Kobelco CK1200 CKE1100 Crawler Crane Workshop Repair Service Manual PDF - MKOBCK1200CKE1100.zip
A full service and repair guide, complete with Electrical Wiring Diagrams, covering the KOBELCO CK1200 and CKE1100 Crawler Cranes — packed with every technical detail needed to service, troubleshoot, fix, and rebuild these machines the way professional technicians do.
The KOBELCO CK1200 and CKE1100 Crawler Cranes workshop service and repair manual contains:
* 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