CRAWLER CRANE SHOP MANUAL CK1200 model ¢KE1100 KOBELCO BOOK CODE —: $5GK00004ZE01AREER | _Aevesbie Machine | _Dnteofeve Renans ‘ox1200_|_From_oxo001 | —_—200888 ‘oxe1100 | From GO 09002 | 70865TABLE OF CONTENTS SAFETY 1. SPECIFICATION 1.4. SPECIFICATION. 14 PERFORMANCE. 11.2. OUTSIDE DIMENSIONS. 11.3 DIMENSIONS AND WEIGHT OF EACH PARTS. 114 STABILITY IN SWINGING AND TRAVELING. 2, MAINTENANCE STANDARDS TEST PROCEDURES 24. MAINTENANCE STANDARD. 2.1.1 PIN, BUSHING, SPRING, LINING AND SHEAVE 21.2 PROPEL DEVICE, 2.4.3 PROPEL BRAKE PLATE, 2.2 PERFORMANCE STANDARD AND TEST PROCEDURE. 2.24 OPERATING SPEED 22.2 POINT AND METHOD OF MEASURING PRESSURE. 223. SLEWING RING 3. GENERAL WORK STANDARD 3.1 TIGHTENING TORQUE OF CAPSCREWS AND NUTS. 3.11 METRIC COARSE THREADS 3.1.2 METRIC FINE THREADS 3.1.3 COARSE THREDS UNC. 3.14 FINE THREADS UNF. 3.18 TIGHTENING TORQUE OF HYDRAULIC FITTINGS. 3.2. STANDARD PARTS. 321 BOLT 322 O-RING. 32.3. BACK-UP RING, 3.2.4 BITE FITTING. 33 CONVERSION TABLE. 33.1 UNIT CONVERSION. 33.2. MILLIMETER : INCH CONVERSION TABLE. 33.3. METER-FOOT CONVERSION TABLE 334 GRADIENT CONVERSION TABLE. 344 TABLE OF UNIT WEIGHT 4, POWER TRAIN 13 13 14 16 412 23 23 240 246 247 247 248 228 33 33 33 34 34 35 37 a7 28 310 342 a2 3413 345 3.16 347 ‘€K12007 CKETI00‘TABLE OF CONTENTS. 4.1. INTRODUCTION. 4.2. ENGINE 42.1. INTRODUCTION 422 REMOVAL. 42.3 REPAIR AND MAINTENANCE 4.2.4 REJNSTALLATION, 4.3. PUMP DRIVE ASSEMBLY. 431. INTRODUCTION 43.2 REMOVAL, 4.33. DISASSEMBLING THE POWER DIVIDER, 4.3.4 CHECK AND REPAIR OF THE POWER DIVIDER. 435 ASSEMBLING THE POWER DIVIDER, 43.6 RENSTALLATION, 5. HYDRAULIC SYSTEM 5.1 LOCATION OF MAIN HYDRAULIC COMPONENTS: 5.2 HYDRAULIC CIRCUITS AND COMPONENTS... 5.2.1 HYDRAULIC CIRCUIT 522 COMPONENT SPECIFICATIONS 5.23 LOCATION OF HYDRAULIC COMPONENTS. 5.3 HYDRAULIC SYSTEM. 5.3.1 PREFACE, 53.2. OUTLINE 5.3.3 OIL FLOW FROM No.1 and No, 2 PUMPS.. 5.3.4 OIL FLOW FROM No.3 AND Not PUMPS 5.35. OIL FLOW FROM No S PUMPS (Control Pumps) 5.3.6 OIL FLOW FROM No.6 PUMP (For Auxiliary Actuator Circuit) 54 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 ALOAD. 62.3 HOLDING ARAISED LOAD. 6.2.4 LOWERING A LOAD (POWERED LOWERING). 62.5 FREE FALL OPERATION 6.2.6 FREE FALL ACCELERATION 63 DRUM LOCK... ‘GK12007 CKETI00 2 5.25 5.27 530 5.33 10 e12 616 618TABLE OF CONTENTS 6.3.1 ASEEMBLY DRAWING. o18 6.3.2 ADJUSTMENT OF DRUM LOCK. 619 6.4 WINCH ASSEMBLY, 620 64.1 WINCH INSTAL. 620 6.4.2 WINCH ASSEMBLY / REDUCTION UNIT WITHOUT FREE FALL (STD.) 6-21 6.4.3 WINCH ASSEMBLY WITH FREE FALL (OPT) 623 65 BRAKE PEDAL. 628 6.5.1 ASSEMBLY DRAWING. 628 6.5.2 ADJUSTING THE BRAKE PEDAL 626 6.6 BLEEDING AIR FROM BRAKE CIRCUIT. 627 7. BOOM HOIST SYSTEM 7.1 APPARATUS AND LOCATION OF COMPONENTS. 13 7.2 CONSTRUCTION AND FUNCTION 15 7.2.1 HYDRAULIC SCHEMATIC. 7s 7.22. RAISING THE BOOM. 78 723 NEUTRAL (MAINTAINING THE BOOM POSITION) 738 7.24 LOWERING THE BOOM 7.40 7.3. BOOM DRUM Lock 742 7.3.1 ASSEMBLY DRAWING... 72 7.3.2 ADJUSTING THE BOOM DRUM LOCK. 743 7.4 DRUM AND REDUCTION UNIT 744 7.4.1 BOOMWINCH ASSEMBLY 744 7.4.2. BOOM DRUM AND REDUCTION UNIT ASSEMBLY 746 8, SWING SYSTEM 8.1 APPARATUS AND LOCATION OF COMPONENTS. 83 82 CONSTRUCTION AND FUNCTION a4 82.1 HYDRAULIC SCHEMATIC. a4 822 SWING. 26 823 STOPPING. 89 83. SWING REDUCTION UNIT. os 42 84. SWING BEARING. . so aa 85 SWINGLOCK. 16 9, PROPEL SYSTEM 9.1 LOCATION OF THE MAJOR COMPONENTS. 23 9.2. CONSTRUCTION AND FUNCTION oa ‘GK12007 CKETI00TABLE OF CONTENTS 92.1 HYDRAULIC SCHEMATIC. 9.22 PROPELLING (RIGHT SIDE FORWARD). 9.2.3 STOPPING. 9.3 PROPEL REDUCTION UNIT. 9.3.1 MOTOR AND REDUCTION UNIT. 94 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. 10.33 ELECTRICAL PART OF FLOOR PLATE & LEFT SIDE STAND PANEL 10.3.4 ELECTRICAL PART OF REVOLVING FRAME 10.35 ELECTRICAL PART OF LEFT DECK 10.36 ELECTRICAL PART OF LEFT GUARD 104 ELECTRICAL PART. 104.1 FUSE BOX (@G73E00004F 1). 10.4.2 WIPER CONTROL UNIT (2480U306) 40.4.3 SWING FLASHER UNIT (2480U306) 10.4.4 PRESSURE SWITCH (CONTROL PRESSURE CUT & FREE FALL) (@¢52800006P 1) 10.4.5 PRESSURE SENSOR. 10.4.6 RELAY BOX (6G24E00024F 1). 10.4.6.1 ARRANGEMENT OF CONNECTOR. 10.4.8.2 RELAY BOX SCHEMATIC 404.7 LEFT SIDE STAND PANEL. 10.5 TROUBLESHOOTING OF EXHAUST GAS THIRD REGULATION ENGINE 105.1. FAILURE DIAGNOSIS FUNCTION. 10.5.2 HOW TO CHECK THE FAILURE CONTENTS. 10.5.3 CHECKING BLOWN-OFF DIAGNOSIS LAMPS. 10.54 ENGINE ECU 11. LOAD SAFETY DEVICE ‘1.1 PART NAMES AND FUNCTIONS 11.4.1 FRONT VIEW. 11.1.2 CONFIGURATION OF SCREENS 11.1.3 DATA TRANSMISSION BETWEEN CONTROLLER AND CARDS. 11.44 DETAILS OF INDICATORS ON MAIN DISPLAY SCREEN. ‘cK12007 CKETIO0 a 904 38 o10 ont 913 103 10-14 10-66 10-66 10-70 1078 10.83 10-86 10-93 10-94 10-94 1096 1097 10-98 1099 104101 10-4101 10-103, 10-108 10-110 104110 10411 10-116 10417 13 13 118 11-13 11-15TABLE OF CONTENTS: 11.4.8 REAR VIEW. 11-19 11.4.6 ITEMS REQUIRED TO BE EXECUTED FOR REPLACEMENT OF CONTROLLER, ‘OR DATA CARD AND INSTRUCTIONS (ln a similar manner to upgrade of program). 11-24 11.2 PREPARATION FOR USE. 11.25 11.3 TURN THE POWER ON 11.28 11.4 UPGRADING PROGRAMS. 11.27 11.4.1 PROCEDURES... 1127 11.42 UPGRADING OF INDICATION PROGRAMS woe 1129 11.43 UPGRADING OF CONTROL PROGRAMS 1132 11.8 STATUS CHECK 1134 11.5.1 SIGNAL CHECK. 11.35 11.52 OPERATION PROGRESS 1137 11.53 COMMUNICATION DATA. 11-40 11.54 INDICATION OF ADJUSTMENT VALUE. 1141 11.5.4.1 ANGLE SENSOR ADJUSTMENT VALUE 0 11-42 411542 LOAD CELL ZERO POINT ADJUSTMENT VALUE 1143 4115.43 ADJUSTMENT VALUE OF LOAD CELL FOR LINE-PULL 1144 115.4.4 RESULT OF MANUFACTURE ADJUSTMENTS "NO LOAD" AND "SOME LOAD" 1145 11.5.4.5 RESULT OF LOAD ADJUSTMENTS "NO LOAD™ AND "SOME LOAD". 11-46 115.48 ADJUSTMENT VALUE OF WORKING RADIUS. 11-47 4115.47 ALTERATION OF ADJUSTED VALUE. 1148 115.48 DELETION OF ADJUSTED VALUE 11-49 11.55 LOAD RECORD 11-50 11.56 TROUBLE RECORD 1153 11.5.7 CHOICE OF LANGUAGE (CKE SERIES ONLY), 1155 11.58 LOAD RECORD (LOAD RECORD IN THE MAIN MENU) 1156 11.6 ADJUSTMENTS. 1187 11.8.1 REMOVING THE INNER PANEL 1187 11.6.2 ADJUSTMENT. 11-58 11.62.1 ANGLE SENSOR ADJUSTMENT 1181 41.822 LOAD CELL ZERO POINT ADJUSTMENT . 11-65 111623 LOAD-LESS ADJUSTMENT & SOME LOAD ADJUSTMENT. 1167 4.624 LVL ADJUSTMENT (LVL SETTING). 1473 111825 RADIUS ADJUSTMENT 1476 11.63 LOAD ADJUSTMENT. 14-78 11.6.4 ADJUSTMENT DATA COPY (INITIALIZATION) 11-80 1.84.1. READING OF THE ADJUSTMENT DATA. snes 1B 11.6.4.2 WRITING OF ADJUSTMENT DATA, 11-84 11.643 INITIALIZATION OF ADJUSTMENT DATA. 11-85 11.6.5 VERSION CHECK. 11-86 11.7 ERROR CODE (ABNORMALITY DETECTION) AND COUNTERMEASURES... 11-87, ‘€K12007 CKETI00‘TABLE OF CONTENTS 114.8 CONTROL OUTPUT, 11.9 RELEASES 11.9.1 RELEASE FUNCTION 1.9.1.1. CRANE RELEASE CHART 1.9.1.2. ALARM SOUND 19.1.3 EXTERNAL INDICATOR LAMPS IN RELEASE CONDITION 11,10MECHANICAL SPECIFICATION. 11.10.1ENVIRONMENTAL PERFORMANCE PARAMETERS 11.40,2LOAD CELL (CRANE). 11.40.3ANGLE SENSOR 11.10.4CONTROLLER, 11.10.41 MODEL NAME, 14.10.4.2SYSTEM INPUTIOUTPUT 11.104. 3MONITOR DISPLAY... 11.10.4.40PERATION SWITCH 14.10.44 INTERNAL PROCESSING SYSTEM 11.104. MEMORY. 11.10.4.7EXTERNAL STORAGE ELEMENT 11.104 30THERS. 11.11 EXTERNAL DIMENSIONS 11,A2ELECTRIC SCHEMATIC DIAGRAM 1112.1 CRANE TYPE. 11.12.2LUFFING TYPE. 11,43CONTROLLER MALFUNCTION EMERGENCY MEASURES. ‘1,ASLOAD SAFETY DEVICE CHECK PROCEDURES. 12. GAUGE CLUSTER 12,1 CONFIGURATION OF DISPLAY. 122 PRIORITY 123 STATUS DISPLAY 12.4 FAULT LOG DISPLAY, 13, TOTAL CONTROLLER 13:1 ARRANGEMENT OF TOTAL CONTROLLER 13.2 COMPOSITION OF SYSTEM « 43.2.1 OUTPUT RELATION TO CONTROLLER 18.3 FUNCTION OF TOTAL CONTROLLER. 13.4 TOTAL CONTROLLER (HARDWARE), 134.1 OUTLINE. 13.42 SPECIFICATIONS OF TOTAL CONTROLLER OUTPUT, 13.43 DETAILS OF TOTAL CONTROLLER CONNECTOR 14.4.4 ARRANGEMENT OF TOTAL CONTROLLER CONNECTOR PIN ‘GK12007 CKET100 6 11-89 a1401 1401 +4401 a4407 11-108 11-109 11-109 11-110 nat 82 4412 182 a4 114 qt 114 10115 14115 114116 a0at7 a0at7 11418 11419 11-120 23 124 126 1216 133 13.4 135 136 1331 1331 13:32 13:36 1337‘TABLE OF CONTENTS. 18.4.5 PROPORTIONAL SOLENOID VALVE MEASURING POSITION 13.44 418.5 ADJUSTMENT OF TOTAL CONTROLLER. 13.45 19.5.1 NECESSITY OF ADJUSTMENT. 13-45 185.2 ADJUSTMENT PROCEDURES OF TOTAL CONTROLLER 13-45 1852.1. OPTION SETTING. 13-45 48.5.2.2 ADJUSTMENT OF HAND THROTTLE AND FOOT THROTTLE. 13.47 18.5.2.3 ENGINE SPEED ADJUSTMENT. 13-48 185.24 WHEN ADJUSTMENT OF TOTAL CONTROLLER IS IMPOSSIBLE... 13-49 18.525 INITIAL ADJUSTMENT OF LIFTING HEIGHT GAUGE 13.50 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 1432 INTERIOR UNIT 1432.1 CASE DISASSEMBLY. 143.22 THERMOSTAT REPLACEMENT. 143.23 EVAPORATOR OR EXPANSION VALVE REPLACEMENT. 14.324 HEATER CORE REPLACEMENT 44.3.2 INTAKE DUMPER ACTUATOR REPLACEMENT. 143.26 WATER VALVE ACTUATOR OR WATER VALVE REPLACEMENT. 14.3.2.7 MODE ACTUATOR REPLACEMENT 143.28 BLOWER MOTOR ASSEMBLY REPLACEMENT. 14.4 OPERATIONAL PRECAUTIONS. 145 INSPECTION AND MAINTENANCE. 145.1 INSPECTIONMAINTENANCE LIST... 14.52 INSPECTIONIMAINTENANCE PROCEDURES 146 ELECTRIC SYSTEM SCHEMATIC. ‘€K12007 CKET100‘TABLE OF CONTENTS ‘GK12007 CKETI00SAFETY 0 (¢k1200/6KE1100SAFETY ‘This section explains “Explanation cf Warning Deseo" "Waring Labels” and Gana aly" [EXPLANATION OF WARNING DESCRIPTION ‘This manulindeatos the contents of warning concomed in safely wth the folowing twee sages according tothe degree of pecsonal ham and material damoge. ‘Since the very inpetant matters or afty ae descbed, understand the contents suey and observe them without ft PREINISEY v¥272 1 avoid dangerous codon esutng innstantanecus death or serous personal ijn. Wirning te avoid dangerous condton which has possibly of death or serous personal injury Warning to avoid dangerous condition wich has pesibilty to cause sight or medium injury or <éamago of tho machine and equipments “Tis manual describes safety warnings suflonty, but dangerous condition which are posible tobe antcpated ‘xo considered Therefore, ake measures fr stety not ely regarding the machine, but aco incusing the working enveonment EXPLANATION OF WARNING LABELS Since the waring labels ae installed inthe machine and inated wth the warning description, cof the postions and contents al warning labels rst. Putthem to tho practical use to secure safety when operating, checking and perforring maintenance + HANDLING OF WARNING LABELS 1. when the waning abe s damaged or tained, err Itt the designated sono shop, 2, Donet remove the warning labels. 3. When the surace of the warring labels sole and fet to be Seen, wpe I cleanly. tages inthe sama way asthe ek 1200/CKE1100 02SAFETY he A CAUTION. 4 DANGER DEATH on suey our RESULT 1F LUNLAWEUL To Puce ae eT oF re Slams DETAIL © TACCUMULATORD 03 ‘Ck1200/CKE1100(€k1200/CKE1100SAFETY ywzoToi01961 MEW 7h DANGER Renn] (Amaam ‘ier raveer 19 exonGe A CAUTION. Moving earte 4, DANGER DEATH on Ry way Rest iF A 4, DANGER (a ven OF Hier LTE eS OF STAY AWAY FROM MACHINE ster murs ot tes IF CLOSE TO POWER LINES. WACHLINE, LOAD AND GROUND NAY BECOME ELECTRIFIED AND DEADLY. ALWAYS sorrr e1geri cowant 1 ema os ‘ck1200/CKE1100SAFETY Ay CAUTIO! CAUTION wuzororoose: DETAIL M A\DANGER) ae KEEP CLEAR OF| SHNG AREA FOR HIGH TEMPERATURE| [AS ENGINES. AND MUFFLERS NAY BE. HEATEO TO. A1GH TENPERATURES, 00. NOT DIRECTLY TOUCH THEN ano. iz0T91003F2 om oP DETAIL_N (WIEW FROM INNER OF DOOR) Sion ak COWAEET IONE eK1200/CKE11004 4 DANGER DETAIL & SAFETY FUEL TANK] Ay CAUTION USE DIESEL || FUEL ONLY. FUEL TANK HYDRAULIC TANK] Ay CAUTION WiGh TEMPERATURE bo nov TOUCH SECTION u-u o7 view $s THYD, OTL TANKT ck1200/CKE1100SAFETY Ce if - 4 u _—— u insioe viewwrw [ SGAITIOR eT = Pee A DANGER || eta INSIDE VIEW (R/#) —— a 4, DANGER A\ CAUTION STAY AVAY FROM MACHINE Hite o°Sotay dase”? ME IF CLOSE TO POWER LINES. Senn iar? WACHINE, LOAD AND GROUND KAY ‘BECOME ELECTRIFIED AND DEADLY. (eK1200/¢KE1100 08Ay CAUTION AN DANGER| “Tat ee ‘ck1200/KE1100SAFETY PRECAUTIONS FOR INSPECTION AND MAINTENANCE. 1. Service and maintenance mus be performed only by authorized personnel who are qualified in compance with a elevant aw er guia, 2. Rogular maintenance or inspection should be quicy performed afer shuting dawn the machine nd ensuring set to persone! and equipment Pst an INSPECTION IN PROGRESS. DO NOT START." waning sign ona readily visible location. (GENERAL SAFETY PRECAUTIONS 1. Woar safety shoes, halmets and clothing suitable forthe job. Ako use protective goggles, mask, glove, ee, asrequres 2. Te ensure sate and correct maintenance, carefully study his SHOP MANUAL and get ly fmiar with te i sirvtons init 3. Pace the machine ase place, Always mani safe clearance around the machine. 4. Before starting crane operat, hota safety mowing. Also, make agreement on standardized hand signals. ‘5 When inspecting or handling the batty ool, donot us exposed fame noary. To avoid fre accident, ony use explosion poet ghing equipment 6. Sartan inspection or msinenance work only afer shuting dow the engine 7. Corain machine components remain hot immediatly ater the engines shutdown, Do nat euch thom, 8. Before removing the radiator cap, walt unt the coolant water get utile onl, Ned, carefuly loosen the ‘ap and release raditer pressure, ad thom remove the cap. 2. Before inspecting or malianing an electrical sytem on the machin, power of the machine by, fr example, ‘disconnecting the batiory cables. 10. mon working at hight area, always woarasafty bo. 1. men taving the operators ab fc an inspection or maintenance work, postan "INSPECTION INPROGRESS, DONOT START.” warning sgn on aradlyvisbolocation, Aso, lok the cab for secury 12, Ber staring a clearing ruben work onthe machine, avays shutdown the engine. 13, se adjusting tre pressure, be absolutely careful about rupture of tr, fying of wheel part "4, Use genuine KOBELCO replacement parts and is ony. 15, Alay keep the ol consiners ean, Protect hem again! ingress of dust or moisture. Aso clean, tosh ison. 18, Once a maintenance works complete, lean the machine, Protect grease nipple, breathers and level gages again ingress of du 17, Always Koop the subjects of eqularinspacton clean to allow prcblems such a leakage, crack, oseness, 10 beret detec 48, Dutng car washing, do net allow high prasure stam o be cect apptedt elecical components an con- 19, Atrremoving O-rings, ol sal, gaskets, et, lan the mourtng ees. The, neal resh O-rings, sal, {g2skeis, ec. Also, romember te thinly apply oto the seal faces of hese parts befor instalation 20. Before dsconnectng pressurized piping rleaso te inside prossure 21. CAUTIONS ec ep work wth weld: Turn OFF the key site, ceconnec the negative terminal on batty ‘9 power of the electrical eeu; provide grounding win t motor rom a weld area; in advance, remove eec- tric components (fr example, controle) o prevent possible damage 22. Dispose indus wasts according ta olavant aw r regulation 23, Exvemely careful dung an inspection or maintenance work under te caer. Remember he possibilty of be Ing crashed ‘Whenjacking up the machine fer an inspection er maintenance work, place blocks below tt prevent cient fang. 26, Provide postive ventilation when rein ol of ue, ising pas, staring the engine. (ek1200/CKE1100 o-40SAFETY 25, Toremove a heavy component (20 kg er heavier), use a crane, etc. Always keep safety In mind 26. toga or unauthorized, or etherwise nonconfoming modification is sty nied. 27, Do not ow ol or dus to depos around the engine. Otherwise, fre accident can result. 28, Store removed atachmons and components safely so that thoy do nt erp ofall down, 28, Aways use corect cols hat have boon wal mained. 30. To prevent personne om being caught by atuning fan et, sha or the Ike, shutdown the engin boere stating an inspection er mainienance work. 31. Battery quid and ols are harmfulto human heath, Htouching any of hse materls, mmeditelywashit away, 22, Make sue to use the Bight i fore ont ‘Ck1200/KE1100SAFETY (ek 1200/6KE1100 nz1. SPECIFICATION cr (ck1200/CKE110041. SPECIFICATION ek1200/CKE11004. SPECIFICATION 4.4 SPECIFICATION AAA PERFORMANCE K1200 “ype ‘Crawler mounted, fly revoiing Ta iting capacity [Sandardboom [50 kg x 365 m (240,000 bs «12 Yel Max. boom nai [Standard boom 70.1 m 230) ‘Max. boom eng Bi Ombaom 21.3 mj (200 beam + TO RIE) ‘Base boom length ____[Saandardbeom | 152m (50) ‘Werking weight (incuding upper and lover machine, courte _ weights carbody weigh, 50 standard boom, nook Bok) ‘Average ground pressure (Gradeabity (an Engine Host ine speed (Wont and ear dum Lowering ne speed (ron and rear um) ‘Boom raising ope speed Boom owerng rape speed ‘Sing speed Propel speed cKE1100 Tipe T Ta ing capacity [Standard boom Max. boom nat [Sandaré boom Max. boom + ‘Base boom length [Sandara boom ‘Werking weight (including upper and lover machine, courier weights, cafbody weights £0 standard boom, hook Bock) ‘Average ground pressure “Hosting speed Wont and ear dam Lowering ine speed (font and ear dur ‘Boom raising rope speed Boom owerng rope speed ‘Swing Prope speed) ‘The main iting! lowering rope sped, the auxiary hosting! lowering rope speed, andthe propel ‘speed vary depending onthe lo, “The rope speed i ofthe fst layer on he drum, 13 ‘Approximately 90,00 kg (218,000) Aopronnatay 92.9 Wa 135 ped 30% ino PTTC-UN 247 000 n= [20 mma 988 nny 120 min. (393 min) 8 in. (157 Win) 48 min. (157 fin) 32 min (32pm) "(a Ok (0670 2 miro) [Crawler mounted, fly revoNing [190,000 kg x 3.6 m (242,504 bs x 12 feet) 70.1 (290 8) ‘iO mboom F213 my (200 Nboom + 70) 152m (60) ‘Approximately 89,000 kp (218,000 ts) [_—Aeproaratay oz ora TSS pe) 30% Fine PHTC-UN 2473000 in 20 mimi, (988 mn) 120 mdm (999 Rn) in. (157 Win) 48 minin-(167 Rin} 32 min’ (32 rm) a7 (0.870 62 milesrou (ek 1200/CKE11004. SPECIFICATION 442 OUTSIDE DIMENSIONS iit atove goand ofeab ‘Wit of upper machine wih operators cab ‘Radous of rear end (wth counterweight Counterweight ground eesrence “Gener of rtaton to boom fot pn Sad mn (SATIS 3200 mm 10-6") [Bn 18478", 4,260 mm 4 158") [100 7-516") Titan above grouna of boom eat pt | eet top of gantry (vorong poston) ‘Overal engi of erawies Distance between centers of tubers ‘Overal with of crawlers (extended) (Oveal of eawier shoe revacted) ‘Wich of erawier shoe ‘Gund cearace of earbody ek1200/KE1100 14 2200 mm (F258) [7380 mi (242-0167 6.770 mm 22-12") 5.800 mm (180-1167) 5.00 mm (17 456") 14.210 mm (136-16) 900 mn @ 1-778), 380 mm(7"*)1. SPECIFICATION. UNIT mm tine) ssonnen 0-6) tron) [ar wn Ta TE Tae EL 16 ‘ck1200/CKE11004. SPECIFICATION 4:42 DIMENSIONS AND WEIGHT OF EACH PARTS chart below shows te dimensions and weight of ach parts For your reference, 1. BASE MACHINE Name ‘imenson rn Gch) Weigh (bs) [aco Machine | wn re a eum + win we ropes sao tse) 60070 (132,430) ‘Base Machine | wou Crawl + vith wire ropes sues eassar2te) ayo 0540 zi it aw at wo oaFo 36210 (79,830) [base Machine + shout Cram | wnout gantry | wnout beom rum op0 With Fe. & Re, rum ropes. S005 08 0 soos 7 4 S385 as gy 33.960 (74880) aqua 949 senso 740 oo By fer 406,700 (CK1200/CKE1100 164. SPECIFICATION Nans Dimension mn neh) Wiiaht ha bs) : 11930 (Crawler ie (26,300) [renter 490 (950)/1 Piece wih ot) ses) | = | 21565449 0 roan) W (©K1200/0KE11004. SPECIFICATION 2. COUNTERWEIGHT a ae TET z iW + 2 a commen] aoe, i a 5 { 3 Ht J er mo fs J sgl aa LL_2 a J ri i commerio] | on, fl af on L ‘ck1200/CKE1100 181. SPECIFICATION 3 AACHEN Tare ST aa ammerstic) 1 — c| eam ae aio Lover com a] de gs aaron He) son 109 0 er oom es) asm oy oss or boom vase) smo) ws ac bom oy semen, is amc) C 3 3 a ar bom z fw ug ih & tak) a 19 ‘cK1200/CKE11004. SPECIFICATION Name Binension am weighing es) 1680 2310 04-46 La 122m 20) 1198 insert boom nt 2835) s2sto wo’) set 122m 40) 1220 Insert boom (2800) (win 9) 3700 22 3) soteseh Pactaion (*-10n!eacn) 280 |i te em sar015 9% 0 “eo . | SO Ne mst 2%69 [som «10 Insert ib 400 (220) — Insert i XM (395) ek 1200/CKE1100 1404. SPECIFICATION Te aaa na ay Ta sea a 2 one = = TT 170 Ioan 5165 (16° 11-59 (3,970) =e) wpe le f=) 4 x0 — Hl a) oe (ck1200/KE11004. SPECIFICATION 444 STABILITY IN SWINGING AND TRAVELING. 1. Winout boom base Counter “Alzound sng Prpalng Sent Peston | wCN | ayn cramer | Wen ared? | Forwaring | Bachwarding Tow gary pion | None a ° o 3 High gory poston | — None ° ° ° ° ow ganty positon | 1001 @ x ° ° High gory poston [voor ° x © ° Lew gnty posion | Trot © x o ° ry postion | 170% ° x ° © iy postion | 240% o x ° o Tigh gant poston | 200% @ x ° ° Low gary poston | 340 x x x x High gnty poston | 940% x x x x 1: Operation avaiable X: Operations uravalbla gh gantry poeion Low gant pon cones mane (©K1200/0KE1100 1424. SPECIFICATION (1) The table onthe previous page above shows the value for oparaton on a fm ground. On 3 weak oun, operate with care afr curing the round. — ‘ound, op coring the tes (2) As apencipe, swinging on ral is prohibited (3) Maximum slope angle 18.7 depres (30%), (4) Traveling forward means he cas, where the coun- terweight sat the lover slope and he raveing backward, whore itis the upper stope Pee] Traveling forward 7? oe Cm = Traveling backwara 143 (ek 1200/KE11004 SPECIFICATION 22, Win boom base Goon [Conrir| Rikon ang ropeing Gent poston wean When oko anae | YS | umcraner [PEO P| Fonarteg | Baccardng oa gay pein None | 0 3 3 3 High garry seston Nowe [0 ° © ° ow panty Beton ior] 0 x ° ° gh carn seston woot | 0 x © ° Low gant pesiten | o deg to| 9x [0 x ° © High gory poston | sO dep | 170" | 0. x ° o ow sani potion zor | 0 x © ° igh garry sestlon zor) 0 x o 3 tow gan postion mor] x x x x High panty seston sot] x x x x 0: Operation avalos X: Operaonis ravalabie enon tn Lew gary poston ou 0 dea = Mae sgl 30 op, (Ck 1200/CKE1100 1442. MAINTENANCE STANDARDS TEST PROCEDURES 24 (ek 1200/¢KE11002, MAINTENANCE STANDARDS TEST PROCEDURES (ck 1200/CKE1100, 222. MAINTENANCE STANDARDS TEST PROCEDURES 2.1 MAINTENANCE STANDARD 24.4 PIN, BUSHING, SPRING LINING AND SHEAVE 1. Pl, Busing =——7 me ag Ut ey vore] tocnton [tem] Povmumonr [-S¢ Si [ UT Tel eet [ramen] # fowmeowr| cm [lee || Ba Somoum | 2 asroworoert| cra | |eren aa, 7 | awsreor | so | leas - so [some [ta | [et . sntepesa | 10 | anorzoros | 30, | [Az] |nence| tS | aorone | P(e v2 | arson | 28, | bes vomroa | + [owmmoros |] (Eel PEt on frente | 3 | _aworitn eo] [ei ronal TER sus | cama | 2 [aoavroroase] (AES, (S522 |nepe| FEA? soonront | « [ensaronsner| (9 [538 nea OEE 23 (¢k1200/KE11002, MAINTENANCE STANDARDS TEST PROCEDURES 2 Sea Fie enh Fie ang Unt oy tocaton | tem | Potnanaer [serrate] USOC TRamedy| Soo fre + wascweooner | TRS | oka raat Fr Re.Drum pawl | "250150 (Compression) (2.893) (P25) TEER). | 6B Ipapgeg FOE ee [eiseey | — so Foes ee [ress ek 1200/CKE1100, 242. MAINTENANCE STANDARDS TEST PROCEDURES 3Steave | res ! = tm day exionent [tem] Patnimer | [5 Pa Sane reeay | OE | sae fe eonvom | 0 | nseroioorrs | san os) ee | pose ryseoe | 10 | aosvoroos | as | Upersneace | 11 | oneanorocere | Bt moma el 2 sui Lemesmmnon | 6 | onion | thy oa | ees) Some] "8 | ten | atm osm _| 20) careyseoe | 6 | oveerornrs | try) | ase ows) | es Fig.24 Front and Rear Dum Lock 25 (cK1200/0KE11002. MAINTENANCE STANDARDS TEST PROCEDURES Wear in: sm (0:18 inet Fig2-2 Paw! (Go82W01005P1) EP) Oy LULL Fig2-3 Boom Drum Lock (ek 1200/KE1100, 262, MAINTENANCE STANDARDS TEST PROCEDURES Weer Ln: 3 0.18neh Fig.2-4 Paw (Gos2wota08h) 27 ck1200/¢KE11002. MAINTENANCE STANDARDS TEST PROCEDURES Fig2-7 Crane Jib ‘cK1200/CKE1100 282, MAINTENANCE STANDARDS TEST PROCEDURES Fig28 Gantry 29 (ck1200/CKE11002, MAINTENANCE STANDARDS TEST PROCEDURES 2:42 PROPEL DEVICE 1. Crawler shoe ‘eneooa0004P3 mene ea, rows een) nit: mine) [Sa Dnensin) Us Remedy Pranoie | 24500177 | 646.081) | euatup Pin__[eaa.as (175)| 0425(167)| or Pier @) | 226 8.08) [2346 (024) | Revlace ‘Winen 6 pes. shoes ae connected by shoe pn and hang vertically distance between pins shoul bo 1378.0 mm (543 inch ‘€K1200/0KE1100 aay Bal vp erapce 0702. MAINTENANCE STANDARDS TEST PROCEDURES 2, Drive tumbler an ek 1200/¢KE1100,2. MAINTENANCE STANDARDS TEST PROCEDURES 2 ae ‘ray vo 7) so ease Um nt Sasa SE Bas Tea Roy aun [eter dare 75009 errroos] a ube oon] cap 2 fompecwoonat | io | Sti | sort tomn] xeon | cap OS Pyoe POTTOM] | 10009 | een 3.1908] 0232 (009) ei Spam [171005 Tetnne on henna] ap foaee(0an8| Toba | Tanne © sper ane our aim | ence es 2 |e faser oan) 207080 Pe x7 085 ex r2001cKE 100 az4, rocker 2. MAINTENANCE STANDARDS TEST PROCEDURES ma 289) nit: mm inch) Sass Si ine Tenor 5 mer =< 121142008) can) ase Sioa] Tose [Sa ia Le eneen sn tae 007 | ea rma a femtaeenet | oso | SH" [Sestnena | oazeon | can | 7 | 59 [yop foz8@om | to | 08000) | 4S, |+0.23 (0.008) | 0.37 (0.014) * soot ors togon) | trace CI [eames 0.075 0.008)| TaNeN | Roplaco Lraectarany 3) | gag fassseaon] 2 000) es [ro 0.42 (0.005) | a exta0oekerte02. MAINTENANCE STANDARDS TEST PROCEDURES 5. Guise roller 10 oat am Ge) ‘Symbol Tem ‘Se Dimension [sabi imi Remedy A Outer diameter | _€220,1) 0722.87) Bulléup o Replace (ck1200/¢KE1100 2442. MAINTENANCE STANDARDS TEST PROCEDURES 5 evar 1 . =a | Oo oO oeTAIL A Us: nm ny Sb_| fan [5 isn ati tn Fass A [net Game] 5038) | — «8 89) | ald Pes 245 eK1200/CKE11002 MAINTENANCE STANDARDS TEST PROCEDURES 242° PROPEL BRAKE PLATE Separator pat Ficton poe Unit: Gch) nome ofiate | wunser | 53 Pireion [wert couy | Se Bako txeve Fiiengite | HOR Bae TaNe Separator plate] 5] 27°89) | pmout of wear: 1.5(0.059)| (98910 525 Ribs) (€k1200/0KE1100 2462. MAINTENANCE STANDARDS TEST PROCEDURES 2.2 PERFORMANCE STANDARD AND TEST PROCEDURE 1. TERMINOLOGY ‘Standard valve: Standard of assembting new machine. ‘nen the value exceeds he standard repalror replace the part a requ to main me chine perfomance and o salty. Temperature of ol: tmeans temperature of hydraulic ol 2. sto the lems of whch it of uses nat shown, efting to standard value asthe guidance, eparcrroplace the part as equred, 224 OPERATING SPEED a] — en —[ oan Tes Bae Sania Vane foctng Eran mi: gh iing Massie trate tte com 10 1 \rvering i" Eee aa al {setmeauna nen the rotation of the drum |17.8 to 20.8 sec. eee Beomtonam: B20 [te range oes mee man ane Raho wi Hghang [Mr ie en rae dan 7 | Temperature of Hyd ot 2 las onl tne r) | (etnemg wan eran J Loeding No load ake average of 3imes measuring. rum | 8:7 10103 see [> Engine win High na |+ Temperature of Hyd. cil: | measure the tne taken to ota machine one SOC(TIS 10 1S""F) ime. + oom Length Standard Mosbure the tine for 2nd roan afer st pee 17.8 10 21.2 see ‘Beem sina rotation | eecng: No lad ako average of 3 mes measuring. Swing Mode Free High | Engine min: High sing Propet |+ Temperature of Hye soe] SOC OT ee eee vectomre + Boom Length: Sts. Boom lrake average of3 nes measuring, Engine min Fgh lng Measure he dscrepancy vouume rested om |. Temperature of yd ot |popelingthe dance of 20 m (65.6 60°C (1131 134"F) [Propel machine fst preliminary more tan 2m scone: sam {6 1 btre rng traning worage of 3 tes measuring swing Speed ‘ease the tne taken wo propel machina he (Stace of 20 (65 0) [Propel machine fest preliminary mere han 2m, eot0a2 471056 sec. (600 mm (.82ineh) lropeting [biscropancy Dacrepancy zones) 2a7 (©K1200/CKE11002, MAINTENANCE STANDARDS TEST PROCEDURES 2.22 POINT AND METHOD OF MEASURING PRESSURE Use apresaure gouge which has surplus ofmore than 10 MPa 1450 por pressures tobe measured. which has passed the inspacton. Porto pressure measizement, clean the pot for pressure measurement 3 98 o be fee fom ol and dust Card ae ear TR cnc canreronst ‘wm aconorasD! Te eco Tao Sea aa Pa —} Eaten ST [Coan oa [seca | Homa tar wren Fat | Tanpenten cae tavern yee ou J row | ortooare ioe poten, Si | tater PERUANO neuer we teas 3 @ Yeo) cost @ 20 iat ——F Engr GT Loa one POO |+ Propel ‘High ising 12 Lock the main winch rum, Ck | Tengen tute ae vary man |. Front 8: 4510 55°C. ‘ring operation. ten | ow pressure ue FE ue ye : stom zap ek 1200/CKE1100, 2482. MAINTENANCE STANDARDS TEST PROCEDURES Ne [fem “eat Gondiion| “eat Proceaiwe ‘Standard vale F Engnereoiton (in), ayer the boom onthe ground eons eacyxnael® {8 Bam dm a19MPa aera PAE] 5, nak the vate rte ring] (40225 a eer Matte vate yom wen] (4225 (11310 131°F) a | Boom | | Engine eveluion (rin) Lock ho upper nolo turn wie sw] High iing lock pn and parking brake. + Temperature of Hyerauc]2, Make te vave aiewe by swing opera | 27.5MPa of a5 10550 ‘eon (2002 5 pa (11310137) Swing mode Free nok 4] swing 249 ck1200/¢KE11002 MAINTENANCE STANDARDS TEST PROCEDURES [Re tem "est Condon "Tesi Procedure Slander va ele Valve 0nPa(tor | Temperature of Hyerate ee co 80°C + 50(122°F + we er Reston vale 54 Pa (782 ps) {Low ing) Control Grout (Pemary pressure) fone) j ELE VRE qf cy Poa ek1200/¢KE1100 2202, MAINTENANCE STANDARDS TEST PROCEDURES 7. Operate thecorvaliovor forte soctonto] be measures (Operate th speed adustnghnod tothe ‘Max positon) “Take pressure out rom te quick coupe ofthe conta vava spo end Standard valve ‘stspeed | engine rotation in) ‘conte reut| Low ising (Secondary | Temperature of Hyeraul pressure) | ot:sorcsscczes) PO oF) 2.5010 2.79 MPa (3620 40s =) 142 to 1.62 MPa (206 10 235, ps) ‘Swing 41210 1.81 MPa (235 0263, =) Front & Rear Oru, 265 102.94 MPa (384 to 427 p=) 3 (809). 2.7510 3.24 MPa (308 0469 p=) 221 ‘ck1200/CKE11002, MAINTENANCE STANDARDS TEST PROCEDURES [Ne] tem Tea Condon Tea Presedue Siandard vas Raise: 206 MPa] | Eninereveiion(in')|y. eet byrne gant ender. (2307 ps) High ating Loner: 49™Pa 12. Rete by lowering the gantry yinder, | Temperature of Hydraulic by tovesng ie san on (711 psy as 13. Reet by operating raw Tna NO oes Cucee (area) ie 208MPa (2086 ps) any > | ing! lowering | Lower eeu iTaY RAGING) haha (2987p) —] 2 log K1200/KE11002 MAINTENANCE STANDARDS TEST PROCEDURES 223° SLEWING RING es CCOUNTERWEIGHT 34 t Counterweiht Measuring Condon ‘Amount pay Been engi: 152m (50). Redoe 0.14 m (20) Loss than 3 mn (0.21 inch) Load: 86.8 (62500 bs) 228 ek1200/¢KE11002. MAINTENANCE STANDARDS TEST PROCEDURES eK 1200/KE11003. GENERAL WORK STANDARD 34 (€k1200/0KE110023. GENERAL WORK STANDARD (ek1200/CKE1100 323. GENERAL WORK STANDARD 3.1 TIGHTENING TORQUE OF CAPSCREWS AND NUTS: Unless otherwise spect ore al srews ana nuts on thst machine tothe valves shown nthe following tbs 34.4 METRIC COARSE THREADS Uni: ko (be) ‘Gatication — tie Coarse Treads Nominal se = 2 “ie Dy | tubicatod [Dy | “tubicaied | by | abated ws __| 005 (925 | 038275 | 086s) | 0867) | t7c2s | 15(100) us| 109788) | o9(6sh | 2674) | 201145 | 4sGi1) | 36260) Mio_| 221159) | 10(130) | 47@an) | 40280) | e5@r8) | 721621) Mia | 37q@se) | 3232) | 616 | 68s) | 146(100) | 12.9°680) Mia | sr) | 600062) | 12826) | 1oace1) | 230,768) | 105 (141) Mi | 9.0(65-1) | 7.6,550) | 195(141) | 16.4719) | 95.0(259)_| 260 210) Mie | 724,69.) | 108 (760) | 27-0 (195) | 250(T68) | 4.00054) | 41.0 097) M20 [_175(127)_[_147(108) | 3800075) | 820252) | 8.01492) |_57.0,412) ‘Mga [230 (166) [19.8(142) | 51.0 60) | «a.0csrt) | 020,668) | 770.657) Maa | 300217) [240 (17a) | 650 (470) | 5501389) | 10.0654) | 96.0 (964) ‘Ma? [440 318) | 36.0260) | 06.0 (604) | 78.0 864) | 178.0 (1281) | 1400 1012) ‘M30__[_ 600 438) | s0.0(a62) | 1310 (648) | 1H00(7=e) | uaa [1.0 (686) | 68.0 492) | 17601273) | 48.0 (1070) | 2 Mae [105.0 760, [aso | | : 3.42 METRIC FINE THREADS ‘iaaiicaton Fe Tread Nominal size = = = ‘by | ubreaied | bey | “tubeeatea [Dy | tabrcated me__| 11788) | o4@en | 25052 | 21116 | 45025 | 98075) mio | 23066 | 1937) | 4954) | 4204) | e068) | 750589) Mi2 | 4029) | sa (246) | a7 | 73628) | 157 (114) | 132058) mie | 9.0(65.1) | 7.5(626) | 200 (145) | 17-2(124) | 97.0268) | 31.0224) ‘M20 | 190(137) | 1.8(114) | 41.0207) | 380246) | 740,635) | 620 448) ‘M24 [820 @32)_|27.0(198) | 700(606) | 56.0406) | 1260 611) | 1050 (760) Mao [ 65.0470) | seo@an | tezo(toa7 | aces) | ‘i M36 [108.0 788) | 91.0668) z 33 ek 1200/¢KE110023. GENERAL WORK STANDARD 3:42 COARSE THREDS UNC km (os) Ciaetcaton| ‘Cease Threads UNC at) Grade Grace 5 Gases Dy | Ubeeated [Oy | Lubricated | Dy | Lubricated ia [08 676) | 07605 | 73@4y | 11796) | 18039 | 15108) wre | serie) | 14010.) | 20ciee) | 22159) | 36060) | sna) 38 | 200 | 2acra) | a5 (26) | 38ers) | 6s ase) | 31983) Tie | asq@zs) | seers | 70@08) | s9u2n | sacto | 631600) 12 | 7.0606) | s9(e27)_| 10.876.) | 9.11658) | 15.2(H10) | 128628) ane | toog2s) | earéos) | 158 (114 | 13040) | 2201789) | 104 139) ‘58 | 140 (101) | 11.6(653) | 220,155) | 15.2(r52) | 94.0 220) | 25.0188) sie | 250 (061) | 2.0952) | a80 7s) | 320232) | S40 (301) | 45.0325) 73 | 290210) | 250(181) | o.0a1) | 510 (988) | 860,622) | r20 (621) + '350(255)_| 90.0217) | @1.0,688) | 76.0550) | 1280 (828) | i080 7) Tie [S10 80) | 4.0311) | 1140 625) | 96.0 687) | 194.0 (1381) | 1540 (114) re_| 71.0 614) | 5900 427) | 169.0 (1150) | 133.0 (662) | 257.0 1850) | 7160 (1862) “133 | 93.0673) | 72.0 64) | 2000 (1512) | 775.0166) | 338.0 2448) | 284.0 (2054) a [12400 @97) | 104.0752) | 2770 2008) | 292.0678) | 48.0 (3248) | 976.0 (2720) 244 FINE THREADS UNF Fine Thveads UNE Nomina size Grade race 5 Gasee Dy] whrcaied [Oy | twbicaied | by | Lubricated wa | does) | oss7y | taco | izes | ar0sa | 17023) aie [ 181132 [15108 | 2803) | 2474) | 20@es | s4(eee) 38 | 32@31) | 271105) | 49054) | 4ten | 70606) | 58420) me | 80062) | 42G04 | 770657) | 64469) | 108761) | 0.11658) 12 _|77(s57) | 64463) | 119681) | 90,718) | 168 (122) | 140 (101) ‘ie | 709 (reap | 02665) | 109(122) | 141 002) | 240(17—) | 18.8 (048) 58 | 155(r12) | 1291033) | 240174) | 200(%46) | 340(246) | 28.0203) ‘| 27-0 (195) | 2200180) | 42008) | 35.0 289) | 58.0(420) | 4900958) 718 | 91.0228) | 2501161) | 660477)_| —55.0(388) | —03.0(673) | 7701887) 4 380275) | 31.0226) | 98.0(r0a) | 22.0(600) | 1980 (o98) | 115.0 (692) Te | 86.0408) | 48.039) [1240 (607) | 104.072) | 207.0 (1454) | 768.0 (7215), “Tat |77.0(557) | 64.0463) | 1580 (1107) | 243.0 (1034) | 270.0 ote) | 2520 (1678) ‘aie | 108.0 (748) | 98.0622) | 231.0 (0677) | 192.0 (1389) | 374.0 2708) | 311.0 (2240), 172 | 136.0(684) | 113.0637) | 9080 2780) | 255.0 (1630) | 498.0 3568) | 410.0 (2066) K1200/CKE1100 3434.5 TIGHTENING TORQUE OF HYDRAULIC FITTINGS _Excossve or insfcient tightening of hes or tube ings an causeolleakand deformation cr damage tothe metal 3. GENERAL WORK STANDARD. ‘Trofeo secure and chain god hing and performance of tings tis necessary oti tothe proper toque “The follows ae the recommended torques, 1. BITE TYPE TUBE FITTINGS. ‘Size eh Tightening xque (Outside ameter tvicknes | kgm (tbs) 10 (0.368) X15 (0059) 5107 61051) 15 (0581) x20 (0079) 7310 16 9410 16) 18 (0.709) x25 (0.008) 1610 17 (11610 123) 220.866) X3.0 (0.118), 201022 (1451 159), 2a (1.102) X40 (0.157), 251020 (181 210) 35 1.378) X60 (0.197), 2. SPLITFIANGES 331036 2381 200) (From SAE Standard) sung ian Dm) | eiaiasern ; sponmce Sa aa a — fe] pewae ae me pone = 2 6 to 6 (43 1058) } Te | ara ar HH 26 034 (188 19 246) | (ek1200/KE1100,|. GENERAL WORK STANDARD 4, Jubilee Cip (Low Pressure and Sucton) ea Darel recienaeegn | wenger ange aes | ee a Cig ig 2 | aie | ost | as | ess | ie—[ ee [ise | aes |p| se | a so eae rp ies sr pee] 3o—| aarti | aan | ag [9 [0 | 3s_[vtae—[ ass as | ae | 097 [se | foarte | aaa an asa so—[ chet | aan [a8 97 [as ss—[ cee | aes [eof saat | so| taw-ae| asso [coe [so [910 | a8 en wo—| sae ste | aren [eon [soe [08 | a oo_[ gana | 70-09 [eo | e910 | aa ae] ater} ae | eso sto | 88 fa_[ arse [woe [eno | 90 | 08 | far_[ aes} o=wo—| sso | ss 108 | iat_[e-baee | —roo-te0 | ogo | 99 | os | ee saeceie [ess | ese | 80 [0 | iio[ “ee 7ae[ 0-10 | —o90 | 99 [3 | 8 aie rare | aezis| ee | to | sa[ eee [ae a00 | a0 | [98 | ao _[-vinrcioiie | aae-ar0 | rao | ot [9 |, arf one iiae | aaa | a0 —| or [90 | gat_[-iraestaie [aise | ru or 8 (©K1200/CKE1100 363.2 STANDARD PARTS 324 eotr ‘Size and kind of bot can be Kentfidas show Deon zseeces isi eeeereeerezes) 3. GENERAL WORK STANDARD Somrorentdnenson of C: Shows come srow tvesds, Shows te crow treads, Showing srengh and kindof bolt shies snows 47 S217: ahowa 77 42:18: shows {07 shows hexagon socket head bot ‘Some ols are stampa strength lass on he heads. oT, zie ar|@ |x © | (cK1200/6KE11002. GENERAL WORK STANDARD 322° O-RING ‘Size and kind of O-Ring are ened shown below |__ soning ride stameter Loe thickness ofthe ng 'P Shows fr tho use of moving part In, (6: For ne use of stationary part ome Ctassiing quality of rubber Net gure bur point of bl, red, green and of yellow oleurs are put on ‘Colour and quantity of pnts classi as folows {1:1 panto be cleur mean Hs70 12:2 pont of Be colour mean Hs80, Colour of point shows “Bain bus and rd tobe of nil rar and ive to be used in the range of temperature of mins 25¢ io120U(77F to 248) Fed for gasoine prot not to be usod noma. Groen o be of fuorine ruber and uted nth ange of temperature of minus 19UI6 2008(88" 103827 ) {point af ve: 2011 nit ubber Hs70 panne be :2012. nai ubber Hs00 1 point rea rir rubber 70 { poitofyolow: Syl rubber Hs70 { poitorgreen: ——fuoence rubber Hs70 (Ck1200/CKE1100 383. GENERAL WO 323° BACKUP RING ‘Size an kindof backup rng ar dents as shown blow. Lan showing ins ameter. : Closing with beso Showing shape To endess mathe Og 85 bia ct 95 pial =I RY 29 RK STANDARD 7h ' ¢k1200/¢KE11003. GENERAL WORK STANDARD 324 BEFITTING au ay” aio RARR ROARS] Te ROTRIE TiO oo Bi a aa mi pai = zs ee a = ans ae ears = zs Bam marae = wastes ara Sart = aoe zamon area j : fees =) TAROT le RNAS] ta ONE Nomnal Diameter GF) (za) (zk) % iio Ba ae = nes aaens Sas = Tia Bais ar z ara peers See A ao Zao so = pene ae an exta0ocKerteo oo2. GENERAL WORK STANDARD Sr Nomina! ameter ‘Made by HARA KOHATSU] — Made by NIHON ANG ade by NON ANC cr) ey 2) rn “BFBNI000 | Fagot 0000 RBN0000| 15 "ZFBN15000 ZASONISDOO KGW 15000 18 “ZF 93016000 ZAg9N10000 2K@3N 16000 2 -ZFBNZ2000 ZAGONZ2000 | ZKB3N22000 Ea [ZFBSN26000 | ZASSNZA000 ZKO3N26000 35 -ZFBNIS000 ZASONI5000 | ZKB3N35000 Nominal Diameter [MSdebyIHARAKONATSU] Mado by NIHON ANG] Made by NIHON ANC er) (ea) 2k) 7 ZFS I0000 ZaS10000 210000 15 7F55515000 7A93S15000 789515000 18 FOI 18000 ZAg3$16000 "ZK@351000_ 2 ZFS0S22000 7ZA93S22000 79572000 28 F5G28000 'ZA89828000 "2K9820000 35 7F50535000 7ZA83S35000 789535000 Tiahtening torque ZE + ZA Type ‘Nominal Diameter @ 6 8 @ % = Tightening fxquo | 621 | 1622 | tesd | asd | wes3 | wed ‘gm bs) caer) | cosets | crs02 te | 60214 | 00420) | 253 220) ‘Tightening toraue 2K Type ‘Nominal Diameter w 5 8 2 % % Tightening Toque | 6s | O27 | a2 | Ws2 | mas? | Mad gm (bs) wasn | sen | 7s) | a2aete | (60214 | 00220 ant (Ck1200/CKE1100,3. GENERAL WORK STANDARO 3.3. CONVERSION TABLE 334 UNIT CONVERSION [Remarks Figuosin( _) show number of zero down a decimal point Example :0(2)1 * 0.001 4. Lent Unt [mm | em oy = a a [ie mm 1 01 | e001 | eoo0et | eases | o.0oa2e08 [con nee | o1eyeaTe on 70 [001 | 0.0001 | 03997 | o.osza0e | o.0r0s36 | os)6214 m_ | tooo | —t00 + | 0001 | sas7 | 3.28088 | 10086 [ogata oo Tooo0o | 7000 | 1 | aea70 | s260.89 | 05561 | 97137 in| 2540_| 2540 | o02s4 | orajsa [1 | 0089 | oczrre [oasre ‘to [~s04e | oa048 | 0,308 | 12 1 [03933 | 0,894 ve | m4 | eras | ogres | o(ayovee | 36 3 1 [oxsssaz ‘ile | Y605547.5] 160954 70] t60035 | 1.60035 | esaed | smo | i760 | t 2. Capacty Ut [a [a fe ae a o_o em 1 [oust [0007 | 0x7 | oero | oraysesi | oey1308 | O82 me] fon0000 [1 [too [1 [eto [_as31 | 1.208 | 2042 te | 1000 [0007 | 1 [oor | ena | o0sssi | Ono1s08 | oz64a) wee | ooo00o | + | —Yooo [+ [soa | ass1 [108 [2042 i] 1639 | orarese | cores [oareas [1 | osre7 | axa2r43 | o00aaae | 26520 | oozes2 | 282 | ozaso [irae 1 | o0sroe | 7.48085, ye | 764so0 | 0.7645 | 7645 | 0765 | a0080_[ 27 1 [201978 gol | 3765 | 0.005785 | 5765 | ooosres| 231 | axsa7 | ocoaet| 1 3. Weight Uni is @ | (eoooweyet | za erat [mt 9 1 35.2740 | Za0062 | a00i102 | o1soee [000 oz | ames 1 0.06280 | o,a)sr25_| _0(g)e7e0 | 014)2836 © 0.45959 16 1 ‘0.00080 | 0.66460 | 0.48636 | 907.185 | S000 000 1 0.90786 | — 090719 ny 701605 | 35840 7230 ie i "101605 me 1000 ss274 22046 | —Tra2si | o08aat 1 [Remakes] nt:ton (ee) nt: on (Usunt)_gt (Bish Uni) ‘eK1200/0KE1100 3423. GENERAL WORK STANDARD 332 MILLIMETER : INCH CONVERSION TABLE 4. immo 99mm O_| coon | o.0see | oorer | over | 0767s | 07960 | ozaee [02766 | osi60 | 0685 40 | oaear [o.4ast | oa72e | atte | 0.612 | oooe | oczae | o.ens | 07037 | 0.7480 20 | o7e74 | 0.9268 | 09661 | o.s055 | 0.9649 | 0904s | 1.0796 | 1.0690 | 1.1024 | 1.1417 0) tert | 1.2205 | +2508 | +2052 | 1.3966 | 1.3760 | 1407s | vase | 1.406% | 1.5958 40 | sree | 16r42 | 1.6595 | 16029 | 1.7329 | 17797 | 19110 | 1.0506 | 1.9008 | 1.9291 '50__| 1.9685 | 2.0079 | 20872 | 20666 | 2.1260 | 2.1654 | 22087 | 2.2uan | 22635 | 2.5728 0 | 2622 | 24016 | 24400 | 2e03 | ster | 2s60r | asses | 20a7e | 26772 | 2.7165 7o__| 27559 | 2.7955 | 2nss6 | 267a0 | 20104 | 2.9526 | 20621 | sos1s | a070e | 3.1102 ‘ad | 2.406 | 3.1000-| a22ea | 22677 | 3.071 | 346s | aese | 34252 | oases | 2.6030 ‘0 | sass | 3.5627 | 36220 | a6616 | 3.7008 | 57402 | a.779s | 3.t69 | 3056s | 3.6976 254mm 343 (ek 1200/CKE11003. GENERAL WORK STANDARD 2. nh Facon inter a | wn | B8A0 | Bano | Tez | on eto] 127.066] Teaao0| ¥7.800| 258700] 2aa600 wea 0367 | 25707 | si.s0r | rasor [101.907] 127307 | sao] 17e.197| 203.597 | 228.907 sa [ o7oe | 26. | 61.594 | resoe | 102994] 127.750 | 19.104| 176558) 203.994 | 720.98 ‘vio_| 1588 | 26900 | 5206 | 77706 | 103.168 | 128.566 | 15.008] 170.08 | 20478 | 20.108 ‘aaz_| 2aet | a7er [sae | 7esot [103961 | 19.301] 164761 | 10.16r| 205581 | 290001 ‘ie [9.478] 26575 | 63.976 | 79:75 | 108775] 190.175 155575] 180975) 206.375] 231.775 so2_|-sae6 | 2536 | s1760 | on 160 | 105560] 130.900 156.909] 10.709] 207.1 | 252509 ‘a6 ares [90.169 [658509 | 0.90 | 100385 191.763] 15.163] 19.505 207 S65 | 235.363 “raz_|5.58_| 90.996 | 96.356 | 01 736 [107 196 3266] 167856] 165 66) 200756| 298 160 si [6.60 | 31.760 | 67-160 | €2580_| 107.050 190350 | 158.750] 188 50 200.550 238 950 oa [ ree | sae | sroee | a3. | 108744 | on tea 50.54] Yano | 710s | 255744 site| 7.008 | 39:8 | sa.708 | o4.198 | 10.898 4 930 | 160200] 185,96] 21.198 | 95.98 ‘waa | e7at | axtor | sesot [ont [ 0.91 | f.7a1 | 16.11 | 105.1 | 2inaos | 297391 xe | 0.55 | 9.05 | 60:05 | 05.725 [1.125 6 525] 01.925 167325] 272725] 298.725 aod [ wot | 95700_| 6.110 | e6.sre_| imate] rar s10| re27r9| 65.19 | 213.510] 28 910 76 | wi119 | sost3 | exis | e7ats | va7i3| rae 9) veasta| wears | 2r43t9| 250713 s1a2_| v4.08 | 37306 | 62706 | 08108 | 19.50 98 50616406 | 169,708 | 26.16 | 240 05 ‘va | #2700 | 38100 | 63500 | eas | 14.300] 19.700] 165.10 t0.500| 215.00 | 24.30 ‘ed_| tao [ane | 64.204 | o0.oe | 115.004 40456 105.004 | 193.296 | 27.69 242.098 ave 14.290 | soa | e588 | 00.88 | i508 | 41.266| ve5.608| 52066 217.460 242666 “araz_| 15.081 | aoast | 65.00% | 01291 [ 6so1| 42061] 16740 152081 |216201| 245 651 sie_—| 15075 | a1276 | eners | ezars [sw7.ars| 4207s] 168.275 | r0n.67s| 210.076 | 264475 ‘a2 | 16.80_| «2060 | 67480_| o2co | 18260 | 19.669| 160009 | 104.400 219969] 245269 1/16 | 17469 | 42.669 | 08.263, | 90065 | T8065 | 144.463] 169.865 | 195.263 | 20.665 | 266.063 ase | 10256 | 49.696 | 60.056 | 04.56 | 1.056 | 145.256] 170656] 198.056 | 77.456 | 240.850 | 19050 | 48450-| 69050 | 95.250 | 120650 48080, 171.450] 196.850 | 722.250 247 650 zeoa_[ wae | as2e4 | roou | ooous [ziaad| wee 172.244 | 107.644 | 225004 | 28444 ‘ene | 20.608 | «6.38 | 71.498 | 99.990 | 1222708] 147638] 173058] 198.498] 225.658 249.238 rsa avast | aban | raza | orasi [2a0or| east] 1731] 100231] 704631] 250.001 "7g _| 72205 | 4725 | 7a025 | 99.425 | 125025] 149 225] 174675] 20.005| 725425 | 250825 zana_| 29010 | seate | 7aate | e010 | vx6r9|is0019| 175a10| zi0.8t9| 726270| 251.619 “ene | 25813 | 0.219 | rats | 100019] r25aT3| va0ara] 1762713] 201919| 777.073 | 252419 3va2_[ 28606 | so006 | 75406 | 1006 | 25.206 15.606 17.006 22408 | 2.86 | 258.208 ek1200/KE1100 a42, GENERAL WORK STANDARD 333 METER-FOOT CONVERSION TABLE. Foot eter Foot Meier Foot Mater 5 152 155 4728 355) 10820 0. 3.05 160 2877 360 10873 15 457 165 60.29 265; 825 70 6:10 10 51.82 310 31278 25 782 18 eM 315 #1420 20 94 100 56.56 380 115382 35 087 786 36.99 5 41735 0 7219) 190 57.91 380 10387 ra 1372 786 Ex 25 12040 30 15:24 20 60.96 400, 12192 55 1678 205 62.8. 405; twa oy 18.29 210 e401 410 12497 65 1988 215 65.55 oo 12549 70 24 220 67.06 420 178.02 76 2.86 225 68.55 225; 170.54 20 24.38 230 70.10 420) 131.06 35 2551 235 7185, 455; 132.59 0 2.43 240 7.18 “40 24. 35 26.96 285 74.8 a5, 135.54 “00 2048 250 76.20 450 197.18 106; 52.00 255 772 455; 138.58 +0 388 260 70.25 460 14021 15; 35.05 205 e077 465; 16179 "20 36.56 210 22.20 470 148.28 725 38.10 215 33.62 475; 14478 730 3062 a0 3534 40 146.30 736 41.15 285 26.87 485 | 7.83 70 “4267 200 28.59 490 129.35 m3 44.20 206 09.02 495; 150.88 180 4572 300 oat 300] 18240 345 ek1200/¢KE1100{3 GENERAL WORK STANDARD 324 GRADIENT CONVERSION TABLE Degree | Peroent Dewres [Percent Degree [__Percont 1 15 16 287 3h e041 2 as Ww 208 2 025 3 52 18 325 38 649 4 70 8 Ma eT ors 5 28 20 34 35 700 6 105 2 384 38 Tar 7 123 2 404 aT 754 3 143 zm | 425 38 784 3 188 26 445 0 a0. 10 176 25 456. 40 39 i 704 28 88 a 269) 2 213 2 510 a 900) 38 234 28 582 933) 4 249 20 554 a 86. 15. 258 30 ST s 000 (ek 1200/CKE1100, 3163. GENERAL WORK STANDARD 3.4 TABLE OF UNIT WEIGHT Weight per Weight por eee cn mate) ce cub. Mater Tad Wa Sand 19) Copper 38 Goal ois 08 ‘Stee T 1s Ces powder 10 Gastron | 72 Coke 05 “Auinur 27 ak 09 ‘Conerete 23 Cedar 04 Sal 20 Cypress a4 Gravel 19) Paviownia 03 1 Weight of wood shat of the ei, 2. Value swon inthe table may well taken for spect. legravay 347 k1200/CKE11003. GENERAL WORK STANDARD ek1200/KE1100 3484, POWER TRAIN at ek 1200/¢KE11004. POWER TRAIN k1200/CKE1100 424. POWER TRAIN 44 INTRODUCTION “This is a uly hyeraulc crawlar crane. “Te cranes engin drives pas ofandom-punger ‘ype double pump and tandem gear double pun eon- ‘nected to each pungersype pump through the power Sider ‘Both ofthe tandem plunger-iype double pump te vat abe. ‘One plunger ype double pumps the main pun, “Tne man pump powers he font and ear rum motors and the right and le crva ator though he two con tol vatves. Ferancther plunger ype double pump, the nner pup powers ho swing moter, and the outer pump powers ‘he boom drum motor, respectively. ‘The tandom gear double pump connect the swing and boom pump fed oo the foe fal brake cooing Tne offen and ear duns, The ine pug of tender oar double pump connected to tho main pump feed restried oo conten, ana th ater pump food Ito the auutary actuator (gantry oylnder/counter- \Woight sf removal yindor ransitr cylin, 43 ek 1200/CKE11004, POWER TRAIN Fig.t-1_ Component Locations S) ck1200/¢KE1100 444. POWER TRAIN 42 ENGINE 424 wTRODUCTION This chapter explains how to remove and renstalthe ‘ongin. Refer to tho manual provided bythe engine rmanutacures for maintenance and epa elas 422 REMOVAL Proceed as follows when remaing the engine rom the roche, Remove he pump die assembly wth the engine. 1. Lower he boom tothe grou, pin the upper spreader othe ower boom, ‘Store the gant in its ave postion. 2. Remove tne grounding cable of he bata. Remove he muti. |4. Remove the ar inet hase from the engine and ir cleaner, 5. Remove the arinter cose hose rom he engine snd alrite cooler. 15. when removing the englne and pump dive assem ts necessary to fst remove the guar 7. inthe engine ol, hydra ol and coolant water. 1 not drain the ol and water when itis hot. Thehotoland water may spout out which could re- sult in personal injury. After the oll and water has cooled, drain tho oll and water. Feallure to observe this precaution may resutin se- lous injury or death 8, Removethe cap screws that hldthe fanguaré tothe ‘lator and take off he radar assem. 8. Label and thon remove the hyerausc hoses rom the hyerause pumps. -Allthe pore and hoses should be plugged ope ent si from geting it ther 10 Label ana then remove the feline and elete hares rom engine Caplin ful ines to proven soar geting ino thom 45 ek1200/CKE11004. POWER TRAIN 11. Recheck tobe sure that no elect nes, me chanlaleannectons and fue ppos are remaining to interior wih tho removal ofthe engine. 12, Use asufcenty strong engine it. (The engine ower dvider combined weights approximately 1800 hg (3807 ts) - Noo tho thvoe designated it ing points on te engine assembly. 13. Remove the nus, washers and bts rm the rb- ber mounts ofthe engine and power vor. 14, Sint itt remove as asngleunithe engine and ump dive assem 18. Check ne rubber mounts and replace them i nec: 423. REPAIR AND MAINTENANCE Regering the repair and maintenance ofthe engine ‘efor to he mandal provided by the menuactrr. ‘The engine manufacturer: HINO MOTORS, LTO, ‘oK1200 Theengine model: CKE100; PIIC-UN (©K1200/0KE11004. POWER TRAIN 424° REINSTALLATION Proceeds follows when tesnstating the engine. (See page 48, 49) 1 Checktomake sure hat no felines exosnt water hoses, mechanical connection paso athe tems re oo intro wh the o-instalision, 2. Ifthe ubber mounts were removed, pace thar, 3. Using a suey strong engine, it the engine and place it ont tre mount pads 4. Use Lecto #271 one ur mount nksing bos snd hon them fo 559 5N-m (472 #44 be) tongue 5. Insta te radiator assembly and fan guar. The space betweon the fon shroud and fan should be ‘ven al arn, Use Lect 271 on the tots ofthe radiator assem by and ghton them wih 314 #31 Nom (232-228, bs) torque. 6. Connect al the elec tines that ware connect ‘es when the engine was emeved 7. Install athe fuelling hat were removed when the engine was removed 8. Insta te quar and connect he batery cabo. 8. Install the airinter cooler hose that wee removed ven te engine was removed, + Donot bring aflame or spark close tothe bat tories. + Since the battery electroyt is lute sulfuric fd, avoid battery acid contact with the kin, eyes, or clothing. ‘accidentally contacted, immediately ush the ‘area with water and consult a doctor immedi: ately. + Wear eye glasses to protect eyes when working ‘th elctralye Feallure to observe this precaution may result in se lous injury or death 40, Install neat hose and mt. 1. neal hyerauc hoses to the hycraulc pugs. 12, Rett the engine wth coolant water and engine ol tothe roquied eves a7 (ck1200/CKE11004. POWER TRAIN +8, Remove the afm th ue nes. 14, ta the engine and set tio owl. Check for wae ter and fat oaks, and any strange noises. [ACAUTION) Before staring the engine, r-chock al local, ful, \watrandhyerauc connections as wells mechanical Be prepared to stop he engine immediatly isome- thing unusual dvelops. Fig2-4 Engine (12) ro arene Taina ran fs So son unecemy osu ek1200/CKE1100 484. POWER TRAIN Fig244 Engine (2-2) rae 8 ie ay arsiyLocknite #271 eam: 22 ‘pp Loerie 927 Tattenng tore: 55859 on ese em viewa ‘opty ocxmiTe #27 one ee saat ben) sepyLocente a ‘Tieng rue 28427910 Geos2 toe) “Tito re 284229 New pestyuocxnite #278 Eee ‘ptyuocxrite #271 Tatars oe op LOCKTITE #271 ‘Titaing torque 6582259 en Gs 2035 bem) ‘ety Lockie #2 “9 (ek1200/CKE11004. POWER TRAIN 43 PUMP DRIVE ASSEMBLY 434 INTRODUCTION ‘This chapter explain how to remove, spect, opr and reinstall the pur eve assem. “The pump sive assembly is mounted cect ont the bof the engine, Itconsss of @couping power ‘iver, tancdem-mountd main pomp (tosh, prope) wingtboom host pup and two tandem gear double rnp connected to each tandem pump. ‘The power ofthe engine istansfered fom a fywhool ‘trough th coupling othe conte cor ofthe power d- vider Thee pars of gears vide tis power between ‘ha malo pur ehaf an! he eningfboom pump shah {and option pump sha. (See page 4-11) 432 REMOVAL Proceed as flows when removing the pump dive as semby. (See page 4-11) Pump dive assembly shouldbe removed fom th on- ‘ine according othe folowing procedure ony ater the ‘engine has been removed rom the machine a5 de ferbod in Section 42, {1 Bran te otin te power divider tough ho parton the lower part ofthe power dvr. 2. Romove the main pump, swngtboom pump and gear pun. Tag ers.) akg 27st) Takg (183s) kg {Gear pum (Cooling) (1asits) (OPTION) Main pump ‘SwingBoom pump Gear pump (Cont) 3. Using @ sutcenty song it device he approx ‘mate weight ofthe power dividers 190 kg (287 Ib), tach te tt ging to suspension sews provided on he power ddr (screw oles: M16) Removothacap screws stint fy wheat housing the engine and move the power dvr slow to ward the back ofthe engine. Remove the coupling and dsconnect the power der 4 The mai par ofthis coupling willbe rornoved with ‘th poner dhvidor connected tots core. ck1200/6KE1100 440