KOBELCO CK1200, CKE1100 Crawler Cranes Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for KOBELCO CK1200, CKE1100 Crawler Cranes, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
KOBELCO CK1200, CKE1100 Crawler Cranes workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
KOBELCO CK1200, CKE1100 Electrical Circuit Chart.pdf
S2GK21002ZE02 - KOBELCO Crawler Crane CK1200 LUFFING OPERATION & MAINTENANCE MANUAL.pdf
S2GK23001ZE09 - KOBELCO CK1200 Crawler Crane OPERATION & MAINTENANCE MANUAL.pdf
S3GK22003ZO04 - KOBELCO CK1200 Crawler Crane Parts Manual.pdf
S5GK00004ZE01 - KOBELCO CK1200, CKE1100 Crawler Crane Workshop Manual.pdf
S5GK00004ZE03 - KOBELCO CK1200, CKE1100 Crawler Crane SHOP MANUAL.pdf
PRODUCT DETAILS:
Total Pages: 2,531 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
KOBELCO CK1200, CKE1100 Electrical Circuit Chart....1
S2GK21002ZE02 - KOBELCO Crawler Crane CK1200 LUFFING OPERATION & MAINTENANCE MANUAL....33
COVER....33
TABLE OF CONTENTS....35
IMPORTANT INFORMATION....39
1. SAFE OPERATING PRACTICES FOR MOBILE CRANES....49
2. OPERATION....69
2.1 TERMINOLOGY OF MACHINE EACH PARTS....69
2.2 LOCATIONS AND TERMS OF OPERATING CONTROLS....70
2.2.1 HANDLING OF EACH SWITCH....72
2.3 LUFFING JIB OPERATION....73
2.3.1 LUFFING BOOM RAISING/LOWERING OPERATION....74
2.3.2 JIB RAISING/LOWERING OPERATION....75
2.3.3 HOOK RAISING/LOWERING OPERATION....77
2.4 FREE FALL OPERATION....80
3. LOAD SAFETY DEVICE....83
3.1 ARRANGEMENT OF EQUIPMENTS....83
3.2 TYPE AND FUNCTIONS OF EQUIPMENTS....86
3.3 CONNECTING PROCEDURE OF WIRING....93
3.4 FUNCTION OF CONTROLLER/MONITOR....98
3.5 OPERATING PROCEDURE OF CONTROLLER....102
3.5.1 SETTING SCREEN....103
3.5.2 SETTING OF THE CRANE CONFIGURATION....107
3.5.3 SELECTION OF MAIN/JIB/AUX. LIFTING....112
3.5.4 SETTING OF WORKING AREA LIMIT VALUE....113
3.5.5 SETTING OF THE TIME....117
3.6 WARNING ALARM AND AUTOMATIC STOP....119
3.6.1 ITEMS OF WARNING ALARM AND AUTOMATIC STOP....119
3.6.2 CONTENTS OF AUTOMATIC STOP....120
3.6.3 RELEASE OF AUTOMATIC STOP....123
3.7 INSPECTION....128
3.7.1 INSPECTION BEFORE RAISING THE BOOM AFTER ASSEMBLY OF....128
3.7.2 INSPECTION AFTER ERECTING THE ATTACHMENT....132
3.8 CAUTION FOR HANDLING THE LOAD SAFETY DEVICE....133
3.9 INDICATION OF ERRORS AND REMEDY....134
3.10 INDICATION OF MESSAGE AND ALARM....135
3.11 CONFIRMATION OF FUNCTION FOR LOAD SAFETY DEVICE....137
4. ASSEMBLY AND DISASSEMBLY OF CRANE ATTACHMENT....139
4.1 ASSEMBLY OF LUFFING ATTACHMENT....141
4.1.1 ARRANGEMENT OF BOOM / JIB / GUY LINE....141
4.1.2 REMOVING CRANE BOOM AND GUY LINE....150
4.1.3 INSTALLING SPECIAL INSERT BOOM (WITH IDLER SHEAVE)....151
4.1.4 CAUTION FOR CANTILEVER....152
4.1.5 CONNECTING LUFFING BOOM TIP ASSEMBLY....152
4.1.6 INSTALLING JIB ATTACHMENT....153
4.1.7 ASSEMBLY OF JIB....154
4.1.8 INSTALLING STRUT GUY LINE....155
4.1.9 INSTALLING JIB HOIST WIRE ROPE....156
4.1.10 CONNECTING STRUT GUY LINE AND STRUT BACKSTOP....157
4.1.11 INSTALLING JIB GUY LINE....160
4.1.12 REEVING OF FRONT AND REAR DRUM WIRE ROPES....161
4.1.13 CONNECTING SAFETY DEVICE....164
4.2 ERECTING THE LUFFING ATTACHMENT....167
4.2.1 CONFIRMATION BEFORE ERECTING THE LUFFING ATTACHMENT....167
4.2.2 ERECTING LUFFING ATTACHMENT....168
4.2.3 CHECK BEFORE STARTING THE WORK....171
4.3 LOWERING THE ATTACHMENT....172
4.3.1 LOWERING THE ATTACHMENT....172
4.4 DISASSEMBLY OF LUFFING ATTACHMENT....177
4.4.1 DISCONNECTION OF WIRING FOR SAFETY DEVICE....177
4.4.2 WINDING UP THE FRONT DRUM/REAR DRUM WIRE ROPES....178
4.4.3 DISASSEMBLY OF JIB....178
4.4.4 DISASSEMBLY OF LUFFING BOOM TIP ASSEMBLY....181
4.4.5 DISASSEMBLING INSERT BOOM....183
4.4.6 REMOVING BASE BOOM....183
4.5 CAUTION WHEN TRANS-PORTING LUFFING BOOM TIP ASSEMBLY....184
5. BOOM AND GUYLINE ARRANGEMENT CHARTS WITHOUT....185
6. WIRE ROPE....189
6.1 SPECIFICATION OF WIRE ROPE....189
6.2 WIRE ROPE LENGTH....189
7. MAINTENANCE....195
7.1 CHECKS....200
7.1.1 CHECK OF ATTACHMENT....200
7.2 OIL/GREASE SUPPLY....204
7.2.1 ATTACHMENT....204
7.2.2 GREASE....205
7.2.3 HYDRAULIC OIL....206
8. REFERENCE MATERIALS....207
8.1 SPECIFICATION....207
8.1.1 PERFORMANCE....207
8.2 DIMENSIONS AND WEIGHT OF EACH PARTS....210
8.2.1 ATTACHMENT....210
8.3 ELECTRIC SCHEMATIC....213
S2GK23001ZE09 - KOBELCO CK1200 Crawler Crane OPERATION & MAINTENANCE MANUAL....227
COVER....227
TABLE OF CONTENTS....229
IMPORTANT INFORMATION....235
1. SAFE OPERATING PRACTICES FOR MOBILE CRANES....245
2. OPERATION....265
2.1 TERMINOLOGY OF MACHINE EACH PART....265
2.2 LOCATIONS AND TERMS OF OPERATING CONTROLS....266
2.2.1 OPERATING SWITCHES....270
2.2.2 GAUGE CLUSTER CONFIGURATION....280
2.2.3 OPERATING THE AIR CONDITIONER....293
2.2.4 AM/FM RADIO (OPTION)....295
2.3 CRANE OPERATION....297
2.3.1 ADJUSTING THE OPERATOR'S SEAT....297
2.3.2 ADJUSTING THE CONTROL LEVER DIRECTION....297
2.3.3 STARTING AND STOPPING THE ENGINE....298
2.3.4 FUNCTION LOCK LEVER....301
2.3.5 PROPELLING OPERATION....302
2.3.6 SWINGING OPERATION....304
2.3.7 BOOM RAISING/LOWERING OPERATION....307
2.3.8 HOOK RAISING/LOWERING OPERATION....309
2.4 FREE FALL OPERATION....312
2.5 HANDLING OF REEVING WINCH (OPTION)....315
2.6 HANDLING OF HYDRAULIC TAGLINE (OPTION)....317
3. LOAD SAFETY DEVICE....319
3.1 ARRANGEMENT OF EQUIPMENTS....319
3.2 TYPE AND FUNCTIONS OF EQUIPMENTS....322
3.3 CONNECTING PROCEDURE OF WIRING....328
3.3.1 CRANE ATTACHMENT....328
3.4 FUNCTION OF CONTROLLER/MONITOR....333
3.5 OPERATING PROCEDURE FOR CONTROLLER....337
3.5.1 SETTING SCREEN....338
3.5.2 SETTING OF THE CRANE CONFIGURATION....343
3.5.3 SELECTING MAIN/AUX LIFTING....349
3.5.4 SETTING OF WORKING AREA LIMIT VALUE....350
3.5.5 SETTING THE TIME....354
3.6 WARNING ALARMS AND AUTOMATIC STOPS....357
3.6.1 WARNING ALARMS AND AUTOMATIC STOP INDICATORS....357
3.6.2 CONTENTS FOR AUTOMATIC STOP....358
3.6.3 RELEASING AUTOMATIC STOP....360
3.7 INSPECTION....367
3.7.1 BEFORE RAISING THE BOOM (UPON COMPLETION OF ATTACHMENT ASSEMBLY)....367
3.7.2 INSPECTION AFTER ERECTING THE ATTACHMENT....370
3.8 CAUTIONS FOR HANDLING THE LOAD SAFETY DEVICE....371
3.9 ERROR MESSAGES AND CORRECTIONS....372
3.10 TABLE OF ERROR MESSAGES AND ALARMS....373
3.11 CONFIRMING PROPER FUNCTIONING OF LOAD SAFETY DEVICE....375
4. ASSEMBLY OF THE MACHINE....377
4.1 STABILITY IN SWINGING AND TRAVELING....377
4.1.1 WITHOUT BOOM BASE....377
4.1.2 WITH BOOM BASE....378
4.2 TRANSLIFTER....379
4.2.1 COMPOSITION OF TRANSLIFTER....379
4.2.2 HANDLING TRANSLIFTERS (1) - (4)....380
4.3 UNLOADING BASE MACHINE....383
4.3.1 ERECTING GANTRY....384
4.3.2 SETTING TRANSLIFTERS....386
4.3.3 UNLOADING BASE MACHINE FROM TRAILER....389
4.4 INSTALLATION OF CRAWLER....391
4.4.1 INSTALLATION OF THE FIRST CRAWLER....391
4.4.2 INSTALLATION OF THE SECOND CRAWLER....393
4.4.3 HOW TO EXTEND AND RETRACT THE CRAWLERS....395
4.5 INSTALLATION OF COUNTERWEIGHT....397
4.5.1 ASSEMBLING COUNTERWEIGHTS....397
4.5.2 INSTALLATION PROCEDURES....402
4.6 ASSEMBLING ATTACHMENTS....408
4.6.1 ASSEMBLY OF BOOM AND FIXED JIB....409
4.6.2 ASSEMBLY OF JIB....422
4.6.3 INSTALLATION OF AUXILIARY SHEAVE....427
4.7 REEVING WIRE ROPE FOR CRANE AND AUXILIARY SHEAVE....428
4.7.1 REEVING FRONT DRUM WIRE ROPE FOR CRANE....428
4.7.2 REEVING REAR DRUM WIRE ROPE TO AUXILIARY SHEAVE....430
4.7.3 REEVING REAR DRUM WIRE ROPE....431
4.8 ERECTING ATTACHMENT....433
4.8.1 CONNECTING SAFETY DEVICE....433
4.8.2 CHECKING SAFETY DEVICE....433
4.8.3 CONFIRMATION BEFORE ERECTING ATTACHMENT....433
4.8.4 ERECTING ATTACHMENT....434
4.8.5 CHECK BEFORE STARTING WORK....435
5. DISASSEMBLY OF THE MACHINE....437
5.1 LOWERING ATTACHMENT....439
5.1.1 LOWERING ATTACHMENT....439
5.2 DISCONNECTING WIRING FOR SAFETY DEVICE....440
5.3 REMOVING BOOM GUY LINE....441
5.3.1 INSTALLATION OF UPPER SPREADER TO BOOM BASE....441
5.3.2 DISASSEMBLING THE JIB....442
5.3.3 REMOVAL OF BOOM GUY LINE....443
5.4 COUNTERWEIGHT REMOVAL....444
5.4.1 DISCONNECT BOOM BASE FROM INSERT BOOM....444
5.4.2 PREPARATIONS FOR OPERATION....445
5.4.3 REMOVAL OF COUNTERWEIGHTS....449
5.5 DISASSEMBLING ATTACHMENT....455
5.5.1 REMOVING UPPER AND INSERT BOOMS....455
5.6 CRAWLER REMOVAL....456
5.6.1 SETTING TRANSLIFTER (Refer to 4.1)....457
5.6.2 REMOVING CRAWLERS....457
5.7 LOADING BASE MACHINE....462
5.7.1 LOADING BASE MACHINE ON TRAILER....462
5.7.2 LOWERING BOOM BASE....463
5.7.3 LOWERING GANTRY....464
5.7.4 FOLDING TRANSLIFTER....465
5.7.5 CAUTION WHEN TRANSPORTING BASE MACHINE....466
5.7.6 HANDLING OF TRAVELING KIT....466
6. WIRE ROPE....467
6.1 UNREELING WIRE ROPE....467
6.1.1 UNREELING WIRE ROPE....467
6.1.2 WINDING WIRE ROPE ONTO DRUM....468
6.1.3 INSTALLING THE ROPES....470
6.1.4 SPECIFICATION OF WIRE ROPE....471
6.1.5 WIRE ROPE LENGTH....472
7. MAINTENANCE....475
7.1 INSPECTIONS....480
7.1.1 UPPER STRUCTURE PARTS AND DEVICES TO BE INSPECTED....480
7.1.1.1 UPPER STRUCTURE INSPECTIONS-DAILY OR EVERY 8 HOURS....482
7.1.1.2 UPPER STRUCTURE INSPECTIONS-MONTHLY OR EVERY 100 HOURS....487
7.1.1.3 UPPER STRUCTURE INSPECTIONS-SEMI-ANNUALLY OR EVERY 600 HOURS....491
7.1.1.4 UPPER STRUCTURE INSPECTIONS-WEEKLY OR EVERY 50 HOURS....492
7.1.2 LOWER STRUCTURE PARTS AND DEVICE TO BE INSPECTED....494
7.1.2.1 LOWER STRUCTURE INSPECTIONS-DAILY OR EVERY 8 HOURS....495
7.1.2.2 LOWER STRUCTURE INSPECTIONS-MONTHLY OR EVERY 100 HOURS....496
7.1.2.3 LOWER STRUCTURE INSPECTIONS-QUARTERLY OR EVERY 250 HOURS....498
7.1.2.4 LOWER STRUCTURE INSPECTIONS-SEMI-ANNUALLY OR EVERY 600 HOURS....499
7.1.3 ATTACHMENT PARTS AND DEVICES TO BE INSPECTED....500
7.1.3.1 ATTACHMENT INSPECTIONS-DAILY OR EVERY 8 HOURS....502
7.1.4 REPLACEMENT STANDARDS FOR WIRE ROPE....505
7.2 OIL/GREASE SUPPLY AND WATER SERVICE....508
7.2.1 UPPER STRUCTURE LUBRICATION (INCLUDING WATER SUPPLY)....510
7.2.2 LOWER STRUCTURE LUBRICATION....512
7.2.3 ATTACHMENT STRUCTURE LUBRICATION....514
7.2.4 GREASE....516
7.2.5 ENGINE OIL....523
7.2.6 FUEL....524
7.2.7 COOLANT....525
7.2.8 HYDRAULIC OIL....527
7.2.9 GEAR OIL....529
7.3 CLEANING/WASHING/CHANGING FILTER ELEMENT AND STRAINER....534
7.4 BATTERY INSPECTION....545
7.5 LOCATION AND USE OF FUSE....548
7.6 OPERATION UNDER UNUSUAL CONDITIONS....550
7.7 MACHINE STORAGE....552
7.8 TIGHTENING TORQUE VALUES....553
7.9 SECURITY PARTS TO BE REPLACED PERIODICALLY....555
7.10 ADJUSTMENT....556
7.10.1 ADJUSTMENT OF FRONT AND REAR DRUM LOCKS....556
7.10.2 ADJUSTMENT OF BOOM DRUM LOCK....557
7.10.3 ADJUSTMENT OF THIRD DRUM LOCK....558
7.10.4 CRAWLER SHOES ADJUSTMENT....559
7.11 CONSUMABLE PARTS LIST....560
8. REFERENCE MATERIALS....565
8.1 SPECIFICATION....565
8.1.1 PERFORMANCE....565
8.1.2 OUTSIDE DIMENSIONS....565
8.2 DIMENSIONS AND WEIGHT OF EACH PARTS....567
8.2.1 BASE MACHINE....567
8.2.2 COUNTERWEIGHT....569
8.2.3 ATTACHMENT....570
8.3 SYSTEM SCHEMATIC....573
8.3.1 HYDRAULIC SYSTEM SCHEMATIC....573
8.3.2 ELECTRICAL WIRING SCHEMATIC....575
9. INITIAL ASSEMBLY OF THE MACHINE....587
9.1 UPPER STRUCTURE (WITH CARBODY) LIFTING PROCEDURES....588
9.1.1 INSTALLATION....588
9.2 LOADING/UNLOADING THE MACHINE FROM/ONTO A TRAILER....589
9.2.1 LOADING ONTO A TRAILER....589
9.2.2 UNLOADING FROM A TRAILER....589
9.3 INSTALLATION OF CRAWLER....589
9.4 INSTALLATION OF GANTRY TO REVOLVING FRAME....590
9.5 INSTALLATION OF BOOM BASE....593
9.5.1 INSTALLATION OF BOOM BASE....593
9.6 INSTALLATION OF BACKSTOP....595
9.7 INSTALLING UPPER AND LOWER SPREADER....596
S3GK22003ZO04 - KOBELCO CK1200 Crawler Crane Parts Manual....603
COVER....603
CONTENTS....609
CONTROL SYSTEM....0
CONTROL ASSY....620
CONTROL LEVER ASSY (BOOM / MAIN / AUX.)....624
CONTROL LEVER ASSY (SWING)....628
CONTROL LEVER ASSY (PROPEL)(PROPEL)....632
REMOTE CONTROL V.INSTAL (BOOM / FRONT / REAR)....634
SWING LOCK ASSY (SWING)....636
BRAKE PEDAL ASSY....638
GRIP ASSY....642
FLOOR PLATE ASSY....644
GRIP ASSY (BOOM)....646
PANEL ASSY....648
PANEL ASSY (LEFT STAND)....650
PANEL ASSY (LEFT STAND)....652
PANEL ASSY....654
PANEL ASSY (BYPASS SWITCH)....656
LAMP & SWITCH ASSY (WITH FREE FALL)....658
DRUM LOCK ASSY (FRONT / REAR)....660
DRUM LOCK ASSY (BOOM)....662
LUB.LINES (FRONT / REAR)....666
LUB. LINES (BOOM)....668
MONITOR INSTAL....670
WINCH SYSTEM (WITH BRAKE)....0
WINCH INSTAL ASSY (WITH FREE FALL)....672
WINCH ASSY (FRONT / WITH FREE FALL)....676
WINCH ASSY (REAR / WITH FREE FALL)....678
WINCH ASSY (WITH FREE FALL)....680
REDUCTION UNIT ASSY....682
BRAKE INSTAL (WITH FREE FALL)....684
3-SECTION VALVE HYD. LINES....686
4-SECTION VALVE INSTAL (WITH FREE FALL)....688
HYD. LINES RETURN (WITH FREE FALL)....690
CONTROL LINES, FLOOR (WITH FREE FALL)....692
BOOM HOIST SYSTEM....0
WINCH INSTAL ASSY (BOOM)....694
WINCH INSTAL (BOOM HOIST)....698
SWING SYSTEM....0
SWING REDUCT INSTAL....702
SWING REDUCT INSTAL....704
SWING REDUCTION ASSY....706
SWING BEARING ASSY....710
SWING BEARING LUB. LINES....712
LINES....0
PUMP HYD. LINES (SUCTION)....714
PUMP HYD. LINES (CONTROL)....718
PUMP HYD. LINES (DELIVERY)....722
RIGHT DECK HYD. LINES....724
MAIN VALVE HYD. LINES....732
GANTRY VALVE LINES....734
SWING CONTROL LINES....738
ACCUMLATOR HYD. LINES....742
FLOOR CONTROL HYD. LINES....744
FLOOR CONTROL HYD. LINES....750
RETURN DRAIN HYD. LINES....752
RETURN BLOCK HYD. LINES....756
SWING MOTOR HYD. LINES....758
SWING MOTOR HYD. LINES....760
2-SECTIONS VALVE (2nd TRAVEL SPEED)(SWING BRAKE)....762
2-SECTIONS VALVE....766
4-SECTIONS VALVE (MOTOR BRAKE)....768
5-SECTIONS VALVE (LIMIT STOP)....770
8-SECTIONS VALVE (WITH SHUTTLE VALVE)....772
WINCH HYD. LINES (FOR FRONT & REAR DRUM)....774
WINCH HYD. LINES (FOR BOOM)....778
OIL COOLER HYD. LINES....780
CLAMP ASSY....782
LOW. HYD LINES....786
SWIVEL JOINT INSTAL....790
SWIVEL JOINT....794
HYD. OIL TANK ASSY....796
HYD. OIL COOLING LINES....800
CONNECTOR ASSY....804
CONNECTOR ASSY....806
HYD. LINE, HEAT UP (OPTION)....808
POWER PLANT....0
POWER PLANT ASSY....812
PUMP INSTAL....818
POWER DIVIDER....820
MUFFLER INSTAL....824
FUEL LINES....826
RADIATOR INSTAL....830
AIR CLEANER INSTAL....832
FUEL TANK ASSY....834
ELECTRIC SYSTEM....0
ELEC ASSY (R.H. DECK)....838
ELEC ASSY (REV. FRAME)....844
ELEC ASSY (FLOOR PLATE)....846
RELAY BOX ASSY....850
ELEC ASSY (L.H. GUARD)....852
ELEC ASSY (CAB)....854
ELEC ASSY (L.H. DECK)....858
WASHER TANK ASSY....864
BATTERY INSTAL....866
JUNCTION BOX ASSY....868
RELAY ASSY....870
HARNESS ASSY (FOR HEAT UP / OPTION)....872
CAB / GUARD / PLATFORM....0
CAB INSTAL....874
CAB ASSY....878
DOOR ASSY....886
RUBBER SHEET INSTAL (OPERATOR’S ROOM)....892
LOCK ASSY....894
SUN VISOR ASSY....896
ROLL BLIND....898
SASH ASSY....900
R.H. GUARD INSTAL....902
R.H. GUARD ASSY....906
L.H. GUARD INSTAL....912
L.H. GUARD ASSY....916
L.H. GUARD ASSY....920
L.H. GUARD ASSY....922
INSULATION ASSY....924
INSULATION ASSY (L.H. GUARD)....928
DRUM GUARD ASSY (FRONT / REAR)(FRONT / REAR)....930
SWING BEARING COVER....934
UNDER COVER ASSY....936
R.H. DECK INSTAL....938
R.H. DECK INSTAL (UNDER OF CAB)....942
STEP ASSY....944
L.H. DECK INSTAL....946
BOOM DRUM COVER INSTAL....950
COVER ASSY (SWING FRAME)....952
COVER ASSY....954
LOWER SYSTEM....0
PROPEL MOTOR ASSY....956
REDUCT ASSY, PROPEL....958
IDLER ASSY....960
IDLER ADJUST ASSY....962
ROLLER ASSY....964
LOWER ROLLER ASSY....966
UPPER ROLLER ASSY....967
MOTOR COVER ASSY....968
LINK ASSY....970
CYLINDER ASSY....972
STEP ASSY....974
ADAPTER ASSY....976
SHOE ASSY....978
TRANSLIFTER ASSY....980
TRANSLIFTER HYD. LINES....984
CRAWLER REMOVAL DEVICE....988
ELEC ASSY....990
CRANE ATTACHMENT....0
LOW. BOOM ASSY....992
UPP. BOOM ASSY....994
INSERT BOOM....996
SPECIAL INSERT BOOM....1000
IDLER SHEAVE ASSY....1002
BOOM POINT SHEAVE ASSY ....1004
IDLER SHEAVE ASSY....1008
SPREADER GUIDE ASSY....1010
GUY CABLE....1012
GUY CABLE....1014
GUIDE ROLLER ASSY (FOR INSERT BOOM)....1016
UPPER SPREADER ASSY....1018
LOW. SPREADER ASSY....1020
BOOM BACK STOP ASSY....1022
BACKSTOP ASSY....1024
JIB ASSY....1026
STRUT ASSY....1028
INSERT JIB....1030
JIB GUY CABLE....1032
JIB POINT SHEAVE ASSY....1034
AUX. SHEAVE ASSY....1036
GUIDE ROLLER ASSY (FOR INSERT JIB)....1038
WIRE ROPE ASSY (MAIN)(LUFFING AUX.)(CRANE AUX.)(THIRD)(BOOM)(LUFFING JIB RAISE)....1040
GANTRY....0
GANTRY ASSY....1044
SUB GANTRY ASSY....1048
GANTRY LUB. LINES....1052
TAGLINE (OPTION)....0
TAGLINE HYD. LINES....1056
TAGLINE ASSY....1060
TAGLINE GUIDE ASSY....1062
GUIDE SHEAVE ASSY....1064
ELEC. ASSY....1066
REEVING WINCH (OPTION)....0
WINCH HYD. LINES....1068
REEVING WINCH INSTAL....1072
REEVING WINCH ASSY....1074
GUIDE ROLLER ASSY....1076
ROLLER ASSY....1080
ROLLER ASSY....1082
ROLLER ASSY....1084
ROLLER ASSY (FOR UPP. BOOM / OPTION)....1086
LUFFING....0
BOOM ASSY, LUFFING....1088
BOOM ASSY, UPP....1090
SHEAVE ASSY, B.POINT....1092
IDLER SHEAVE ASSY (BOOM)....1094
STRUT ASSY, JIB....1096
STRUT SHEAVE ASSY (FRONT STRUT)....1098
STRUT ASSY, JIB....1100
SHEAVE ASSY....1102
INSERT BOOM ASSY....1104
ROLLER ASSY, GUIDE....1106
LOWER JIB ASSY....1108
JIB BACKSTOP ASSY....1110
AUX. SHEAVE ASSY....1112
UPP BOOM ASSY....1114
ROPE SOCKET ASSY....1116
IDLER SHEAVE ASSY....1118
CABLE ROLLER ASSY (FOR UPP. BOOM)....1120
B.POINT SHEAVE ASSY....1122
JIB BACKSTOP ASSY....1124
JIB BACKSTOP ASSY....1126
HYD.OIL TANK INSTAL....1128
HYD.OIL TANK ASSY....1130
TRAVELING KIT....1132
GUY CABLE ASSY (LUFFING BOOM BASE)....1134
GUY CABLE ASSY (LUFFING JIB BASE)....1136
GUY CABLE ASSY (30mm)....1138
THIRD (OPTION)....0
CONTROL ASSY....1140
CONTROL ASSY....1142
BRAKE PEDAL ASSY....1144
DRUM LOCK ASSY....1146
DRUM LOCK LUB. LINES....1148
POTENTIOMETER INSTAL (FOR THIRD DRUM)....1150
WINCH INSTAL....1152
WINCH ASSY....1154
WINCH ASSY....1156
REDUCTION UNIT ASSY....1158
HYD. LINES ASSY....1160
HYD. LINES WINCH....1162
HYD. LINES ASSY....1166
VALVE INSTAL (4-SECTION VALVE)....1168
VALVE INSTAL (5-SECTION VALVE)....1170
VALVE INSTAL (8-SECTION VALVE)....1172
VALVE INSTAL (ADD. PARTS)....1174
ACCUMLATOR INSTAL....1176
CONTROL LINES, FLOOR....1178
HYD. LINES ASSY....1180
HYD. LINES ASSY (WITH FREE FALL)....1182
PLUG ASSY (FREE LESS)(WITH FREE)....1186
GANTRY SHEAVE ASSY....1190
DRUM COVER ASSY....1194
HARNESS ASSY....1196
LABEL ASSY....1198
IDLER SHEAVE ASSY....1200
SAFETY DEVICE....0
SAFETY DEVICE HARNESS (FOR GANTRY)....1202
SAFETY DEVICE HARNESS (FOR BASE)....1206
SAFETY DEVICE HARNESS (FOR LOW. BOOM)(FOR UPP. BOOM)....1208
SAFETY DEVICE HARNESS (FOR JIB)....1212
SAFETY DEVICE HARNESS (FOR LUFFING)....1214
SAFETY DEVICE HARNESS (BOOM ANGLE DETECTOR)....1222
HOOK OVERHOIST L/S (FOR CRANE)....1224
HOOK OVERHOIST L/S ....1226
HOOK OVERHOIST LIMIT SWITCH (FOR AUX. SHEAVE & JIB)....1228
LIMIT SWITCH ASSY....1230
LIMIT SWITCH ASSY (BASE MACHINE SIDE)(BOOM SIDE)....1232
COUNTERWEIGHT / FRAME....0
COUNTERWEIGHT ASSY....1234
SWING ALARM LAMP ASSY....1236
REV. FRAME ASSY....1238
RUBBER INSTAL....1240
C/W REMOVAL DEVICE....1244
C/W REMOVAL DEVICE....1248
HYD LINES, GANTRY....1252
REMOTE CONTROL ASSY....1256
CONNECTOR ASSY....1258
LABEL....0
LABEL (FOR BASE MACHINE)....1260
LABEL ASSY(FOR BASE MACHINE)....1268
LABEL ASSY(FOR ATTACHMENT)....1270
LABEL ASSY(SWITCH PANEL)....1272
OTHERS....0
AIR CONDITIONER (INDOOR UNIT)....1274
AIR CONDITIONER (OUTDOOR UNIT)....1280
AIR CONDITIONER UNIT....1284
UPPER FINAL (COVER)....1288
UPPER FINAL (ENGINE CONTROL SWITCH)....1290
UPPER FINAL (BASE)....1292
UPPER FINAL....1294
UPPER FINAL (PEDAL COVER)....1296
UPPER FINAL (ANTI SLIP)....1298
SPARE PART KIT....1300
TOOL ASSY....1302
SEAT ASSY....1304
GUARD INSTAL (CAB LEFT WINDOW)....1306
WIPER INSTAL (FOR FRONT LOWER WINDOW / OPTION)....1308
WASHER TANK INSTAL (OPTION)....1310
CAMERA INSTAL (OPTION)....1312
BACK LIGHT (CAMERA OPTION)(BACK LIGHT / OPTION)....1316
MONITOR INSTAL (OPTION)....1320
HARNESS ASSY (OPTION)....1324
RADIO INSTAL (COVER)(RADIO OPTION)....1326
FOOT ACCELERATOR (RIGHT)(RIGHT & LEFT / OPTION)(LEFT / OPTION)....1328
CALL ASSY / ONE-WAY CALL (OPTION)....1332
AUX. PLATFORM....1334
AUX. PLATFORM (OPTION)....1338
TRAVELING KIT....1342
DRUM TURN SENSOR INSTAL....1344
SWITCH INSTAL (FOR DURM TURN SENSOR)....1346
DRUM TURN SENSOR GRIP INSTAL....1347
GRIP ASSY....1348
FAN ASSY N(OPTION)....1350
MIRROR INSTAL (OPTION)....1352
HOLDER ASSY....1354
DRUM LIGHT (OPTION)....1356
HEAD GUARD (OPTION)....1360
LAMP ASSY (OPTION)....1362
EXTINGUISHER INSTAL (OPTION)....1364
NOISE FILTER (FOR WIPER MOTOR)....1366
HANDRAIL INSTAL....1368
OVER PAYOUT PREVENTIVE DEVICE (OPTION)....1370
PEDAL SENSOR INSTAL (OPTION)....1374
BOOM CONTROL PEDAL INSTAL (BOOM HOIST / OPTION)....1376
LEVEL GAUGE INSTAL (OPTION)....1378
LIFE HAMMER INSTAL (OPTION)....1380
JIB CONTROL ASSY (FOR LUFFING)....1382
ELEC ASSY (OPTION)....1386
LIMIT SWITCH INSTAL (FOR PROPEL CONTROL LEVER / OPTION)....1390
INDEX OF PART NO.....1393
S5GK00004ZE01 - KOBELCO CK1200, CKE1100 Crawler Crane Workshop Manual....1416
COVER....1416
TABLE OF CONTENTS....1418
SAFETY....1426
1. SPECIFICATION....1438
1.1 SPECIFICATION....1440
1.1.1 PERFORMANCE....1440
1.1.2 OUTSIDE DIMENSIONS....1441
1.1.3 DIMENSIONS AND WEIGHT OF EACH PARTS....1443
1.1.4 STABILITY IN SWINGING AND TRAVELING....1449
2. MAINTENANCE STANDARDS TEST PROCEDURES....1452
2.1 MAINTENANCE STANDARD....1454
2.1.1 PIN, BUSHING, SPRING, LINING AND SHEAVE....1454
2.1.2 PROPEL DEVICE....1461
2.1.3 PROPEL BRAKE PLATE....1467
2.2 PERFORMANCE STANDARD AND TEST PROCEDURE....1468
2.2.1 OPERATING SPEED....1468
2.2.2 POINT AND METHOD OF MEASURING PRESSURE....1469
2.2.3 SLEWING RING....1474
3. GENERAL WORK STANDARD....1476
3.1 TIGHTENING TORQUE OF CAPSCREWS AND NUTS....1478
3.1.1 METRIC COARSE THREADS....1478
3.1.2 METRIC FINE THREADS....1478
3.1.3 COARSE THREDS UNC....1479
3.1.4 FINE THREADS UNF....1479
3.1.5 TIGHTENING TORQUE OF HYDRAULIC FITTINGS....1480
3.2 STANDARD PARTS....1482
3.2.1 BOLT....1482
3.2.2 O-RING....1483
3.2.3 BACK-UP RING....1484
3.2.4 BITE FITTING....1485
3.3 CONVERSION TABLE....1487
3.3.1 UNIT CONVERSION....1487
3.3.2 MILLIMETER : INCH CONVERSION TABLE....1488
3.3.3 METER-FOOT CONVERSION TABLE....1490
3.3.4 GRADIENT CONVERSION TABLE....1491
3.4 TABLE OF UNIT WEIGHT....1492
4. POWER TRAIN....1494
4.1 INTRODUCTION....1496
4.2 ENGINE....1498
4.2.1 INTRODUCTION....1498
4.2.2 REMOVAL....1498
4.2.3 REPAIR AND MAINTENANCE....1499
4.2.4 RE-INSTALLATION....1500
4.3 PUMP DRIVE ASSEMBLY....1503
4.3.1 INTRODUCTION....1503
4.3.2 REMOVAL....1503
4.3.3 DISASSEMBLING THE POWER DIVIDER....1505
4.3.4 CHECK AND REPAIR OF THE POWER DIVIDER....1506
4.3.5 ASSEMBLING THE POWER DIVIDER....1507
4.3.6 RE-INSTALLATION....1508
5. HYDRAULIC SYSTEM....1514
5.1 LOCATION OF MAIN HYDRAULIC COMPONENTS....1516
5.2 HYDRAULIC CIRCUITS AND COMPONENTS....1517
5.2.1 HYDRAULIC CIRCUIT....1517
5.2.2 COMPONENT SPECIFICATIONS....1521
5.2.3 LOCATION OF HYDRAULIC COMPONENTS....1525
5.3 HYDRAULIC SYSTEM....1535
5.3.1 PREFACE....1535
5.3.2 OUTLINE....1535
5.3.3 OIL FLOW FROM No.1 and No. 2 PUMPS....1536
5.3.4 OIL FLOW FROM No.3 AND No.4 PUMPS....1538
5.3.5 OIL FLOW FROM No.5 PUMPS (Control Pumps)....1540
5.3.6 OIL FLOW FROM No.6 PUMP (For Auxiliary Actuator Circuit)....1543
5.4 VALVES....1546
6. HOIST SYSTEM....1554
6.1 APPARATUS AND LOCATION OF COMPONENTS....1556
6.2 CONSTRUCTION AND FUNCTION....1557
6.2.1 HYDRAULIC SCHEMATIC....1557
6.2.2 LIFTING A LOAD....1559
6.2.3 HOLDING A RAISED LOAD....1561
6.2.4 LOWERING A LOAD (POWERED LOWERING)....1563
6.2.5 FREE FALL OPERATION....1565
6.2.6 FREE FALL ACCELERATION....1569
6.3 DRUM LOCK....1571
6.3.1 ASEEMBLY DRAWING....1571
6.3.2 ADJUSTMENT OF DRUM LOCK....1572
6.4 WINCH ASSEMBLY....1573
6.4.1 WINCH INSTAL....1573
6.4.2 WINCH ASSEMBLY / REDUCTION UNIT WITHOUT FREE FALL (STD.)....1574
6.4.3 WINCH ASSEMBLY WITH FREE FALL (OPT.)....1576
6.5 BRAKE PEDAL....1577
6.5.1 ASSEMBLY DRAWING....1577
6.5.2 ADJUSTING THE BRAKE PEDAL....1579
6.6 BLEEDING AIR FROM BRAKE CIRCUIT....1580
7. BOOM HOIST SYSTEM....1582
7.1 APPARATUS AND LOCATION OF COMPONENTS....1584
7.2 CONSTRUCTION AND FUNCTION....1586
7.2.1 HYDRAULIC SCHEMATIC....1586
7.2.2 RAISING THE BOOM....1587
7.2.3 NEUTRAL....1589
7.2.4 LOWERING THE BOOM....1591
7.3 BOOM DRUM LOCK....1593
7.3.1 ASSEMBLY DRAWING....1593
7.3.2 ADJUSTING THE BOOM DRUM LOCK....1594
7.4 DRUM AND REDUCTION UNIT....1595
7.4.1 BOOM WINCH ASSEMBLY....1595
7.4.2 BOOM DRUM AND REDUCTION UNIT ASSEMBLY....1597
8. SWING SYSTEM....1600
8.1 APPARATUS AND LOCATION OF COMPONENTS....1602
8.2 CONSTRUCTION AND FUNCTION....1603
8.2.1 HYDRAULIC SCHEMATIC....1603
8.2.2 SWING....1605
8.2.3 STOPPING....1608
8.3 SWING REDUCTION UNIT....1611
8.4 SWING BEARING....1613
8.5 SWING LOCK....1615
9. PROPEL SYSTEM....1616
9.1 LOCATION OF THE MAJOR COMPONENTS....1618
9.2 CONSTRUCTION AND FUNCTION....1619
9.2.1 HYDRAULIC SCHEMATIC....1619
9.2.2 PROPELLING (RIGHT SIDE FORWARD)....1621
9.2.3 STOPPING....1623
9.3 PROPEL REDUCTION UNIT....1625
9.3.1 MOTOR AND REDUCTION UNIT....1626
9.4 ADJUSTMENT....1628
10. ELECTRIC SYSTEM....1630
10.1 ELECTRICAL WIRING SCHEMATIC....1632
10.2 CONNECTOR LIST....1643
10.3 ARRANGEMENT OF ELECTRICAL PART....1695
10.3.1 ELECTRICAL PART OF CAB....1695
10.3.2 ELECTRICAL PART OF RIGHT DECK....1699
10.3.3 ELECTRICAL PART OF FLOOR PLATE & LEFT SIDE STAND PANEL....1707
10.3.4 ELECTRICAL PART OF REVOLVING FRAME....1712
10.3.5 ELECTRICAL PART OF LEFT DECK....1715
10.3.6 ELECTRICAL PART OF LEFT GUARD....1722
10.4 ELECTRICAL PART....1723
10.4.1 FUSE BOX (GG73E00004F1)....1723
10.4.2 WIPER CONTROL UNIT (2480U306)....1725
10.4.3 SWING FLASHER UNIT (2480U306)....1726
10.4.4 PRESSURE SWITCH (CONTROL PRESSURE CUT & FREE FALL) (GG52S00006P1) ....1727
10.4.5 PRESSURE SENSOR....1728
10.4.6 RELAY BOX (GG24E00024F1)....1730
10.4.6.1 ARRANGEMENT OF CONNECTOR....1730
10.4.6.2 RELAY BOX SCHEMATIC....1732
10.4.7 LEFT SIDE STAND PANEL....1735
10.5 TROUBLESHOOTING OF EXHAUST GAS THIRD REGULATION ENGINE....1739
10.5.1 FAILURE DIAGNOSIS FUNCTION....1739
10.5.2 HOW TO CHECK THE FAILURE CONTENTS....1740
10.5.3 CHECKING BLOWN-OFF DIAGNOSIS LAMPS....1745
10.5.4 ENGINE ECU....1746
11. LOAD SAFETY DEVICE....1750
11.1 PART NAMES AND FUNCTIONS....1752
11.1.1 FRONT VIEW....1752
11.1.2 CONFIGURATION OF SCREENS....1757
11.1.3 DATA TRANSMISSION BETWEEN CONTROLLER AND CARDS....1762
11.1.4 DETAILS OF INDICATORS ON MAIN DISPLAY SCREEN....1764
11.1.5 REAR VIEW....1768
11.1.6 ITEMS REQUIRED TO BE EXECUTED FOR REPLACEMENT OF CONTROLLER OR DATA CARD AND INSTRUCTIONS....1773
11.2 PREPARATION FOR USE....1774
11.3 TURN THE POWER ON....1775
11.4 UPGRADING PROGRAMS....1776
11.4.1 PROCEDURES....1776
11.4.2 UPGRADING OF INDICATION PROGRAMS....1778
11.4.3 UPGRADING OF CONTROL PROGRAMS....1781
11.5 STATUS CHECK....1783
11.5.1 SIGNAL CHECK....1784
11.5.2 OPERATION PROGRESS....1786
11.5.3 COMMUNICATION DATA....1789
11.5.4 INDICATION OF ADJUSTMENT VALUE....1790
11.5.4.1 ANGLE SENSOR ADJUSTMENT VALUE....1791
11.5.4.2 LOAD CELL ZERO POINT ADJUSTMENT VALUE....1792
11.5.4.3 ADJUSTMENT VALUE OF LOAD CELL FOR LINE-PULL....1793
11.5.4.4 RESULT OF MANUFACTURE ADJUSTMENTS "NO LOAD" AND "SOME LOAD" ....1794
11.5.4.5 RESULT OF LOAD ADJUSTMENTS "NO LOAD" AND "SOME LOAD"....1795
11.5.4.6 ADJUSTMENT VALUE OF WORKING RADIUS....1796
11.5.4.7 ALTERATION OF ADJUSTED VALUE....1797
11.5.4.8 DELETION OF ADJUSTED VALUE....1798
11.5.5 LOAD RECORD....1799
11.5.6 TROUBLE RECORD....1802
11.5.7 CHOICE OF LANGUAGE (CKE SERIES ONLY)....1804
11.5.8 LOAD RECORD (LOAD RECORD IN THE MAIN MENU)....1805
11.6 ADJUSTMENTS....1806
11.6.1 REMOVING THE INNER PANEL....1806
11.6.2 ADJUSTMENT....1807
11.6.2.1 ANGLE SENSOR ADJUSTMENT....1810
11.6.2.2 LOAD CELL ZERO POINT ADJUSTMENT....1814
11.6.2.3 LOAD-LESS ADJUSTMENT & SOME LOAD ADJUSTMENT....1816
11.6.2.4 LVL ADJUSTMENT (LVL SETTING)....1822
11.6.2.5 RADIUS ADJUSTMENT....1825
11.6.3 LOAD ADJUSTMENT....1827
11.6.4 ADJUSTMENT DATA COPY (INITIALIZATION)....1829
11.6.4.1 READING OF THE ADJUSTMENT DATA....1831
11.6.4.2 WRITING OF ADJUSTMENT DATA....1833
11.6.4.3 INITIALIZATION OF ADJUSTMENT DATA....1834
11.6.5 VERSION CHECK....1835
11.7 ERROR CODE (ABNORMALITY DETECTION) AND COUNTERMEASURES....1836
11.8 CONTROL OUTPUT....1838
11.9 RELEASES....1850
11.9.1 RELEASE FUNCTION....1850
11.9.1.1 CRANE RELEASE CHART....1850
11.9.1.2 ALARM SOUND....1856
11.9.1.3 EXTERNAL INDICATOR LAMPS IN RELEASE CONDITION....1857
11.10 MECHANICAL SPECIFICATION....1858
11.10.1 ENVIRONMENTAL PERFORMANCE PARAMETERS....1858
11.10.2 LOAD CELL (CRANE)....1859
11.10.3 ANGLE SENSOR....1860
11.10.4 CONTROLLER....1861
11.10.4.1 MODEL NAME....1861
11.10.4.2 SYSTEM INPUT/OUTPUT....1861
11.10.4.3 MONITOR DISPLAY....1863
11.10.4.4 OPERATION SWITCH....1863
11.10.4.5 INTERNAL PROCESSING SYSTEM....1863
11.10.4.6 MEMORY....1863
11.10.4.7 EXTERNAL STORAGE ELEMENT....1864
11.10.4.8 OTHERS....1864
11.11 EXTERNAL DIMENSIONS....1865
11.12 ELECTRIC SCHEMATIC DIAGRAM....1866
11.12.1 CRANE TYPE....1866
11.12.2 LUFFING TYPE....1867
11.13 CONTROLLER MALFUNCTION EMERGENCY MEASURES....1868
11.14 LOAD SAFETY DEVICE CHECK PROCEDURES....1869
12. GAUGE CLUSTER....1870
12.1 CONFIGURATION OF DISPLAY....1872
12.2 PRIORITY....1873
12.3 STATUS DISPLAY....1875
12.4 FAULT LOG DISPLAY....1885
13. TOTAL CONTROLLER....1890
13.1 ARRANGEMENT OF TOTAL CONTROLLER....1892
13.2 COMPOSITION OF SYSTEM....1893
13.2.1 OUTPUT RELATION TO CONTROLLER....1894
13.3 FUNCTION OF TOTAL CONTROLLER....1895
13.4 TOTAL CONTROLLER (HARDWARE)....1920
13.4.1 OUTLINE....1920
13.4.2 SPECIFICATIONS OF TOTAL CONTROLLER OUTPUT....1921
13.4.3 DETAILS OF TOTAL CONTROLLER CONNECTOR....1925
13.4.4 ARRANGEMENT OF TOTAL CONTROLLER CONNECTOR PIN....1926
13.4.5 PROPORTIONAL SOLENOID VALVE MEASURING POSITION....1933
13.5 ADJUSTMENT OF TOTAL CONTROLLER....1934
13.5.1 NECESSITY OF ADJUSTMENT....1934
13.5.2 ADJUSTMENT PROCEDURES OF TOTAL CONTROLLER....1934
13.5.2.1 OPTION SETTING....1934
13.5.2.2 ADJUSTMENT OF HAND THROTTLE AND FOOT THROTTLE....1936
13.5.2.3 ENGINE SPEED ADJUSTMENT....1937
13.5.2.4 WHEN ADJUSTMENT OF TOTAL CONTROLLER IS IMPOSSIBLE....1938
13.5.2.5 INITIAL ADJUSTMENT OF LIFTING HEIGHT GAUGE....1939
14. AIR CONDITIONER....1942
14.1 OPERATION ITEMS....1944
14.2 SAFETY MONITOR FUNCTIONS....1945
14.3 DISASSEMBLY AND ASSEMBLY PROCEDURE....1948
14.3.1 SPECIAL CONSIDERATIONS DURING REPLACEMENT....1948
14.3.2 INTERIOR UNIT....1950
14.3.2.1 CASE DISASSEMBLY....1950
14.3.2.2 THERMOSTAT REPLACEMENT....1953
14.3.2.3 EVAPORATOR OR EXPANSION VALVE REPLACEMENT....1954
14.3.2.4 HEATER CORE REPLACEMENT....1955
14.3.2.5 INTAKE DUMPER ACTUATOR REPLACEMENT....1956
14.3.2.6 WATER VALVE ACTUATOR OR WATER VALVE REPLACEMENT....1957
14.3.2.7 MODE ACTUATOR REPLACEMENT....1958
14.3.2.8 BLOWER MOTOR ASSEMBLY REPLACEMENT....1958
14.4 OPERATIONAL PRECAUTIONS....1959
14.5 INSPECTION AND MAINTENANCE....1960
14.5.1 INSPECTION/MAINTENANCE LIST....1960
14.5.2 INSPECTION/MAINTENANCE PROCEDURES....1960
14.6 ELECTRIC SYSTEM SCHEMATIC....1964
S5GK00004ZE03 - KOBELCO CK1200, CKE1100 Crawler Crane SHOP MANUAL....1966
COVER....1966
TABLE OF CONTENTS....1968
SAFETY....1976
1. SPECIFICATION....1988
1.1 SPECIFICATION....1990
1.1.1 PERFORMANCE....1990
1.1.2 OUTSIDE DIMENSIONS....1991
1.1.3 DIMENSIONS AND WEIGHT OF EACH PARTS....1993
1.1.4 STABILITY IN SWINGING AND TRAVELING....1999
2. MAINTENANCE STANDARDS TEST PROCEDURES....2002
2.1 MAINTENANCE STANDARD....2004
2.1.1 PIN, BUSHING, SPRING, LINING AND SHEAVE....2004
2.1.2 PROPEL DEVICE....2011
2.1.3 PROPEL BRAKE PLATE....2017
2.2 PERFORMANCE STANDARD AND TEST PROCEDURE....2018
2.2.1 OPERATING SPEED....2018
2.2.2 POINT AND METHOD OF MEASURING PRESSURE....2019
2.2.3 SLEWING RING....2024
3. GENERAL WORK STANDARD....2026
3.1 TIGHTENING TORQUE OF CAPSCREWS AND NUTS....2028
3.1.1 METRIC COARSE THREADS....2028
3.1.2 METRIC FINE THREADS....2028
3.1.3 COARSE THREDS UNC....2029
3.1.4 FINE THREADS UNF....2029
3.1.5 TIGHTENING TORQUE OF HYDRAULIC FITTINGS....2030
3.2 STANDARD PARTS....2032
3.2.1 BOLT....2032
3.2.2 O-RING....2033
3.2.3 BACK-UP RING....2034
3.2.4 BITE FITTING....2035
3.3 CONVERSION TABLE....2037
3.3.1 UNIT CONVERSION....2037
3.3.2 MILLIMETER : INCH CONVERSION TABLE....2038
3.3.3 METER-FOOT CONVERSION TABLE....2040
3.3.4 GRADIENT CONVERSION TABLE....2041
3.4 TABLE OF UNIT WEIGHT....2042
4. POWER TRAIN....2044
4.1 INTRODUCTION....2046
4.2 ENGINE....2048
4.2.1 INTRODUCTION....2048
4.2.2 REMOVAL....2048
4.2.3 REPAIR AND MAINTENANCE....2049
4.2.4 RE-INSTALLATION....2050
4.3 PUMP DRIVE ASSEMBLY....2053
4.3.1 INTRODUCTION....2053
4.3.2 REMOVAL....2053
4.3.3 DISASSEMBLING THE POWER DIVIDER....2055
4.3.4 CHECK AND REPAIR OF THE POWER DIVIDER....2056
4.3.5 ASSEMBLING THE POWER DIVIDER....2057
4.3.6 RE-INSTALLATION....2058
5. HYDRAULIC SYSTEM....2064
5.1 LOCATION OF MAIN HYDRAULIC COMPONENTS....2066
5.2 HYDRAULIC CIRCUITS AND COMPONENTS....2067
5.2.1 HYDRAULIC CIRCUIT....2067
5.2.2 COMPONENT SPECIFICATIONS....2071
5.2.3 LOCATION OF HYDRAULIC COMPONENTS....2075
5.3 HYDRAULIC SYSTEM....2086
5.3.1 PREFACE....2086
5.3.2 OUTLINE....2086
5.3.3 OIL FLOW FROM No.1 and No. 2 PUMPS....2087
5.3.4 OIL FLOW FROM No.3 AND No.4 PUMPS....2089
5.3.5 OIL FLOW FROM No.5 PUMPS (CONTROL PUMPS)....2092
5.3.6 OIL FLOW FROM No.6 PUMP (FOR AUXILIARY ACTUATOR CIRCUIT)....2095
5.4 VALVES....2098
6. HOIST SYSTEM....2106
6.1 APPARATUS AND LOCATION OF COMPONENTS....2108
6.2 CONSTRUCTION AND FUNCTION....2109
6.2.1 HYDRAULIC SCHEMATIC....2109
6.2.2 LIFTING A LOAD....2111
6.2.3 HOLDING A RAISED LOAD....2113
6.2.4 LOWERING A LOAD (POWERED LOWERING)....2115
6.2.5 FREE FALL OPERATION....2117
6.2.6 FREE FALL ACCELERATION....2121
6.3 DRUM LOCK....2123
6.3.1 ASEEMBLY DRAWING....2123
6.3.2 ADJUSTMENT OF DRUM LOCK....2124
6.4 WINCH ASSEMBLY....2125
6.4.1 WINCH INSTAL....2125
6.4.2 WINCH ASSEMBLY / REDUCTION UNIT WITHOUT FREE FALL (STD.)....2126
6.4.3 WINCH ASSEMBLY WITH FREE FALL (OPT.)....2128
6.5 BRAKE PEDAL....2129
6.5.1 ASSEMBLY DRAWING....2129
6.5.2 ADJUSTING THE BRAKE PEDAL....2131
6.6 BLEEDING AIR FROM BRAKE CIRCUIT....2132
7. BOOM HOIST SYSTEM....2134
7.1 APPARATUS AND LOCATION OF COMPONENTS....2136
7.2 CONSTRUCTION AND FUNCTION....2138
7.2.1 HYDRAULIC SCHEMATIC....2138
7.2.2 RAISING THE BOOM....2139
7.2.3 NEUTRAL (MAINTAINING THE BOOM POSITION)....2141
7.2.4 LOWERING THE BOOM....2143
7.3 BOOM DRUM LOCK....2145
7.3.1 ASSEMBLY DRAWING....2145
7.3.2 ADJUSTING THE BOOM DRUM LOCK....2146
7.4 DRUM AND REDUCTION UNIT....2147
7.4.1 BOOM WINCH ASSEMBLY....2147
7.4.2 BOOM DRUM AND REDUCTION UNIT ASSEMBLY....2149
8. SWING SYSTEM....2152
8.1 APPARATUS AND LOCATION OF COMPONENTS....2154
8.2 CONSTRUCTION AND FUNCTION....2155
8.2.1 HYDRAULIC SCHEMATIC....2155
8.2.2 SWING....2157
8.2.3 STOPPING....2160
8.3 SWING REDUCTION UNIT....2163
8.4 SWING BEARING....2165
8.5 SWING LOCK....2167
9. PROPEL SYSTEM....2168
9.1 LOCATION OF THE MAJOR COMPONENTS....2170
9.2 CONSTRUCTION AND FUNCTION....2171
9.2.1 HYDRAULIC SCHEMATIC....2171
9.2.2 PROPELLING (RIGHT SIDE FORWARD)....2173
9.2.3 STOPPING....2175
9.3 PROPEL REDUCTION UNIT....2177
9.3.1 MOTOR AND REDUCTION UNIT....2179
9.4 ADJUSTMENT....2181
10. ELECTRIC SYSTEM....2182
10.1 ELECTRICAL WIRING SCHEMATIC....2184
10.2 CONNECTOR LIST....2195
10.3 ARRANGEMENT OF ELECTRICAL PART....2247
10.3.1 ELECTRICAL PART OF CAB....2247
10.3.2 ELECTRICAL PART OF RIGHT DECK....2251
10.3.3 ELECTRICAL PART OF FLOOR PLATE & LEFT SIDE STAND PANEL....2259
10.3.4 ELECTRICAL PART OF REVOLVING FRAME....2264
10.3.5 ELECTRICAL PART OF LEFT DECK....2267
10.3.6 ELECTRICAL PART OF LEFT GUARD....2274
10.3.7 HARNESS PART NUMBER LIST (ALL MODELS)....2275
10.4 ELECTRICAL PART....2277
10.4.1 LOCATION AND USE OF FUSE....2277
10.4.2 FUSE BOX (GG73E00004F1)....2279
10.4.3 WIPER CONTROL UNIT (2480U306)....2281
10.4.4 SWING FLASHER UNIT (2480U306)....2282
10.4.5 PRESSURE SWITCH (CONTROL PRESSURE CUT & FREE FALL) (GG52S00006P1)....2283
10.4.6 PRESSURE SENSOR....2284
10.4.7 RELAY BOX (GG24E00024F1)....2286
10.4.8 LEFT SIDE STAND PANEL....2291
10.5 TROUBLESHOOTING OF EXHAUST GAS THIRD REGULATION ENGINE....2295
10.5.1 FAILURE DIAGNOSIS FUNCTION....2295
10.5.2 HOW TO CHECK THE FAILURE CONTENTS....2296
10.5.3 CHECKING OF DIAGNOSIS LAMP FUNCTION....2301
10.5.4 ENGINE ECU....2302
11. LOAD SAFETY DEVICE....2306
11.1 PART NAMES AND FUNCTIONS....2308
11.1.1 FRONT VIEW....2308
11.1.2 CONFIGURATION OF SCREENS....2313
11.1.3 DATA TRANSMISSION BETWEEN CONTROLLER AND CARDS....2318
11.1.4 DETAILS OF INDICATORS ON MAIN DISPLAY SCREEN....2320
11.1.5 REAR VIEW....2324
11.1.6 ITEMS REQUIRED TO BE EXECUTED FOR REPLACEMENT OF CONTROLLER OR DATA CARD AND INSTRUCTIONS....2329
11.2 PREPARATION FOR USE....2330
11.3 TURN THE POWER ON....2331
11.4 UPGRADING PROGRAMS....2332
11.4.1 PROCEDURES....2332
11.4.2 UPGRADING OF INDICATION PROGRAMS....2334
11.4.3 UPGRADING OF CONTROL PROGRAMS....2337
11.5 STATUS CHECK....2339
11.5.1 SIGNAL CHECK....2340
11.5.2 OPERATION PROGRESS....2342
11.5.3 COMMUNICATION DATA....2345
11.5.4 INDICATION OF ADJUSTMENT VALUE....2346
11.5.5 TROUBLE RECORD....2355
11.5.6 CHOICE OF LANGUAGE (CKE SERIES ONLY)....2357
11.5.7 LOAD RECORD (LOAD RECORD IN THE MAIN MENU)....2358
11.6 ADJUSTMENTS....2359
11.6.1 REMOVING THE INNER PANEL....2359
11.6.2 ADJUSTMENT....2360
11.6.3 LOAD ADJUSTMENT....2381
11.6.4 ADJUSTMENT DATA COPY (INITIALIZATION)....2383
11.6.5 VERSION CHECK....2389
11.7 ERROR CODE (ABNORMALITY DETECTION) AND COUNTERMEASURES....2390
11.8 CONTROL OUTPUT....2394
11.9 RELEASES....2406
11.9.1 RELEASE FUNCTION....2406
11.10 MECHANICAL SPECIFICATION....2414
11.10.1 ENVIRONMENTAL PERFORMANCE PARAMETERS....2414
11.10.2 LOAD CELL (CRANE)....2415
11.10.3 ANGLE SENSOR....2416
11.10.4 CONTROLLER....2417
11.11 EXTERNAL DIMENSIONS....2421
11.12 ELECTRIC SCHEMATIC DIAGRAM....2422
11.12.1 CRANE TYPE....2422
11.12.2 LUFFING TYPE....2423
11.13 CONTROLLER MALFUNCTION EMERGENCY MEASURES....2424
11.14 LOAD SAFETY DEVICE CHECK PROCEDURES....2425
12. GAUGE CLUSTER....2426
12.1 CONFIGURATION OF DISPLAY....2428
12.2 PRIORITY....2429
12.3 STATUS DISPLAY....2431
12.4 FAULT LOG DISPLAY....2441
13. TOTAL CONTROLLER....2446
13.1 ARRANGEMENT OF TOTAL CONTROLLER....2448
13.2 COMPOSITION OF SYSTEM....2449
13.2.1 OUTPUT RELATION TO CONTROLLER....2450
13.3 FUNCTION OF TOTAL CONTROLLER....2451
13.4 TOTAL CONTROLLER (HARDWARE)....2476
13.4.1 OUTLINE....2476
13.4.2 SPECIFICATIONS OF TOTAL CONTROLLER OUTPUT....2477
13.4.3 DETAILS OF TOTAL CONTROLLER CONNECTOR....2481
13.4.4 ARRANGEMENT OF TOTAL CONTROLLER CONNECTOR PIN....2482
13.4.5 PROPORTIONAL SOLENOID VALVE MEASURING POSITION (VOLTAGE)....2489
13.5 ADJUSTMENT OF TOTAL CONTROLLER....2491
13.5.1 NECESSITY OF ADJUSTMENT....2491
13.5.2 ADJUSTMENT PROCEDURES OF TOTAL CONTROLLER....2491
13.6 CONTROLLER MALFUNCTION EMERGENCY MEASURES....2498
14. AIR CONDITIONER....2500
14.1 OPERATION ITEMS....2502
14.2 SAFETY MONITOR FUNCTIONS....2503
14.3 DISASSEMBLY AND ASSEMBLY PROCEDURE....2506
14.3.1 SPECIAL CONSIDERATIONS DURING REPLACEMENT....2506
14.3.2 INTERIOR UNIT....2508
14.4 OPERATIONAL PRECAUTIONS....2517
14.5 INSPECTION AND MAINTENANCE....2518
14.5.1 INSPECTION/MAINTENANCE LIST....2518
14.5.2 INSPECTION/MAINTENANCE PROCEDURES....2518
14.6 ELECTRIC SYSTEM SCHEMATIC....2522
KOBELCO CK1200, CKE1100 Crawler Cranes Repair Service Manual
