIO
I'"m~gs
No. 6 No. 7 No. 8 No. 9 No. 10 I WN II 1:~ms
SHIFT O. OOO O. OOO 0. OOO 0. OOO O. OOO I RADIUS II !tt
SPAN 1. OOO 1. OOO 1. OOO 1. 0 00 1. 0 00 I ~
THE INtlCAl~ I
l~Ee:io~ilaNENI VALUE
No. 11 No. 12 No. 13 No. 14 No. 15 ImP I;;gig Ii~:h Ir:h Ii:';!x Ii:'ib I
SHIFT O. OOO -2. 003 O. OOO 0. OOO 0. OOO
SPAN 1. OOO 1. 061 I. OOO 1. 0 00 1. OOO Im:r IFdx Itd: Ir:h It;;b It;d! I
I~pur 1;;;u I-tin Irdi Ii:';H It:H I
In CK2500 and CKE2500, No.12 is used as the boom angle detector. And No. 1 is used as the jib angle detector. While
adjustment is not provided, "0.000 (in the lines of SHIFT)" and "I.OOO (in the lines of SPAN)" are indicated.
5-5
5.4.2 Load Cell Zero Point Adjustment Value
On the "ADJUSTMENT VALUE" screen, move the cursor"~" onto the "LOAD CELL ZERO POINT", and press the
(SET) switch. Then, the table showing the load cell zero point adjustment values appears.
THE INDICATION OF THE ADJUSTMENT VALUE

LOAD CELL ZERO POINT
I RATIO
(Ill
11111111111111111111111111111111111
10 70 •• IO 100
I a. !~!:iL~ II a-e1ELf~.1
No. 1 No. 2 No. 3 No. 4 No. 5 I d·JI I
ttl!!t61~ I
i L1 [ Vl 1. 01 5 1. OOO 1. OOO 1. OOO 1. OOO II
I
II":~~~gs
RATIO
i L2 [ VJ 1. OOO 1. OOO 1. OOO 1. OOO 1. OOO I A~mc II
i L3 [ Vl 1. 0 00 1. OOO 1. OOO 1. OOO 1. OOO
I LO~Q
RATED
II I:~~~gs
i L4 [ VI 1. OOO 1. OOO 1. OOO 1. OOO 1. OOO I RADIUS II jtt
TIE IHDICATIDN Of THE ADJUSTNENT VALUE
No. 6 No. 7 No. 8 No. 9 No. 10 LOAD CELL ZERO POINT
i L5 [ V] 1. OOO 1. OOO 1. OOO 1. OOO 1. OOO

i L6 [ Vl
i L7 [ VI
1. OOO
1. OOO
1. OOO
1. OOO
1. OOO
I. 0 00
1. OOO
1. OOO
1. OOO
1. OOO Imll It1ii Inll IHi I!~Ii Imi I
Iitmll mii Im11 Imi1 Imi1 Ii~i l I
In CK2500 and CKE2500, No.I of the iLl is used as the boom raising load cell. And No. 1 of the iL4 is used as the jib load
cell. While adjustment is not provided, "I.OOO" is indicated.
5.4.3 Adjustment Value of Load Cell for Line-Pull

On the "ADJUSTMENT VALUE" screen, move the cursor"~" onto the "A LOAD CELL FOR LINE-PULL", and press
the (SET) switch. Then, the table showing the adjustment values of load cell for line-pull appears.
THE INDICATION OF THE ADJUSTMENT VALUE

A LOAD CELL FOR LINE-PULL
!NE IHICATIOH OF IRE ADJUSTNENI YALUE
M A R A LOAD CELL FOR LI NE-PULL
SHIFT 0. OOO O. OOO O. OOO

SPAN 1. OOO 1. OOO 1. OOO
M::: MAIN, A= AUX., R = THIRD

While adjustment is not provided, "0.000 (in the line of SHIFT)" and "I.OOO (in the line of SPAN)" are indicated.
Since CK2500 and CKE2500 is not equipped with this load cell, it can be ignored.
5-6
5.4.4 Result of Manufacture Adjustments "NO LOAD" and "SOME LOAD"
On the "ADJUSTMENT VALUE" screen, move the cursor"~" onto the "Fo/o (MANUFACTURER)", and press the
(SET) switch. Then, the table showing the results of manufacturers adjustments, "NO LOAD" and "SOME LOAD",
appears on the screen.
(Fo = NO LOAD, o = SOME LOAD)
THE INDICATION OF THE ADJUSTMENT VALUE F0/6{Ml GR- I

!R~~:o !!ell!!~IUle!t!lO!!!IIIIOIIIII
. R ANGL_ ii_ -· ___ y; I
!
No. I No. 2 No. 3 No. 4 No. 5 I ~~1 111
BOOM/JIB O. OOO O. OOO O. OOO O. OOO O. OOO RATIO MA!N·I:DUNDS
~
No SHIFT O. OOO O. OOO O. OOO O. OOO O. OOO •1000
No SPAN I. OOO I. OOO I. OOO I. OOO I. OOO POUNDS
•1000
S. SHI FT O. OOO O. OOO O. OOO 0. OOO O. OOO RADIUS It
s. SPAN I. OOO I. OOO I. OOO I. OOO I. OOO
..
•..
TU IIIIClTIN flf TH !IJHIIIBII rAI.IE F0/I ..
'
~ ....
No. 6 No. 7 No. 8 No. 9 No. 10 •
BOOM/JIB O. OOO O. OOO O. OOO 0. OOO O. OOO . .........
_.. ,. ....
No SHIFT O. OOO O. OOO O. OOO O. OOO 0. OOO
....
No SPAN
S. SHI FT
I. OOO
O. OOO
I. OOO
O. OOO
I. OOO
O. OOO
1. OOO
O. OOO
I. OOO
O. OOO .. ......
"''
...
s. SPAN 1. OOO I. OOO I. OOO I. OOO 1. OOO •••
For group No. 1 to 30, adjustment with a load or without load for ten types of boom lengths is possible.
First, the table of group No. 1 is displayed. ("GR-1" can be seen in the upper right side of the screen.) Whenever the@
switch is pressed, the screen changes from GR-1 to GR-30. Whenever the§ switch is pressed, screens appear in the
following orders: GR-1, GR-30, GR-29, ....
In respect of No. I to 10, boom length or Jib length (BOOM/JIB) on which adjustment is conducted, shift and span of
adjustment without load (No SHIFT, No SPAN), and shift and span of adjustment with a load (S. SHIFT, S. SPAN) are
indicated.
While adjustment is not provided, "0.000 (in the lines of BOOM/JIB, No SHIFT, S. SHIFT)" and "1.000 (in the lines of No
SPAN, S. SPAN)" are indicated.
Correcting function is actuated only when the lengths of booms that have not been adjusted are adjusted between the
intended booms.
For example, if the 40 ft. and 80 ft booms are adjusted., 50 ft., 60 ft., and 70 ft. booms are corrected by the adjustment
values of the correcting function. However, the adjustment values cannot be used for 30 ft. and 90 ft. or longer booms.
5-7
5.4.5 Result of Load Adjustments "NO LOAD" and "SOME LOAD"
On the "ADJUSTMENT VALUE" screen, move the cursor"~" onto the "Fo/8 (USER)", and press the "SET" switch.
Then, the table showing the results of user adjustments, "NO LOAD" and "SOME LOAD", for the selected mode appears
on the screen.
IR~~t OHII IJ! 111 !! 111 !! II q!! 111111111111

j e. ANGLE Ii e. P, ELEY, I
I ,JI
0
,11
~-~I MAIN I
I RATIO II I"
THE INDICATION OF THE ADJUSTMENT VALUE I Afmc l~I=====!, :~~~gs
FO/o (USER) I WN II I:~~~gs
M A R
I RADIUS II 1,1
THE INDICATION Of IHE ADJUSTMENT IALUE
No SHI FT 0. OOO O. OOO O. OOO F0/5 (USER)
No SPAN I. OOO 1. OOO I. OOO

s. SHI FT O. OOO 0. OOO O. OOO
s. SPAN I. OOO 1. OOO 1. OOO
M = MAIN, A= AUX., R = THIRD

While adjustment is not provided, "0.000 (in the lines of SHIFT)" and "I.OOO (in the lines of SPAN)" are indicated.
5.4.6 Adjustment Value of Working Radius

On the "ADJUSTMENT VALUE" screen, move the cursor "~" onto the "RADIUS", and press the (SET) switch. Then,
the table showing the adjustment value of working radius appears on the screen.
Adjustment values of group No. 1 to 30 can be displayed on this screen, and the table of group No. 1 to 10 is displayed first.
To display the table of groups No. 11 to 20, press the @ switch.
While adjustment is not provided, "0.000 (in the lines of SHIFT)" and "I.OOO (in the lines of SPAN)" are indicated.
I R~~)I O !!I II (!111 !!I II !!III!!! 111111111111

I B· ANGLE Ii B, p. ELEY· I
THE INDICATION OF THE ADJUSTMENT VALUE I d,JI ,11
RADIUS
No. 1 No. 2 No. 3 No. 4 No. 5
SHIFT O. OOO O. OOO O. OOO O. OOO O. OOO
SPAN 1. OOO 1. OOO L OOO 1. OOO 1. OOO
11E INDICATIDN Df THE ADJUSTMENT VALUE
No. 6 No. 7 No. 8 No. 9 No. 10 A I S
SHIFT O. OOO O. OOO O. OOO 0. OOO 0. OOO

SPAN 1. OOO 1. OOO 1. OOO I. OOO 1. OOO Im:r I1M: It;ih Iv:'lh Ifib 1,;ih I
Im:r Ii;d: Itd: IJ;d: IFil: 1i~dl I
5-8
5.5 Load Record
This controller features the function to record the data of hazardous statuses for easier investigation of causes of troubles
(load record).
The recording is started when the moment ratio or boom angle exceeds the upper or lower limit values, and data are
recorded for ten seconds in total, from the time five seconds before the peak to the time four seconds after the peak every
second.
On the "ADJUSTMENT VALUE" screen, move the cursor"~" onto the "LOAD RECORD", and press the (SET) switch.
Then, the load records can be checked.
Unit record (records for 10 seconds) is displayed in two pages. To scroll down the page, press the (ID key, and press the
(ID key to scroll up the page.
Up to 200 units ofrecords (400 pages) are available.
IATII
Ill
IMl HIMilL i11JUY I•• ''5-

j'OCJll:::ar.J&'...~ NI
j' OCJOll1"::a'...,UI! NI
.::.l'WQT°::a'...~ NI
............_.t .::.l' W'.Dl"::li.'...,UI! NI
.:J.' W'.Dl"::li.'....:u= NI
0/ 8/ 1
096
096
18: 6: 8
O. OP
O. OP
1100400100110
o. OP
o. OP
0 ft
0. 0 ft
o.
2
10396
103%
1 0
17. SP
A
1 7. OP
40. 8dea-
37. 411}
8. 6deo
Four seconds after
the peak of moment ratio
0000000 0000000 0000000 0000000 1000000 49. 4deo
0/ 8/ 1
096
0"
0000000
18: 6: 7
O. OP
0. OP
1100400100110
OP
o. OP
0000000
o. o. 0 ft
o. 0 ft
0000000
2
106%
10696
0000000
1 0
17. SP
A
1 7. OP
40. 8dea-
1000000
37.4ft
8. 6deo
49.4deo
} Three seconds after
}
0/ 8/ 1 18: 6: 6 1100400100110 2 1 0 A
096 O. OP 0. OP o. 0 ft I O 6% 17. SP 17. OP 37.4ft Two seconds after
096 O. OP OPo. o. 0 ft 106% 40. 8deg- 8. 6deo the peak of moment ratio
0000000 0000000 0000000 0000000 1000000 49.4deo
0/ 8/ 1
0 96
0%
0000000
18: 6: 5
O. OP
O. OP
1100400100110
o. OP
o. OP
0000000
0 f t
0 ft
0000000
o.
o.
2
I 12%
I 1 2 96
0000000
I 0
17. SP
A
1 7. OP
40. 8dea-
1000000
37.4ft
8. 6deo
49. 4deo
} A second after the peak
moment ratio
0/ 8/ 1
096
096
0000000
18: 6: 4
O. OP
O. OP
0000000
o.
o.
1100400100110
OP
OP
o. 0 ft
o. 0 ft
0000000
2
1 1 6 96
1 I 6 96
0000000
1 0
17. SP
A
1 7. OP
40. 8deo-
1000000
37.4ft
8. 6deo
49. 4deo
} Peak of moment ratio
5-9
Page
2P
16: 6: 3
}
0/ 6/ 1 1100400100110 2 1 0 A
096 O. OP O. OP o. 0 f t I I 696 17. 5P 17. OP 37.4ft A second before
0% O. OP O. OP 0 f t o.I 16% 40. 8deg- 8. 6deg the peak of moment ratio
0000000 0000000 0000000 0000000 1000000 49. 4deg
0/ 6/ 1
0%
0%
0000000
,a,
O. OP
O. OP
5: 2
0000000
1100400100110
O. OP
0. OP
o. 0 f t
o. 0 f t
0000000
2
1 1 696
1 1 696
0000000
1 0
17. 5P
A
17. OP
40. 8deg-
1000000
37.4ft
8. 6deg
49. 4deg
} Two seconds before
0/ 8/ 1
0%
0%
0000000
18: 6: 1
0, OP
O. OP
1100400100110
O. OP
O. OP
0000000
o. 0 f t
o. 0 f t
0000000
116%
2
1 1 696
0000000
1 0
17. 5P
A
17. OP
40. 8deg-
1000000
37. 4ft
8. 6deg
49. 4deg
} Three seconds before
0/ 6/ 1
0%
0%
0000000
1 8: 6: 0
O. OP
O. OP
1100400100110
O. OP
O. OP
0000000
o. 0 f t
0 ft
0000000
o.
2
1 1 696
11696
0000000
1 0
17. 5P
A
1 7. OP
40.8deg-
1000000
37.4ft
8. 6deg
49. 4deg } Two seconds before
1 8: 5:59 1 0 A
}
0/ 8/ 1 1100400100110 2
0 96 O. OP O. OP o. 0 f t 110% 1 7. 5P 17. OP 37.4ft A second before
096 O. OP O. OP 0. 0 f t 1 1 096 40. 8deg- 8. 6deg the peak of moment ratio
0000000 0000000 0000000 0000000 1000000 49. 4deg
IMeanings of numerals I
P = POUNDS X 1OOO
"t" is indicated when the indicating unit is ton.
No.OF PART LINE

DATE TIME DATA CODE (Ml Al 3rd)
I I I "m" is indicated
0/ 8/ 1 18: 6: 8 1100400100110 2 0 when the indicating unit is meter.
RATIO
(M)
II
ACTIAL
LOAD
(M)
II
RATED
LOAD
(M)
II I
RADIUS
(M)
RATIO
r®--i I
ACTIAL
LOAD
(A)
I I
RADrus
(A)
I
I \
0% 0. OP O. OP 0. 0 ft 103% 17. 5P 37.4ft

ACTIAL RATED
RATIO LOAD LOAD RADIUS ALL-
(3rd) (3rd) (3rd) (3rd) RATIO BOOM ANGLE llBANGLE
II II r---i r--1 I I
0% 0. 0 P 0. OP 0. 0 f t 103% 40. 8deg- 8. 6deg
0000000 0000000 0000000 0000000 1000000 49. 4deg

J_ _ _ __,
I
1-1to1-7 2-1to2-7 3-1 to3-7 4-1 to 4-7 5-1to5-7 Jib offset angle
5-10
No. Signal Signal level
1-1 Luffing jib LS
1-2 Boom backstop LS (right)
1-3 Boom overhoist LS (Crane) !:Normal
1-4 Limit switch Boom backstop LS (left) O:Overhoist
1-5 Not used
1-6 Anti-two block LS (aux.)
1-7 Anti-two block LS (main)
2-1 Gantry fix link LS (Not used) 0: Un-connection I :Connection
2-2 Boom fix SW (Not used) I :Fix position O:Normal position
2-3 Master key SW
2-4 Release switch Over load release SW 1: Release position
2-5 Boom overhoist release SW O:Normal position
2-6 Anti-two block release SW
2-7 Not used
3-1 Not used
3-2 Gantry cylinder LS (Not used) !:Contact O:Un-contact
3-3 Not used
3-4 Limit switch Not used
3-5 Not used
3-6 Not used
3-7 Not used
4-1 Not used
4-2 Third drum lower
4-3 Third drum hoist
4-4 Operation Rear drum lower !:Operation
4-5 Rear drum hoist O:Neutral
4-6 Front drum lower
4-7 Front drum hoist
5-1 Communication !:Trouble 0:Normal
5-2 Not used
5-3 Not used
5-4 Operation Jib drum lower
5-5 Jib drum hoist !:Operation
5-6 Boom drum lower O:Neutral
5-7 Boom drum hoist
5-11
5.6 Erasing Load Record
The load record can be initialized for the indication program version 1.13 and control program version 1.12 or later.
If the dip switch No.6 is turned on while the load record is indicated, the screen changes as shown below.
II. on
RATIO 111111111111111111
10 7G 10 10
II 100
II 11 llllll 1111 I
.
B· ANGLE II B· p. ELEY· I
I ··JI ul
~-~I HAIN I
II A~mc IFI
II ===l1:~ms
RATIO '"
I W:0° II I:~ms
I RADI us 11 1, 1 ! i :.Next
page
lT:Next
page
0
Set: Erase
Date
If the (SET) switch is pressed and held for three seconds or longer, the load record is initialized. To stop the initialization,
tum off the dip switch No.6 before pressing the (SET) switch.
5. 7 Trouble Record
On the ''.STATUS CHECK" screen, move the cursor "::::;," onto the "TROUBLE RECORD", and press the (SET) switch.
Then, the screen shown below appears.
Past ten trouble records (trouble No. and dates of trouble occurrence) are displayed on this screen.
Trouble No. means message No. For details, refer to the message list of page 7-2.
When the number of trouble records exceeds ten, the oldest data is erased.
TROUBLE No. DATE

36 2000. 711.1643
44 2000. 711.1642
0 2000. O o. 0 0
0 2000. O o. 0 0
0 2000. · 0 o. 0 0
0 2000. O o. 0 0 TROUIL! RECOAD
0 2000. O o. 0 0 NL
0 2000. O o. 0 0
0 2000. O o. 0 0
0 2000. O o. 0 0 - ...
5-12
IErasing trouble records I
Previous trouble records can be erased prior to use of the controller together with other machines.
While trouble records are displayed, tum the dip switch No.6 ON.
Then, the messages shown below appear. To erase the records, press the (SET) switch. To cancel erasing, press the
(MENU) switch.
TROUBLE No. DATE

36 2000. 711. 1643
44 2000. 711.1642
0 2ono. O o. 0 0
0 2000. O o. 0 0
O o. 0 0
TROUBLE RECORD
0 2000.
0 2000. O o. 0 0
0 2000. O o. 0 0
0 2000. O o. 0 0
0 2000. O o. 0 0
0 2000. O o. 0 0
Data are erased. 1,ta .,, ""'
r,o ICI II u 1, .,,,c,.,,11,uv tt te "'' ••
Push SET if it is aood.Cancellation is to Push MENU. I I
Press the (SET) switch. Then, all the trouble records are erased, and the screen returns to the initial status.
IR~~t OwI!!! 111!!I II !!I' I!!!' 11 !I! Oii i !

I i ANGL@ Ii 8, P ELEY I
TROUBLE
0
0
No. DATE
2000. O o.
2000. O o.
0
0
0
0
I ·~~TIO §"I :oo,.. 01000
0 2000. O o. 0 0 POUNDS
*1000
0 2000. O o. 0 0 RADIUS It
0 2000. O o. 0 0 TROUBLE RECORD I
0 2000. O o. 0 0 TI ••
0 2000. O o. 0 0
0 2000. O o. 0 0
0 2000. O o. 0 0
0 2000. O o. 0 0
Data was erased. o.............
After erasing, tum off the dip switch No.6.
5-13
5.8 Load Record (Load record in the main menu)
IErasing load records I
Previous load records can be erased prior to use of the controller together with other machines.
While load records are displayed (both of records displayed in the order of moment ratio and those displayed in the order
of date are acceptable), tum the dip switch No.6 ON.
Then, the messages shown below appear. To erase the records, press the (SET) switch. To cancel erasing, press the
(MENU) switch.
ILOAO RECORD(RECENT VALU81 t ,I. :Next Paoe ! <•)

RATIO 1111111111111111111111111111111111
to H IO II IOI
j
RATIO RADIUS BOOM JIB MODE DATE
24 43 100 2 M 2000. 711. 1631
34 43 100 2 M 2000. 711. 1623
97 43 100 2 M 2000. 711. 1623
58 43 100 2 M 2000. 711. 1623
148 95 100 2 M 2000. 711.1429
0 0 0 0 2000. 0 o. 0 0
0 0 0 0 2000. 0 o. 0 0
0 0 0 0 2000. 0 o. 0 0
0 0 0 0 2000. 0 o. 0 0
0 0 0 0 2000. 0 o. 0 0
Data are erased.
Push SET ii it is good.Cance(latjon is to Push MENU.
Press the (SET) switch. Then, the records are erased and the screen is reset as shown below.
I LOAD RECORD (MAX VALUE) I t ,I. :Next page IRATIO

<•J 11111111111111111111111111111111111
IO 1t IO It ltO
RATIO RADIUS BOOM JIB MOOE DATE

0 0 0 0 2000. O o. 0 0
0 0 0 0 2000. O o. 0 0
0 0 0 0 2000. 0 o. 0 0
0 0 0 0 2000. O o. 0 0
0 0 0 0 2000. O o. 0 0
0 0 0 0 2000. O o. 0 0 I I
0 0 0 0 2000. O o. 0 0
.
RATIO IADiUS BOON JIB NOOE OAT
O o. 0
•0 •0 0 011, • 0. II
0 0 0 0 2000. 0
•0 0 0
•0
oto. •
010. 0. •
1. a
0 0 0 0 2000. O o. 0 0 0 0 0 Oto. I 0. 0 0
0 0 0 0 2000. O o. 0 0
0 • 0 . I
otO. t
0. I
...
D D D t. • 0
•
D
0
n
0
D
010, 1 a.. a
Data was erased. •• 0
• 010. • a. a
D D 10. t 0. 0 0
Data ••• .,.aud.
5-14
6. ADJUSTMENTS
AwARNING
Prior to adjustment, be sure to check the items below.
1. Input crane configuration 2. Main/jib lifting selection
In this section, the adjustment of sensors installed to the crane and various coefficients, and other functions are
described.
6.1 Removing the Inner Panel

The dip switches that are needed for adjustment are located when you remove cover.
Take off 2Q)screws shown below to remove the cover.
Do not lose the cover or the screws.
COLOA [Q] CONTRAST

MOOE
El (""l
l=f=J
MENU Cover
§(ID§ C TRAST
EJ~
LOAD SAFETY DEVICE
Q)Screw
6-1
6.2 ADJUSTMENT
While the menu screen is displayed, turn ON the dip switch No.3 of the controller.
Then, the "ADJUSTMENT" screen is displayed.
II
.
RA("T)I o 1111111111111111111111111111111111
60 70 60 90 100
I
.
B. ANGLE II B. P. E LEV. I
I deJI ttl
~R-A_T_ 1 o~II MAIN
%
A~ ~~L
6 11::====::: ~?~~gs
RATED II POUNDS
~=L=O=A=D===:· ::=· ====: *I OOO
,___R_A_o_1u_s~ ! f t
RATED LOAD LOAD
TABLE RECORD
RATED LOAD
CURVE
WORKING
AREA
SETT ING
=>I ADJUSTMENT
=::;A:;:D:;:JU;:;:;S;;::;T;:;:M;;E;:;:;N:;;:T=~
::=,
. DATA
t ~ :choice
Move the cursor "::::}" onto the "ADJUSTMENT", and press the (SET) switch. Then, the screen shown below appears.
I
.
RA(~)I
~
o 1111111111111111111111111111111111
60 70 60 90 100
I
.
I B. ANGLE 11 B. P. ELEY. I
I deJj n!
MAIN
RATIO %
:==A::;;C::;;T;::;:UA:;:;L~ ::======::::! POU NO S
LOAD llclDOO
::===;R;;=A~T~E;';;D===: ::====::: POUNDS
::==L=O=A~P==::::: ::======: *1 Ooo
RADIUS ft
ADJUSTMENT
!MANUFACTURER ADJUSTMENT!
I LOAD ADJUSTMENT I
t i :choice
6-2
Move the cursor "~" onto the "MANUFACTURER ADJUSTMENT", and press the (SET) switch. Then, the screen
shown below appears.
II
.
RA("T)I a 11111111
60 70
Ii 60I 111111111111111
90 I 00
I
I II I I II I .
B. ANGLE ii B. P. ELEV. I
I deJI ttl
I MAIN I
MANUFACTURER ADJUSTMENT
ANGLE SENSOR AOJUSTMENT I

LOAD CELL ZERO POINT ADJUSTMENT I
LOAD-LESS ADJUSTMENT I
SOME LOAD ADJUSTMENT I
LVL ADJUSTMENT I
RAD I us ADJUSTMENT I
t l ho Ice
SET =To the choice screen
6-3
• MANUFACTURE ADJUSTMENT
This adjustment should be performed when the indicated angle

I ANGLE SENSOR ADJUSTMENT
I is different from the actual angle or the angle detector is
replaced.
(Adjustment should be performed within the specified range.
If the adjusted value is out of the range, the adjustment is
invalid.)
This adjustment should be performed if the output voltage is

I LOAD CELL ZERO POINT ADJUSTMENT I deviated when no load is applied to the load cell.
invalid.)
This adjustment should be performed if the indicated actual

I LOAD-LESS ADJUSTMENT
I load is excessively deviated when a light load such as a hook is
lifted.
invalid.)
This adjustment should be performed if the indicated actual

I SOME LOAD ADJUSTMENT
I load is excessively deviated when a load is lifted after the load-
less adjustment is carried out.
invalid.)
Automatic stop points (alarm points) can be changed.

I LVL ADJUSTMENT
I
This adjustment should be performed if the indicated working

I RADIUS ADJUSTMENT I radius is excessively different from the actual working radius.
invalid.)
Since limitations are provided for these adjustments, they cannot be completed when the adjusted values are excessively
deviated. In such a case, ensure that the sensors are free from any fault, crane configuration is input correctly, and
adjustment procedures are appropriate.
· LOAD ADJUSTMENT
This adjustment should be performed when "LOAD-LESS

LOAD-LESS ADJUSTMENT
I I ADJUSTMENT" of MANUFACTURE ADJUSTMENT is
rejected. It is valid for adjusted attachments only.
This adjustment should be performed when "SOME LOAD

I SOME-LOAD ADJUSTMENT
I ADJUSTMENT" of MANUFACTURE ADJUSTMENT is
rejected. It is valid for adjusted attachments only.
6-4
6.2.1 Angle Sensor Adjustment
Move the cursor "~" onto the "ANGLE SENSOR ADJUSTMENT", and press the (SET) switch. Then, the screen shown
below appears.
IR~~)I o 1! J!l !!
It '!!II I 11 It 1!!!11111111111 I
I B, ANGLE II R· P, ELEY· I
I d·JI ,ii
I HAIN I
I ANGLE SENSOR ADJUSTMENT I
!THE ADJUSTMENT OF THE LOWER BOOM ANGLE SENSOR!

t, =Chalc1
SET =Ta the choice 1cr11n
If the boom and the jig are equipped with the angle sensors, several choices are displayed.
(1) Move the cursor"~" onto the intended angle sensor (angle sensor to be adjusted), raise the boom close to the upper
limit, and press the (SET) switch. Then, the screen shown below appears.
IR~~I 1! II IHI II!! 111 !! 11 qH1111111 11111

O
I B, ANGLE ii B, p. ELEY· I
I 10. 3d·JI 99. 1111
~-~f HAIN I
RATIO II 1 9!•
I A~mc II 7. 3! :~~~gs
I R:ow II 3 8. 11 :~~~gs
I RAD I us U 3 7. g ! 1t
Fit it to the actual boom angle with--. and push SET.

I 69. 71 i1t
Fit it to the actual boom angle with +--+,and Push SET.
69. 71 deg
(2) Measure the actual boom angle with a level or an angle gauge, enter the measured boom angle in the [ ] on the screen,
and press the (SET) switch. Then, the screen shown below appears.
6-5
I R~~:o !!lll!!'ll!!lll!!IIIJ!!lllllllllll j
I B· ANGLE jj e e. ELEY I
I 10. 3d•JI 99. 1ul
,-----,I HAIN I
RATIO II 19!"
I A~ml II 7. 3! =~~~gs
! RLAotAen° II 3 8 · 1!=~~~gs
! RADIUS U 37. 9! t t
. Fii ll h Ot achtl •eo• ... ,. •10 --..... ,.,. SET.

I 89, 11 ...
Push SET after you make an actual boom angle change
at more than 25deg.
Push SET after YOU make an actual boom angle change at

more than 25deo.
(3) After lowering the boom by 25° or more, stop it and press the (SET) switch. Then, the screen shown below appears.
NOTE
Angle of 25° is just a guideline for lowering the boom, and this guideline should not be necessarily
observed. However, remember that the adjustment is effective if the boom is lowered with an angle as
large as possible.
Fil II lo I.. acl11I h11 11111 ,11• .... , •• "'• SET.

Fit it to the actual boon anale with ....... and Push SET. I u. 71 ...
I 40. 51 dea ,. •• SET 1fttr HI ..,. II Hhll ' " ' ... ,. clllll:11 at
1111 1•11 tu ...
flt It h IN acltal ,.,, 11111 ,1n --.. 11• t111t SET.
I 40. 11 •11
( 4) Measure the actual boom angle with a level or an angle gauge, enter the measured boom angle in the [ ] on the screen,
and press the (SET) switch.
In this case, the maximum angle is adjusted first, and the minimum angle is adjusted next. Of course, the reverse order is
also acceptable.
6-6
(5) When the adjustment is successfully completed, messages shown below are displayed (numerals in [ ] are changed
whenever adjustment is complete).
Press the (SET) switch. Then, the screen returns to that before the adjustment is performed.
II xm~c
RATIO II
II I'"m:gs
I. AAteo
LOAD
II.. I. *1000
PouNos
I RAD I us II If t
Adlustment went well. Push SEt
bi::axg~~:'::~te0:e~:ga I
Flt II le tit acl1tl ..., 11111 tl 11 •--. 111 ,111 SET.
ANGLE TO ADJUST 69. 71 deo 40. 51 deo I n. 11 o,
VOLTAGE 5. 821 V 3. 87) V h .. SET lltlf ... Nkl It ICIHI , ... Ill II ell1111 at
Mrt tllH Jlltlo
,11 11 11 n, 101111
.... u,1, ,m ..... 111 ' " ' su.
I 40. s 111
Ml1tlllll tHI NII.PHI SET.
ANGLE TO AtlUST I et. 'II Ito I 40. SI In
YOLTAGE I s. 121 Y I s. 171 Y
(6) When the adjustment is not successfully completed, messages shown below are displayed (numerals in [ ] are
changed whenever adjustment is complete).
Press the (SET) switch. Then, the screen returns to that before the adjustment is performed. Re-perform the
adjustment correctly.
IR~~:o !!'IIJ!I Il!!ll 1!!111 !!!11111111111 I

I B· ANGLE Ii 8, p. ELEY, I
I d,JI j "'
HAfN I
I RATIO II I"
I xm~c II Im~gs
I Rto~eoo II I=~~~gs
I RA01us II jrt
Adlustme-nt is failure. Push SET. and ad lust it again. Fil It to th 1ctu1I hu Utlt wltll --.111f 111111 SET.
I 75. !II du
ANGLE TO ADJUST 75. 21 deg 44. 51 deg
Pull ser atttt 11k1 u h11 ch1H at
VOLT AGE 5. 6 I) V 3. 44) V Hfl thl 1540,
111 1ctu1t 11111
fit It to the 1ct11I IIOOI ... ,.•Ith ......... •uth SET,

I 44. 51 o,
A1Jul1ut 11 r,11.,.. Pul SET. 111 11Jnt II 1111,.
ANGLE TO AOJUIT [ 7 5. 21 In I 44. 51 lu
VOLIAGE [ 5. I tl Y I 3. 441 Y
6-7
6.2.2 Load Cell Zero Point Adjustment
Errors in output voltage (1.0 V) when no load is applied to the load cell can be adjusted.
(1) Move the cursor"~" onto the "LOAD CELL ZERO POINT ADJUSTMENT", and press the(SET)switch. Then, the
I R~;)1 0
B. ANGLE
!! !l l!
111
II
111 111
B. P. ELEV.
u !!!
111
I
111111111111
..____ _d--e.,eJ I ft I
MAIN
RATIO %
;::::::;A:::;;C::;;:T;:;:UA:;::;L;:::::; ::====::::: POUNDS
LOAD *1000
;:=R;;=A;=:T;:;;;E=::D;:::::; :======::::; POUNDS
:=::::L::O=A=D:::::::::: :=======: * I OOO
RADIUS If t
LOAD CELL ZERO POINT
ADJUSTMENT
~ !THE ADJUSTMENT OF THE BOON LOAD CELL!
t i =Choice
(2) For the crane with several load cells, number of load cells is displayed on this screen. Move the cursor "~" onto the
load cell item you intend to adjust, and press the (SET) switch. Then, the screen shown below appears.
6-8
I 1~: ui IIwII wII wII u111, 111111111
R
0
I e. ANGLE jj e. P, ELEY, I
Make the tension aPPlied to the load cell become a zero. I d·JI ,t!
I MA IN I
Push SET if it is aood. II Am~c
RATIO
IIII I'":?ms
I WN II I:?~~gs
I RADIUS II Ift
TRE AoJUs1MENTOF TRE
eoo11 LO.t,o CELL
N1k1 lb hnlH 1nlld h t111 111• cell •tcoH I ura.
ZERO OFFSET VALUE OF LOAD CELL [ 1. 0 51 V Pul SfT If II II lotl,
ZERO OFFSET YALUE OF LOAD CELL I I. 051 V
(3) Decrease the tension applied to the load cell by removing the load cell completely or loosening the wire rope as far as
possible. When this step is complete, press the (SET) switch.
* When the displayed load cell voltage is not in the rage from 0.8 to 1.2 V, the load cell is judged to be faulty and the
adjustment is rejected. In such a case, replace the load cell.
(4) When the adjustment is successfully completed, the screen shown below appears. Press the (SET) switch is to return
to the previous screen.
Make the tension aPPI ied to the load eel I become a zero.
IR1~, 1
0 !l 11 '!! 111 HI II!! II '!l! 11111111111 j
I B- ANGLE Ii B· p. ELEY· I
I d·JI ttl
Push SET if it is oood. HAIN I
II Am~[ IIII
RATIO
I'":?~~gs
Adiustment went wel I. Push SET
I "toW II I:?~~gs
I us II
RAO I It f
THE ADJUSTMENT OF THE
BOOM LO>D CfU
ZERO OFFSET VALUE OF LOAD CELL [ 1. 0 51 V M1,1 ne tlHIII .... lid tt Utt laal CIII blCDII I ltrl.
h1• SET II It II IHI.
A•Jutant Hit . . 11.P111ll SET
!EID OFFSET VALUE OF LOAD CELL I I , 0 51 V
6-9
(5) When the adjustment is not successfully completed, the screen shown below appears.
Ensure that no tension is applied to the load cell, and re-perform the adjustment.
I R~~,1 0 !!I II HI 11 !l 111 !!I Iq!!' 1111111111 I

I e. ANGLE II e. e. my I
I d,J1 ttl
f MAIN I
II xm~c II11 I'":mgs

Adjustment is failure. RATIO
Push SET after you reconfirm whether the tension aPPlied
to the I oad c eI I is a zero. I RLAoTN II I:mgs
I RADIUS Ii I
ft
THE ADJUSTMENT OF THE I
ROON LOAD CELL .
ZERO OFFSET VALUE OF LOAD CELL [ 1. 4 71 V NOt tht teulu IHII .. tt th 111• ctll hcnt • un.
P11~ SET II II 11 tttl.
AUut111t II fall1n.
Pok SET tfhr HI nc11flr1 1~1thr Ut 1111111 11,11,,
lt t,, 111• ctl I h I uro.
ZERO OFFSET IALUE OF LOAD CELL I I, 4 71 V
6-10
6.2.3 LOAD-LESS ADJUSTMENT & SOME LOAD ADJUSTMENT
LOAD-LESS ADJUSTMENT ........ When this item is selected, tare weight component, including boom weight can be
adjusted. Select this item if the actual load is not identical to the displayed load when
a light load weighing as same as the hook block is lifted.
SOME LOAD ADJUSTMENT ....... When this item is selected, load component can be adjusted. Select this item, if error
that occurs when a heavy load is lifted is greater than that occurs when a light load
weighing as same as the hook block is lifted.
When "LOAD-LESS ADJUSTMENT" is selected, the following screen appears.
I. 91 POUNDS; I OOO
\
Enter the weight of the hook block.
The current lifted load must be the load of the hook block only.
Adjust the value in [ ] to the weight of hook block. The entered value is decreased with the § switch, and increased
with the @ switch.
After the adjustment, press the (SET) switch. Then, the next screen appears.
* If the two hooks are used, enter the sum of their weights.
6-11
Adjust the load at the maximum boom angle point, minimum boom angle point, and arbitrary five points between them.
To start the adjustment, stop the boom at an arbitrary point, and press the (SET) switch.
I. Input point !. (Be sure to set up)

Close to the maximum angle First
point Second
, ~oint Third Can be omitted
point
' Fourth
,point
Fifth
, , point (Be sure to set up)
Close to the minimum angle
(1) First, raise the boom to the point near the maximum boom angle (75° to 80° ), and press the (SET) switch.
Value close to the maximum boom angle
Push SET after You make a boom or jib a maximum an;le

I LPAP-LIII ARJUIIMCNI j
'" uu a 1u, •••, ,m,en m aUtr'" dMQ,
·-
....., luH1 lH ,11t1lllt1l1 •UII lk Nil NltH 11111
1 ,• • - ,...
hH SO' lfllr "' atlt I Niii IF Jll I Nliftl Niii
(2) Then, the load can be adjusted at zero to five points to the minimum boom angle point.
Lower the boom to arbitrary points, stop it, and press the (SET) switch.
The maximum and minimum boon angle points are absolutely necessary for this adjustment, and five points between
them can be set arbitrarily or omitted (there is no rule of the number of points, and intervals of points).
However, note that fine adjustment is possible when many points are set in the boom angle range as wide as possible.
To omit the points set arbitrarily, press the (Q) switch. Then, the message instructing to lower the boom to the
minimum boom angle is displayed.
I lllATIO 11111 :11
.<•>1110H II l'I.
II
II.•
••
~V .
.. II I
I •.JI II
"
a.\TID
PDUNDI
-~~~:~
•JOOD
It can be adiusted in 0-5 points between the 111n11um ~-:.' .... PDUNDI
•1000
It
an11le from the maximum an11le. Push SET after you make it IADIUS
j I.D~g-~111 6RJYlfttlHf
stop in each PO int. Push ,t. when YOU omit the 111idd le. YH Nlli
·-
i IHf Nh I ..... ,.. . ., tlllf HI
INII I
....., 1u1•1 UM NHUN111 wlll n,...., 1tl1lt ,1111 '
I •· •-•m
,.,. Ill lfhr • • UII I MN U Jiii I ....... 11111
It CN N NI.. IM II ... Nitti NI .... IN 1111...

... It IHI t.. NII ... 1111~ ..... Sit llttt JN MN U
UH 11 Nil Mltf.,.111 & .... ,.. 1111 INalHt•
6-12
For example,
• When the boom is lowered to 70° and stopped as the first arbitrary point, and the (SET) switch is pressed, the message
informing that the first point is recorded appears.
Boom stop angle
LP&O-LES9 APJU!ITMENT
,,. 111,, 111• 111, 1 ...._,. .. ser ,rt., ,..
cN,1: ,
ltllH l11IN Ill HtHINtll 111• Ill .... Nit It tl t•
I t.U-IHI
The lst Point was memorized. , .... IIT lfttr '" .. -.I .... tt n• I ... 1...... ,.
II en N .., ..... It H ...... hlNM ... till••
UIII lt11 tN IHIIN Hiia. Pt1• SH lfttr HI .. h It
~-4--- "'.... II ...... 1,Lh•• l ••• HI NII IN

ltt ............ ,u...
1uo ..
• Next, when the boom is lowered to 60° and stopped as the second arbitrary point, and the (SET) switch is pressed, the
message informing that the second point is recorded appears.
Boom stop angle
LOAQ·Liis APJYifHENI I
YN ule I lett ..1, I Nd.,-d lfl llht HI 1HII: t
HMlt IHHt IN IIPUINtll tilt tie IIHI: NltH •Ill
The 2nd point was memorized. ,,.11,-1111t1

llttl . , llltt PN Ilk I hlil II Jfl I 1111 ... Utl•
It UI H 1U11h• It t-1 Hltlt hi .... t• •ltl ...

Ntlt It• ... ntllN INle.,.,1: Sit Ille, rN IIU1 11
IIP It IHI Nltt.PtM I tMI 1N Nit IN tlHle.
~ - + - - - - T I I 111 Niii UI INlflllL
• When the fifth points are recorded after other arbitrary points are set in similar manners, the message instructing to
adjust the boom angle to the minimum and press the (SET) switch.
The same message appears even when the @ switch is pressed to omit arbitrary points.
I RATIO
,., •
11111111111111111111111111111111111
1t .. .. uo
...
AATIO 3 ll
-~!~=- 1. 3:IIUNOS
1000
~~ ....... 46. 9 : OUNDS
1000
IADIUI 33. 4 I
-
I LOAP LESS AOJUITNENI I
The 5th Point was memorized. , .. Hh • INd cth a lefLP!stl! SET dllt rN c~~ I
111hr IHHt 1'1 ttrtaUHII alO IU Ntl tthllt 110
11.11-,...
h1!1 ar tfttl tN aah I MN t1 11, I NII... Hiit
II CH .. dl.. td I• H Nitti Hltttt tN 1111...
Push SET after YOU make a boom or iib a minimum U1t lo taclli N\11, h1,'
11111 fru tN Qllltll utte. .. ,, SH lftlt rH aNt It
*A ,._ e;JI ttl; IIIUli.
nt 10 Nht NI ....,111&.
hd HT artar rn 11t1 1 1111 11 I!\ 1 •l1ln, 11111.
6-13
• When the (SET) switch is pressed after the boom is lowered to the point near the minimum angle, adjustment results are
displayed.
The message shown below appears if the adjustment is normally completed.
However, figures in [ ] may be changed according to situations.
30.
5•
i,..,~....i~~-s~ m::•
l-,lilllll....,i~~-3!_;1
6
=~==·
1t
Adjustment went well.Push SET. A N
....
IUNr 1111,1 t.. Ht•INIII
............"
fN 111:1 I IIM .. 1, I HA ••
•II• lltll '"-'"' 1
IN hlll NltH 1111
lull Jl1' 1fter ,.. IHI a MN • Jiii 1 1l1IN1 INlt.

It INN .. J11IN 11 ... NIIII Nl9N1 IN 1ltl1N
Ntll lr• tN NII- 11111. .... IIT 1llw ,n ••• II
IIN II .... M11t.P11• I, IHI ... lllt ... 1ICll1.
hi Ill Niii Ill INltlH...
FO ADJUSTMENT INCLINATION Kl [ 0.8781 PIM Slf dte, NI 11,1 I .... It Jiii I 1111... 11111.
MfHIMII Hit 1111.Pnll Ill.
FO ADJUSTMENT SHIFT K2 [ ~ 1761 N IIMIIIIIIJ IIICl.111111• 11 I Llltl
N IIAIIIIIT 11111 a I Lilli
• If the adjustment is not normally completed, the message instructing of re-adjustment is displayed as shown below.
The displayed adjustment results are cancelled if this message appears.
r"'fl!ffiinr""=-1 ~OUNOS "

Adjustment is failure. Push SET, and adiust it aoa.in.
1---0---~
l-,IM!li-ll·---1 :::::,
•1000
, t
,.......c:l,..,m••~.~.~....:::.;,.~••yj..~••$,.,r,:1. CIIMI I
!!~ 1111•, ,., .., .. 1u,1, ,1111 th "'' .. 101 ,1111
• I LII-IHI
" " SIT alllt •• DII I UM II 1111 I 1IIIIH IHII.
It IM N Mluld II H NIIU khlN Ut 1111-
11111 hM I......_ lltlt. .. 111 UT 11111 Jh N .. It
11 .. 11 IHI 1tl1LPIU' IN~ •• •It lk , .... ._
.... SIT lflH .,. •llt I .... W Jn I 1111 . . NII ..
FO ADJUSTMENT INCLINATION Kl [ l 9991 MJNlNll II f1ll1t .. ,1111 SIT. 11, HJ11t ll IHI ..
FO ADJUSTMENT SHIFT K2 [9l 999] N 1111111111 IIICLIIITI• II I ,1111

HIIJll11111J•1n Ul5'Htl
Correcting function is actuated only when the lengths of booms that have not been adjusted are adjusted between the
intended booms.
For example, if the 12.2 m and 24.4 m booms are adjusted, 15.2 m, 18.3m, and 21.3 m booms are corrected by the
adjustment values of the correcting function. However, the adjustment values cannot be used for 9 m and 27.4 m or
longer booms.
6-14
When "SOME LOAD ADJUSTMENT" is selected
Only the first procedure and the adjustment result of the "SOME LOAD ADJUSTMENT" are different from those of the
"LOAD-LESS ADJUSTMENT". Other procedures and displays are identical.
• First, lift a load of which weight is already known, and adjust the displayed value in [ ] to the lifted load (lifted load
includes the weights of hook block and wire rope).
:OUNDS
Han11 the load which wei11ht is understood about. Push SET
a1000·
POUNDS after vou check a number inside the Parenthesis with the
•1000
~~ ft
hook wei11ht with+--..
SONE LOAO AOIUaTNENT f I. 81 POUNDS* I OOO
NNt tN IIN tllltl •h•t It 1N1nl... tklt.,.tll IP
all" , .. r:Nlt I ....., IHI.. IM NtttO•II 1UI 1111
NM1tl ..l1UII• .... t
11.u-,...
Enter the lifted load.
• Adjustment procedures are identical to those of the "LOAD-LESS ADJUSTMENT".
• The adjustment results are displayed on the bottom of the screen as shown below.
6 ADJUSTMENT INCLINATION K3
6 ADJUSTMENT SHIFT. K4
• Adjustment for luffing crane

For main lifting, adjust in a similar manner shown pages from 6-11 to 6-15.
For jib lifting, fix the boom angle, and adjust by modifying the jib angle in a similar manner shown pages from 6-11 to
6-15.
6-15
6.2.4 LVL adjustment (LVL setting)
L VL means the level of moment ratio that the machine is automatically stopped and the alarm is issued.
It is usually set at 100%, and can be altered in the range from 95 to 110%.
• Increase or decrease the LVL with the §) or § switch to the intended value, and press the (SET) switch.
NOTE
LVL adjustment is available only while the dip switch No.5 is in the "ON" status. When it is in the "OFF"
status, the moment ratio level that the machine is automatically stopped and the alarm is issued is set to
100% as usual.
Set UP the load rate which makes it stoP automaticallY.
It can be set UP in 95-110" of the ranges.
[ 1 00] %
I LVL ADJUSTMENT
Stt •• till tod ut1 1Ucll 1111.11 it ttu ul0Htlc1llr.
It CH •• HI U ii ts-1101 If tht UIHI.

+---+ : Increase or Decrease
SET :Setting completion 1 11001" I
..... : Iner•••• or Dtcre111

SET 1s1ttln1 ca•1l1tlon
6-16
(LVL Function]
The following drawings are some examples of L VL function.

CD When the L VL function is OFF.
~- __ ~ 5%Hysteresis
Alarm -
Warning -
'
1
-- - - -
Operate - - -90-. - - -95 100' - - - - -
Load Ratio (%)
When the L VL function is OFF, the intermittent warning sounds at 90% and the steady alarm at 100% and higher.
When retreating from the alarm stage, there is a 5% lag factor, so the intermittent alarm is reactivated when the 95%
load factor is recovered. This alarm will discontinue when the load drops below 90%.
@ When the L VL function is ON and set to 90%.

~ 5%Hysteresis
14- ./..:.j
Alarm -
Warning - ''
I I
Operate 100
85 90 95
Load Ratio (%)
Because the LVL function is to alarm within a set load ratio, in this case the steady alarm stage occurs at 90%. When
retreating from the alarm stage, there is 5% lag factor, so the intermittent warning alarm is reactivated when the 85%
factor is recovered.
® When the LVL function is ON and set to 110%.

.,,,....- 5%Hystel:'esis
i----/-.-j
Alarm -
Warning,-
Operate ...__......,,_ _ _1...__ __..1_ __.1.___..__1__

90 95 100 105 110
Load Ratio ( %)
When L VL is set at 110%, the figure above applies.

Please note the following points.
· L VL is also affected by the work area limit parameters. It operates by referencing the smaller value set by the Load
Setting switch in "Setting the Work Area Limit Values".
· The LVL operational lag (hysterics) is -5%.
· The load ratio is not affected by L VL function.
· The overload (intermittent sound) warning point does not change from 90%.
6-17
6.2.5 Radius Adjustment
When the deflection of the boom causes the difference between the indicated radius and the actual radius, perform this
adjustment.
(1) Adjust the boom angle close to the maximum angle. Move the cursor"~" onto the "RADIUS ADJUSTMENT", and
press the (SET) switch. Then, the screen shown below appears.
IR~~:a. 0!! 111 !! 111 !l' 11 !!I II!!! 111111111111

I ANGLE Ii B P ELEY I
I d.JI ,ii
I HAIN I
Fi t i t to t he act uaI work i ng rad i us wi t h +- -+, and Push

SET. 3 7. OJ ft
I RAD I us ADJUSTMENT I
flt It •• th 1Chal lltkllt raOu 1lt) ........ lVIII
SET. I 37. OI ft
Measure the actual radius with a measuring tape, and enter it in the [ ] on the screen, and press the (SET) switch.
(2) Adjust the boom angle close to the minimum angle, and press the (SET) switch. Then, the screen shown below
appears.
IR~~: O!!I!!!!111 !! 111 !! 11 qJ!l 1111111111 !

I R ANGL f Ii B, P ELEY I
I d·JI 111
I HAIN
I ::;;A~;:;~;;:;~~;;::L~lII:I~===l "
l=I
RATIO
POUNDS
Push SET after you make a radius change. : 1:

1 0
::11::::::: Hms
:LAO:t,.Eo:
Fit it to the actual working radius with+--+, and Push I RADI us II ft

~I::RA::::o=,u==s==AD~J==us==r=ME=N=T:;"'
SET.
7 1. 91 ft Flt It It th 1ch1I Hrkl11 r1'1u 1ltll
SET, I 37. Cl It
-.........
Pull SET 11 hr 111 11k1 , 11~ 111 ch111.
Flt II h th aclul 1erkl11 udlH wltll ..... 11• ,11111
SET. I 71. II It
Measure the actual radius with a measuring tape, and enter it in the [ ] on the screen, and press the (SET) switch.
6-18
(3) When the adjustment is successfully completed, the screen shown below appears. To return to the previous screen,
press the (SET) switch.
II R~~,10
8 ANGLE
!!I''!II!'' !!' 111!' 11I!!!' 11111111111
B p. ELEY,
I d·JI 111
..-----,I HAIN
I II "
I xm~c 1:,:1==~ :~~~~s
RATIO
I. RATED
LOAD
II.. POUNDS
*1000
I RADIUS II ft
I RADIUS ADJUSTMENT
Adjustment went wel I. Push SET. Flt II t, t111 actnl 1trklu ulht 1IU -.u, ,u•
SET. I 37. Q ft
RADIUS ADJUSTMENT INCLINATION 1. 003)
'°' Hh a u•t11 daue.
RADIUS ADJUSTMENT SHIFT o. 696) Puatr. SET 1fht
flt It tl Ot athtl HtklH rldfu 1IU1 .. ..., HI 111,
m. I 71. II It
AU11t111t nit HI I. P11• SET.

IADIUS AIIJUSTIIEJIT INCLINATION I. 0031
IADIUS AIIJUSTIIEJIT SHIFT o. 9951
6-19
6.3 User adjustment
Perform the user adjustment only when the load detector should be temporarily adjusted if it is faulty and the indicated
load differs from the actual load. In this adjustment, no limitation is provided for the adjustment values.
If the setup of the crane status is altered, the adjustment values are deleted, and they are returned to operation based on the
adjustment values provided by manufactures. This adjustment should be used as the temporary measure for emergency.
1. When the dip switch No.3 of the controller is turned on, selection items for the "Adjustment" appear on the screen.
111 I/ 111 11111111 ii I/ II II j

II Acli' o !111111111
.
R
~
II
B. ANGLE
60 70
I
80
B. P. ELEV.
90 100 _
I deJJ ttlMAIN
I I
RATIO
ACTUAL
II 1%
Ill<IOOO
POUNDS
LOAD I Ill<IOOO
RATED
LOAD I POUNDS
RADIUS It t
RATED LOAD LOAD
I_ TABLE RECORD
RATED LOAD
I. CURVE
WORK I NG
I_ AREA
I SETT ING
=>I .
MANUFACTURER
ADJUSTMENT
:=I==;.A~DJ;:;':U~S~T;;:ME~N~T;:::==:
. DATA
t • :Choice
2. When the cursor is moved onto the "Adjustment" and the (SET) switch is pressed, the screen shown below appears.
II Acli o IIIIIIIIII111111111 II IIII II 11 lII 11111 j

_
R
~
1
B. ANGLE
60 70
B.
80
p, ELEV.
90 100 _
I d...J I ttlMAIN
I I
RATIO
ACTUAL
II 1%
IPOUNDS
LOAD
RATED
II :t<IOOO
I*1000
POUNDS
LOAD II
RADIUS
II It t
ADJUSTMENT
I MANUFACTURER AD J us TMENT
=>I USER ADJUSTMENT
t • :Choice
6-20
3. When the cursor is moved onto the "User adjustment" and the (SET) switch is pressed, the screen shown below
appears.
II R
.
A(!)I O
~
111 11111
60 70
II 80II 1111190 " I100
II I1111111! 111 I
.
B. ANGLE II B. P. ELEV. I
I deJI ttl
I MAIN I
~R-AT-10~11 1%
A~6~~L II:=====:j ~~g~gs
RtoTAEDD 11 I ~n~gs
RAO I us 11 If t
I USER ADJUSTMENT I
~ I ADJUSRMENT OF LOAD-CELL
t + =Choice
4. When the (SET) switch is pressed next, the screen shown below appears.
Procedures of "LOAD-LESS ADJUSTMENT" and "SOME LOAD ADJUSTMENT" are the same as those of the
"Manufacturers adjustment".
I R~~,' 0 HI II w"ll 111 !! 111 !!! 11111111111 I

I B. ANGLE ii B. p. ELEY- I
I d
0
JI ttl
MAIN
I RATIO
ACTUAL POUNDS
I.:==;R;;=A;:;;T;:;;E~D~
LOAD *1000
:=======: POU N OS
l:=·==:::;L=O=AD===!!======! *1000
I RADIUS f t
I ADJUSRMENT OF LOAD-CELL
LOAD-LESS ADJUSTMENT
SOME LOAD ADJUSTMENT
t+ =Choice
6-21
6.4 Adjustment Data Copy (Initialization)
The manufacture adjustment values are stored in the flash memory in the controller, and used for actual operation. They
can be copied down into the data card in case of disorder of the controller.
Even if a controller is replaced with a new controller, re-adjustment is unnecessary if the copied data of adjustment values
in the used data card are written on the new controller.
(1) Tum the dip switch No.3 ON. Then, the "ADJUSTMENT DATA" is added to the menus and displayed.
II
.
RATIO I I I I I I I I I I I I I I I I I I I 111111111111111
(%)
B. ANGLE
so 10
II
eo
B. P. ELEV.
so 100
I
I deJ '~--.===ft~I----. MAIN
RATIO %
:======: POUNDS
:=A;::;C.:;;T.:;:U;:;Ae=;:L~
LOAD *1000
::=~R:;::A~T~E~D~ :======: POUNDS
::=:::L=O=A=D===:::::: :====~ * I OOO
RADIUS ft
RATED LOAD LOAD

TABLE RECORD
RATED LOAD
CURVE
WORKING
AREA
SETTING
ADJUSTMENT
~ ADJUSTMENT
- , ,....__ _D""'A"'-T:..:.A..:--_ __,
t ~ :choice
Move the cursor"::::}" onto the "ADJUSTMENT DATA", and press the(SET)switch. Then, the screen shown below
appears.
6-22
RATIO
(%)
!I I I I 70I I I I I80I I I I 11111111111111111111
60 90 100
B. ANGLE 11 8. p, E LEV. I
'--------"'deJ I ft
MAIN
I
RATIO %
::::=A;::;C;;::;;T;:;:U;::;A::;:L==; ::=====: POUNDS
LOAD *1000
:=:;;:R:;::A;.;:T;;;:EO;;==: ::::=====: POUNDS
::::==L=O=A=D===: !=======: * I OOO
.__R_A_D_I_u_s__. .....____ __.! f t
ADJUSTMENT DATA
READING OF THE (It is replaced after the Practice.

ADJUSTMENT DATA and old value is Jost.I
WRITING OF THE
ADJUSTMENT DATA
ADJUSTMENT DATA (It is initialized after the Prac
INITIALIZATION lice. and old value lost. l
t i =Choice
Following three functions are available :
Copied data in the data card can be read out and written into the
READING OF THE
flash memory in the controller. When this item is selected, data
I ADJUSTMENT DATA I of adjustment values stored in the flash memory are erased and
replaced with new data. Ensure that the stored data may be
replaced with new data before selecting this item.
WRITING OF THE
Data of adjustment values in the flash memory can be copied in
the data card. They usually are copied automatically when any
I ADJUSTMENT DATA I adjustment is performed. Select this item when you need to copy
them in other cases.
ADJUSTMENT DATA Data of adjustment values in the flash memory can be initialized.
I INITIALIZATION I
6-23
6.4.1 Reading of the Adjustment Data
Move the cursor ":::::>" onto the "READING OF THE ADJUSTMENT DAT A", and press the (SET) switch. Then, the
I R~~ll
O
J!l 11 !!I "!! 111 !!I II !w11111111111
I g. ANGLE O B, P, ELEY, I
I ··JI ttlHAIN I
CoPY data in the memory card are written inside the
controller.Data until now are erased because it is II Am~[ II:====:,
RATIO II '"=~~~gs
replaced in the inside data of the controller after the
Practice. I WN II I:~~~gs
Push + if YOU carrY it out. And. Push MENU if You stoP !RADIUS II 111
it. (KeeP Pushing + for more than three seconds.) REAOl NCi OF
ADJU\TMENT CATA
THE I
Cu, .. h II 11111 ....,, Ctrl .,. trltltn luld, tllt
CHtnll,r.0111 tntfl ... .,, uu,• ~ICHU It II
rulactl 11 lh 1111111 l1ta of th c11tnl hr 1fhr lh
,ractlu.
Puk l II JOI cur, It 111,An4.,11-. NENU
It. (Xu, tnU111 ; tor 11n Ou tllru Hco11l1. I
alu If'°'
To execute this job, press and hold the (ID switch for three seconds or longer. To cancel it, press the (MENU) switch.
When this job is successfully completed, the screen shown below appears.
To return to the previous screen, press the (SET) switch.
Copy data in the memory card are written inside the

I R~~)I
O
!! 111 !! II' l! 111 wII!!! 111111111111
i B- ANGLE II 8, P, ELEY, I
controller.Data until now are erased because it is I d·JI ,t1
replaced in the inside data of the controller after the I HAIN I
Practice.
Push + if YOU carry it OU t. And, Push MENU if YOU stop
it. (KeeP Pushing+ for more than three seconds.)
An adjustment data area is being looked uP.
It is beginning to read adjustment data.
1,u, ts ,,he'i'n':ga ''t':i'anstetr,ed '',t o',thiFrii'eino'rrr::j Co,r hh 11 lh 111or, ear• ar, •rfttH lnaldt lh
cutnlltt.Oah 111tll 1n 1t1 uud ~•entt It 11
It is being kePt in the flash memory. ruhu• It t••
lul•• ••t•
tf t111 cotlrtl ltr afhr th
tttct let.
Pull 4 If ,01 urn It 11t. A••· ,ult NENU If nu 1to,
11. OCett •nhlu, for 11u lhH tltru seconds.I
It was comp I et ed. Push SET. At ••Jutaut dill 1r11 It t11l1tt tub• u.
It 11 h1IHIU to rn4 1dJu1ta11t ••ta.
H•·1,·,i1ht. ttauhr·rd--t. .. :ti\1:-,1Hon.J
It 11 l1ti11 kut ill U11 1111'- •Horr.
ft •n com,11t1d. Pull SET,
6-24
If error messages shown below appear on the screen after the execution of this job, the data card may not be fully inserted.
In such a case, make sure that the card is securely inserted, and then, retry the excution.
COPY data in the memory card are written inside the

controller. Data unt i I now are erased because it is
rePlaced in the inside data of the controller after the
Practice.
Push ,!. if you carry it out. And. Push MENU if YOU stoP
it. (Keep Pushing ,!. for more than .three seconds.}
An adjustment data area is being looked uP.
C1n ••ta 11 th 111tr, e1rlll 111 wrlltH 1111•1 n1
IMfilu stm··e nt ::H:a"t a\ a: re-'a ·, r'M• e':r:e n·ce·Je:rr:trr/:! CHhtlltr. Oah Ultll ••• an true• llltCUII It 11
rullc:" I• tllt lulO .. 1, et till ctltttlhr ,rtu t..
,,actle,.
P111, sl 11 UII etrn ll 11t.A11lll,1111i. NENU If,.. 1t11
Jt. 1110 Hdlll l hr Htl 0111 l~tll HCHIIIL)
All 1'J11t1Ht 111111 trll h hlH IH.lf ,,_
WO,rf11n kiat,--,1:c11·'.r1l ,cnci iuorD
6-25
6.4.2 Writing of Adjustment Data
Move the cursor "~" onto the "WRITING OF THE ADJUSTMENT DATA", and press the (SET) switch. Then, the
Data inside the controller are copied on the memory card.

Push ,I, if you earn it out. And. Push MENU if YOU stoP
it. (Keep Pushing ,I, for more than three seconds.)
Data l11U1 lh CIIIUlllf an c.. 1,, 11 .......,, CHf.

Pull ,I. II , .. earn It tit, Aaf,.11111 IENU If JOI•tl•
ft. (bH ,ullht , for 11r1 1•11 tllnt 11co1•a. J
To execute this job, press and hold the @switch for three seconds or longer. To cancel it, press the (MENU) switch. The
previous screen appears.
IR~~>' 0 !!I II!! 1111!' II!! 111 !!! 111111111111

I 9. ANGLE Ii e. e. ELEY, I
I d·JI
I
It!
HAIN I
II Afml
RATIO II
11~=~1'"=~ms
I WN II I:~~~gs
!RAOtusU !rt
WR It CNG OF THE I
MJUSJMENT P-'U
Otta lul•• n, c11lt1llar au c,,1 .. 11 th 1t11u car,.
Pull ' II ... cart, It atl . ......... NEMU II "' ltll
II, lleu 11111111 ,I. hr urt 011 Uru 11co1•s.)
It was comPleted. Push SET. A• dJulaut hta u11 11 "111 latkd 11.
Ml11t111t fall art hl11 tnultrnf h th 111orr.
It ... CNO llltj, , ... !ET,
If error messages similar to those on the screen of the "WRITING OF THE ADJUSTMENT DATA", make sure that the
card is securely inserted, and then, retry the excution.
6-26
6.4.3 Initialization of Adjustment Data
Move the cursor "::::>" onto the "ADJUSTMENT DATA INITIALIZATION", and press the (SET) switch. Then, the screen
shown below appears.
I e. !!' II!!'e.II!! 111!!' II J!!ll 111111111 !

j
R~~,10
ANGLE jj p. ELEY, I
I d~I ,t!
I HAIN I
Al I adjustment data inside the control I er are
initialized.All the adjustment data until now are i=I
I 'i'iA~;.;;~;;;~~i'i'c=!,:I=,II ==~,'"m:gs
RATIO
erased after the Practice.

Push ,I, if You carrY it out.And.Push MENU if you stop
WN II?=====lI:~~:gs
I)==!!!!!!!!!::=!:
I RADIUS II Iu
it. (Keep Pushing ,I, for more than three seconds.) ,........!,=rAo;.c;J'i'i'us"tarrME;;l;N!..t=-o"'A"r"A==!,I
INfTLAU ZATLON .
All ••111111111 hh luUt th c11tnl 1tr art
ltltl1ll11,.A11 t•e 1fh1tat1l fata Hiii HW IU
111114 alter tH ,ract lee.
Pt•• , II ,111 cur, U nt. A... ,.,111 NEiii If " ' atn
ii. flttt JU.hi ' fir llrt Iba t•r11 HCHfL)
To execute this job, press and hold the @switch for three seconds or longer. To cancel it, press the (MENU) switch. The
previous screen appears.
I RATIO
(!I) 10
11111111111111111111111111111111111
70 10 to 100
I e ANGLE II 8. e. ELEY, I
Al I adjustment data inside the control I er are I d·JI ,ti
I HAIN I
initialized. Al I the adjustment data unt i I now are
ll=TiRA..;Tinlo;==li l=! ===l' "
erased after the Practice. I Am~c09II I=~ms
Push i if YOU carrY it out. And. Push MENU if You stop :=, "iiRL~~T;!l;jfo~ ll~=====l, m~gs
it. (Keep Pushing i for more than three seconds.) I RAD Ius I If t
r'i'iAoi<'iJiiius"tmME~Nrt'i<'OA"t;;=A==.
During the data elimination. INLTLALltATLQN 1.
All dlulont iah tulle Ila mtnller m
llllhllHd.AIJ th .. JHlllll f&ta Htll 111 HI
erud afler tlia ,net let.
Pull i II HI earr, II 11t. .A, ..... , NEIIU If 101 •h•
11. (I,.,
,usuu I for Nrl 011 1'ttl HCH ... )
It was comp I et ed. Push SET. o,u111 th 1hh 11111ut1u.
It ... CHtlll9'. Pull set.
6-27
6.5 Version Check
Versions of "indication program", "control program", and "data" can be displayed by the step shown below.
When both the "(ID" and "@" switches are pressed for three seconds or longer at a time, display of versions is started.
The previous screen reappears when they are released.
(Version screen can be accessed from any screen.)
11111111111111111111111111111111
I
.
R~~)IO
BO 70 80 90 I 00 . Model name
Part number of program
Control program version

CKE800
INDICATION CPU :uoo - - - - - - - - r - Indication program version

Model name
CKE800 Data version for code setting
Part number of Data card
GG62T01004D2
DATA 1 :V 1.00
DATA 2 :V 1.00 - - - - - - - - ; - - Data version for lifting capacity
Crane STD. Waloht

BOOM: IOOfeet J 18: 30feet
Jib anole IOdeo
HOOK : Ma Use Aux. Uae
L/No : Ma Au x. ,----~
* Versions and P/No. shown in the left

figure are some example. Actually
displayed versions may differ from them.
6-28
7. ERROR CODE (ABNORMALITY DETECTION)
AND COUNTERMEASURES
When an abnormality is detected, error messages are displayed in the message display window. Some abnormalities may
cause lamp displays too. The machine will stop and a steady alarm sound comes on. The auto-stop mechanism can be
bypassed by using the Overhoist Release switch, but the alarm sound will continue.
· Status display
Message Buzzer Display conditions (machine statuses)
(1) Out of angle. Pee- Out of capacity set range
(2) Stop by the hook overhoist is canceled. - The hook overhoist automatic stop release switch is actuated.
(3) Stop by the boom/jib overhoist is canceled. - Input from the boom/jib raising/lowering stop cancel switch is detected.
(4) Stop by the overload is canceled. - Overload status is canceled.
(5) Overload condition. Boo- The loading ratio exceeds the specified level.
(6) Head wind is strong. - The head wind load alarm is issued.
(7) Boom is lowered too much. Boo- The boom is out of the maximum working radius area.
(8) Boom is raised too much. Pee- The boom is out of the minimum working radius area.
(9) Jib is lowered too much. Boo- The jib is out of the maximum working radius range.
(10) Jib is raised too much. Pee- The jib is within the minimum working radius range.
(11) Boom is lowered too much. Boo- The main boom angle is smaller than the lower limit.
(12) Boom is raised too much. Pee- The main boom angle exceeds the upper limit.
(13) Jib is lowered too much. Boo- The jib offset angle exceeds the upper limit.
(14) Jib is raised too much. Pee- The jib offset angle is smaller than the lower limit.
(17) Hook overhoist. Pee- The main hook overhoist limit switch is actuated.
(18) Hook overhoist. Pee- The aux. hook overhoist limit switch is actuated.
(21) Boom overhoist. Pee- The boom overhoist limit switch (boom foot, backstop No. 1) is actuated.
(22) Jib overhoist Pee- The jib overhoist limit switch is activated.
(24) Overload forecast. Boo, boo- Loading ratio is 90% or more, and lower than the specified level.
(25) It met the setup value of the load limitation. Boo- Lifting load exceeds the lifting load limit value set by operator.
(26) It met 90% of the load limitation value. Boo, boo- Lifting load exceeds 90% of the lifting load limit value set by operator.
(27) Boom angle reached upper limitation value. Pee- The boom reaches the boom angle upper limit point (stop point) set by operator.
(28) Boom angle reached lower limitation value. Pee- The boom reaches the boom angle lower limit point (stop point) set by operator.
(29) Jib angle reached upper limitation value. Pee- The jib reaches the jib angle upper limit point (stop point) set by operator.
(30) Jib angle reached lower limitation value. Pee- The jib reaches the jib angle lower limit point (stop point) set by operator.
(31) Working radius reached limitation value. Pee- The boom reaches the working radius limit point (stop point) set by operator.
(32) Boom point elevation reached limitation value. Pee- The boom reaches the boom height limit point (stop point) set by operator.
(33) Jib point elevation reached limitation value. Pee- The jib height reaches the limit value (stop point) preset by the operator.
(56) Check mode (Overload condition) Boo- In the overload check mode
(60) Boom overhoist Pee- The boom overhoist limit switch (second backstop) is activated.
(64) Danger!! Set the gantry fix cable. Boo--- The boom is raised without gantry fixing cable.
(65) Change to the self removal mode. Boo--- The gantry is low.
7-1
· Error message
Message Buzzer Display conditions (machine statuses)
(34) Code setup error. Boo- Crane data in the controller is abnormal.
(35) Adjustment data are unusual. Adjust it again. Pi Adjustment data is out of the normal range.
(36) The trouble of the load cell for the boom (I). Boo- The boom load detector is faulty.
(39) The trouble of the load cell for the jib (2). Boo- The jib load detector is faulty.
(44) The trouble of the lower boom angle sensor. Boo- The boom angle detector is faulty.
(47) The trouble of the lower jib angle sensor. Boo- The jib angle detector is faulty.
(57) Communication unusual - Communication with the total controller is abnormal.
7-2
8. CONTROL OUTPUT
(1) Controller output signal (Type No.01) STD type crane (main boom only, with aux. sheave and fixed jib) - (3-drums type)
Digital indication Alarm output Crane control output External indication output
Whole Alarm output Conditions
Automatic stop
moment Mode required for <90% 90%~ LVL~
Boom Point Jib Moment ratio Actual load Rated load Working radius ratio restoration from
indication :, d) Winch I
~
angle elevation angle Alarm sounds u
Winch2 Winch3 Raising I automatic stop <LVL
(bar &"' § "'
(3-digits) (3-digits) (3-digits) (4-digits) "' ::, c: c: Main Third
indicator) Q.)
ol 0 0 U O Com-
(3-digits) (3-digits) (3-digits)
Main
winch
Aux.
winch
Main
winch
Aux.
winch
Main
winch
Aux.
winch
Main
winch
Aux.
winch
(3-digits) Main Aux.
winch winch
Over-
load
Boo ..
Over-
hoist
Pii..
~
"'"'
Q.)
::s >
Q.)
u
·5
-
r~
<r:: 0
u
~~
-o
<r:: u
winch
Up Up
Aux. winch
Down
winch
Up
Boom raising
Up Down
Restora- pulsory
tion cancel-
lation
Blue Yellow Red
- Not Not - Not Not Not Not Not Not Not Not Not Not Not Not Not - - - - - - OFF OFF
Power OFF OFF OFF OFF OFF OFF OFF OFF
indicated indicated indicated indicated indicated indicated indicated indicated indicated indicated indicated indicated indicated issued issued
- Not Not - - - - - - OFF OFF
Allowable working area 01 Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated
issued issued
ON ON ON ON ON ON ON
Overload - Indicated in yellow Indicated Indicated Indicated Intermit- - - - - - - - - -
prenotice II Indicated Indicated Indicated Indicated
in yellow
Indicated Indicated
tent
(24) 11 K B OFF ON OFF
Main/Aux.
single mode Indicaied Con-
Overload 12 Indicated Indicated - Indicated in red Indicated Indicated Indicated Indicated
in red
Indicated Indicated
tinuous
- (5) 2 L c OFF OFF ON OFF ON OFF F z OFF OFF ON
Overload - Indicated Indicated Indicated Intermit- - - - - - - - - - OFF
Q.) Main and prenotice 13 Indicated Indicated
in yellow in yellow
Indicated Indicated Indicated Indicated Indicated Indicated
in yellow
Indicated Indicated
tent
(24) 11 K B OFF ON
"O
0 aux. Indicated Indicated Indicated Con-
a winches Overload 14 Indicated Indicated -
in red in red
in red
Indicated Indicated
tinuous
• Oil
>< c: Indicated Intermit-
"'·-
"' 4::
"O;.::::
Main
Overload
orenotice
15 Indicated Indicated -
in yellow
Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated
tent
- (24) 11 K B - - - - - - - - OFF ON OFF
winch Indicated Con-
c: "'
"'::,
c: 0 Overload 16 Indicated Indicated -
in red
Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated
tinuous
· - Q.)
Indicated Intermit-
"O
::s"' ;:!c: Overload 17 Indicated Indicated - Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated - (24) 11 K B - - - - - - - - OFF ON OFF
"'
0 "3 Aux. prenotice in yellow tent
,-..l
a
"<ii
winch
Overload 18 Indicated Indicated - Indicated
Indicated
Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated
Con- - (5) 2 L c OFF OFF ON OFF ON OFF F z OFF OFF ON
in red tinuous
Indicated Indicated Intermit-
Main winch max. load set point
( area limitation)
19 Indicated Indicated -
in red
Indicated Indicated Indicated
in green
tent
- (5) 2 M c OFF OFF ON OFF ON OFF F z OFF OFF ON
Indicated Indicated Intermit-
Aux. winch max. load set point
( area limitation)
20 Indicated Indicated - Indicated
in red
in green
Indicated Indicated Indicated Indicated Indicated
tent
- (5) 2 M c OFF OFF ON OFF ON OFF F z OFF OFF ON
Indicated Indicated Indicated .nnt1re1y Con-
Boom over-lowering 31 in red
Indicated - --- --- --- --- 0.0 0.0
in red in red
indicated Indicated Indicated
in red tinuous
- (7) 4 N D OFF OFF ON OFF ON OFF D z - - -
Indicated - - Con- - - - - - - -
Boom over-raising 32 Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated (8) 5 N D ON ON D T
in red tinuous
Main winch radius excess - Indicated - Intermit- - - - - - - - - - - - - -
"':::, 33 Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated M J
(area limitation prenotice) in yellow tent
:.a Indicated Con-
"'
i:i:::
Main winch radius excess
(area limitation alarm) 34 Indicated Indicated - Indicated Indicated Indicated Indicated Indicated Indicated
in yellow
Indicated Indicated Indicated Indicated -
tinuous
(31) 14 M J - - - - - OFF J z - - -
Aux. winch radius excess - Indicated - Intermit- - - - - - - - - - - - - -
( area limitation prenotice) 35 Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated M J
in yellow tent
Aux. winch radius excess Indicated Con-
(area limitation alarm) 36 Indicated Indicated - Indicated Indicated Indicated Indicated Indicated Indicated Indicated
in yellow
Indicated Indi~ated Indicated -
tinuous (31) 14 M J - - - - - OFF J z - - -
Boom over-lowering Indicated - - Intermit- - - - - - - - - - - - - -

41 Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated M D
( area limitation orenotice) in yellow tent
Q.) Indicated Con-
"@)
c:
Boom over-lowering
( area limitation alarm)
42
in yellow
Indicated - Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated -
tinuous (28) 13 M D - - - - - OFF D z - - -
--< Boom over-raising 43
Indicated
Indicated - Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated - Intermit- - - M D - - - - - - - - - - -
( area limitation orenotice) in yellow tent
Boom over-raising Indicated Con-
(area limitation alarm) 44 in yellow
Indicated - Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated -
tinuous (27) 13 M D - - - - OFF - D z - - -
c: Point elevation Indicated Indicated Intermit-
0 61 - Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated - - - M J - - - - - - - - - - -
-~ (area limitation orenotice) in yellow in yellow tent
> Indicated Indicated Con-
Q.) Point elevation 62 - Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated - (32) 15 M J - - - - OFF - J z - - -
µ:J (area limitation alarm) in yellow in yellow tinuous
Indicated Con-
..c:
Main winch hook overhoist 71 Indicated Indicated - Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated
in red
Indicated -
tinuous (17) 10 p A OFF OFF ON OFF ON OFF A s - - -
B Indicated Con-
-~ Aux. winch hook overhoist 72 Indicated Indicated - Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated in red - (18) 10 p A OFF OFF ON OFF ON OFF A s - - -
-"'
:§
,-..l
Boom overhoist 74
Indicated
in Red
Indicated - Indicated Indicated Indicated Indicated Indicated Indicated
Indicated Indicated
in red in red
Indicated Indicated Indicated -
tinuous
Con-
tinuous (21) 5 Q A OFF OFF ON OFF OFF ON A R - - -
Jib overhoist - Indicated Indicated - Con- - - -
75 Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated (23) 10 Q A ON OFF ON ON ON OFF A R
in red in red tinuous
-
Head wind alarm 81 Indicated Indicated - Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated - (6) 3 - - - - - - - - - - OFF OFF OFF
"'....
Q.)
Attachment self-standing En!irely -
6 and stowing 91 Indicated Indicated - --- --- --- --- 0.0 0.0 Indicated Indicated in\11cated Indicated Indicated
m red
- (1) - - - (ON) (ON) ON (ON) ON ON A s OFF OFF ON
Attachment assembly Not Not -
and disassembly 92 Indicated Indicated Message display - - - - ON ON ON ON ON ON - OFF OFF ON
[Notes]
- issued issued
[Details of alarm and automatic stop condition symbols]
I. Symbols"-" shown on the columns of alarm sounds, crane control output, and external indication output in the table above indicate that A. When the status is cancelled, the machine immediately restores automatically. L. Alarm is issued when the moment ratio exceeds the LVL.
the corresponding items are not the subjects of control. B. When the moment ratio is decreased to 89.5%, the status is cancelled (automatically restored). M. Alarm is issued when the set values are exceeded and the machine is operated in hazardous directions.
2. In the columns of the crane control output (automatic stop) and external indication output, "OFF" indicates the stop status, and "ON" C. When the moment ratio is decreased by 0.5% from the overload automatic start point, the status is cancelled (automatically restored). N. Alarm is issued when the boom angle exceeds the limit angle.
indicates the operable status. D. When the boom is returned to the safety side by 0.4° or more from the limit angle, the status is cancelled (automatically restored). P. Alarm is issued when overhoist occurs and the machine is operated in hazardous directions.
3. In respect of automatic stop, priority is given in the following order: condition No.92, 71 to 75, 91, 01 to 62 (except for 81). E. When the boom is returned to the safety side by 2.0° or more from the limit angle, the status is cancelled (automatically restored). Q. Alarm is issued when overhoist occurs.
4. Point elevation is indicated only when the indication is requested on the setting screen. F. When the moment ratio is decreased by 5.0% from the overload automatic stop point, the status is cancelled (automatically restored). R. The status cannot be cancelled whatever cancel switch is operated.
J. When the radius or elevation is returned by 0.1 m (0.1 feet) to the safety side from the prenotice set radius or height, the status is S. Automatic stop is cancelled only while the hook overhoist cancel switch is operated.
cancelled (automatically restored). T. Automatic stop is cancelled only while the boom overhoist cancel switch is operated.
K. Alarm is issued when the moment ratio is 90% or more. Z. Automatic stop is cancelled only while the overload cancel switch is operated.
8-1
(2) Controller output signal (Type No.03) Luffing crane (main, auxiliary, boom, luting jib) - (4-drums type)
Alarm output Crane control output External indication output
Boom
. Moment ratio
Digital indication
Actual load Rated load Working radius

Whole
moment
ratio
Mode
indication
Alarm sounds
Alarm output
;i
&~ "
u
=~ Winch I
Automatic stop Conditions
required for
restoration from <90%
90%1'
<LVL LVL~
angle
Point
elevation
Jib offset Jib (3-digits) (3-digits) (3-digits) (4-digits) (bar ~
==
00 "'=
uo
Winch2 Raise/Lower I Raise/Lower 2 automatic ston
angle angle indicator) """ §~ §~ Front Rear Boom Jib
Com-
Over- Over-
~ -~ § Restora- pulsory Blue Yellow Red
(3-digits) (3-digits) (3-digits) (3-digits) Main
winch
Luffing
jib
Aux.
winch
Main
winch
Luffing
jib
Aux.
winch
Main
winch
Luffing
jib
Aux.
winch
Main
winch
Luffing
jib
Aux.
winch
(3-digits) Main
winch
Luffing
jib
Aux.
winch
load
Boo ..
hoist
Pii .. "
~
0"'
>-;;;
-"'=
..,,:o
u ~8 Up Up Down Up Down Up Down tion cancel-
lation
Power OFF - Not Not Not Not Not Not Not Not Not Not Not Not Not Not Not Not Not Not Not Not Not Not
indicated indicated indicated indicated indicated indicated indicated indicated indicated indicated indicated indicated indicated indicated indicated indicated indicated indicated indicated indicated issued issued - - - - OFF OFF OFF OFF OFF OFF OFF - - OFF OFF OFF
Allowable working area Not Not -
01 Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated issued issued - - - - ON ON ON ON ON ON ON - ON OFF OFF
Overload prenotice II Indicated Indicated Indicated Indicated Indicated in yellow Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated lntermit- - - - - - - - - - - OFF OFF
in yellow tent (24) II K B ON
Indicated Con- -
Overload 12 Indicated Indicated Indicated Indicated Indicated in red Indicated Indicated Indicated Indicated Indicated
in red
Indicated Indicated Indicated tinuous (5) 2 L c OFF OFF ON ON OFF ON OFF F z OFF OFF ON
Main winch max. load set point 21 Indicated Indicated Indicated Indicated Indicated mmcateo Intermit- - - -
(area limitation prenotice) in yellow
Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated (24) II K B - - - - - - - OFF ON OFF
in green tent
Main winch max. Joad set point 22 Indicated Indicated Indicated l!]dicated Con- -
] (area limitation alarm) Indicated Indicated
in red Indicated Indicated Indicated Indicated Indicated
m !!reen
Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated
tinuous (5) 2 L c OFF OFF ON ON OFF ON OFF F z OFF OFF ON
.J Jib max. load set point Indicated Indicated Intermit-
(area limitation prenotice) 23 Indicated Indicated Indicated Indicated Indicated
in yellow
Indicated Indicated Indicated Indicated Indicated in green Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated tent
- (24) II K B - - - - - - - - - OFF ON OFF
f!~e~fl~nl?a~?o~e!~:;:) 24 Indicated Indicated Indicated Indicated Indicated tn~1cated

m red
Indicated Indicated Indicated Indicated Indicated tnct1cated
m green
Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Con-
tinuous
- (5) 2 L c OFF OFF ON ON OFF ON OFF F z OFF OFF ON
Aux. wmch max: load set pomt 25 Indicated Indicated Indicated Indicated Indicated Indicated Inmcatea Indicated Indicated Indicated Indicated Indicated I!]O!Cated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Interm1t- - - - - - - - - - -
(area limitation prenotice) in yellow m green tent (24) II K B OFF ON OFF
Aux. wmcll max. toad set pomt Indicated l!]d1catea _Con- -
(area limitation alarm) 26 Indicated Indicated Indicated Indicated Indicated Indicated in red Indicated Indicated Indicated Indicated Indicated
m green
Indicated Indicated Indicated Indicated Indicated Indicated Indicated tmuous (5) 2 L c OFF OFF ON ON OFF ON OFF F z OFF OFF ON
Boom over-lowering 31 ln~icated Indicated --- --- --- --- --- --- Indicated Indicated nmcateo Entirely in- Con- -
(only for main lifting) mred
Indicated Indicated 0.0 0.0 0.0
in red in red in red dicatedinred
Indicated Indicated Indicated tinuous (7) 4 N D OFF OFF ON ON OFF ON OFF D z OFF OFF ON
Hoom over-ra1smg Con-
(onlv for main liftmi!)
32 ln~1cated Indicated
mred
Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated - tinuous (8) 5 M D ON ON ON OFF ON ON ON D T - -
Jib over-lowering Indicated lilCIIcatea --- --- --- --- --- --- Indicated Indicated Indicated Entirely in- Con- -
(only for jib and aux. lifting) 33 Indicated Indicated
in red in red 0.0 0.0 0.0
in red in red in red dicatedinn:d
Indicated Indicated Indicated tinuous (13) 6 N D OFF OFF ON ON OFF ON OFF D z OFF OFF ON
Jib over-ra1smg Indicated IDOICim,u Lon-
(only for jib and aux. lifting) 34 Indicated Indicated
in red in red Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated - tinuous (14) 7 M D ON ON ON ON ON OFF ON D T - -
Mam wmch radms excess Indicated Intenmt-
(area limitation prenotice) 35 Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated in yellow Indicated Indicated Indicated Indicated Indicated Indicated - tent - - M J - - - - - - - - - - - -
:a Mam wmcll radms excess
(area limitation alarm) 36 Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated tncucated Indicated Indicated Indicated Indicated Indicated Indicated - .Con- (31) 14 M J - - - - OFF - OFF J z - -
ol in yellow tmuous
Luffing jib radius excess Indicated Intermit- -
(area limitation prenotice) 37 Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated
in yellow Indicated Indicated Indicated Indicated Indicated - tent - - M J - - - - - - - - - - -
Luftmg Jib radius excess Indicated Con-
(area hmitation alarm) 38 Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated
in yellow
Indicated Indicated Indicated Indicated Indicated - tinuous (31) 14 M J - - - - OFF - OFF J z - - -
Aux. wmch radius excess Indicated 1nterm1t- -
(area limitation nrenotice) 39 Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated in vellow Indic:1ted Indicated Indicated Indicated - tent - - M J - - - - - - - - - - -
Aux. winch radius excess Indicated Con-
(area limitation alarm) 40 Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated in yellow Indicated Indicated Indicated Indicated - tinuous (31) 14 M J - - - - OFF - OFF J z - - -
Boom over-lowering 41 Indicated Indicated Intermit-
(area limitation prenotice) in yellow
Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated - tent - - M D - - - - - - - - - - - -
Hoom over-lowermg 42 11nct1catea Indicated _Con- -
(area limitation alarm) in yellow
Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated - tinuous (28) 13 M D - - - - OFF - - D z - -
Boom over-raising . :, Intermit- -
(area limitation prenotice)
43 Indicated
in yellow
Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated - tent - - M D - - - - - - - - - - -
Boom over-raising-:, 44 Indicated Indicated Indicated Con-
(area limitation alirm) in yellow
Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated - tinuous (27) 13 M D - - - OFF - - - D z - - -
Jib over-lowermg 45 Indicated Indicated I Indicated lnd1cated lnterm1t-
(area li~itation prenotice) in yellow in yellow Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated - tent - - M D - - - - - - - - - - -
~
-;;;, f~~e~l~~\fa1i~~na~arm) 46 Indicated Indicated I Inmcatea tnct1catec1 Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated - con-
(30) 13 M D - - - - - - OFF D z - - -
c in yellow in yellow tinuous
< Jib over-raising 47 Indicated Indicated Indicated Indicated Intermit- - -
(area limitation prenotice) in yellow in yellow Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated - tent - - M D - - - - - - - - - -
Jib over-raising 48 Indicated Indicated Indicated Indicated Con-
(area limitation alarm) in yellow in yellow Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated - tinuous (29) 13 M D - - - - - OFF - D z - - -
Boom low. limit angle --- --- Entirely in- Con- -
(only for jib and aux. lifting) 49 Indicated Indicated Indicated Indicated --- Indicated Indicated Indicated 0.0 0.0 0.0 Indicated Indicated Indicated
dicatedinrcd
tinuous (II) 4 N D OFF OFF ON ON OFF - - D z OFF OFF ON
Boom upp. limit angle
(only for Jib and aux. lifting) 50 ln?1catea
mred
Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated - Con-
(12) 5 N D ON ON ON OFF ON - - D T - - -
tinuous
Jib offset low. limit angle Indicated Indicated Con- - -
(only for main lifting) 51 Indicated Indicated
in red in red Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated - tinuous (14) 7 N D - - - ON OFF OFF ON D T -
Jib offset upp. limit angle Indicated Indicated --- --- Entirely in· Con- -
(only for mam lifting) 52 Indicated Indicated
in red in red --- Indicated Indicated Indicated 0.0 0.0 0.0 Indicated Indicated Indicated
dica1edinred
Indicated Indicated Indicated tinuous (13) 6 N D OFF OFF ON OFF ON ON OFF D z OFF OFF ON
Pomt etevanon 61 11nct1cated 11nct1catect Ind1catect lntermu-
- - - - -
·i
ui
(area limitation prenotice)
Pomt elevation
(area limitation alarm)
in yellow in yellow
62 IIndicated IIndicated
in yellow in yellow
Indicated
Indicated
in yellow
Indicated
in yellow
Indicated
Indicated
Indicated
Indicated
Indicated
Indicated
Indicated
Indicated
Indicated
Indicated
Indicated
Indicated
Indicated
Indicated
Indicated
Indicated
Indicated
Indicated
Indicated
Indicated
Indicated
Indicated
Indicated
Indicated
Indicated
Indicated
Indicated
Indicated
Indicated
Indicated
Indicated
Indicated
-
-
tent
_Con-
tmuous (32)
-
15
M
M
J
J -
-
-
-
-
-
OFF
-
- OFF
-
-
-
J
-
z -
-
-
Indicated Indicated Indicated Con- -
Hook overhoist (I) 71 Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated
in red in red in red - tinuous (17) 10 p A OFF OFF ON ON OFF ON OFF A s - -
Indicated lndicatea Indicated _Con- -
]
Hook overhoist (2) 72 Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated
in red in red in red - tmuous (18) 10 p A OFF OFF ON ON OFF ON OFF A s -
-~ Boom overhoist (lst) 73 11n~1catect Indicated

mred
Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated
in red
Indicated
in red
In~~ed Indicated l!"!dicated Indicated Indicated - .Lon-
tmuous (21) 5 Q A ON ON ON OFF ON ON ON A T - - -
·g Boom overhoist (2nd) 74 In~icated Indicated
mred
Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated
in red
Indicated
in red
Indicated
in red
Indicated Indicated Indicated Indicated - Con-
tinuous (60) 5 Q A OFF OFF ON OFF ON ON ON A R ·- - -
::l Indicated Indicated Indicated Indicated Indicated Con- - -
Jib overhoist 76 Indicated Indicated
in red in red Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated
in red in red in red
Indicated Indicated Indicated Indicated - tinuous (22) 7 Q A OFF OFF ON ON OFF OFF ON A R -
-··
77 In~icated Indicated Indicated Con-
Strut over-raising
mred
Indicated
in red Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated - tinuous (58) - Q A ON ON ON ON OFF OFF ON A R - - -
Strut over-lowering 78 In~icated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicaterl Indicated Indicated - Con- - - - -
mred in red tinuous (59) Q A ON ON ON OFF ON ON OFF A R
~
Head wind alarm 81 Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated Indicated - - (6) 3 - - - - - - - - - - - OFF OFF OFF
! Attachment self-standing
and stowinP-
Attachment assembly
91 Indicated Indicated Indicated Indicated --- --- --- --- --- --- 0.0 0.0 0.0 Indicated Indicated Indicated Entirely in-
dicatedinred Indicated Indicated Indicated -
Not
-
Not
(I) - - - ON ON ON ON ON ON ON - - OFF OFF ON
and disassemblv
92 Indicated Indicated Indicated Indicated Message display issued issued - - - - ON ON ON ON ON ON ON - - OFF OFF ON
[Notes]
l. Symbols "-" shown on the columns of alarm sounds and, crane control output, in the table above indicate that the corresponding items are not the subjects of [Details of alarm and automatic stop condition symbols]
control. A. When the status is cancelled. the machine inunediately restores automaticaily. L. Alarm is issued when the moment ratio exceeds the LVL.
2. In the columns of the crane control output (automatic stop). "OFF" indicates the stop status, and "ON" indicates the operable status. B. When the moment ratio is decreased to 89.5%, the statu::.is crncelled (automatically restored). M. Alarm is issued when the set values are exceeded and the machine is operated in hazardous directions.
3. From No. 0 l to 78 shown in the table above, priority is given to OFF of conditions other than the drum control output over ON. C. When the moment ratio is decreased by 0.5% from the overload automatic start point, the status is cancelled (automatically restored). N. Alarm is issued when the boom angle exceeds the limit angle.
4. Priority is given in the following order: condition No.92. 71 to 78, 91, 11 to 62. D. When the boom is returned to the safety side by 0.4° or more from the limit angle, the status is cancelled (automatically restored). P. Alarm is issued when overhoist occurs and the machine is operated in hazardous directions.
5. Point elevation and jib offset angle are indicated only when the indication is requested on the setting screen. E. When the boom is returned to the safety side by 2.0° or more from the limit angle, the status is cancelled (automatically restored). Q. Alarm is issued when overhoist occurs.
F. When the moment ratio is decreased by 5.0% from the overload automatic stop point, the status is cancelled (automatically restored). R. The status cannot be cancelled whatever cancel switch is operated.
J. When the radius or elevation is returned by 0.1 m (0.1 fee.t) to the safety side from the prenotice set radius or height, the status is cancelled (automatically S. Automatic stop is cancelled only while the hook overhoist cancel switch is operated.
restored). T. Automatic stop is cancelled only while the boom overhoist cancel switch is operated.
K. Alann is issued when the moment ratio is 90% or more. Z. Automatic stop is cancelled only while the overload cancel switch is operated.
8-2
9.RELEASES
When an operation has been auto-stopped, the release functions are as explained in the following chart.
9.1 Release Function

9.1.1 Crane Release Chart
Standard Crane Release Chart
Release Switch Boom Hook Hoist Up

Stop Condition
Operation Raise Down Main Auxiliary Third
Hook Overhoist (Main) No Operation 0 x x x x
Hook overhoist 0 0 0 0 0
Boom overhoist 0 x x x x
Overload 0 x x x x
Hook&Boom 0 0 0 0 0
Hook & Overload 0 0 0 0 0
Boom & Overload 0 x x x x
All three 0 0 0 0 0
Hook Overhoist (Aux.) No Operation x x x x
0
Overload 0 x x x x
Hook&Boom 0 0 0 0 0
All three 0 0 0 0 0
Overload (100%) No Operation x x x x
0
Boom Low. Limit Angle
(Stop type) Hook overhoist 0 x x x x
Overload 0 0 0 0 0
Hook &Boom 0 x x x x
Boom & Overload 0 0 0 0 0
All three 0 0 0 0 0
* The hook lowering is always possible. 0 : Can move X : Cannot move
9-1
Standard Crane Release Chart
Release Switch Boom Hook Hoist Up

Stop Condition
Operation Raise Down Main Auxiliary Third
Overload (100%) No Operation 0 0 0 0 0
Boom low. limit angle
(Alarm type)
Boom overhoist 0 0 0 0 0
Overload 0 0 0 0 0
Hook&Boom 0 0 0 0 0
All three 0 0 0 0 0
Boom upp. limit angle No Operation x 0 0 0 0
(Controled by LMI)
Hook overhoist x 0 0 0 0
Boom overhoist 0 0 0 0 0
Overload x 0 0 0 0
Hook&Boom 0 0 0 0 0
Hook & Overload x 0 0 0 0
All three 0 0 0 0 0
Boom overhoist (CR) No Operation x 0 x x x
(Limit switch)
Hook overhoist x 0 x x x
Boom overhoist x 0 x x x
Overload x 0 x x x
Hook& Boom x 0 x x x
Hook & Overload x 0 x x x
Boom & Overload x 0 x x x
All three x 0 x x x
Overload (200%) No Operation 0 x x x x
Hook overhoist 0 x x x x
Overload 0 x x x x
Hook&Boom 0 x x x x
Hook & Overload 0 x x x x
All three 0 x x x x
Crane jib overhoist No Operation 0 x 0 x 0
(Option)
Hook overhoist 0 x 0 x 0
Boom overhoist 0 x 0 x 0
Overload 0 x 0 x 0
Hook & Boom 0 x 0 x 0
Hook & Overload 0 x 0 x 0
Boom & Overload 0 x 0 x 0
All three 0 x 0 x 0
* The hook lowering is always possible. 0 : Can move X : Cannot move
9-2
Luffing Crane Release Chart (Main Mode 1/2)
Release Switch Boom Jib Hook Hoist Up

Stop Condition
Operation
Raise Down Raise Down Front Rear
Hook overhoist (Main)
No Operation 0 x 0 x x x
Hook overhoist 0 0 0 0 0 0
Boom overhoist 0 x 0 x x x
Overload 0 x 0 x x x
Hook overhoist
(Jib/Auxiliary)
I
Overload (100%)
Boom overhoist
Overload
0
0
x
x
0
0
x
x
x
x
x
Hook overhoist 0 x 0 x x x
/.l Boom overhoist 0 x 0 x x x
/D Overload 0 0 0 0 0 0

(Controled by LMI)
No Operation x 0 0 0 0 0
Hook overhoist x 0 0 0 0 0
Boom overhoist 0 0 0 0 0 0
i
Overload x 0 0 0 0 0

(Controled by LMI)
Hook overhoist 0 x 0 x x x ..
/1 Boom overhoist
Overload
0
0 0
x 0
0
x
0
x
0
x
9-3
Luffing Crane Release Chart (Main Mode 2/2)

Stop Condition
Operation
Boom overhoist
(Backstop No. 1 L/S) No Operation x 0 0 0 0 0
/l Overload x 0 0 0 0 0
Boom overhoist
(Backstop No. 2 L/S) No Operation x 0 x 0 x x
Hook overhoist x 0 x 0 x x
Boom overhoist x 0 x 0 x x
/ Overload x 0 x 0 x x
Jib upp. limit angle

(Small offset angle) No Operation 0 x x 0 0 0
Hook overhoist 0 x x 0 0 0
I
Overload 0 x x 0 0 0
Jib low. limit angle
(Large offset angle) No Operation x 0 0 x x x
Hook overhoist x 0 0 x x x
I
Jib overhoist L/S
Boom overhoist
Overload 0
x
0
0
x
0
x
x
0
x
x
x
x
No Operation 0
0/ Hook overhoist 0 x x 0 x x
/
Boom overhoist 0 x x 0 x x
Overload 0 x x 0 x x
9-4
Luffing Crane Release Chart (Jib or Aux. Mode 1/2)

Stop Condition
Operation
Hook overhoist (Main)
I
Overload 0 x 0 x x x
Hook overhoist
(Jib/Auxiliary)
I
Overload (100%)
Boom overhoist
Overload
0
0
x
x
0
0
x
x
x
x
x
f
Hook overhoist 0 x 0 x x x
Overload 0 0 0 0 0 0

(Controled by LMI)
No Operation x 0 0 0 0 0
Overload x 0 0 0 0 0

(Controled by LMI)
No Operation 0 x 0 0 x x
Hook overhoist 0 x 0 0 x x
/1 Boom overhoist
Overload
0
0
x
0
0
0
0
0
x
0
x
9-5
Luffing Crane Release Chart (Jib or Aux. Mode 2/2)

Stop Condition
Operation
Boom overhoist
(Backstop No. 1 L/S) No Operation x 0 0 0 0 0
/~ Overload 0 0 0 0 0 0
Boom overhoist
No Operation x 0 x 0 x x
(Backstop No. 2 L/S)
Hook overhoist x 0 x 0 x x
Boom overhoist x 0 x 0 x x
~ Overload x 0 x 0 x x
Jib upp. limit angle

(Controled by LMI)
No Operation 0 0 x 0 0 0
Hook overhoist 0 0 x 0 0 0
/
Overload 0 0 x 0 0 0
Jib low. limit angle

(Controled by LMI)
x x x x
(I Hook overhoist 0 0
/
Jib overhoist L/S
Boom overhoist
Overload
0
0 0
x 0
0
x
0 0
x x
No Operation 0 x x 0 x x
=/ Hook overhoist 0 x x 0 x x
I
Boom overhoist 0 x x 0 x x
Overload 0 x x 0 x x
9-6
9.1.2 Alarm Sound
(1) Crane
0: emitted (pi--) e: emitted (Boo-) X: not emitted
Front Front Rear Rear 3rd 3rd Boom Boom

~ n
n winch up winch down winch up winch down winch up winch down raise lower
Hook overhoist (main) 0 x 0 x 0 x x 0

Hook overhoist (aux.) 0 x 0 x 0 x x 0
Boom upper limit angle x x x x x x 0 x
Boom overhoist (L/sw) O regardless of operation
Overload e regardless of operation
Crane jib overhoist O regardless of operation
* When any hazardous condition occurs, and any circle is found in the line of the hazardous condition in the table
above, alarm sounds are emitted.
(2) Luffing 0: emitted (pi--) e: emitted (Boo-) X: not emitted

Front Front Rear Rear Boom Boom Jib Jib
~ n
c winch up winch down winch up winch down raise lower raise lower
Hook overhoist (main) 0 x 0 x x 0 x 0

Hook overhoist (Jib/aux.) 0 x 0 x x 0 x 0
Boom upper limit angle x x x x 0 x x x
Jib upper limit angle x x x x x x 0 x
Boom overhoist No.I L/S O regardless of operation
Boom overhoist No.2 L/S O regardless of operation
Jib overhoist L/S O regardless of operation
Boom low. limit angle e regardless of operation
Jib low. limit angle e regardless of operation
Overload e regardless of operation
* When any hazardous condition occurs, and any circle is found in the line of the hazardous condition in the table
above, alarm sounds are emitted.
9.1.3 External Indicator Lamps in Release Condition
1. The overload external indicator lamps are forcibly lit to indicate the moment ratio of 100% or more by the release
switch.
External indicator
Release condition
-90% (green) 90%-100% (yellow) 100%- (red)
Normal condition 0 x x
Hook overhoist x x 0 ·.·
Overload x x 0
Boom overhoist x x 0
Hook overhoist and overload x x 0
Hook overhoist and boom overhoist x x 0
Overload and boom overhoist x x 0
Hook overhoist, overload, and x x 0
boom overhoist
9-7
Alarm sounds
(1) For the hook overhoist, boom upper limit angle, and jib upper limit angle, alarm sounds are emitted only when the
operation toward the hazardous side is performed while the machine is in the hazardous condition.
Even when the machine is in the hazardous condition, the alarm sounds are not emitted when the operation toward the
safe side is performed or the lever is at the neutral position.
(2) For the overload, boom lower limit angle, jib lower limit angle, boom overhoist (limit switch), and jib overhoist (limit
switch), the alarm sounds are emitted regardless of the lever operation when the machine is in the hazardous condition.
The alarm sounds cannot be cancelled.
9-8
10. MECHANICAL SPECIFICATION
10.1 Environmental Performance Parameters
Power: DC24V battery (20 - 32V)
Capable temperature : -20to 70°C

(However, since the LC display temperature limit is Oto 40°C, when the temperature is
outside of this range, it may not be visible)
Storage temp. : -40 to 80°C
Humidity: 95%
Protective structure : Outdoor elements Water proofed, sealed structures

Inside elements Dust proofed (no sealed structures)
Vibration proof : Complies with Authorized Standards
Shock proof : Complies with Authorized Standards
Electronic "Noise" Proofing: No mechanical damage with DC lOOOV 1 µ S added while the power is on.
No mechanical malfunction with DC 700V lOOnS added while the power is on.
Item locations : Outdoor Detector link, angle changers, connecting cables,

transit boxes etc. (outdoor elements)
Oper. cabin Controllers etc. (inside elements)
10.2 Load Cell (Crane)
Model name: LTP-S-300-KNS8
Detective capacity : Guy-cable support power
Rated capacity : 30 ton (147.lKN)
Load capacity : 150%
Output voltage : with no load lV±O.OlV (at shipping)

with rated load 5V±0.040V
Power source : DC10V±5% (under 30 mA)
Output resistance : Appr. under 100 D
Insulated resistance : 500M n /above 25VDC
Non Lineality : ±1%RO
Hysteresis : ±1%RO
Temperature compensation range: -30°C to+ 65°C
Temperature capacity : -35°C to+ 75°C
Temperature effect at zero point: ±0.1 % RO/C
Temperature effect at output : ±0.1%RO/C
10-1
Output cable : None
apex classification 5P water proof plug AE770L14-05P
Vibration proof : 7 .1 G 33Hz up/down for 4 hours and left/right, front/back for 2 hours.
Shock proof : 25G, 15mS
Water proof : Conforms to IP67 or equivalent (JIS C0920 non-seaping type)
Durability : 5 X 105 times
Noise proof : DC700V 1OOns
Total integrity : 2.9%RO
Weight: About 10 kg
A Input + (Power)
B Output + (Signal)
c Output - (Earth)
D Input - (Earth)
E Body earth
SeaId
10-2
10.3 Angle Sensor
10.3.1 Type 1
Deflection angle 113.5° or more (from -13.5 to+ 100° , provided that the angle of a horizontal line
is 0° .)
Total precision Single linearity ± 1.2° (including hysteresis when vibrated)
Responsibility Approx. 1 sec. (at a room temperature, under an atmosphere)
Detector output Output must be 1.5±0.1 V when the angle of the detector is 0° , and then, it must
turned linear.
Operating temperature From -20°C to+ 70°C
Storage temperature From -40 °C to +80 °C
Vibration-proof 70 m/S 2 (7.14G) 67 Hz
Shock resistance 245 m/S 2 (25G)
Moisture resistance From Oto 95% RH
Built-in potentiometer (CP-3F)
Effective electrical angle 120° ± 1.5° (detected angle)
Total resistance 1 kQ±20%
Rated voltage 1.0 w (at 70°C)
Dumper oil Silicon oil (1000 cSt)
Weight Approx. 1.2 kg
A
<-
0 Jli2SCOCO~iP! 0
NC +12V(Red)
Output(White)~'.
.
L.+
'.. Seald
0 OV(Brack) Plug
VIEW A
2 (Output)
1 (OV) ~ 3 (12V)
10-3
10.3.2 Type 2
Model name: MLA-901A - **C
Detection capacity : Boom angle against ground
Valid operating range : O to ± 90 degree
Operation range : 360 deg. endless
Rated output sensitivity : 0.255VN±0.5%
Input voltage : IOV
Input resistance : 50KD ±5%

Output resistance : (25000+141.6X 8) D ±5%
Detecting accuracy : ±1 deg.
Initial inbalance : Set within±5deg.
Insulate resistance : IOOM D /50VDC
Output cable : Cab tire crolobren cable 0.5mm 2 X 4
Cable analysis : Bending radius : RIOO, Tensile strength : 8kg
Cable apex: 5P waterproof plug AE776L14-05S+MT12-14+MS3180-14CAL
Control method : Oil damper
Monitor: With outside weight Odeg., 30deg., 60deg., 90deg. Monitorable
Case material : Plastic (Toshiba premix AP-902S)
Surfacetreatment: Non, stripe (Black)
Temperature range : -20to 70°C
Store temp. : -40to 80°C
Weight: appr. l.2kg (main body), appr. 65g/m (cable)
r1 RED A
11
II WHITE
II B
500kQ
I
,, t 11
11 BLACK
0
c
II
11 GREEN
D
® 11
11 SEALD
LL--0 E
~ oUID
~
A-C Resistance : 50k0
A-B Resistance(R) : =25000+ 141.6 x ()
0
10-4
10.4 Controller
10.4.1 Model Name
LSD-1500A
10.4.2 System lnpuVOutput
(1) Load input 1 to 7

Corresponding transducer Voltage output type load transducer
Input range From 1 to 5 V (from Oto rated load)
Faulty when the load is 110% or more, or -10% or less of rating
Frequency characteristic 2Hz
Detective resolution 0.03%RO
Detective precision ±0.1%RO
Input connector CN12M 1-174961-1
(2) Angle input 1 to 4
Corresponding transducer Potentiometer type jib angle transducer
Input range From 0.75 to 7.83 V (Error occurs when it is 8.08 V or more or 0.45 V or less)
Frequency characteristic 1 Hz
Detective resolution 0.07°
Detective precision ±0.2°
Others Disconnection detective function
Input connector Input 1 to 3: CN13M 1-179019-1
Input 4: CN14M 1-174957-1 (Common to input 5)
(3) Angle input 5
Input range From 0.75 to 9.25 V (Error occurs when it is 9.5 V or more or 0.45 V or less)
Frequency characteristic 1 Hz
Detective resolution 0.08°
Detective precision ±0.3°
Others Disconnection detective function
Input connector CN14M 1-174957-1 (Common to input 4)
(4) Digital input 1 to 20
Input type No-voltage contact (ON: Grounded, OFF: Open)
Input judgment level ON when the contact resistance is 500 Q or less (when the power supply voltage is 24
V, and the contact current is 14 mA)
ON when it is approximately 200 Q or less under the power supply voltage of 20 V, or
it is approximately 1 kQ or less under the power supply voltage of 32 V.
(5) Digital output 1 to 20
Output type Relay contact (ON : 24 V, OFF : Open)
Rated current capacity 2.5A
Allowable rush-in current 5 A or less. Output for indicator lamp is 10 A or less.
Others Short-circuit protection
(6) Analogue output 1 to 3
Output range (1) Tension: From Oto 5 V (from O ton to rating)
(2) Boom angle : From Oto 5 V (from O to 90° )
(3) Jib angle : From Oto 5 V (from -90 to 90° )
Resolution 5 mV or less
Precision ±0.5% from indicated value
Data upgrading time 0.2 sec. or shorter
10-5
(7) Serial communication 1
Application Data communication with controller (for details of communication, refer to the
separate sheet)
Interface Conforms to RS-232C
Baud rate 9600BPS
Start bit 1
Data bit 8
Parity bit 1 (even number)
Stop bit 1
Communication connector CN18M 1-174954 (Common to communication 2)
(8) Serial communication 2
Application Data transmission to PC (hysteresis data)
Interface Conforms to RS-232C
Baud rate 19200BPS
Start bit
Data bit 8
Parity bit 1 (even number)
Stop bit 1
Communication connector CN18M 1-174954 (Common to communication 1)
(9) Sound output
Application Overhoist alarm and voice alarm
Output sound pressure 75 dB (A) at lm
(10) Alarm output

Application Overload alarm
Output sound pressure 75 dB (A) at lm
10.4.3 Monitor Display

Element used 7 .2 type STN semipermeable color liquid crystal
640 X 480 dots, vertically used
10.4.4 Operation Switch

Seat switch 8 key switches
Upward, downward, leftward, and rightward arrow keys, MENU key, SET key,
assembly and disassembly key, and stowing mode key
Dip switch 8 switches

Program upgrading permission, manufacturer's adjustment permission, and other
spare switches
10.4.5 Internal Processing System

CPU H8/3048 (CONTROL), H8/2633 (INDICATION)
Control frequency 200 mS or less
10.4.6 Memory
Flash memory Capacity :2MB
Application : Storage of programs, adjustment values, set values, display data,
load hysteresis, and selected capacity data
10-6
One-time PROM Capacity : 128 KB
Application : Storage of sound data
S-RAM Capacity : 512 Kbit

Application : For operation
10.4.7 External Storage Element

Smart media Capacity : 4MBor8MB
Application : Storage of capacity data, adjustment values, and set values
Format : Only for this unit
(Reading and writing with the PC is performed through the special
adapter)
10.4.8 Others
Clock and calendar Back-up with the super capacitor
functions Charged when the power is supplied. Buck-up for approx. one month is possible when
fully charged.
10-7
11 . EXTERNAL DIMENSIONS
135 110 -;;.
00000
0000000
,. II
000000000
00000000000
00000000000 "" 0
( 00000000000 )
OOO 00000000000
00000 00000000000
00000 000000000
00000 0000000
OOO 00000
0
,-t
,-t
1,
--
ft 0
CNIIMD CNUMI:
:I
CHISM CNl5N
~ I: :I
8 eel
(
0
(Q)CDNUAST
§[QJ.!..
LOAD SAFETY DEVICE
a~ 0
)
CN17M
D I: :I I: :I
.
I: :I: :I
CNl3M
CNl2M
CNl4M
- I
~
11·- E!5 .·I I
11-1
12. ELECTRIC SCHEMATIC DIAGRAM
Load cell
M/L
181 Red
182 White Boom angle
detector
183 Black
Es
101 Red Main hook overhoist LIS

10 White Aux.hook overhoist LIS
115 Green
Crane jib overhoist LIS
Eo Black (Option)
Crane Type
12-1
Red
Wh I te
Black
BOOM
LOAD C.ELL
BOOM
ANGLE SENSOR
JIB
Red ANGLE SENSOR
L
Wh I te
M
Black
I
JIB
OVER HOIST L/SW
JIB
LOAD CELL
Red
White
Black
ATB (MA IN)
JUNCTION BOX
Luffing Type
12-2
13. CONTROLLER MALFUNCTION EMERGENCY MEASURES
When the controller is malfunctioned, as an emergency measure, set the M/L bypass switch in the left side stand to the
"crane bypass" or "luffing bypass" position depending on the attachment used.
Then, immediately repair the controller. Though all the operations become possible by performing the step above, the
indication, warning, and stop functions (overhoist limit function is available) are still unavailable.
A DANGER
While the load safety device controller functions correctly, the bypass circuit is not actuated even
when the M/L bypass switch is set to the "bypass" position.
M/L BYPASS SWITCH
13-1
14. LOAD SAFETY DEVICE CHECK PROCEDURES
1. Check of working radius indication
( 1) Display the appropriate working radius within the working area in the boom lowering direction in the indicator.
(2) Measure the working radius with a measuring tape, and check that it is the same as the indicated working radius.
2. Check of load indication

(1) Lift a load of which correct weight is known.
(2) Check that the load (lifted load+ hook weight + sling weight) is the same as the indicated actual load.
14-1
KOBELCO
SHOP MANUAL CK2500
CKE2500
GAUGE CLUSTER
TABLE OF CONTENTS
1. CONFIGURATION OF DISPLAY ........................................... 1 - 1
2. PRIORITY ··································· ······ ························· 2 - 1
3. STATUS DISPLAY · · ·· ·· ·· ·· · · ··· ·· · ·· · · · ·· · · ·· ··· · ·· ··· · ·· ··· ··· · ·· ·· ·· · · · 3 - 1
4. FAULT LOG DISPLAY · · · · · · · · · · ··· ·· · · · · · · · · · · · · · ··· ·· · · · · · · · · ·· ·· · · · · · · · · 4 - 1

CK2500 JD-00001 ~
CKE2500
2nd. Edition 2002.08 ssm270 rnCD

1. CONFIGURATION OF DISPLAY
r- - - - NORMAL DISPLAY. - - - -c--,
The number of the
I I
ENGINE SPEED
title of descriptions
(Refer to operation manual) LIFTING HEIGHT
3 (1)
DISPIAY SCREEN
SELECTOR
SWITCH'v
DISPIAY SCREEN
Push the check. I SELECTOR , *
. - - - - - - - - - - switch for I SWITCH!!,. '
ALTEMTION OF ·5~econds I ENGINE OIL
ENGINE OIL ~
CHANGE INTERVAL I _ CHANGE INTERVAL
1------1,1----1----'-~
6 Setting switch I 3 (2)
'-----------' I DISPIAY SCREEN
DISPIAYSCREENJ' SELECTOR
I SELECTOR SWITCH'v
r-------------L-
I Push the check1
SWITCH!!,.
--- ,- - - - ,I
I switch for I ,.
5 seconds I
I WIND ALARM - WIND VELOCITY
I SETTING - I
I 8 ... I 3(7) I
I Setting switch I I
L-------------1-- -----J~-- ___ .J
DISPIAY SCREEN
I
I FAULTY
FAULT INDICATOR
r-------,
1 SELECTOR
I DISPIAY SCREEN SWITCH'v , - - - -,-...1 WARNING I
Push the check.I SELECTOR I I
SWITCH!!,. * 1....c- - - ---J 4(1) I
,--AD-JU_S_TME--NT---F-- switch for I NORMAL I I
0
NUMBER OF WIRE 5_seconds I NUMBER OF WIRE
ROPE LAYERS ON - I ROPE LAYERS ON Setting switch I I
FRONT DRUM 1------+--l--~;1 FRONT DRUM .-----__;.... ~, SELF CHECK I
7(2) Setting switch I 3 (3)
I
'---~-=-------' I
I
' . DISPIAY SCREEN
SELECTOR
SWITCH'v
~----'
Push the zero I
switch for
4(2)
L------...1
I
DISPIAYSCREEN 5 seconds
Push the checkll SELECTOR
switch for SWITCH_r=!!,.--~-~·~t--~
ADJUSTMENT OF 5 seconds I
NUMBER OF WIRE NUMBER OF WIRE
ROPE LAYERS ON I ROPE LAYERS ON Push both of
REAR DRUM i------'-'-+--~:: REAR DRUM the check switch
Setting switch 3 (4) and buzzer switch, STATUS DISPLAY
7(2) and hold them for r - - - - - --,
DISPIAY SCREEN
1------•--''I
5 seconds.
I
DISPIAY SCREEN
SELECTOR
SWITCH/!,.
'
'.
SELECTOR
SWITCH 'v
-C -----J,
Setting switch L _
REFER TO
CHAPTER 3
_ _ _ _ ..J
I
I
.----.!..-.-...!.---~
NUMBER OF WIRE Push the check
REEVING MAIN switch for
WIRE ROPE Setting switch
5 seconds
3 (5)
DISPIAY SCREEN
' SELECTOR
SWITCH'v FAULT LOG DISPLAY
DISPIAY SCREEN r-------,
SELECTOR
'.
SWITCHr'--1!,.---'--....L.--~
I REFERTO I
NUMBER OF WIRE - I CHAPTER4 I
REEVING AUX. IL _ _ _ _ _ _ ..J.I
WIRE ROPE
3 (6)
DISPIAY SCREEN
SELECTOR
SWITCH'v
L----------------~
1-1
2. PRIORITY
1. All the display items are divided into seven groups, Ato G.
The priority is given to them in the alphabetical order, A (highest) to G (lowest).
2. While the items in higher priority groups are displayed on the screen of the gauge cluster, the items in lower priority
groups are not displayed.
For example, while the "M/L stop release" (in the group A) is displayed on the screen, the "self check function" (in the
ground E) is not displayed. The items in lower priority groups are displayed after the display o(the items in higher
priority groups is ended.
3. When some items in the same group are required to be displayed, they are displayed by turns.
4. The normal display is replaced by the display of the items in higher priority groups, since the normal display has the
lowest priority. It can be forcibly displayed with flashing by pushing the zero switch, and holding it for 5 seconds or
longer.
Input signal to controller Detection condition

Priority No. Display items Disappeared Displayed Standstill Running Input Buzzer
from screen on screen E/G E/G delay alarm
Nonnal Faulty -
I CPU fault communication communication 0 0 0
A 2 M/L stop release
Unrelated to CK2500
3 M/L bypass
4 Preheating - I 0 -
B
5 Preheating completion - I 0 -
6 Fault log display
c 7 Mechatronic adjustment
8 Status display
9 E/G (engine) oil pressure - 0 0 © ©
10 Radiator water temperature - 0 0 0 0 0
D
II E/G oil filter - 0 0 0 0
12 E/G air cleaner - 0 0 0 0
E 13 Self check function 0
14 Charge I - 0 ©
15 Remaining fuel level Out ofE zone Within E zone 0 0 ©
16 Sub tank water level 0 - 0 0
17 Control primary pressure - 0 0 0
18 Hydraulic oil temperature - 0 0 0 0
19 E/G stop
20 Main winch cooling oil temperature
F
21 Aux. winch cooling oil temperature
22 Winch filter clog
23 Main winch emergency ESM actuation Unrelated to CK2500
24 Aux. winch emergency ESA actuation
25 3rd winch emergency EST actuation
26 Hook overhoist stop release
27 Boom overhoist stop release
G 28 Normal display
* I. Input signal *2. Input delay *3. Buzzer alarm

I : +24 V level © : 5.0 sec. ©: Buzzer sounds emission intermittently continues for 0.2 sec. with intervals of 0.3 sec (it cannot be
0 : GND level O : 1.5 sec. stopped with the buzzer stop switch).
: Open level - : No delay 0: Buzzer sounds emission intermittently continues for 0.5 sec. with intervals of 0.5 sec (it can be
stopped with the buzzer stop switch).
LI.: Buzzer sounds emission intermittently continues for 0.2 sec. with intervals of 0.3 sec., and is stopped
5 sec. later.
Blank: None
2-1
3. STATUS DISPLAY
The current machine statuses can be displayed on the liquid NO. I
MAIN CONT. PIN
crystal display screen of the gauge cluster by using the data
JJ22E00005FI
from the total controller. Fifty-seven types of display PROGRAM VER
screens are available (refer to P.3-2 to P.3-9). VERO. 13
[Procedures]
1. Start the engine.
2. Push both of the check switch and buzzer switch at the same time, and hold them for 5 seconds or longer.
First, the No.I items, parts code of the total controller and program version, are displayed.
* While the items in the group A or B are displayed, the machine does not enter the status display mode. Correct the
conditions that lead to the display of the items in group A or B.
3. Whenever the display screen. selector switch Vis pushed, the screen is scrolled up once, while it is scrolled down once
whenever the display screen selector switch .6. is pushed. When the display screen selector switch V or L::,. is left
pushed, the screen is scrolled continuously.
4. To end the status display mode, push the setting switch. Then, the screen returns to the normal display.
5. If the key switch is not set to the "OFF" position and the status display mode is actuated again, the screen which had
been displayed just before the normal screen was returned appears.
If the key switch is set to the "OFF" position, the No.1 screen appears.
~
D
eJ
•c
SETTING SWITCH
DISPLAY SCREEN
SELECTOR(6 'v)SWITCH
3-1
CONTENTS OF STATUS DISPLAY
Display example Operation instruction Range of indicated values Remarks
N0.1
MAIN CONT. P/N
JJ22E00005F1
PROGRAM VER
VER0.13
N0.2
Low High
ENGINE SET 2205
The setting value is changed depending on the positions of the
MEAS 2201 hand throttle or foot throttle. 800±40rpm 2180±40rpm
ENGINE PRS. ON With E/G oil pressure: LIVE
No E/G oil pressure: DEAD
N0.3 The components are

Low High normal if the values
A-7 of the "POS." are
changed between O
GRIP VOLT. 4.2V The values are changed depending on the hand throttle 0.5V 4.5V and I00% when the
operation, low or high. E/G speed is
POS. 100% 0% 100% changed between
low and high.
MOTOR STEP 256 The step value is changed according to the E/G speed 39STEP 376STEP * If they are not
adjustment of the TC. changed to O or
POS. 100% 0% 100% 100%, re-adjust.
N0.4
STEP.MOTOR
F-1 COIL-A .1.M.. The component is normal when the Villues are within
the range 1.0 to 1.5 V during operation.
F-2COIL-B 1.6A
B-24 LIMIT OFF After the key switch is set to the "OFF" position, the
code "ON" appears, and remains displayed for approx.
3 sec.
N0.5
The status of the main winch (front drum) motor tilting angle • COMP.:
SOL VALVE solenoid valve is displayed. command value
from controller
C-2 FR-MOTOR • Main winch lever operation I-speed ~ 2-speed Before I-speed Halfway neutral
to 2-speed: ON to I-speed: OFF • MEAS.:
COMP. OFF feed back value
• Inching It is fixed to the "OFF" tegardless of lever operation.
MEAS. OFF The fault
(disconnection) is
indicated by
displaying the
N0.6 following codes:
The status of the aux. winch (rear drum) motor tilting angle COMP. OFF
SOL VALVE solenoid valve is displayed. MEAS. ON
C-3 RE-MOTOR • Aux. winch lever operation I-speed ~ 2-speed Before I -speed Halfway neutral ·connector voltage
to 2-speed: ON to I-speed: OFF ON: 24V
COMP. OFF OFF: I to2V
• Inching It is fixed to the "OFF" regardless of lever operation. (At open)
MEAS. OFF
Check procedures
I) Measure the
voltage at the
N0.7 connector.
2) Measure the
SOL VALVE resistance of the
solenoid valves.
C-4 3RD-MOTOR Unrelated to CK2500 3) Replace with
nearby solenoid
COMP. OFF valves and
connectors.
MEAS. OFF
NO.a
SOL VALVE CLM
C-7 FR CLUTCH Unrelated to CK2500
COMP. OFF
MEAS. OFF
3-2
N0.9
SOL. VALVE ESM
C·B FR SAFETY
Unrelated to CK2500
COMP. OFF
MEAS. OFF
N0.10
SOL. VALVE CLA
C·10 RE CLUTCH
Unrelated to CK2500
COMP. OFF
MEAS. OFF
N0.11
SOL. VALVE ESA
C· 11 RE SAFETY
Unrelated to CK2500
COMP. OFF
MEAS. OFF
N0.12
SOL. VALVE CLT
C·133RDCLUTCH
Unrelated to CK2500
COMP. OFF
MEAS. OFF
N0.13
SOL. VALVE EST
C·14 3RD SAFETY
Unrelated to CK2500
COMP. OFF
-
MEAS. OFF
-
N0.14
SOL. VALVE The status of the main winch boost solenoid valve is displayed.
C·15 FR-BOOST • The main winch lever is at the neutral position. ON

COMP. OFF • Position other than the neutral. OFF
-
MEAS. OFF • Return the lever to the neutral position. The code is changed to the "ON" I sec. later (if the
- lever is not at the neutral position within I sec., the
"OFF" code remains displayed).
N0.15
SOL. VALVE The status of the aux. winch boost solenoid valve is displayed.
C-16 RE·BOOST • The aux. winch lever is at the neutral position. ON

COMP. OFF • Position other than the neutral. OFF
MEAS. OFF • Return the lever to the neutral position. The code is changed to the "ON" I sec. later (if the
lever is not at the neutral position within I sec., the
"OFF" code remains displayed).
N0.16
SOL. VALVE
C·17 3RD·BOOST Unrelated to CK2500
COMP. OFF
MEAS. OFF
3-3
N0.17
SOL. VALVE
The status of the main winch drum turn detection grip is
C-18 FR-GRIP displayed.
COMP. OFF • Set the main winch grip switch to the "ON" position, and The display of the codes "ON" and "OFF" is repeated
raise or lower the main winch. with the drum rotation.
MEAS. OFF The repeating speed of the "ON" and "OFF' codes
display is proportional to the drum rotation speed.
N0.18
SOL. VALVE
The status of the aux. winch drum turn detection grip is
C-19 RE-GRIP displayed.
COMP. OFF • Set the aux. winch grip switch to the "ON" position, and The display of the codes "ON" and "OFF" is repeated
-- raise or lower the aux. winch. with the drum rotation.
MEAS. OFF The repeating speed of the "ON" and "OFF" codes
display is proportional to the drum rotation speed. It
remains set to the "ON" while the power is supplied.
N0.19
SOL. VALVE
C-20 FR-FREE ACC
Unrelated to CK2500
COMP. OFF
--
MEAS. OFF
--
N0.20
SOL. VALVE
C-21 RE-FREE ACC
Unrelated to CK2500
COMP. OFF
--
MEAS. OFF
N0.21
RELAY
C-1 BATIERY
Unrelated to CK2500
COMP. OFF
MEAS. OFF
KEY SWITCH OFF
N0.22
RELAY
C-5 FEATHERING
Unrelated to CK2500
COMP. OFF
--
MEAS. OFF
--
N0.25
SOL. VALVE The inching switch is set to the "ON" position or the boom ON
lever is at the neutral position.
C-31 BOOM INCHING
COMP. OFF The inching switch is set to the "OFF' position and the boom OFF
lever is operated.
MEAS. OFF
3-4
N0.40 The value is changed according to Trimmer min. value Trimmer max. value • COMP.:
the speed adjusting trimmer value. command value
PROPO·VALVE E/GLow 336mA 650mA from controller
D-1 BOOM RAISE E/G High 448mA 650mA • MEAS.:
feed back value
COMP. 600mA 45K The value is changed when the boom raising is At the stop: 200mA
stopped (due to boom upper limit). The components are
MEAS. 600mA 4SK normal if the values
of the "MEAS" are
increased according
to the changes in
N0.41 The value is changed according to Trimmer min. value Trimmer max. value the values of the
the speed adjusting trimmer value. "COMP.".
PROPO-VALVE E/GLow 336mA 650mA
D-2 BOOM LOWER E/G High 448mA 650mA
COMP. 600mA 4SK The value is changed when the boom lowering is slowly The trimmer control value is decreased to 200mA.
stopped (due to overload and boom lower limit).
MEAS. 600mA 4SK Check procedures
I) Measure the
current value at
the connector
N0.42 The value is changed according Trimmer min. value Trimmer max. value clamp with a
to the speed adjusting trimmer value. meter.
PROPO-VALVE I-speed Low 330mA 740mA
2) Measure the
D-3 FR-RAISE I-speed High 364mA 740mA voltage of the
controller
COMP. 600mA 46K 2-speed Low 342mA 740mA internal
detection
MEAS. 600mA 46K 2-speed High 390mA 740mA resistance.
The value is changed when the main winch raising is stopped At the stop: 200mA 3) Measure the
Idue to overhoistl: proportional
N0.43 The value is changed according Trimmer min. value Trimmer max. value valve resistance.
to the speed adjusting trimmer value.
PROPO·VALVE I-speed Low 330mA 740mA 4) Replace with
nearby solenoid
D-4 FR-LOWER I-speed High 364mA 740mA valves and
connectors.
COMP. 600mA 49K 2-speed Low 342mA 740mA
MEAS. 600mA 49K 2-speed High 390mA 740mA
N0.44 The value is changed according Trimmer min. value Trimmer max. value
PROPO·VALVE I-speed Low 330mA 740mA
D-5 RE-RAISE I-speed High 364mA 740mA
COMP. 600mA S3K 2-speed Low 342mA 740mA
MEAS. 600mA S3K 2-speed High 390mA 740mA

The value is changed when the aux. winch raising is stopped At the stop: 200mA
(due to overhoist).
N0.4S The value is changed according Trimmer min. value Trimmer max. value
PROPO·VALVE I-speed Low 330mA 740mA
D-6 RE-LOWER I-speed High 364mA 740mA
COMP. 600mA SOK 2-speed Low 342mA 740mA
MEAS. 600mA SOK 2-speed High -390mA 740mA
D-17 JIB RAISE E/GHigh 540mA 700mA
COMP. 600mA S2K The value is changed when the jib raising is stopped. At the stop: 200mA
MEAS. 600mA S2K
D-18JIBLOWER E/GHigh 540mA 700mA
COMP. 600mA S2K The value is changed when the jib lowering is stopped. At the stop: 200mA
MEAS. 600mA S2K
3-5
NO.SO Free high Free low or Brake
PROPO-VALVE I E/GLow 250mA 543mA
0-9 SWING CONST I E/G High 250mA 650mA
COMP. 600mA 51K When the swing operation has not been performed for ten 650mA
seconds or longer.
MEAS. 600mA 51K
N0.51 The control lever is at the neutral position, and the E/G speed About700mA
is low.
PROPO-VALVE The same conditions as the above, but the E/G speed is high. About IOOmA
0-12 MAIN PUMP Main, aux. and boom winch I -speed relief and the E/G speed is About700mA
low.
COMP. 600mA 47K The same conditions as the above, but the E/G speed is high. About380mA
MEAS. 600mA 47K
N0.52 The control lever is at the neutral position, and the E/G speed About IOOmA
is low.
PROPO-VALVE The same conditions as the above, but the E/G speed is high. About IOOmA
0-13 BOOM PUMP Main, aux. and boom winch I-speed relief and the E/G speed is About400mA
low.
COMP. 600mA 47K The same conditions as the above, but the E/G speed is high. About IOOmA
MEAS. 600mA 47K
N0.53 The swing lever is at the neutral position. 150mA

PROPO-VALVE The swing lever is fully operated Free mode Brake mode
0-14 SWING REAC * When operating, actuate the swing brake and insert the 510mA 250mA
swing lock pin.
COMP. 600mA 47K
MEAS. 600mA 47K
N0.54 Trimmer min. value Trimmer max. value

The value is changed according to the tag-line trimmer value.
PROPO-VALVE 700mA IOOmA
0-15TAG-LINE
COMP. 600mA 47K
MEAS. 600mA 47K • Unrelated when this optional component is not equipped.
N0.62
• Voltage:
POTENTIO. potentiometer
output
A-1 FR-MOTOR Trimmer min. value Trimmer max. value • Value:
The value is changed according to the main winch drum speed AID converted
3.SV 185 adjusting trimmer value. 0.5V 5V values
A-2 RE-MOTOR Trimmer min. value Trimmer max. value

The value is changed according to the aux. winch drum speed The components are
3.SV 185 adjusting trimmer value. 0.5V 5V normal if the output
is changed
N0.63 according to the
changes in the
POTENTIO. potentiometer
output.
A-3BOOM Trimmer min. value Trimmer max. value
The value is changed according to.the boom drum speed
3.SV 185 adjusting trimmer value. 0.5V 5V Check procedure
I) Measure the
A-7 GRIP Low High voltage at the
The value is changed depending on the hand throttle status. connector.
3.SV 185 0.4-0.8V 4.6-5V
3-6
N0.64
POTENTIO.
A-8 FOOT SLOT Low High
The value is changed depending on the foot throttle status.
3.5V 185 (Unrelated when this optional component is not equipped.) I.OV 4.4V
A-6TAG-LINE Trimmer min. value Trimmer max. value
The value is changed depending on the tag-line trimmer value.
3.5V 185 (Unrelated when this optional component is not equipped.) 0.5V 5V
N0.66 The value is changed according to the speed adjusting
trimmer value.
POTENTIO.
A-24 JIB MOTOR Trimmer min. value Trimmer max. value
3.5V 185 0.5V 5V
N0.68 The components are

normal if the values
PRESS. SENSOR are changed when
the respective
A-11 SWING PUMP The swing lever is at the neutral position. 0.5V Ok conditions are
satisfied.
3.5V 270K E/G FULL, swing relief 3.3V 350k
A-12 BOOM PUMP Unrelated to BM700HD Check procedure:
3.5V 270K Replace with
another sensor.
N0.69
After the
PRESS. SENSOR replacement,
• if the indicated
A-13 FR-RAISE The lever is at the neutral position. 0.5V Ok value is changed:
-the sensor is
3.5V 23K The lever is at the 2-speed position, at the full speed. 4.3V 28.5k faulty.
A-14 FR-LOWER The lever is at the neutral position. 0.5V Ok • if the indicated
value is not
3.5V 23K The lever is at the 2-speed position, at the full speed. 4.3V 28.5k changed:
-the harness or
NO. 70 controller is
faulty.
PRESS. SENSOR
: A-15RE-RAISE The lever is at the neutral position. 0.5V Ok
3.5V 23K The lever is at the 2-speed position, at the full speed. 4.3V 28.5k
A-16 RE-LOWER The lever is at the neutral position. 0.5V Ok
3.5V 23K The lever is at the 2-speed position, at the full speed. 4.3V 28.5k
N0.81
STOP SIGNAL
BOOM RAISE ON When the boom is raised up to the upper limit height. Stop: ON Usually: OFF
BOOM LOWER OFF When the machine is in the overload or overhoist status, or the Stop: ON Usually: OFF
boom exceeds the workin~ area limit.
JIB RAISE OFF When the jib is raised up to the upper limit height. Stop: ON Usually: OFF
When the machine is in the overload, overhoist status, or the Usually: OFF
JIB LOWER OFF boom exceeds the working area limit. Stop: ON
N0.82
STOP SIGNAL
FR-RAISE ON When the machine is in the overhoist status. Stop: ON Usually: OFF
FR-LOWER ON
RE-RAISE ON
RE-LOWER ON
3-7
N0.94
MECHATRO ADJT. Adjustment switch (in the total controller) Adjustment: TEST Normal: RUN
CONT.SW TEST
HOIST REEVING The value is changed depending on the status of the M/L
number of part line setting switch. ·
FRONT 1
The value is changed depending on the status of the M/L
REAR 4 number of part line setting switch.
N0.95
SWITCH SIGNAL
ADJUST START OFF Adjustment start connector (in the switchboard) Connection: ON Unconnected: OFF
FR INDICATOR OFF Main winch drum tum detection grip ON/OFF switch Operation: ON Stop:OFF
RE INDICATOR OFF Aux. winch drum tum detection grip ON/OFF switch Operation: ON Stop:OFF
S/MINCHING OFF Governor inching connector lower (stepping motor) Connection: ON Unconnected: OFF
N0.97
SWITCH SIGNAL
M/LBYPASS ON Unrelated to CK2500
FUNCTION LOCK ON The value is changed when the function lock lever is Lock: OFF Release: ON
operated.
N0.99
OPERATION
BOOM RAISE ON The value is changed when the boom control lver is Neutral: OFF Operation: ON
operated.
BOOM LOWER ON
JIB RAISE ON The value is changed when the jib control lever is operated.
JIB LOWER ON
N0.100
SWING
The code is changed depending on the operation of the swing Neutral: OFF Operation: ON
·OPERATE ON lever.
POWER OFF No setting

FREE-HIGH OFF The code is changed depending on the operation of the swing Free high: OFF Others: OFF
neutral mode.
BRAKE OFF Brake :ON Others: OFF
N0.101 If the indicated

value I or 10
LAYER remains displayed
and it is not
FRONT 1 Rotate the main winch drum until the wire rope wraps on it are changed, re-adjust.
changed.
REAR 3 Rotate the aux. winch drum until the wire rope wraps on it are
changed.
The indicated secondary pressure values of the proportional valves in the display No. 40 to 54 and the pressure values
of the pressure sensor in the display No. 68 to 70 are converted values, and may be different from actual values.
For the display No. 40 to 54, if the differences between the indicated "COMP." values and "MEAS." values are within
20%, the valves are normal.
3-8
4. FAULT LOG DISPLAY
The logs of faults which have been found by the self check of the total controller are stored in the controller, and can be
displayed on the display screen of the gauge cluster.
If faults do not re-appear on job sites, first, check the fault log display for the convenience of troubleshooting.
1. DISPLAY PROCEDURES
(1) Set the key switch to the "ON" position.
(2) Enter the fault finding mode.
(Push both of the check switch and buzzer switch at the same time and hold them for 5 sec. or longer.)
(3) Push the check switch and hold it for 5 sec. or longer while the machine is in the status display mode.
Then, the fault logs are displayed.
(Example)
If no fault has occurred in the past:
-- - -- -NO-ER-RGR-- - - - - -----
If faults have occurred in the past:
5000 Hr
A-2 R-MOTOR P
---------------------------
C-5 FERTHER V
F-1 SIM ERROR
(4) The displayed fault logs remain displayed on the screen for an hour. If there are four or more fault logs to be displayed
at a time, the displayed fault logs are changed automatically.
(Example)
5000 Hr 5000 Hr
A-2 R-MOTOR P
--------------------------- ,II(
C-5 FERTHER V
> D-2
D-3
BM LOWER PV
F-RAISE PV
F=i----s,MERRO_R_________ Displayed alternately
(a) (b)
(5) To display the logs of faults occurred at other time (for example, logs of faults occurred at the time other than 5000
Hr), switch the display with the display screen selector switch 'v or L:::..
Former fault logs can be displayed by pushing the display screen selector switch L:::., and later logs can be displayed by
pushing the display screen selector switch 'v .
(6) To end the fault log display, push the setting switch.
Then, the status display mode returns.
4-1
2. DELETION OF FAULT LOGS
Note) When deleting fault logs, all the fault logs occurred at the time indicated are deleted, and it is impossible to
delete them individually.
(I) Display the fault logs occurred at the time intended.
(2) Push the zero switch and hold it for 5 sec. or longer. All the fault logs occurred at the time indicated are deleted.
(3) After all the fault logs are deleted, the message "NO ERROR" appears on the display screen.
3. NOTES ON FAULT LOGS

• Even when a fault occurs, if the same type fault already occurred in the past, and the log of the fault has already been
stored, a new log of the fault is not stored.
• The hour indicated in the hourmeter on the display is a reference (for the replacement of the controller), and indicates
the total period of the controller operation. It is not related to the hourmeter on the carrier.
Owing to the facts above, be sure to delete fault logs after faults are corrected.
It is recommended to store the hourmeter value of the controller together with that of the hourmeter of the carrier.
2.-(2) ZERO SWITCH
1.-(6) SETTING SWITCH
1.-(3) CHECK SWITCH-+---11--i
(iliiii/dispiay) G
~(2)0
1.-(5) DISPLAY SCREEN

SELECTOR(.6. ?)SWITCH
4-2
4. CONTENTS OF FAULT LOG DISPLAY
CONTENTS OF DISPLAY SELF CHECK

A-1 F-MOTORP (SELF CHECK 6) DO
A-2 R-MOTORP (SELF CHECK 6) D1
A-3 BM-MOTORP (SELF CHECK 6) D2
A-6 TAG-LINEP (SELF CHECK 6) D5
A-7 GRIPP (SELF CHECK 6) D6
A-8 FOOTP (SELF CHECK 7) DO
A-11 SW-PUMPS (SELF CHECK 7) D1
A-13 F-RAISE S (SELF CHECK 7) D3
A-14 F-LOWERS (SELF CHECK 7) D4
A-15 R-RAISES (SELF CHECK 7) D5
A-16 R-LOWERS (SELF CHECK 7) D6
A-24 TIBMOTORP (SELF CHECK 5) D2
B-24 S/PTERROR (SELF CHECK 9) DO
C-2 F-MOTORV (SELF CHECK 3) DO
C-3 R-MOTORV (SELF CHECK 3) D1
C-15 F-BOOSTV (SELF CHECK 4) D3
C-16 R-BOOSTV (SELF CHECK 4) D4
C-18 F-GRIPV (SELF CHECK 4) D6
C-19 R-GRIPV (SELF CHECK 5) DO
C-31 HYDSOURCEV (SELF CHECK 13) D2
4-3
CONTENTS OF DISPLAY SELF CHECK
D-1 BMRAISEPV (SELF CHECK 1) DO
D-2 BMLOWERPV (SELF CHECK 1) Dl
D-3 F-RAISEPV (SELF CHECK 1) 02
D-4 F-LOWERPV (SELF CHECK I) 03
D-5 R-RAISEPV (SELF CHECK cl) 04
D-6 R-LOWERPV (SELF CHECK I) 05
D-9 SWCONSTPV (SELF CHECK 1) 06
D-12 M-PUMPPV (SELF CHECK 2) 02
D-13 BMPUMPPV (SELF CHECK 2) 03
D-14 SWREACTPV (SELF CHECK 2) 04
D-15 TAG-LINEPV (SELF CHECK 2) 05
D-17 JIBRAISEPV (SELF CHECK 10) DI
D-18 JIBLOWERPV (SELF CHECK 10) 02
D-19 3RDRAISEPV (SELF CHECK 14) 05
D-20 3RDLOWERPV (SELF CHECK 14) 06
F-1 S/MERROR (SELF CHECK 8) 05
F-2 S/MERROR (SELF CHECK 8) 06
H-3 ROM DATA (SELF CHECK 9) Dl
H-4 MEC. SET (SELF CHECK 9) 03
H-6 MEC. RECEIVE (SELF CHECK 9) 05
NO ERROR
4-4
KOBELCO
SHOP MANUAL CK2500
CKE2500
TOTAL CONTROLLER
TABLE OF CONTENTS
1. ARRANGEMENT OF TOTAL CONTROLLER · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 1- 1
2. COMPOSITION OF SYSTEM · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2 - 1
2.1 Output Relation to Controller · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2-2
3. FUNCTION OF TOTAL CONTROLLER · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3 - 1
4. TOTAL CONTROLLER (HARDWARE) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 4-1
4.1 Outline · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 4 - 1
4.2 Specifications of Total Controller Output · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 4-2
4.3 Details of Total Controller Connector · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 4-6
4.4 Arrangement of Total Controller Connector Pin · · · · · · · · · · · · · · · · · · · · · · · · 4-7
4.5 Proportional Solenoid Valve Measuring Position · · · · · · · · · · · · · · · · · · · · · · · 4 - 14
5. ADJUSTMENT OF TOTAL CONTROLLER · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 5- 1
5.1 Necessity of Adjustment · · · .... · .. · .............. · ...... · .... · ...... · 5- 1
5.2 Adjustment Procedures of Total Controller · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·
5.3 Checkpoints and Recommended Remedy When · · · · · · · · · · · · · · · · · · · · · · ·
the Engine Does not Stop
5- 1
5-9 I
I
CK2500 JD-00001 ~
CKE2500


1. ARRANGEMENT OF TOTAL CONTROLLER
"WIPERINTERMITTEN
UNIT (FRONT UPP.)
WIPER INTERMITTEN WIPER INTERMITTENT UNIT (SKY LIGHT)
UNIT (FRONT LOW.)
TOTALCONTROLLER(TC
AIR-CONDITIONER UNIT
RELAY BOX:
1-1
2. COMPOSITION OF SYSTEM
GAUGE CLUSTER
STOP SIGNAL
JIB TENSION
• INDICATION DATA
(HEIGHT OF GROUND
ENGINE TURN, INPUT DATA
TROUBLE DATA)
....
• SWITCH SIGNAL
TOTAL CONTROLLER
lollll~--------1: CLUSTER SIGNAL
r...~--------1: HAND THROTILE
MAINTENANCE
PARSONAL
jKcCEIVE
[fRANSMIT
I ""~-------I: SENSOR I
COMPUTER
....,_---.-----,.-----,-1
lollll~--------1: TRIMMER/SWITCH
.___ _ _ _ _ _ _ ____.
., , ·u ., , ., ,
PROPORTIONAL SOLENOID STEPPING u HtK~
VALVE VALVE MOTOR OUTPUT
OUTPUT OUTPUT
2-1
2.1 Output Relation to Controller
Items Input/Output Signal types Outline
Indicator Input/Output Serial communication The SW setting data are received from the
indicator.
The indication signals of the OK monitor, engine
speed, lifting height, wind speed, faults, etc. are
transmitted depending on the SW setting
conditions.
Maintenance personal Input/Output Serial communication This PC is used for down-loading of programs.
computer
Hand throttle Input Analogue O to 5 V The grip signals from the engine throttle are input.
Sensor Input The values from the pressure sensor, engine turn
sensor, wind speed sensor, etc. are input.
Cab inside switch/ Input The values from the switches and trimmers in the
trimmer cab are input.
Proportional valve Output 24V PWMoutput

lOOto 700mA Constant current circuit (Max 1 A)
Disconnection detection
W/short-circuit protection
Solenoid valve Output 24V lA Disconnection detection

Stepping motor Output 24V 1.5 to 2 A Disconnection detection

2-2
3. FUNCTION OF TOTAL CONTROLLER
The total controller features the following main three functions:
CD Control of main body, @ Cluster control, and® Adjt1stment.
The function items and outline are shown below.
* The control function of the items with 0-marks in the column of commonality is similar to that of the Mastertech Series
items (excepting differences in constant).
CD Control of main body
No. Function items Commonality
1 Accelerator control & engine stop 0
2 Power control
3 Speed control of front and rear drums
4 Speed control of boom and jib drums
5 Swing reaction 0
7 Boom raising stop 0
8 Boom lowering slow stop 0
9 Front drum hoisting stop
10 Rear drum hoisting stop 0
11 Jib raising stop
12 Jib lowering slow stop 0
15 Engine reverse prevention 0
16 Lifting height gauge (optional) 0
17 Boost control
18 Motor tilting angle control
19 Main pump control release 0
20 Boom pump control
21 Drum tum detection grip control
22 Tagline control 0
23 Wind sensor
24 Control lever interlock control
28 Back light of gauge cluster
29 Over pay out prevention
30 Front drum or rear drum selection
31 Negative brake actuated
@ Cluster control
1 Indication control (refer to the pages relating to the cluster)
2 Communication control
® Adjustment function
1 Adjustment 1 Engine stop position
2 Adjustment 2 Memory of high and low idle positions of S/M and no-load speed
3 Adjustment 3 Optional setting
4 Adjustment 4 Hand throttle range setting
3-1
1. ACCELERATOR CONTROL & ENGINE STOP
(I) Origin processing
When the key switch is set to the ON position, the actuation of the origin limit switch is started after the motor is run
until the origin limit switch is set to the OFF status. If the origin limit switch cannot be actuated, error signals are
transmitted, and the motor enters the free status.
(2) Accelerator control
The stepping.motor is controlled according to the command either from the hand throttle or foot throttle, of which
order is higher.
(3) Engine stop
• When the key switch is set to the OFF position, the stepping motor moves to the OFF position, and remains there for
2.5 seconds.
• Four seconds after the key switch is set to the OFF position, the battery relay is de-energized.
When any abnormality occurs to the motor, the motor enters the free status.
Hand throttle
potentiometer
~.:__·-+----':==---<11~1
5K!l~ t!fN-102
mf1
[!
~CN-104
~
Foot throttle
2200
18
Total controller
(TC) CN-108 1 ,b-=IL-+--'~
potentiometer t "lb-~J.L..--4..../--4= 3A
+24V
(Optional) 3 h---'......__.....,
CN-10 3~61'-""""'---t=~::::t-----'
LS
LS-13
Battery relay
t-24V Key switch
~1 3
a)cN-106
Key sw.roNJsignal
(ON=24V)
2. POWER CONTROL
The target speed is calculated by the hand throttle. Then, the pump is controlled so that the target speed is in agree with
actual speed of the engine. The power is controlled in the following order; first, the main pump power is decreased to
maximally, and next, the boom pump power is decreased.
Total Controller (TC)
~--'-_ ___,.....,..___ _--<l~~CN-102

----q1~J
-+--'V',lv-................
~-....:-----"""-''-----<l~~CN-104 0.7A
-+--'V',lv-....bl.::..wL..----q1~ SOL-70
Foot throttle
potenti0JI1eter CN-101
(Optional) 0.7A
SOL-50
Main pump power reduction
3-2
3. SPEED CON1ROL OF FRONT AND REAR DRUMS
Boom raising
Fr.drum motor speedls>-e------==::::::----<1 ! press. reduce
adjusting trimmer ~ 3 b-filfil_...,c:':""':::~-'
Re.drum motor speedis>------===:!----<1: cN-1 o4

adjusting trimmer ~ 6 Boom lowering
press. reduce
~1l._....-:;:~~~
Boom motor speedls>-------====----<1 ! Total Controller
adjusting trimmer ~ 9 ( TC)
Fr.drum hoisting
Hand throttle Is ~~ICN-1 o2 press. reduce
potentiometer~ 1~J b.filjL_~~~____.
Foot throttle R
potentiometer <'>-----~'-'-'----a17 CN-104
16)
1
(Optional) L..'.: 10
t------===-----<:l;Oj
i---------"'-"-"""--~3CN-105
Fr.drum lowerin
t----:l>----===---<116 Re.drum hoisting
press. reduce
press. sensor
l---l>---==----a1 7
6--@§J~....-::::-::~~
O. 7A
Re.drum lowering
press.reduce
l>-.§fill<.:'::~~-.1
0. 7A
1 Jib raising
Jib motor speed J,.__1.1~-<'o---'-"'-"----' press. reduce
control trimmer >-------""-"-=----,, ~CN-104 1
-+----'II\Jlr--=-"=----<b1aj
0. 7A
Jib lowering
press. reduce
Fr.(Re. )drum hoisting/lowering

proportional valve current
~--=2:::n;::;d..::S.c.pe;:.:e:..::d:.. :E::c/..::Gc..:H:.=1:c·gi::.h_ ®
,11 ~-2....:.nd.:.___Sp~e:...;:e..:.d_E..:.../G_..:.:Lo~w- @
lst Speed E/G Low

~~---------CD
' - - - - - ' - - - - - - - - - - - - ' - ' - - Fr.(Re.)drum speed adjusting
Min. Max. trimmer
• While the lever is set to the lst speed position: if the engine speed is increased from low to high under the
characteristic status CD, the current value is close to that of the characteristic status @.
• While the lever is set to the 2nd speed position: if the engine speed is increased from low to high under the
characteristic status ®, the current value is close to that of the characteristic status ©.
• When the lever is set from the I st to the 2nd speed position: the I st speed characteristics (CD, @) are switched to the
2nd speed characteristics (®, ©). After that, the speed is increased by setting the lever to the 2nd speed position.
* When the trimmer is set to the maximum position, the proportional valve is fully opened, and the status
becomes identical to that of no trimmer.
3-3
4. SPEED CONTROL OF BOOM AND JIB DRUMS
Jib raising/lowering proportional valve current

Boom raising/lowering proportional valve current
I
I
,,
,,
1IE/G Low CD
',
II
11
11
11
~------------~"""--'.!-Boom speed trimmer
Jib speed trimmer
• If the engine speed is increased from low to high under the characteristic status G), the current value is close to that
of the characteristic status @.
* When the trimmer is set to the maximum position, the proportional valve is fully opened, and the status
becomes identical to that of no trimmer.
5. SWING REACTION
A reaction is applied to the lever depending on swing loads.
Swing pump
pressure sensor
Total controller
(TC)
+ 2 L 4 V,_e_h1~·~~~~
sw-10-®
Brake Swing reaction
Swing reaction
proportional valve current - - - - ~ Neutral free (High/Low)
~ - - - - - - - - - - - - . . . . . . . , - Swing pump pressure
3-4
7. BOOM RASING STOP
8. BOOM LOWERING SLOW STOP
0. 7A
2
17CN-102 Boom raise
1~
18 1 press. reduce
2 315
SW-27-@
16)
17 CN-104 CN-101
18
0.7A
3 Boom lower
Total controller
+24V press. reduce
RELAY BOX (TC) 4 21
2
SW-27-@
Boom raise stop 1_1
(Normal:+24V)
I I
Boom lower stop 2 CN-102
(Normal:+24V)
I I 4 [l
L_J
Boom raise proportional valve current Boom lower proportional valve current
I
I
I
I
Stop ---J- - _:--,.______
Boom angle
0 Boom angle
Boom raise stop Boom lower stop
signal input signal input
3-5
9. FR. DRUM HOISTING STOP
10. RE. DRUM HOISTING STOP
CN-101
I
Total controller
+24V
--,
YBOX (TC) SW-29-@
Fr._&Re.drum
hoist stop
(Normal: +24V)
lf=I·
_ I 137
o-~-e----=-"'-'-'---a
I
a
i i 7
CN-102
I I
L ___ _J
Fr. drum hoist proportional valve current Re. drum hoist proportional valve current
Stop - - - -+---------- Stop - - - -+----------

I I
0 0
Fr.&Re drum hoist Fr.&Re.drum hoist
stop signal input stop signal input
3-6
11. JIB RAISING STOP
12. JIB LOWERING SLOW STOP
Hand throttle 16J

17 CN-102
potentiometer
18
14 495
Foot throttle
potentiometer 17 CN-104
1~ CN-101
18
(Optional) 0.7A
15 49
Total controller soL-59 Jib lower
press. reduce
(TC) 500
49
SW-57-@
+24V
RELAY
Jib lower stop
(Normal:+ 24V) 1-1
Jib raise stop
(Normal:+24V)
I I }-102 [\
j Jib hoisting speed reduce j Jib lowering slow stop
Jib raise proportional valve current Jib lower proportional valve current
I
I
I
I
Stop - - --t--------,---- Stop - ~ - - ------------
I 1
Jib angle
0 Jib angle
Jib raise stop Jib lower stop sig-
signal input nal input
3-7
15. PREVENTION OF ENGINE REVERSE
If the engine oil pressure remains low for three seconds or longer while the engine is running, the engine is forcibly
stopped.
Total controller 1 P-,!===!---,'-'<-----,

(TC) 2 p-==---;-';"-;::~~
CN-108 12,h,....J:"-"-"''---'--'-~
13:P--''==ic'----',,-f--+-' 3A
3h--""-'=1----'
+24V
CN-10 3(1so---=L-..-+-o a---+--~

LS
LS-13
3-8
16. LIFTING HEIGHT GAUGE (OPTIONAL)
Fr.drum hoist
pressure sensor 1':)cN-105
Total controller
(TC)
+ t------==----<1
Re.drum hoist
pressure sensor
Signal t------'::::':=-----a
~}N-108
2
Fr.drum turn sensor CN-101 4
Re.drum turn sensor

J
4 CN-107
6 • Number of part line
5 · Wire rope wraps
7 • Main/jib selection
B Gauge
(1) The number of drum rotation is detected with the drum tum sensor as the pulse count.
(2) The number of wire rope wraps on the rotating drum is calculated on the basis of the wire rope wraps adjusted with the
cluster as a standard.
(3) The length of unwound wire rope is calculated from the coefficients and pulse numbers of the wire rope wraps.
(4) The lifting height by the winch is calculated by dividing by the number of part line.
(5) The changes in the lifting height are increased or decreased. When there is any winch pressure sensor input, the
changes are regarded to occur to the hoisting side, while they are regarded to occur to the lowering side when in other
cases.
(6) The difference between the height at the zero reset and current height is calculated, and find the changes in actual
lifting height, and the changes are indicated on the display screen of the cluster.
(7) The lifting height indicated on the gauge cluster is automatically changed depending on the selection by the main/jib
selector switch.
Mode Crane
Hook Main I Aux.
Lifting height Main I Aux.
3-9
17. BOOST CONTROL
Fr.drum hoist
pressure sensor 1---~1-------""-'=--d;>~JCN-105
Fr.drum lower i-----J---:::::::---<116
l-----l--....,,.,=---c117
pressure sensor Total controller
Re.drum hoist
i-------==---<14 (TC)
Signal t-------=:':"'---d5
pressure sensor 1-----e----"'-""=---cl6
Re.drum lower t----Jl----'.::::::=--<17

pressure sensor t----ll----'="""1..-<18
CN-108
14
15
16
17 Fr.drum boost
18
r11
CN-108 l
2
To prevent a momentary drop of a lifted load, apply a constant boost to the motor while the lever is in the neutral
position.
The boost solenoid valve is controlled as shown in the table below.
Lever Boost solenoid valve

Neutral Energized
Neutral-+Hoisting, lowering Immediately de-energized
Hoisting, lowering-+Neutral Energized a second after the lever is returned to the neutral position
Remained de-energized if the lever is operated within a second after
the lever is returned to the neutral position
3-10
18. MOTOR TILTING ANGLE CONTROL
Fr.drum hoist
pressure sensor
Fr.drum lower
pressure sensor
·~
16
17
Re.drum hoist 4
pressure sensor 5
6
Re.drum lower 7
pressure sensor 8
Total controller
14 (TC)
5 1 o. BA Fr.drum moter
16 '--N--' SOL-12 tilting angle select
17
18 2 O. BA Re.drum moter
CN-109 '--N--' SOL-l 3 tilting angle select
signal (Normal :24V)

L-L
+24
Inching speed select
239
o - - - - ~= = --<19) CN-1 o6
The motor tilting angle solenoid valve is controlled as shown in the table below.
Conditions Tilting angle solenoid valve Priority

The lever is within the lst speed range Energized 2 *1
While the inching speed mode is selected Remained de-energized 1
*l The hoisting and lowering pressure sensors for the front and rear drums detect from 99 .5 to 128.0 psi
(0.7 to 0.9 MPa) (7 to 9 kgf/cm 2).
3-11
19. MAIN PUMP CONTROL RELEASE
20. BOOM PUMP CONTROL
9
Fr.drum hoist
pressure sensor + ~ 1 01
3
CN-105 Pump control
Fr.drum lower i-----,---=:=--q16 release relay
l---~>---..=.<=----<117
pressure sensor
CN-109
i-------==~-q4
Re.drum hoist Signal 1-------=:=!'"-q 5
pressure sensor 1----.--~~-<l6
O.BA
Boom
Re.drum lower 1-----,>----==--q? inching speed
i-------i>---~~-<ia
pressure sensor
14 CN-108
15
16
17
18 Total controller
+24 (TC)
Boom raise signal PSW-9 <11---1ocn----="""'--q 6
(raise:+24V)
Pressure switch
Boom lower signaiJ.sw-10---1

(Lower: + 24V)
Pressure switch
CN-102
Pressure switch
Jib lower signa~sw- 13 ....__--1
(raise:+24V)
Pressure switch
The pump control release relay (R-19) is controlled under the conditions shown in the table below.
Conditions Pump control release relay Statuses

CD No input is received by the front and rear drum
The flow rate of the main
hoisting or lowering pressure sensors and jib De-energized
pump is minimum.
raising or lowering pressure switch.
@ Any input is received by the front and rear drum
The flow rate of the main
hoisting and lowering pressure sensors and jib Energized
pump is normal.
raising or lowering pressure switch.
The boom inching solenoid (SOL-6) is controlled under the conditions shown in the table below.
Conditions Boom inching solenoid Statuses

CD No input is received from the boom pressure De 0 energized The flow rate of the boom
switches. pump is minimum.
@ Any input is received from either of the boom Energized The flow rate of the boom
pressure switches. pump is normal.
3-12
21. DRUM TURN DETECTION GRIP CONTROL (OPTIONAL)
The grip solenoid valve is controlled according to the input to the drum tum sensor.
Fr.drum turn
sensor
Re.drum turn
sensor
Total controller
(TC)
Fr.drum turnf.OFF
select SW-33
.,.,oN,.__ _--'-'=-a
OFF
Re.drum turn ON SW-34
select
ON
Drum turn sensor input OFF
+24V
Grip sol. output J ov
22. TAGLINE CONTROL
>-e------=::::::=----<l~~CN-102
--t--'VV\.--~~---01~
Tugline trimmer
(optional)
Total controller
(TC)
Tagline proportional valve current
StopQ ----------,
I I
I I
I I
I I
I I
I I
I I
I I
Max tension Q -t----------
Min. Max. Tugline trimmer
3-13
23. WIND SENSOR
1 1
Wind sensor Wind 8 O)
(Optional) sensor
r-~-'-'-""'19=-~--a;, 1 CN-108 2
Total controller 3
(TC) CN-107 4
· Wind data
• Caution setting
Gauge value
'
The wind velocity is calculated with the input voltage (AC) from the wind velocity sensor, and the data is transmitted to the
gauge cluster.
When the wind velocity exceeds the set value (caution point) on the cluster gauge, buzzer sounds are intermittently from
the gauge clust~r. and the warning signals are transmitted to the M/L (wind warning lamp flashes).
FunctionlockLS
(Work: +24V)
Charge signal
L
24. CONTROL LEVER INTERLOCK
+24V LS-1
234
2~CN-104 1
2
Boom remote control
raise press.reduce
(E/GRun: +24V) 1-----a1~CN-102
E/G Oil press. 3

2)cN-110
(E/G Run : OPEN)
Total controller 4
+24V (TC) 0.7A
5 Main hoist remote
Boom raise signaJsw-s<1>----c 6 CN-101 control
(Raise: +24V) raise press.reduce
Boom raise press. SW 6
Boom lower signal . 0. 7A
(Lower: +24V) PSw- 10 11 7 Main hoist remote
control
Boom lower press. SW CN-102 8 lower press.reduce
Jib raise signalpsw- 12 <1>----t 5
(Raise: +24V) 0.7A
9 Awe. hoist remote
Jib raise press. SW control
raise press.reduce
Jib lower signal PSW-13~---c 9-
(Lower : +24V) 0. 7A
Jib lower press. SW Awe. hoist remote
control
Main hoist lower press.reduce
10
press.sensor
3 CN-105 O. 7A
Main lower
press. sensor
'J
16
17
Jib remote control
raise press.reduce
Awe. hoist
press. sensor
Awe. lower
}-108 SW- 57-@
Jib remote control
lower press.reduce
press. sensor
( 1) When the lever is operated and the engine is started while the interceptive lever for getting on and off is in the working
side, the drum is stopped with the minimum proportional valve output.
(2) When the interceptive lever for getting on and off is set to the working position while the engine is running and the
lever is operated, the drum is stopped with the minimum proportional valve output.
(3) When the drum is stopped in the statuses (1) or (2) shown above, it can be operated by setting the lever to the neutral
position.
3-14
28. BACK LIGHT OF GAUGE CLUSTER
Total controller
Headlight (TC)
~ SW- 21 111
Jr-
2~CN-104
Gauge
When the head light switch (SW-21) is made, data is transmitted to the gauge cluster.
The back light becomes lit up when it receives the data from the gauge cluster.
29. OVER PAY OUT PREVENTION (ONLY FOR EUROPE)
~E_ur~op~e_m_o_de_l_se_le_m_ _-a
4
)cN-ttOCN-t05~S
CN-108(11 D - ' " - ' - " " - - - - - - ' Sgl.~~6 Re.drum boost
\ ~.a-~
Total controller
(TC) Fr. drum lowering remote
bflfill_-~-"'-='-----' control press. reduce
Fr. drum over pay out J
prevention limit switch f----1LLS_-'it---<125 CN_ O CN_ 1 O1
31 1 4
Re. drum over pay out ~ - - L - . - - - - a 2 6 Re. drum lowering remote
LS-32 control press. reduce
prevention limit switch !JNIL___,.,.,-.....i=."'----
When only a few part lines of wire rope remain on the front drum (rear drum), unwinding of the wire rope is stopped.
3-15
4. TOTAL CONTROLLER (HARDWARE)
4.1 Outline
..
0 0 0
------,
r .JL .
I II I
• j ~I
I" - - = '
I. I
CD I ~11
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...z 811
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u Iull
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z
u
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r ".:. .,11 r ·11
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...z
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ru
...z
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u ,u11
... I II
...z
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zl
u lull
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r ~l I
I 11 I
.. "lr .
0 0
= =
000000000000000000000000 I
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:==~gg=s===
I
,-L
CN100
11 CN110
CN110
-
CN109
CN109
il== rNl°b
CN111
11
- ..
4-1
4.2 Specifications of Total Controller Output
1. ANALOGUE INPUT [A]
Trouble
Item Name Range Input voltage judgment Note
Al Fr. drum motor speed adjusting trimmer 0-FULL 0.43-4.9 V Less than 0.2 V All resistance 5 KQ
A2 Re. drum motor speed adjusting trimmer t t t t

A3 Boom motor speed adjusting trimmer t t t t
A4 Jib motor speed adjusting trimmer t t t t
AS SpareA/D - - - -
A6 Taglirie trimmer (optional) t t ' Less than 0.2 V All resistance 5 KQ
A7 Hard throttle potentiometer LOW-HIGH t t t

AS Foot throttle potentiometer (optional) t l.OV-4.4 V t All resistance 2 KQ
A9 Spare AID - - - -
AlO SpareA/D - - - -
All Swing pump pressure sensor 0-500 kg/cm 2 0.5-4.5 V Less than 0.2 V All resistance 10 KQ
Al2 Spare AID - - - -
A13 Fr. drum hoisting pressure sensor 0-30kg/cm 2 t t All resistance I O KQ
A14 Fr. drum lowering pressure sensor t t t t

Al5 Re. drum hoisting pressure sensor t t t t
A16 Re. drum lowering pressure sensor t t t t
A19 SpareA/D - - - -
(AC0.87-
A22 Wind velocity sensor (2-90 m/sec) 44.3 V)
- AC Input
A23 Spare AID - - -
A24 Spare AID - - -
2. PULSE INPUT (INTERRUPT) [E]

Trouble
Item Name Status Signal level judgment Note
Electro-magnetic
El Engine turn sensor 0-2500rpm Vp-p3.0-45 V No pick-up
143 pulses/rpm 6 kHz
Proximity sensor
E2 Fr. drum turn sensor 0-500 rpm 3 V/OPEN t 96 pulses/rpm 683 Hz
E3 Re. drum turn sensor t t t t

E4 Interrupt input spare - t t Proximity sensor
4-2
3. DIGITAL INPUT [B]
Trouble
Item Name Status Signal level judgment
BI Fr. drum select Operable/Inoperable GND/OPEN No
82 Re. drum select Operable/Inoperable GND/OPEN t
83 Spare - GND/OPEN t
84 Adjustment start Adjustment/Normal GND/OPEN t
85 -
86 Swing brake mode select (Free high) Free high select/OFF +24/0PEN t
87 Swing brake mode select (Brake) Brake select/OFF t t
88 Fr. drum tum detect grip (optional) ON/OFF GND/OPEN t
89 Re. drum tum detect grip (optional) ON/OFF GND/OPEN t
BIO Key switch "ON" Key switch ON/OFF +24V/OPEN t
Bll Stepping motor inching Inching ON/OFF GND/OPEN t
812 Swing control Control/Neutral GND/OPEN t
813 E/GPSW E/G Stop/Start GND/OPEN t
814 Inching selection Normal/Inching +24V/OPEN t
BIS Boom raise stop Stop/Normal OPEN/+24V t
816 Boom lowering stop Stop/Normal OPEN/+24V t
817 Jib raising stop Stop/Normal +24V/OPEN t
818 Jib lowering stop Stop/Normal +24V/OPEN t
819 Jib raise pressure switch Control/Normal +24V/OPEN t
820 Boom raise pressure switch Control/Neutral +24V/OPEN t
821 Fr. drum hoisting stop Stop/Normal OPEN/+24V t
822 Re. drum hoisting stop Stop/Normal OPEN/+24V t
823 Spare - +24V/OPEN t
824 Origin LS Origin/OFF +24V/OPEN t
826 Fr. drum over pay out prevention Normal/Over pay out +24V/OPEN t
827 Re. drum over pay out prevention Normal/Over pay out +24V/OPEN t
829 Boom lowering pressure switch Control/Neutral +24V/OPEN t
831 Back light ON/OFF GND/OPEN t
833 Model select - GND/OPEN t
834 Charge signal With power generation/Without power generation +24V/OPEN t
835 E/G oil filter clog Clog/Normal GND/OPEN t
837 Hydraulic oil temperature switch Higher temperature/Normal GND/OPEN t
838 Control primary pressure Lower pressure/Normal GND/OPEN t
839 Radiator water level Normal/Lower water level GND/OPEN t
840 E/G water level Lower pressure/Normal GND/OPEN t
841 Air cleaner clog Clog/Normal GND/OPEN t
842 E/G preheat Preheat/Normal +24V/OPEN t
843 Spare - GND/OPEN No
846 Jib lowering pressure switch Control/Stop +24V/OPEN t
4-3
4. ANALOGUE OUTPUT [H]
Trouble
Item Name Status Signal level judgment
Hl E/G speed signal 0-2180rpm 0.5-4.9 V No
H2 Spare 0-4.9V t
* Provide the external protection against short-circuit (resistance insertion).
5. PROPORTIONAL VALVE OUTPUT [D]
Item Name Output current Dither Trouble judgment

The indicated value is 100 mA
D1 Boom remote control raising deceleration 200-650 mA 200 mAp-p 70 Hz or lower, and the feed back is
25 mA or lower.
D2 Boom remote control lowering deceleration t t t
D3 Fr. drum remote control hoisting deceleration 200-740 mA t t
D4 Fr. drum remote control lowering deceleration t t t
D5 Re. drum remote control hoisting deceleration t t t
D6 Re. drum remote control lowering deceleration t t t
D7 Jib drum remote control hoisting deceleration 150-740mA t t
D8 Jib drum remote control lowering deceleration 150-740mA t t
D9 Swing constant speed 303-466mA t t
DIO Spare proportional valve - t t
Dll Spare proportional valve - t t
D12 Main pump power reduction I00-700mA t t
D13 Spare proportional valve I00-750mA t t
D14 Swing reaction 150-SIOmA t t
DIS Tagline (optional) I00-700mA 400 mAp-p 62.5 Hz t
6. STEPPING MOTOR OUTPUT [F]
Item Name Trouble judgment
FI Stepping motor The output current is less than 1 A, or is remained at 2 A or more for 13 seconds.
4-4
7. DIGITAL OUTPUT [C]
Trouble
Item Nanie Status Signal level judgment
Cl Battery relay energizing Energized/De-energized +24V/OPEN Broken down wire
C2 Fr. drum motor tilting angle selection Tilting angle minimum/maximum +24V/OPEN t
C3 Re. drum motor tilting angle selection Tilting angle minimum/maximum +24V/OPEN t
C4 Spare - +24V/OPEN t
C5 Pump control release relay energizing Release/Control +24V/OPEN t
C6 -
C7 Fr. drum negative brake Disengage/Engage +24V/OPEN t
CS Re. drum negative brake Disengage/Engage +24V/OPEN t
C9 Boom drum negative brake Disengage/Engage
ClO Spare - +24V/OPEN t
Cll Spare - +24V/OPEN t
Cl2 -
Cl3 Spare - +24V/OPEN t

Cl5 Fr. drum motor boost Boost/Normal +24V/OPEN t
Cl6 Re. drum motor boost Boost/Normal +24V/OPEN t
Cl8 Fr. drum tum detection grip (optional) ON/OFF +24V/OPEN t
Cl9 Re. drum tum detection grip (optional) ON/OFF +24V/OPEN t
C21 Jib drum negative brake Disengage/Engage +24V/OPEN t
C22 Boom pump inching speed Inching speed/Normal +24V/OPEN
C23 Boom drum lock alarm Alarm ON/Alarm OFF +24V/OPEN
C24 Spare - GND/OPEN
C25 - - GND/OPEN
8. COMMUNICATION
Communication
Item Communication counterpart Communication system speed
l Indicator TTL (2-way) 4800 bps
2 Spare - -
3 PC (or handy checker) RS232C (2-way) 4800 bps
The channel can be used for No.2 and 3 by switching operation.
4-5
4.3 Details of Total Controller Connector
l·CN101 ! ! CN102 ! ! CN103 ! ! CN104 !

AMP 1-178203-6(100P)
l CN105 ! ! CN106 ! ! CN107 ! ! CN108 !

AMP 3-178780-6(76P)
1 2 3 4 5
6 7 8 9
! CN111 l
O-SUB9P CONNECTOR
CN100 CN110 ! CN109 !

AMP'i 72040-1 (5P) AMP 2-173866-1 (30P)
4-6
4.4 Arrangement of Total Controller Connector Pin
Connector No. Pin No. Port name Specifications
CNIOO I +24V
Powet supply
2 +24V
3 GND
Grounding
4 GND
5 Vacancy

CNIOI I DI+
Boom remote control raising pressure reduction proportional valve
2 DI-
3 D2+
Boom remote control lowering pressure reduction proportional valve
4 D2-
5 D3+
Fr. drum remote control hoisting pressure reduction valve
6 D3-
7 D4+
Fr. drum remote control lowering pressure reduction valve
8 D4-
9 D5+
Re. drum remote control hoisting pressure reduction valve
10 D5-
11 D6+
Re. drum remote control lowering pressure reduction valve
12 D6-
13 D7+
Jib drum remote control hoisting pressure reduction valve
14 D7-
15 D8+
Jib drum remote control lowering pressure reduction valve
16 D8-
17 DIO+
Swing constant speed proportional valve
18 DIO-
19 Dll+
Spare proportional valve
20 Dll-
21 Dll+
Spare proportional valve
22 Dll-
23 Dl2+
Main pump power reduction proportional valve
24 Dl2-
25 Dl3+
Boom pump power reduction proportional valve
26 Dl3-
27 Dl4+
Swing reaction proportional valve
28 Dl4-
29 Dl5+
Tagline proportional valve (optional)
30 DI5-
31 EI+
Engine turn sensor
32 EI-
33 E2 Fr. drum turn sensor
34 E3 Re. drum turn sensor
4-7
CN102 1 815 Boom raising stop
2 816 Boom lowering stop
3 817 Jib drum hoisting stop
4 818 Jib drum lowering stop
5 819 Jib raise pressure switch
6 820 Boom hoisting pressure switch
7 821 Fr. drum hoisting stop
8 822 Re. drum hoisting stop
9 823 Spare D/1
10 828 Spare D/1
11 829 Boom lowering pressure switch
12 834 Charge signal
13 +5v
14 A6 Tagline trimmer (optional)
15 G
16 +5v
17 A7 Hand throttle POT
18 G
19 +5V
20 A26 Spare AID
21 G
22 E4 Spare interrupt

CN103 1 +5V
2 Al9 Spare AID
3 G
4 +sv
5 A20 Spare AID
6 G
7 +5V
8 A21 Spare AID
9 G
10 +5V
11 A24 Spare AID (pressure sensor)
12 G
13 +5V
15 G
16 824 Origin LIS
4-8
CN104 1 +5V
2 Al Fr. drum motor speed adjusting trimmer
3 G
4 +5V
5 A2 Re. drum motor speed adjusting trimmer
6 G
7 +5V
8 A3 Boom motor speed adjusting trimmer
9 G
10 +5V
11 A4 Jib motor speed adjusting trimmer
12 G
13 +5V
14 A5 Spare AID
15 G
16 +5V
17 A8 Foot throttle POT (optional)
18 G ..
19 +5V
20 A9 Spare AID (trimmer) ..
21 G
22 +5V
23 AIO Spare AID (trimmer)
24 G
25 826 Fr. drum over pay out preventive LIS
26 827 Re. drum over pay out preventive LIS
27 830 Function lock limit switch
28 831 Back light
4-9
CN105 l C22 Boom pump inching speed
2 C7 Fr. drum negative brake
3 +5v
4 All Swing pump pressure sensor
5 G
6 +5v
8 G
9 +5v
Fr. drum hoisting pressure sensor
10 A13
11 C8 Re. drum negative brake
12 C23 Boom drum lock alarm
13 ClO Boom drum negative brake
14 Cll SpareD/0
15 Vacancy
16 +5v
17 A14 Fr. drum ·lowering pressure sensor
18 G
19 Hl+
E/G speed A/0
20 Hl-
21 H2+
Spare A/0
22 H2-
23 G Fr. drum hoisting pressure sensor
24 C13 SpareD/0
25 C14 SpareD/0
26 C15 Fr. drum motor boost

CN106 1 Bl Fr. drum selection
2 B2 Re. drum selection
3 B3 Spare D/1
4 B6 Swing brake mode (Free high)
5 B7 Swing brake mode (Brake)
6 B8 Fr. drum turn detect grip selection (optional)
7 B9 Re. drum turn detect grip selection (optional)
8 810 Key switch "ON"
9 B14 Inching selection
10 825 Spare D/1
11 B42 E/G preheat signal
12 Cl Battery relay energizing
13 C26 Spare D/0
14 C27 Spare D/0
,
15 C28 SpareD/0
16 Vacancy
4-10
CN107 I TxDI
2 Rx DI
M/L communication (RS232C)
3 GNDI
4 SHGI
5 TxD2
6 RxD2
Monitor communication (TTL level)
7 GND2
8 SHG2
9
Vacancy
10
11 B4 Adjustment start
12 Bll Stepping motor inching

CN108 I FI+
Stepping motor phase A
2 FI-
3 SHG Stepping motor shield
4 +5V
5 Al5 Re. drum hoisting pressure sensor
6 G
7 +5V
8 AI6 Re. drum lowering pressure sensor
9 G
10 +5V Not used
11 CI6 Re. drum motor boost
12 F2+
Stepping motor phase B
13 F2-
14 +5V
15 Al7 Spare AID
16 G
17 +5V
18 Al8 Spare AID
19 G
20 A22
Wind velocity sensor (optional)
21 G
22 Cl7 SpareD/0
4-11
CN109 1 C2 Fr. drum motor tilting angle selection
2 C3 Re. drum motor tilting angle selection
3 C4 SpareD/0
4 C5 Pump control relay energizing
5 Cl8 Fr. drum tum detection grip (optional)
6 Cl9 Re. drum tum detection grip (optional)
7 C20 SpareD/0
8 C21 Jib drum negative brake
9 Vacancy
10 Vacancy
11 C24 SpareD/0
12 C25 Spare D/0

CNllO 1 812 Swing operation
2 813 E/GPSW
3 832 Spare D/1
4 833 Model selection
5 835 Engine oil filter clog
6 836 Engine start
7 837 Hydraulic oil temperature
8 838 Control primary pressure
9 839 Radiator water level
10 840 Engine water temperature
11 841 Air cleaner clog
12 843 Spare D/1
13 844 Spare D/1
14 845 Spare D/1
15 846 Jib lowering pressure switch
16 (+24V) Not used
17 A23 Spare AID
18 G Spare AID
4-12
CNIII I Vacancy Maintenance PC communication
2 RxD (RS232C)
3 TxD
4 Vacancy
5 GND
6 Vacancy
7 Vacancy
8 Vacancy
9 Vacancy
4-13
4.5 Proportional Solenoid Valve Measuring Position
d h
Proportional valve detection resistance

Detected
Item Name Output current Dither
resistance
1 Boom remote control raising pressure reduction 150-740mA 200 mAp-p 160 Hz 723
2 Boom remote control lowering pressure reduction t t 739
3 Fr. drum remote control hoisting pressure reduction t t 755
4 Fr. drum remote control lowering pressure reduction t t 769
5 Re. drum remote control hoisting pressure reduction t t 787
6 Re. drum remote control lowering pressure reduction t t 801
7 Jib drum remote control hoisting pressure reduction t t 819
8 Jib drum remote control lowering pressure reduction t t 834
9 Swing constant speed 250-650mA --- 851
10 - --- --- 865
11 - --- --- 883
12 Main pump power reduction 100-700mA 200 mAp-p 70 Hz 898
13 Boom pump powe,r down 100-750mA t 915
14 Swing reaction 150-510mA t 931
15 Tagline (optional) 100-700mA 400 mAp-p 60 Hz 1045
4-14
5. ADJUSTMENT OF TOTAL CONTROLLER
5.1 Necessity of Adjustment
-- Optional
Throttle
range
Engine stop
position
Engine
speed
Repair cont setting adjustment adjustment adjustment
Replacement of hand throttle or foot throttle x 0 x x
Replacement of stepping motor x x 0 0
Governor cable x x 0 0
Jib drum 0 x x x
Foot throttle 0 x x x
Installation/
removal of Speed detection grip 0 x x x
optional Tagline 0 x x x
equipment
Wind velocity sensor 0 x x x
Replacement of total controller assembly 0 0 0 0
Downloading of program x x x x
0: Necessary X: Unnecessary
5.2 Adjustment Procedures of Total Controller

5.2.1 Optional Setting
1. Set the engine key to the "ON" position

(the engine is not started).
2. Set the adjustment switch to the "TEST" position.
3. Press the "CHECK" switch of the cluster gauge

several times to display the optional setting items
on the display screen of the cluster.
G-7
OPT 3RD WINCH
0
5-1
4. Select any intended optional item with the adjuster
".6." and "V" switches on the cluster.
5. If the optional setting is necessary, input "O" with
the adjuster "+" or " - " switch.
If the optional setting is unnecessary, input " X "
with the "+" or " - " switch. SETTING
SWICH
G-8 G-8
OPT TAG-LINE OPT TAG-LINE
0 ,X
DISPLAY SCREEN SELECTOR ADJUSTER ( +, -)

(~. v') SWITCHES SWICHES
6. After the completion of input of "O" or" X" against all the items, push the "Setting switch" on the cluster.
* Adjustment values can be input into the controller by pushing the "Setting switch".
Remember that the adjustment becomes ineffective unless the "Setting switch" is pushed.
7. Return the adjustment switch to the "RUN" position.
Optional setting
1. Adjustment switch: "TEST" position
2. Select any intended display item by using
the "CHECK" switch.
3. "O" and "X"
5. Setting switch: "ON" position
6. Adjustment switch: "RUN" position
5-2
5.2.2 Adjustment of Hand Throttle and
Foot Throttle

G-16
CPU THROTTLE
LOW ADJUST
several times until the message "THROTTLE
LOW ADJUST" appears on the display screen of
the cluster.
4. Set the hand throttle and foot throttle to the low

idling positions. G-17
THROTILE
5. Disconnect the adjusting connector (CN171). CPU HI-ADJUST
Then, the adjustment values are stored by the

controller, and the message "THROTTLE HI-
ADJUST" is displayed on the display screen of the
cluster.
6. Set the hand throttle and foot throttle to the high

idling positions.
G-5
FINJSH
7. Disconnect the adjusting connector (CNl 71). CPU
ORPM
Then, the adjustment values are stored by the
controller, and the message "FINISH" is displayed
TOTAL CONTROLLER (TC)
8. Return the "ADJUSTMENT" switch to the "RUN"

position.
Adjustment of hand throttle & foot throttle CN171

the "CHECK" switch.
4. Hand and foot throttles: "LOW IDLING" position
5. Adjusting connector: "CONNECTED"
6. Hand and foot throttles: "HIGH IDLING" position
7. Adjusting connector: "DISCONNECTED"
RELAY BOX
5-3
5.2.3 Stop Position of Stepping Motor


several times until the message "STEP2" appears
G-2
4. Connect the adjusting connector (CN171). STEP2
CPU
GAP SET
Then, the stepping motor is moved to the stop
position.
5. At that time, adjust the cable and ball joint until the
clearance between the engine governor and stop
position bolt is I mm.
6. After the adjustment is complete, disconnect the

adjusting connector (CN171).
Then, the stepping motor automatically returns to
the origin.
7. Return the "ADJUSTMENT" switch to the "RUN"

position.
Adjustment of stepping motor stop position

the "CHECK" switch.
5. Governor cable adjustment
5-4
5.2.4 Engine Speed Adjustment
* Prior to the adjustment, sufficiently warm up the

machine.


several times until the message "TEST3" appears
G-3
STEP3 .
4. Start the engine, and connect the adjusting CPU ENG. START
connector (CNl 71 ). Then, the engine speed is
accelerated gradually.
G-4
5. When the engine speed reaches the high idling set
value range from 2100 to 2140 rpm, it is decreased CPU STEP4
MEMORY 1500RPM
gradually.
6. When the engine speed reaches the low idling set

value, the message "STEPS" is displayed on the G-4
display screen of the cluster.
CPtl STEP4
MEMORY 1500RPM
7. After the adjustment is complete, disconnect the
adjusting connector (CN171).
8. Return the "ADJUSTMENT" switch to the "RUN" G-5

position. CPU FINISH
740RPM
Adjustment of engine speed
the "CHECK" switch.
5. Engine automatic adjustment
5-5
5.2.5 When Adjustment of Total Controller is Impossible
1. After the adjusting connector is connected while the message "STEP3 Engine start is possible." is displayed on the
display screen of the cluster, the message "CPU adjustment is impossible." appears, and the adjustment is impossible.
• Condition: when the engine speed is 420 rpm or slower.
• Cause: the reading by the engine tum sensor is incorrect.
• Remedy: after the measurement and adjustment of the tum sensor voltage, perform the adjustment A.
High idling 3 V (AC) or more
TOTAL CONTROLLER(TC)
CN171
RELAY BOX
2. The message "STEP4 CPU adjustment is in progress." is changed to "CPU adjustment is impossible.", and the
adjustment is impossible.
• Condition: when the engine speed is reduced after stepping of the governor motor while the engine speed is 850 rpm
or higher during the engine speed reading.
• Cause: the reading by the engine tum sensor is incorrect.
• Remedy: after the measurement and adjustment of the tum sensor voltage, perform the adjustment A.
High idling 3 V (AC) or more
3. The message "STEP4 CPU adjustment is in progress." is displayed, and the speed is not reduced.
• Condition: abnormal rotation (out-of-phase) occurs on the high idling side.
• Cause: faulty connection of the link and rod of the governor motor
• Remedy: after the adjustment of the link and rod, perform the adjustment A.
* If out-of-phase condition occurs even after re-adjustment, connect the inching connector (CN290) once just before
the out-of-phase condition occurs, as a temporary remedy. Then, temporary high idling is provided, and the speed
starts to be reduced.
4. The message "CPU ROM data" is displayed.

(1) Noises are input. Completely perform all the total controller adjustment procedures.
(2) This message is also displayed on the display screen of a new controller (adjustment). Completely perform all the
total controller adjustment procedures.
5-6
5.2.6 Initial Adjustment of Lifting Height
Gauge
If the drum is rotated without a wire rope wrap
during the wire rope replacement, or the drum is
rotated with the wire rope caught in during the
disassembly and the assembly of the boom, the
wire rope layers on the drum must be adjusted.
If the adjustment is not performed correctly, the
lifting height may not be changed, or the displayed
value may be incorrect. Be sure to adjust it
correctly.
The initial adjustment of the lifting height gauge
must be performed for both of the main winch and
the.aux. winch.
The adjustment steps are identical to the front drum
and the rear drum .
The adjustment steps for the front drum are
described below.
1. Winch up and down the main hook block, and stop

it at the position where the wire rope layers on the
drum changes.
(1) Display the "Front drum layers display screen".
FRONT DRUM LAYER
2
INCHING OFF F6 R1
CD Push the flash switch for more than 5 seconds.

Then, the displayed value of the wire rope wraps on
the drum flashes.
5-7
@ Whenever the adjuster "+" switch is pushed, the
wire rope wraps on the drum increases by 1. It can
be continuously increased by pushing the switch.
Whenever the adjuster "-" switch is pushed, it SETTING EXAMPLE OF
decreases by l . WIRE ROPE WRAPS
Adjust the displayed value of the wire rope wraps lst.LAYER ++ 2nd.LAYER=[2)
on the drum to the current correct value. It can be 2nd.LAYER ++ 3rd.LAYER =[3]
judged by the distance between the drum flange 3rd.LAYER ++ 4th.LAYER =~
end and the wire rope. Refer to the diagram below. 4th.LAYER ++ 5th.LAYER=[5]
5th.LAYER ++ 6th.LAYER =[ID
"'"'
@ Push the setting switch after adjusting the value.

The adjustment is complete, and the screen returns
to the normal status.
© If no alteration is required, select another display

screen with the display screen selector switch
without pushing the setting switch.
Then, the alteration is canceled, and the value
returns to the original one.
® Follow the steps described in the "(l) USE OF

LIFTING HEIGHT GAUGE" of the section 7, and
ensure that the lifting height value changes in
accordance with the setting.
® When the indicated lifting height is incorrect, the

sensor gap adjustment may be improper. Adjust
the gap of the proximity sensor.
If the indicated lifting height is still incorrect, The center of the proximity
consult with your nearest KOBELCO service shop. sensor must be nearly aligned
with the drum fin end.
GAP ADJUSTMENT 3mm

(ALLOWANCE 3 TO 4 mm)
VIEW A
5-8
5.3 CHECKPOINTS AND RECOMMENDED REMEDY WHEN THE ENGINE
DOES NOT STOP
I. Set the engine key switch to the "ON" position

(the engine does not run).
2. Set the adjuster switch to the "TEST" position.
0--2
3. Set the inching switch to the "NORMAL" position,
STEP2
and the operation mode selector switch to the CPU GAP ADJUSl
"CRANE" position.
Then, the message "STEP2" is displayed on the
display screen of the cluster.
BOLT
4. Connect the adjusting connector (CNI 71).

The stepping motor runs, and then stops at the stop
position. At this time, check the clearance (Q)
between the governor lever and the bolt stop
position.
TOTAL CONTROLLER (TC)
CN171
RELAY BOX
5. If Q exceeds 2 mm, check the following points

before adjusting the cable length. CLEARANCE
+
(If Q is 2 mm or less, the engine stops.)
(I) Check that the manual operation cable, which is

used only when the throttle grip is faulty, is not
tensioned.
• Check that a clearance is present at the top of the
long hole.
• If any clearance is present, the cable can be
adjusted by pushing it in the arrow direction.
5-9
(2) Check that the clamped section (2 positions) of the
controller cable are not loose.
11 11 11
11 11 11
II II 11
II 11 11
II
II
11
ii
II
II I
- - - --did
=~--===-
CLAMP SECTION
6. Ifno irregularity was found in the procedure above,

adjust the cable length atthe ball joint section so
that the clearance between the stop position bolt
and the governor lever is approx. 1 mm.
7. After the cable length is adjusted, the low idling

and high idling positions are displaced from the
correct positions. Thus, refer to page 5-5, and
adjust the positions.
5-10
KOBELCO
SHOP MANUAL CK2500
CKE2500
- - - - TRANSLIFTER SYSTEM-----
TABLE OF CONTENTS
1. LOCATION OF MAIN COMPONENTS · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 1 - 1
2. CONSTRUCTION AND WORKING PRINCIPLE · · · · · · · · · · · · · · · · · · · · · · · · · · 2 - 1
2. 1 Outline · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · : · · · · · · · · · · · · · · · · · · · · · 2 - 1
2. 2 Working Principle · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2 - 2
2.2.1 Raising the Translifter · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2 - 2
2.2.2 Lowering the Translifter · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2 - 4
3. REMOTE CONTROL SWITCH · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3 - I
CK2500
CKE2500 JD-00001-

1. LOCATION OF MAIN COMPONENTS
The translifter system consists of the vertical cylinder, horizontal cylinder, remote control switch and junction box.
VERTICAL CYLINDER
VERTICAL
CYLINDER
CRAWLER FIXING PIN
CYLINDER
CONTROL VALVE
VERTICAL
CYLINDER CRAWLER FIXING PIN
CYLINDER
VERTICAL CYLINDER
14'-5.3"(4400mm)
1-1
RECEPTACLE "A" CONNECTING CABLE
(24 79R2151)
JUNCTION BOX
(JJ24E00005Pl)
CN-3
Connect to receptacle "A"

with connecting cable
POWER "ON" LAMP
CRAWLER FIXING PIN

CYLINDER CONTROL
SWITCH (Fr.)
CRAWLER FIXING PIN

CYLINDER CONTROL
VERTICAL CYLINDER SWITCH (Re.)
CONTROL SWITCH
(Re.L.H.) VERTICAL CYLINDER
CONTROL SWITCH
(Re.R.H.)
•
RETRACT
1-2
2. CONSTRUCTION AND WORKING PRINCIPLE
2.1 Outline
To Boom Foot Pin/
The pressurized oil discharged from the gear pump (the outside one among the two) is controlled by the gantry/translifter Reevin Winch
selector valve, and is led to the translifter control valve through the swivel joint.
The pressurized oil controlled by the remote controller is discharged into the respective cylinders.
I
A1
'-J
81
p T
T2
To Boom
To Main Control Valve To Swing SWIVEL JOINT
sol 86
FRONT(R.H.)
TRANSLIFTER
Sol 87
FRONT(R.H.)
Er: Sol 88
CRAWLER
REMOVAL Sol 89
MPC DEVICE
FRONT
(L.H.)
PS!
EL: Sol 90
P/5
,--------~
FRONT REAR
T/5
r---1 (L.H.) (L.H.) sol 91
L __ ~ L..'...J
TRANSLIFTER
I
T
L_ To Control Circuit
Fig; 2-1 Hydraulic Schematic

2-1
2.2 Working Principle
The working principle is common to the four translifter vertical cylinders. The working principle of the horizontal
cylinders is identical to that of the vertical cylinders except that the crawler fixing pin cylinder lack the double pilot check
valves.
The working principle of the translifter cylinders is described below taking the front right vertical cylinder as an example.
2.2.1 Raising the Translifter

The pressurized oil discharged from the auxiliary actuator pump flows through the gantry control valves (SOL-26, SOL-
27), and is led into the hydraulic selector solenoid valves (SOL-44, SOL-45).
If the hydraulic selector switch in the operator's cab is in the "NEUTRAL" position, the pressurized oil flows through the
solenoid valves, and returns to the tank without any load.
When the hydraulic selector switch is set to the "TRANSLIFfER" position, the SOL-44 trips, causing the pressurized oil
to flow through the swivel joint and into the translifter control solenoid valve. If the translifter control solenoid valve
remains unactuated, the pressurized oil flows through the valve, and returns to the tank without any load.
When the "Fr. R.H." vertical cylinder switch is set to the "EXTEND" side, the SOL-80 trips, causing the pressurized oil not
only to flow into the head side of the vertical cylinder but also to open the lowering side check of the double pilot check
valve. As a result, the oil in the rod side returns to the tank, and the cylinder is extended.
2-2
To Boom Foot Pin/
Reeving Winch
82
---
81
p T
~·----'I'--~

To Swing
To Boom
l
! LU
r~ SWIVEL JOINT
T2
'
--~~~--~~~~-- L-~~~~~·~~~~~~I
Pf
Sol 87
sol 88
j
sol 89
PC
I! ~-~1r~. sol 90
' ! '\........1.---+--------t---j P/5
,--------~
I !
T/5
T
sol 91
! ~ L_ -~ To Control Circuit
~-------------- Fig. 2-2 Raising The Translifter
2-3
2.2.2 Lowering the Translifter
The pressurized oil discharged from the auxiliary actuator pump flows through the gantry control valves (SOL-26, SOL-
27), and is led into the hydraulic selector solenoid valves (SOL-44, SOL-45).
If the hydraulic selector switch in the operator's cab is in the "NEUTRAL" position, the pressurized oil flows through the
solenoid valves, and returns to the tank without any load.
When the hydraulic selector switch is set to the 'TRANSLIFTER" position, the SOL-44 trips, causing the pressurized oil
to flow through the swivel joint and into the translifter control solenoid valve. If the translifter control solenoid valve
remains unactuated, the pressurized oil flows through the valve, and returns to the tank without any load.
When the "FRONT R.H." vertical cylinder switch is set to the "RETRACT" side, the SOL-81 trips, causing the pressurized
oil not only to flow into the rod side of the vertical cylinder but also to open the lowering side check of the double pilot
check valve. As a result, the oil in the head side returns to the tank, and the cylinder is retracted.
2-4
To Boom Foot Pin/
Reeving Winch
~
A2 v 82
-
~;
\J
"
81
' l=_ p
:]
T

To Boom r~ T2
'
To Swing SWIVEL JOINT
w
~ ~
Sol BO Sol 86
Ai
81
So I 87
FRONT(R.H.) REAR(R.H.) A2
Er: --EJ Sol 82

82
A3
Sol SB
83
A3 l SOI 89
MPC
------{.>i( Sol 83
- - - - ; . - > , ( B3 l
FRONT CA4l A4
.--~~~~~~-~~~~~~~~,
(L.H.) --4.--.rt---_-'l'---, c B4 l '-==;:--+t---t==-::::1::'___-"'-1
EL: __ Br~ 84
So I 90
I
i
PSl
- - - - + ~ \.......l-4--------t-----1P/S i
Sol 84
A5
85
T/5
85 So I 91
A6 I
L __ ~ ~ 86
T
L_ To Control Circuit
Fig. 2 _3 Lowering The Translifter
2-5
3. REMOTE CONTROL SWITCH
fj-_ --CN-4
< :CN~
TRANSUFTER
EX[jND
L------------
POWER SOURCE
CONTROL BOX
~- Ext.
-/ SOL-80
Vertical Cylinder Ext.
SW-T2
(Front R.H.)
' o-----o---<---+-------4""\. Vertical Cylinder Ret.
Ret.
(Front R. H.)
SOL-81
Ext. Vertical Cylinder Ext.
SW·T3
(RearR. H.)
Vertical Cylinder Ret.
Ret.
(RearR. H.)
SOL-82
Ext.
SW-T4 Crawler Pin Ext.
(Rear)
Crawler Pin Ret.
Ret. (Rear)
SOL-83
Ext.
SW·TS Crawler Pin Ext.
(Front)
Ret. Crawler Pin Ret.
(Front)
SOL-84
SW·T6
(RearL. H.)
Ret.
(RearL. H.)
SOL-85
SW·T7
(Front L. H.)
Ret.
(Front L. H.)
LED,..;
-- - - -- - -
3-1
KOBELCO
SHOP MANUAL CK2500
CKE2500
JIB HOIST SYSTEM
TABLE OF CONTENTS
1. APPARATUS AND LOCATION OF COMPONENTS · · · · · ·· · · .. · · · · · · ·· · · · 1- 1
2. CONSTRUCTION AND FUNCTION · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2- 1
2.1 Hydraulic Schematic · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2- 1
2.2 Raising the Jib · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2- 2
2.3 Neutral (Maintaining the Jib Position) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2- 4
2.4 Lowering the Jib · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2- 6
3. JIB DRUM LOCK · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3- 1
3.1 Assembly Drawing · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3- 1
3.2 Adjusting the Jib Drum Lock ········································· 3- 2
CK2500 JD-00001 ~
CKE2500
2nd. Edition 2002.08 S5JD300 IE(D

The jib hoist system consists of the jib drum motor, a reduction unit, the jib drum itself and the drum lock mechanism.
The pressurized oil for the jib hoist system is supplied by the No. I pump installed on the engine's power divider. From this
pump, the oil flows through the control valve to power the motor for the jib drum.
DRUM LOCK
JIB DRUM
11
LOCK SWITCH
11
___ II
---~-
1-1
@ 2. CONSTRUCTION AND FUNCTION
8-t
. I a, co, SOL-59 a, _ __
B, A,B
~-!1A,B,
--t
a, • a, 1 I
I I
Dr JIB
-------r---- I
1
I
p T
1.-1--JIB CONTROL
PEDAL (OPT.)
To CONTROL VALVE
iI
I
I
I
I
From P3, P4 I
I
I
I
I
I
BJ I
(FRONT> CREAR)
KR3H-9U09
II P
a, KR3H-9N99 I
(Q]JJ)
Al 81 Cl 01
P2'
I
p,.
SOL-1
S, SOL-50 A2 C2 02
I
3• I
I
PB
([[j)
DRl to DRl 1 To
MAST BOOM FOOT PIN ACC
REEVING WINCH
T/S
~.i.---------------.._~P/S
Tl to T17
L __ ~ T9
Fig. 2-1 Hydraulic Schematic 2 -1

2.2 Raising the Jib
Pressurized hydraulic oil from the No. I pump flows continuously through the control valve.
While the function lock lever is in the "Operation" position, pressurized oil is also flowing from the control pump, past the
accumulator and then through the valve block and the remote control valve.
Shifting the jib hoist control lever to "Raise" directs control system oil through the remote control valve and valve block
and into the QID port of the control valve. This pressure shifts the spool.
Control pressure is simultaneously applied to release the negative brake mechanisms.
This allows the oil pressure from the No.1 pump to activate the jib hoist motor and drive the drum to raise the jib.
2-2
~
8-tl a,<D SOL-59
~-!
--, I A. 84
a4' I I
-- I
------+-...l..- Dr
1
I
p I
I T
I
I
I I lI I
S/P
r--- lI
L I
.-:-·
•
f. ~-1 - ~ - - ~b-.~ -
t
b, I
1
r------------~----------+---,-----:::::'....J
~.~!-,-
61 • .. j ,__._ _ JIB CONTROL
:wllbJ... : SOL-58 ' ~ PEDAL (OPT.)
1-f~J~ I !·-~ I
lb, cm b.
8----1
Q])
To CONTROL VALVE
i
I
I
DOWN
(FRONT) (REAR) p
KR3H-9U09 KR3H-9N99
Al 81 Cl Dl
----
P21 1Pl
I
p.,
D, J SOL-50
I
3' I
I
([[D
DR1 to DR11 To
REEVING WINCH
T/S
L ----------{ T1 to T 17
~~~..;:J i=.::-;:i - -- ] L __ :J T9
L ______ _- - - - - - - - - - - - - - - - - - - - - - - - - -
Fig. 2-2 Raising the Jib 2 -3
2.3 Neutral (Maintaining the Jib Position)
With the jib hoist control lever returned to its neutral position, the control pressure is cut off, and the oil flow from the No. I
pump is again allowed to pass through the control valve and flow freely back to the oil reservoir.
At the same time, the oil pressure to the jib drum motor negative brake is also released back to the reservoir. Both braking
mechanisms then re-engage to hold the jib hoist drum in position.
2-4
(]])
8-tI a, <D> SOL-59 a, _ __
As Bs
~-!
--t A, B,
a, a, 1 II
I I
------4'-"
I
__,.__
I Dr JIB
I
p T
/-1-1 I
I
I
I S/P
r--- !I I
L _l ----r j _11 1 :--- I
-=--~
I
I
r------::::_-::::_---~----.=-.::-1T--~-T-- I
I
MAI
b,
b.'::IE--~
2
1 ~ 1
I I
I
bs
I
b/ - ~
I
.J
I I
1
I
I
I !.__~ I I !•__, I
1
' ' SOL-58 ' SOL-54
I b, cm b,
G----i
'C:F at)
~-------1 To CONTROL VALVE

iI
From P3, P4
(FRONT) (REAR) p
KR3H-9U09 a, KR3H-9N99
Al BI Cl DI
----
P21
I
p,.
SOL-I
- - --::T"if2 - - - - C2 02
I
3' I
I
([BJ)
DR! to DR! I To
REEVING WINCH
T/S
TI to T17
L __ ~ T9
Fig. 2-3 Neutral (Maintaining Jib Position) 2- 5

2.4 Lowering the Jib
Pressurized hydraulic oil from the No. I pump flows through the control valve while oil from the control pump oil flows
past the accumulator and into the valve block and the remote control valve. (The function lock lever remains in the
"Operation" position.)
Shifting the jib hoist control lever to "Lower" directs control system oil through the remote control valve and through the
valve block and into the@ port of the control valve to shift the spool.
At the same time, control pressure is applied to the jib drum motor negative brake to release.
Oil pressure from the No. I pump is applied to the lowering side of the jib hoist motor. This line pressure opens the
counterbalance valve and drives the jib hoist motor so that the jib drum lowers the jib.
2-6
9p)
8-• ta,<D SOL-59
a,
As a.
~-,
a•....-.---,
-1
I
I
I
I
A, B,
I
------J('----+--
I JIB
1
COUNTER BALANCE
VALVE
p T
I I
I I I I
SIP JIB(OPT)
L -t.----,-
: r~-r----l--------+~--~---J
!I --
b1'
1- T.T ! I
~-t I
II
-b-.- - ~
4 I I I I
I
MA
II
I
SOL-58 , ~
SOL-54
1-r~=J~
,vJI1:ti.J__ ;
I 1·-_, _ 1
I
I
I
I
I b, <lll b, I
I
8--i t
I
I
I
DOWN UP,
I
I
To CONTROL VALVE I
I
I
I
From P3. P4 I
I
I
I
I
I
I
(FRONT> (REAR) I
I
KR3H-9U09 KR3H-9N99 I
I
@])
At 81 Cl 01
----
P21 I Pl.
I
p 12
S, SOL-50
I
3• I
I
ffi
DRt to DRtt To
REEVING WINCH
T/S
L_ Tt to Tt7
L __ ~ T9
L _________~~~-~~-----
Fig. 2-4 Lowering the Jib 2- 7
3. JIB DRUM LOCK
3.1 Assembly Drawing
Tightening torque:
12.3ft •lbs(16. 7N · m)
Tightening torque:
12.3ft · lbs(16. 7N •m)
Tightening torque:
28.9ft · lbs(39.2N •m)
Tightening torque:
50.lft · lbs(68N ·m)
Tightening torque: ·
13.Sft · lbs(18. 7N •m)
I I
I I
Tightening torque:
_____ _I I 28.9ft · lbs(39.2N · m)
--------~ Tigh~ening torque:
13.Sft · lbs(18. 7N · m)
• When the assembly is complete, fill grease until it is squeezed out from the clearances of the pawl.
3-1
3.2 Adjusting the Jib Drum Lock
A WARNING
Do not adjust the jib hoist drum locks until the jib
has been lowered to the ground.
CD Shift the drum lock switch in the LOCK position

and check to see that the pawl is engaged in the
bottom of the drum ratchet.
ratchet, adjust the spring length to allow the pawl to
be engaged in the bottom.
@ With the LOCK position, adjust the respective

@ Push the drum lock knob in the RELEASE position

by at least 0.87 inch (22 mm).
I I
2.60inch(66mm)
Operate the knob to the LOCK position and to the I I
RELEASE position and confirm that the pawl ~
moves smoothly. _____ _I I
--------~
A WARNING
Keep hands and clothing clear of the rotating
drum.
3-2

CKE2500 Service Manual

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KOBELCO

SHOP MANUAL CK2500

Model Applicable Machine Note Model Applicable Machine Note

Revision Date of Issue Book Code

lst. Edition 2000.03 S5JD0401E

2nd. Edition 2002.08 S5JD0401E(l)

[Unit: inch (mm)]

Std. dimension Usable limit See

Fr.& 1 JJ82W01024Pl 1.732 1.725 Replace Fig.

Pawl Boom Drum 2 JJ82W01007Pl 1.732 1.725 Replace Fig.

Luffing 3 GB82W01008Pl 1.772 1.765 Replace Fig.

Luffing Jib Foot 5 JJ13A01016Pl 4.330 4.310 Replace Fig.

Strut Foot 6 JJ12A01018Pl 3.150 3.140 Replace Fig.

Fr.& 7 2405T1151 1.732 1.743 Fig.

Luffing 9 2405U101D4540 1.772 1.776 Replace Fig.

Luffing Jib Foot 11 2405R41D21 4.330 4.354 Replace Fig.

Strut Foot (Front) 12 2405R41Dl3 3.150 3.171 Replace Fig.

i---- Free Length

[Unit: inch (mm)]

Gantry stopper 23 JJ61F01042Pl 16.063 (408) 15.260 (387.6) Fig. 1-12

Standard root diameter

[Unit: inch (mm)]

Boom point 30 JL06A01004Pl 494±1.5 491 14.0

for Main 32 2407U140 587.4 584 15.5 Fig. 1-9

Lower spreader 34 JJ06A01010Pl 418 +3 415 12.5 Fig. 1-12

35-1 JJ06A01010Pl 418 ~3 415 12.5

Luffing boom point sheave 36 JL06A01004Pl 494±1.5 491 Replace 14.0

Taper boom guide sheave 38 JJ06A01010Pl 418 +3 415 12.5

Fr. strut sheave 40 JL06A01004Pl 494±1.5 491 14.0

Jib idler 42 GG63A01051Pl 495.6 14.0

Gantry peak 43 JJ61F01031Pl 550 0+3 547 12.5 Fig. 1-12

20 Figl-2 Front & Rear Drum Lock

Figl-3 Boom Drum Lock

Figl-5 Luffing Jib Drum Lock

Figl-8 Crane Jib

Figl -9 Aux. Sheave(For Main) Figl-10 Aux. Sheave(For Luffing)

Figl -11 Luffing Crane

[Unit: inch (mm)]

Std. Dimension Usable limit Remedy

Pin hole (D) 1.772 (45 +:;5) 1.850 (47.0)

Pin 1.75 (44.45 '.li.2) 1.673 (42.5) Build-up or Replace

Pitch (P) 10.984 (279 ~i:;)

SECTION A-A SECTIONB-B

[Unit: inch (mm)]

Symbol Item Std. Dimension Usable limit Remedy

[Unit: inch (mm)]

Symbol Item Std. Dimension Usable limit Remedy

[Unit: inch (mm)]

Symbol Item Std. Dimension Usable limit Remedy

"'I IE. 2.362(60)

[Unit: inch (mm)]

Symbol Item Std. Dimension Usable limit Remedy

A Height of Guide Bar 5.315 (135) 4.528 (115)

2.1 OPERATING SPEED

Connector and hose for measuring pressure.

No. Item Test Condision Test Procedure Standard Value

Main · Engine revolution ( 1) Lower the hook onto the ground.

PRESSURE GAUGE RELIEF

PRESSURE GAUGE PORT

Control · Engine revolution ( 1) Operate the control lever for the

RELIEF VALVE(MAST RAISE)

RELIEF VALVE(MAST LOWER)

MAIN CONTROL VALVE

COUNTER WEIGHT: FULL