Kobelco CK1200 / CKE1100 Crawler Crane Shop Manual – S5GK00004ZE01

This complete service repair workshop manual PDF download for the Kobelco CK1200 / CKE1100 Crawler Crane has easy to read text sections with top quality diagrams, pictures and illustrations. The step by step instructions show you how to fault find or complete any repair or overhaul, correctly and efficiently, saving time and avoiding costly mistakes. All specifications and tolerances are listed. Functions of components and systems are also explained.

APPLICABLE MODELS :

Kobelco CK1200 – From GK04-03001 – 2006.03
Kobelco CKE1100 – From GK04-03002 – 2006.03

TABLE OF CONTENTS :

1. SPECIFICATION
2. MAINTENANCE STANDARDS TEST PROCEDURES
3. GENERAL WORK STANDARD
4. POWER TRAIN
5. HYDRAULIC SYSTEM
6. HOIST SYSTEM
7. BOOM HOIST SYSTEM
8. SWING SYSTEM
9. PROPEL SYSTEM
10. ELECTRIC SYSTEM
11. LOAD SAFETY DEVICE
12. GAUGE CLUSTER
13. TOTAL CONTROLLER
14. AIR CONDITIONER

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Book Code : S5GK00004ZE01
Total Pages : 550

This service repair workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same Repair Service manual your local dealer will use when doing a repair.

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1. SPECIFICATION
1.1 SPECIFICATION
1.1.1 PERFORMANCE
1.1.2 OUTSIDE DIMENSIONS
1.1.3 DIMENSIONS AND WEIGHT OF EACH PARTS
1.1.4 STABILITY IN SWINGING AND TRAVELING

2. MAINTENANCE STANDARDS TEST PROCEDURES
2.1 MAINTENANCE STANDARD
2.1.1 PIN, BUSHING, SPRING, LINING AND SHEAVE
2.1.2 PROPEL DEVICE
2.1.3 PROPEL BRAKE PLATE
2.2 PERFORMANCE STANDARD AND TEST PROCEDURE
2.2.1 OPERATING SPEED
2.2.2 POINT AND METHOD OF MEASURING PRESSURE
2.2.3 SLEWING RING

3. GENERAL WORK STANDARD
3.1 TIGHTENING TORQUE OF CAPSCREWS AND NUTS
3.1.1 METRIC COARSE THREADS
3.1.2 METRIC FINE THREADS
3.1.3 COARSE THREDS UNC
3.1.4 FINE THREADS UNF
3.1.5 TIGHTENING TORQUE OF HYDRAULIC FITTINGS
3.2 STANDARD PARTS
3.2.1 BOLT
3.2.2 O-RING
3.2.3 BACK-UP RING
3.2.4 BITE FITTING
3.3 CONVERSION TABLE
3.3.1 UNIT CONVERSION
3.3.2 MILLIMETER : INCH CONVERSION TABLE
3.3.3 METER-FOOT CONVERSION TABLE
3.3.4 GRADIENT CONVERSION TABLE
3.4 TABLE OF UNIT WEIGHT

4. POWER TRAIN
4.1 INTRODUCTION
4.2 ENGINE
4.2.1 INTRODUCTION
4.2.2 REMOVAL
4.2.3 REPAIR AND MAINTENANCE
4.2.4 RE-INSTALLATION
4.3 PUMP DRIVE ASSEMBLY
4.3.1 INTRODUCTION
4.3.2 REMOVAL
4.3.3 DISASSEMBLING THE POWER DIVIDER
4.3.4 CHECK AND REPAIR OF THE POWER DIVIDER
4.3.5 ASSEMBLING THE POWER DIVIDER
4.3.6 RE-INSTALLATION

5. HYDRAULIC SYSTEM
5.1 LOCATION OF MAIN HYDRAULIC COMPONENTS
5.2 HYDRAULIC CIRCUITS AND COMPONENTS
5.2.1 HYDRAULIC CIRCUIT
5.2.2 COMPONENT SPECIFICATIONS
5.2.3 LOCATION OF HYDRAULIC COMPONENTS
5.3 HYDRAULIC SYSTEM
5.3.1 PREFACE
5.3.2 OUTLINE
5.3.3 OIL FLOW FROM No.1 and No. 2 PUMPS
5.3.4 OIL FLOW FROM No.3 AND No.4 PUMPS
5.3.5 OIL FLOW FROM No.5 PUMPS (Control Pumps)
5.3.6 OIL FLOW FROM No.6 PUMP (For Auxiliary Actuator Circuit)
5.4 VALVES

6. HOIST SYSTEM
6.1 APPARATUS AND LOCATION OF COMPONENTS
6.2 CONSTRUCTION AND FUNCTION
6.2.1 HYDRAULIC SCHEMATIC
6.2.2 LIFTING A LOAD
6.2.3 HOLDING A RAISED LOAD
6.2.4 LOWERING A LOAD (POWERED LOWERING)
6.2.5 FREE FALL OPERATION
6.2.6 FREE FALL ACCELERATION
6.3 DRUM LOCK
6.3.1 ASEEMBLY DRAWING
6.3.2 ADJUSTMENT OF DRUM LOCK
6.4 WINCH ASSEMBLY
6.4.1 WINCH INSTAL
6.4.2 WINCH ASSEMBLY / REDUCTION UNIT WITHOUT FREE FALL (STD.)
6.4.3 WINCH ASSEMBLY WITH FREE FALL (OPT.)
6.5 BRAKE PEDAL
6.5.1 ASSEMBLY DRAWING
6.5.2 ADJUSTING THE BRAKE PEDAL
6.6 BLEEDING AIR FROM BRAKE CIRCUIT

7. BOOM HOIST SYSTEM
7.1 APPARATUS AND LOCATION OF COMPONENTS
7.2 CONSTRUCTION AND FUNCTION
7.2.1 HYDRAULIC SCHEMATIC
7.2.2 RAISING THE BOOM
7.2.3 NEUTRAL
7.2.4 LOWERING THE BOOM
7.3 BOOM DRUM LOCK
7.3.1 ASSEMBLY DRAWING
7.3.2 ADJUSTING THE BOOM DRUM LOCK
7.4 DRUM AND REDUCTION UNIT
7.4.1 BOOM WINCH ASSEMBLY
7.4.2 BOOM DRUM AND REDUCTION UNIT ASSEMBLY

8. SWING SYSTEM
8.1 APPARATUS AND LOCATION OF COMPONENTS
8.2 CONSTRUCTION AND FUNCTION
8.2.1 HYDRAULIC SCHEMATIC
8.2.2 SWING
8.2.3 STOPPING
8.3 SWING REDUCTION UNIT
8.4 SWING BEARING
8.5 SWING LOCK

9. PROPEL SYSTEM
9.1 LOCATION OF THE MAJOR COMPONENTS
9.2 CONSTRUCTION AND FUNCTION
9.2.1 HYDRAULIC SCHEMATIC
9.2.2 PROPELLING (RIGHT SIDE FORWARD)
9.2.3 STOPPING
9.3 PROPEL REDUCTION UNIT
9.3.1 MOTOR AND REDUCTION UNIT
9.4 ADJUSTMENT

10. ELECTRIC SYSTEM
10.1 ELECTRICAL WIRING SCHEMATIC
10.2 CONNECTOR LIST
10.3 ARRANGEMENT OF ELECTRICAL PART
10.3.1 ELECTRICAL PART OF CAB
10.3.2 ELECTRICAL PART OF RIGHT DECK
10.3.3 ELECTRICAL PART OF FLOOR PLATE & LEFT SIDE STAND PANEL
10.3.4 ELECTRICAL PART OF REVOLVING FRAME
10.3.5 ELECTRICAL PART OF LEFT DECK
10.3.6 ELECTRICAL PART OF LEFT GUARD
10.4 ELECTRICAL PART
10.4.1 FUSE BOX (GG73E00004F1)
10.4.2 WIPER CONTROL UNIT (2480U306)
10.4.3 SWING FLASHER UNIT (2480U306)
10.4.4 PRESSURE SWITCH (CONTROL PRESSURE CUT & FREE FALL) (GG52S00006P1)
10.4.5 PRESSURE SENSOR
10.4.6 RELAY BOX (GG24E00024F1)
10.4.6.1 ARRANGEMENT OF CONNECTOR
10.4.6.2 RELAY BOX SCHEMATIC
10.4.7 LEFT SIDE STAND PANEL
10.5 TROUBLESHOOTING OF EXHAUST GAS THIRD REGULATION ENGINE
10.5.1 FAILURE DIAGNOSIS FUNCTION
10.5.2 HOW TO CHECK THE FAILURE CONTENTS
10.5.3 CHECKING BLOWN-OFF DIAGNOSIS LAMPS
10.5.4 ENGINE ECU

11. LOAD SAFETY DEVICE
11.1 PART NAMES AND FUNCTIONS
11.1.1 FRONT VIEW
11.1.2 CONFIGURATION OF SCREENS
11.1.3 DATA TRANSMISSION BETWEEN CONTROLLER AND CARDS
11.1.4 DETAILS OF INDICATORS ON MAIN DISPLAY SCREEN
11.1.5 REAR VIEW
11.1.6 ITEMS REQUIRED TO BE EXECUTED FOR REPLACEMENT OF CONTROLLER OR DATA CARD AND INSTRUCTIONS
11.2 PREPARATION FOR USE
11.3 TURN THE POWER ON
11.4 UPGRADING PROGRAMS
11.4.1 PROCEDURES
11.4.2 UPGRADING OF INDICATION PROGRAMS
11.4.3 UPGRADING OF CONTROL PROGRAMS
11.5 STATUS CHECK
11.5.1 SIGNAL CHECK
11.5.2 OPERATION PROGRESS
11.5.3 COMMUNICATION DATA
11.5.4 INDICATION OF ADJUSTMENT VALUE
11.5.4.1 ANGLE SENSOR ADJUSTMENT VALUE
11.5.4.2 LOAD CELL ZERO POINT ADJUSTMENT VALUE
11.5.4.3 ADJUSTMENT VALUE OF LOAD CELL FOR LINE-PULL
11.5.4.4 RESULT OF MANUFACTURE ADJUSTMENTS “NO LOAD” AND “SOME LOAD”
11.5.4.5 RESULT OF LOAD ADJUSTMENTS “NO LOAD” AND “SOME LOAD”
11.5.4.6 ADJUSTMENT VALUE OF WORKING RADIUS
11.5.4.7 ALTERATION OF ADJUSTED VALUE
11.5.4.8 DELETION OF ADJUSTED VALUE
11.5.5 LOAD RECORD
11.5.6 TROUBLE RECORD
11.5.7 CHOICE OF LANGUAGE (CKE SERIES ONLY)
11.5.8 LOAD RECORD (LOAD RECORD IN THE MAIN MENU)
11.6 ADJUSTMENTS
11.6.1 REMOVING THE INNER PANEL
11.6.2 ADJUSTMENT
11.6.2.1 ANGLE SENSOR ADJUSTMENT
11.6.2.2 LOAD CELL ZERO POINT ADJUSTMENT
11.6.2.3 LOAD-LESS ADJUSTMENT & SOME LOAD ADJUSTMENT
11.6.2.4 LVL ADJUSTMENT (LVL SETTING)
11.6.2.5 RADIUS ADJUSTMENT
11.6.3 LOAD ADJUSTMENT
11.6.4 ADJUSTMENT DATA COPY (INITIALIZATION)
11.6.4.1 READING OF THE ADJUSTMENT DATA
11.6.4.2 WRITING OF ADJUSTMENT DATA
11.6.4.3 INITIALIZATION OF ADJUSTMENT DATA
11.6.5 VERSION CHECK
11.7 ERROR CODE (ABNORMALITY DETECTION) AND COUNTERMEASURES
11.8 CONTROL OUTPUT
11.9 RELEASES
11.9.1 RELEASE FUNCTION
11.9.1.1 CRANE RELEASE CHART
11.9.1.2 ALARM SOUND
11.9.1.3 EXTERNAL INDICATOR LAMPS IN RELEASE CONDITION
11.10 MECHANICAL SPECIFICATION
11.10.1 ENVIRONMENTAL PERFORMANCE PARAMETERS
11.10.2 LOAD CELL (CRANE)
11.10.3 ANGLE SENSOR
11.10.4 CONTROLLER
11.10.4.1 MODEL NAME
11.10.4.2 SYSTEM INPUT/OUTPUT
11.10.4.3 MONITOR DISPLAY
11.10.4.4 OPERATION SWITCH
11.10.4.5 INTERNAL PROCESSING SYSTEM
11.10.4.6 MEMORY
11.10.4.7 EXTERNAL STORAGE ELEMENT
11.10.4.8 OTHERS
11.11 EXTERNAL DIMENSIONS
11.12 ELECTRIC SCHEMATIC DIAGRAM
11.12.1 CRANE TYPE
11.12.2 LUFFING TYPE
11.13 CONTROLLER MALFUNCTION EMERGENCY MEASURES
11.14 LOAD SAFETY DEVICE CHECK PROCEDURES

12. GAUGE CLUSTER
12.1 CONFIGURATION OF DISPLAY
12.2 PRIORITY
12.3 STATUS DISPLAY
12.4 FAULT LOG DISPLAY

13. TOTAL CONTROLLER
13.1 ARRANGEMENT OF TOTAL CONTROLLER
13.2 COMPOSITION OF SYSTEM
13.2.1 OUTPUT RELATION TO CONTROLLER
13.3 FUNCTION OF TOTAL CONTROLLER
13.4 TOTAL CONTROLLER (HARDWARE)
13.4.1 OUTLINE
13.4.2 SPECIFICATIONS OF TOTAL CONTROLLER OUTPUT
13.4.3 DETAILS OF TOTAL CONTROLLER CONNECTOR
13.4.4 ARRANGEMENT OF TOTAL CONTROLLER CONNECTOR PIN
13.4.5 PROPORTIONAL SOLENOID VALVE MEASURING POSITION
13.5 ADJUSTMENT OF TOTAL CONTROLLER
13.5.1 NECESSITY OF ADJUSTMENT
13.5.2 ADJUSTMENT PROCEDURES OF TOTAL CONTROLLER
13.5.2.1 OPTION SETTING
13.5.2.2 ADJUSTMENT OF HAND THROTTLE AND FOOT THROTTLE
13.5.2.3 ENGINE SPEED ADJUSTMENT
13.5.2.4 WHEN ADJUSTMENT OF TOTAL CONTROLLER IS IMPOSSIBLE
13.5.2.5 INITIAL ADJUSTMENT OF LIFTING HEIGHT GAUGE

14. AIR CONDITIONER
14.1 OPERATION ITEMS
14.2 SAFETY MONITOR FUNCTIONS
14.3 DISASSEMBLY AND ASSEMBLY PROCEDURE
14.3.1 SPECIAL CONSIDERATIONS DURING REPLACEMENT
14.3.2 INTERIOR UNIT
14.3.2.1 CASE DISASSEMBLY
14.3.2.2 THERMOSTAT REPLACEMENT
14.3.2.3 EVAPORATOR OR EXPANSION VALVE REPLACEMENT
14.3.2.4 HEATER CORE REPLACEMENT
14.3.2.5 INTAKE DUMPER ACTUATOR REPLACEMENT
14.3.2.6 WATER VALVE ACTUATOR OR WATER VALVE REPLACEMENT
14.3.2.7 MODE ACTUATOR REPLACEMENT
14.3.2.8 BLOWER MOTOR ASSEMBLY REPLACEMENT
14.4 OPERATIONAL PRECAUTIONS
14.5 INSPECTION AND MAINTENANCE
14.5.1 INSPECTION/MAINTENANCE LIST
14.5.2 INSPECTION/MAINTENANCE PROCEDURES
14.6 ELECTRIC SYSTEM SCHEMATIC

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