Kobelco CK1200 / CKE1100 Crawler Crane Repair Service Shop Manual - S5GK00004ZE01

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This complete service repair workshop manual PDF download for the CK1200 / CKE1100 Kobelco 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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