Kobelco CK1200 CKE1100 Crawler Crane Shop Manual S5GK00004ZE03 – PDF DOWNLOAD

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Kobelco CK1200 CKE1100 Crawler Crane Shop Manual S5GK00004ZE03 – PDF DOWNLOAD

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Kobelco CK1200 CKE1100 Crawler Crane Shop Manual S5GK00004ZE03 – PDF DOWNLOAD

Language : English
Pages : 560
Downloadable : Yes
File Type : PDF

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Kobelco CK1200 CKE1100 Crawler Crane Shop Manual S5GK00004ZE03 – PDF DOWNLOAD

SAFETY:
PRECAUTIONS FOR INSPECTION AND MAINTENANCE:

1. Service and maintenance must be performed only by authorized personnel who are qualified in
compliance with a relevant law or regulation.
2. Regular maintenance or inspection should be quickly performed after shutting down the machine
and ensuring safety to personnel and equipment.
Post an “INSPECTION IN PROGRESS. DO NOT START.” warning sign on a readily visible location.

GENERAL SAFETY PRECAUTIONS:

1. Wear safety shoes, helmets and clothing suitable for the job. Also use protective goggles,
mask, gloves, etc., as required.
2. To ensure safe and correct maintenance, carefully study this SHOP MANUAL and get fully
familiar with the in- structions in it.
3. Place the machine in a safe place. Always maintain safe clearance around the machine.
4. Before starting crane operation, hold a safety meeting. Also, make agreement on standardized
hand signals.
5. When inspecting or handling the battery or oil, do not use exposed flame nearby. To avoid fire
accident, only use explosion-proof lighting equipment.
6. Start an inspection or maintenance work only after shutting down the engine.
7. Certain machine components remain hot immediately after the engine is shut down. Do not touch
them.
8. Before removing the radiator cap, wait until the coolant water gets sufficiently cool. Next,
carefully loosen the cap and release radiator pressure, and them remove the cap.
9. Before inspecting or maintaining an electrical system on the machine, power off the machine
by, for example, disconnecting the battery cables.
10. When working at a high lift area, always wear a safety belt.
11. When leaving the operator’s cab for an inspection or maintenance work, post an “INSPECTION IN
PROGRESS. DO NOT START.” warning sign on a readily visible location. Also, lock the cab for
security.
12. Before starting a cleaning or lubrication work on the machine, always shut down the engine.
13. While adjusting tire pressure, be absolutely careful about rupture of a tire, flying of wheel
part.
14. Use genuine KOBELCO replacement parts and oils only.
15. Always keep the oil containers clean. Protect them against ingress of dust or moisture. Also,
fill clean, fresh oils only.
16. Once a maintenance work is complete, clean the machine.
Protect grease nipples, breathers, and oil level gages against ingress of dust.
17. Always keep the subjects of regular inspection clean to allow problems such as oil leakage,
crack, looseness, etc., to be readily detected.
18. During car washing, do not allow high pressure steam to be directly applied to electrical
components and con- nectors.
19. After removing O-rings, oil seals, gaskets, etc., clean the mounting seats. Then, install
fresh O-rings, oil seals, gaskets, etc. Also, remember to thinly apply oil to the seal faces of
these parts before installation.
20. Before disconnecting pressurized piping, release the inside pressure.

TABLE OF CONTENTS:

Kobelco CK1200 CKE1100 Crawler Crane Shop Manual S5GK00004ZE03 – PDF DOWNLOAD

COVER.......................................................................................................  1
TABLE OF CONTENTS...........................................................................................  3
SAFETY...................................................................................................... 11
1. SPECIFICATION............................................................................................ 23
	1.1 SPECIFICATION....................................................................................... 25
		1.1.1 PERFORMANCE................................................................................... 25
		1.1.2 OUTSIDE DIMENSIONS............................................................................ 26
		1.1.3 DIMENSIONS AND WEIGHT OF EACH PARTS........................................................... 28
		1.1.4 STABILITY IN SWINGING AND TRAVELING........................................................... 34
2. MAINTENANCE STANDARDS TEST PROCEDURES.................................................................... 37
	2.1 MAINTENANCE STANDARD................................................................................ 39
		2.1.1 PIN, BUSHING, SPRING, LINING AND SHEAVE....................................................... 39
		2.1.2 PROPEL DEVICE................................................................................. 46
		2.1.3 PROPEL BRAKE PLATE............................................................................ 52
	2.2 PERFORMANCE STANDARD AND TEST PROCEDURE............................................................. 53
		2.2.1 OPERATING SPEED............................................................................... 53
		2.2.2 POINT AND METHOD OF MEASURING PRESSURE........................................................ 54
		2.2.3 SLEWING RING.................................................................................. 59
3. GENERAL WORK STANDARD.................................................................................... 61
	3.1 TIGHTENING TORQUE OF CAPSCREWS AND NUTS............................................................. 63
		3.1.1 METRIC COARSE THREADS......................................................................... 63
		3.1.2 METRIC FINE THREADS........................................................................... 63
		3.1.3 COARSE THREDS UNC............................................................................. 64
		3.1.4 FINE THREADS UNF.............................................................................. 64
		3.1.5 TIGHTENING TORQUE OF HYDRAULIC FITTINGS....................................................... 65
	3.2 STANDARD PARTS...................................................................................... 67
		3.2.1 BOLT.......................................................................................... 67
		3.2.2 O-RING........................................................................................ 68
		3.2.3 BACK-UP RING.................................................................................. 69
		3.2.4 BITE FITTING.................................................................................. 70
	3.3 CONVERSION TABLE.................................................................................... 72
		3.3.1 UNIT CONVERSION............................................................................... 72
		3.3.2 MILLIMETER : INCH CONVERSION TABLE............................................................ 73
		3.3.3 METER-FOOT CONVERSION TABLE................................................................... 75
		3.3.4 GRADIENT CONVERSION TABLE..................................................................... 76
	3.4 TABLE OF UNIT WEIGHT................................................................................ 77
4. POWER TRAIN.............................................................................................. 79
	4.1 INTRODUCTION........................................................................................ 81
	4.2 ENGINE.............................................................................................. 83
		4.2.1 INTRODUCTION.................................................................................. 83
		4.2.2 REMOVAL....................................................................................... 83
		4.2.3 REPAIR AND MAINTENANCE........................................................................ 84
		4.2.4 RE-INSTALLATION............................................................................... 85
	4.3 PUMP DRIVE ASSEMBLY................................................................................. 88
		4.3.1 INTRODUCTION.................................................................................. 88
		4.3.2 REMOVAL....................................................................................... 88
		4.3.3 DISASSEMBLING THE POWER DIVIDER............................................................... 90
		4.3.4 CHECK AND REPAIR OF THE POWER DIVIDER......................................................... 91
		4.3.5 ASSEMBLING THE POWER DIVIDER.................................................................. 92
		4.3.6 RE-INSTALLATION............................................................................... 93
5. HYDRAULIC SYSTEM......................................................................................... 99
	5.1 LOCATION OF MAIN HYDRAULIC COMPONENTS...............................................................101
	5.2 HYDRAULIC CIRCUITS AND COMPONENTS...................................................................102
		5.2.1 HYDRAULIC CIRCUIT.............................................................................102
		5.2.2 COMPONENT SPECIFICATIONS......................................................................106
		5.2.3 LOCATION OF HYDRAULIC COMPONENTS..............................................................110
	5.3 HYDRAULIC SYSTEM....................................................................................121
		5.3.1 PREFACE.......................................................................................121
		5.3.2 OUTLINE.......................................................................................121
		5.3.3 OIL FLOW FROM No.1 and No. 2 PUMPS............................................................122
		5.3.4 OIL FLOW FROM No.3 AND No.4 PUMPS.............................................................124
		5.3.5 OIL FLOW FROM No.5 PUMPS (CONTROL PUMPS)......................................................127
		5.3.6 OIL FLOW FROM No.6 PUMP (FOR AUXILIARY ACTUATOR CIRCUIT)......................................130
	5.4 VALVES..............................................................................................133
6. HOIST SYSTEM.............................................................................................141
	6.1 APPARATUS AND LOCATION OF COMPONENTS................................................................143
	6.2 CONSTRUCTION AND FUNCTION...........................................................................144
		6.2.1 HYDRAULIC SCHEMATIC...........................................................................144
		6.2.2 LIFTING A LOAD................................................................................146
		6.2.3 HOLDING A RAISED LOAD.........................................................................148
		6.2.4 LOWERING A LOAD (POWERED LOWERING)............................................................150
		6.2.5 FREE FALL OPERATION...........................................................................152
		6.2.6 FREE FALL ACCELERATION........................................................................156
	6.3 DRUM LOCK...........................................................................................158
		6.3.1 ASEEMBLY DRAWING..............................................................................158
		6.3.2 ADJUSTMENT OF DRUM LOCK.......................................................................159
	6.4 WINCH ASSEMBLY......................................................................................160
		6.4.1 WINCH INSTAL..................................................................................160
		6.4.2 WINCH ASSEMBLY / REDUCTION UNIT WITHOUT FREE FALL (STD.)......................................161
		6.4.3 WINCH ASSEMBLY WITH FREE FALL (OPT.)..........................................................163
	6.5 BRAKE PEDAL.........................................................................................164
		6.5.1 ASSEMBLY DRAWING..............................................................................164
		6.5.2 ADJUSTING THE BRAKE PEDAL.....................................................................166
	6.6 BLEEDING AIR FROM BRAKE CIRCUIT.....................................................................167
7. BOOM HOIST SYSTEM........................................................................................169
	7.1 APPARATUS AND LOCATION OF COMPONENTS................................................................171
	7.2 CONSTRUCTION AND FUNCTION...........................................................................173
		7.2.1 HYDRAULIC SCHEMATIC...........................................................................173
		7.2.2 RAISING THE BOOM..............................................................................174
		7.2.3 NEUTRAL (MAINTAINING THE BOOM POSITION).......................................................176
		7.2.4 LOWERING THE BOOM.............................................................................178
	7.3 BOOM DRUM LOCK......................................................................................180
		7.3.1 ASSEMBLY DRAWING..............................................................................180
		7.3.2 ADJUSTING THE BOOM DRUM LOCK..................................................................181
	7.4 DRUM AND REDUCTION UNIT.............................................................................182
		7.4.1 BOOM WINCH ASSEMBLY...........................................................................182
		7.4.2 BOOM DRUM AND REDUCTION UNIT ASSEMBLY.........................................................184
8. SWING SYSTEM.............................................................................................187
	8.1 APPARATUS AND LOCATION OF COMPONENTS................................................................189
	8.2 CONSTRUCTION AND FUNCTION...........................................................................190
		8.2.1 HYDRAULIC SCHEMATIC...........................................................................190
		8.2.2 SWING.........................................................................................192
		8.2.3 STOPPING......................................................................................195
	8.3 SWING REDUCTION UNIT................................................................................198
	8.4 SWING BEARING.......................................................................................200
	8.5 SWING LOCK..........................................................................................202
9. PROPEL SYSTEM............................................................................................203
	9.1 LOCATION OF THE MAJOR COMPONENTS....................................................................205
	9.2 CONSTRUCTION AND FUNCTION...........................................................................206
		9.2.1 HYDRAULIC SCHEMATIC...........................................................................206
		9.2.2 PROPELLING (RIGHT SIDE FORWARD)...............................................................208
		9.2.3 STOPPING......................................................................................210
	9.3 PROPEL REDUCTION UNIT...............................................................................212
		9.3.1 MOTOR AND REDUCTION UNIT......................................................................214
	9.4 ADJUSTMENT..........................................................................................216
10. ELECTRIC SYSTEM.........................................................................................217
	10.1 ELECTRICAL WIRING SCHEMATIC........................................................................219
	10.2 CONNECTOR LIST.....................................................................................230
	10.3 ARRANGEMENT OF ELECTRICAL PART.....................................................................282
		10.3.1 ELECTRICAL PART OF CAB.......................................................................282
		10.3.2 ELECTRICAL PART OF RIGHT DECK................................................................286
		10.3.3 ELECTRICAL PART OF FLOOR PLATE & LEFT SIDE STAND PANEL.......................................294
		10.3.4 ELECTRICAL PART OF REVOLVING FRAME...........................................................299
		10.3.5 ELECTRICAL PART OF LEFT DECK.................................................................302
		10.3.6 ELECTRICAL PART OF LEFT GUARD................................................................309
		10.3.7 HARNESS PART NUMBER LIST (ALL MODELS)........................................................310
	10.4 ELECTRICAL PART....................................................................................312
		10.4.1 LOCATION AND USE OF FUSE.....................................................................312
		10.4.2 FUSE BOX (GG73E00004F1)......................................................................314
		10.4.3 WIPER CONTROL UNIT (2480U306)................................................................316
		10.4.4 SWING FLASHER UNIT (2480U306)................................................................317
		10.4.5 PRESSURE SWITCH (CONTROL PRESSURE CUT & FREE FALL) (GG52S00006P1)............................318
		10.4.6 PRESSURE SENSOR..............................................................................319
		10.4.7 RELAY BOX (GG24E00024F1).....................................................................321
		10.4.8 LEFT SIDE STAND PANEL........................................................................326
	10.5 TROUBLESHOOTING OF EXHAUST GAS THIRD REGULATION ENGINE.............................................330
		10.5.1 FAILURE DIAGNOSIS FUNCTION...................................................................330
		10.5.2 HOW TO CHECK THE FAILURE CONTENTS............................................................331
		10.5.3 CHECKING OF DIAGNOSIS LAMP FUNCTION..........................................................336
		10.5.4 ENGINE ECU...................................................................................337
11. LOAD SAFETY DEVICE......................................................................................341
	11.1 PART NAMES AND FUNCTIONS...........................................................................343
		11.1.1 FRONT VIEW...................................................................................343
		11.1.2 CONFIGURATION OF SCREENS.....................................................................348
		11.1.3 DATA TRANSMISSION BETWEEN CONTROLLER AND CARDS...............................................353
		11.1.4 DETAILS OF INDICATORS ON MAIN DISPLAY SCREEN.................................................355
		11.1.5 REAR VIEW....................................................................................359
		11.1.6 ITEMS REQUIRED TO BE EXECUTED FOR REPLACEMENT OF CONTROLLER OR DATA CARD AND INSTRUCTIONS....364
	11.2 PREPARATION FOR USE................................................................................365
	11.3 TURN THE POWER ON..................................................................................366
	11.4 UPGRADING PROGRAMS.................................................................................367
		11.4.1 PROCEDURES...................................................................................367
		11.4.2 UPGRADING OF INDICATION PROGRAMS.............................................................369
		11.4.3 UPGRADING OF CONTROL PROGRAMS................................................................372
	11.5 STATUS CHECK.......................................................................................374
		11.5.1 SIGNAL CHECK.................................................................................375
		11.5.2 OPERATION PROGRESS...........................................................................377
		11.5.3 COMMUNICATION DATA...........................................................................380
		11.5.4 INDICATION OF ADJUSTMENT VALUE...............................................................381
		11.5.5 TROUBLE RECORD...............................................................................390
		11.5.6 CHOICE OF LANGUAGE (CKE SERIES ONLY).........................................................392
		11.5.7 LOAD RECORD (LOAD RECORD IN THE MAIN MENU)...................................................393
	11.6 ADJUSTMENTS........................................................................................394
		11.6.1 REMOVING THE INNER PANEL.....................................................................394
		11.6.2 ADJUSTMENT...................................................................................395
		11.6.3 LOAD ADJUSTMENT..............................................................................416
		11.6.4 ADJUSTMENT DATA COPY (INITIALIZATION)........................................................418
		11.6.5 VERSION CHECK................................................................................424
	11.7 ERROR CODE (ABNORMALITY DETECTION) AND COUNTERMEASURES.............................................425
	11.8 CONTROL OUTPUT.....................................................................................429
	11.9 RELEASES...........................................................................................441
		11.9.1 RELEASE FUNCTION.............................................................................441
	11.10 MECHANICAL SPECIFICATION..........................................................................449
		11.10.1 ENVIRONMENTAL PERFORMANCE PARAMETERS........................................................449
		11.10.2 LOAD CELL (CRANE)...........................................................................450
		11.10.3 ANGLE SENSOR................................................................................451
		11.10.4 CONTROLLER..................................................................................452
	11.11 EXTERNAL DIMENSIONS...............................................................................456
	11.12 ELECTRIC SCHEMATIC DIAGRAM........................................................................457
		11.12.1 CRANE TYPE..................................................................................457
		11.12.2 LUFFING TYPE................................................................................458
	11.13 CONTROLLER MALFUNCTION EMERGENCY MEASURES.........................................................459
	11.14 LOAD SAFETY DEVICE CHECK PROCEDURES...............................................................460
12. GAUGE CLUSTER...........................................................................................461
	12.1 CONFIGURATION OF DISPLAY...........................................................................463
	12.2 PRIORITY...........................................................................................464
	12.3 STATUS DISPLAY.....................................................................................466
	12.4 FAULT LOG DISPLAY..................................................................................476
13. TOTAL CONTROLLER........................................................................................481
	13.1 ARRANGEMENT OF TOTAL CONTROLLER....................................................................483
	13.2 COMPOSITION OF SYSTEM..............................................................................484
		13.2.1 OUTPUT RELATION TO CONTROLLER................................................................485
	13.3 FUNCTION OF TOTAL CONTROLLER.......................................................................486
	13.4 TOTAL CONTROLLER (HARDWARE)........................................................................511
		13.4.1 OUTLINE......................................................................................511
		13.4.2 SPECIFICATIONS OF TOTAL CONTROLLER OUTPUT....................................................512
		13.4.3 DETAILS OF TOTAL CONTROLLER CONNECTOR........................................................516
		13.4.4 ARRANGEMENT OF TOTAL CONTROLLER CONNECTOR PIN................................................517
		13.4.5 PROPORTIONAL SOLENOID VALVE MEASURING POSITION (VOLTAGE).....................................524
	13.5 ADJUSTMENT OF TOTAL CONTROLLER.....................................................................526
		13.5.1 NECESSITY OF ADJUSTMENT......................................................................526
		13.5.2 ADJUSTMENT PROCEDURES OF TOTAL CONTROLLER....................................................526
	13.6 CONTROLLER MALFUNCTION EMERGENCY MEASURES..........................................................533
14. AIR CONDITIONER.........................................................................................535
	14.1 OPERATION ITEMS....................................................................................537
	14.2 SAFETY MONITOR FUNCTIONS...........................................................................538
	14.3 DISASSEMBLY AND ASSEMBLY PROCEDURE.................................................................541
		14.3.1 SPECIAL CONSIDERATIONS DURING REPLACEMENT....................................................541
		14.3.2 INTERIOR UNIT................................................................................543
	14.4 OPERATIONAL PRECAUTIONS............................................................................552
	14.5 INSPECTION AND MAINTENANCE.........................................................................553
		14.5.1 INSPECTION/MAINTENANCE LIST..................................................................553
		14.5.2 INSPECTION/MAINTENANCE PROCEDURES............................................................553
	14.6 ELECTRIC SYSTEM SCHEMATIC..........................................................................557

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• This is the SAME exact manual used by your dealers to fix your vehicle.
• The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
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