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Kato PREMIUM CITYRANGE CR-200RF Instruction Manual

Kato PREMIUM CITYRANGE CR-200RF Instruction Manual

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Instruction manual (61 pages)

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Instruction manual (158 pages)

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Applicable serial No.: 0051－

WARNING

・ You must read and understand this manual before operating

or servicing this crane.

If you do not do so, you may cause serious injury or death

including damage to the equipment etc.

・ All people who come into contact with this crane must read

and be familiar with the contents of this manual. Keep it in

the crane so it will be available to anybody who needs it.

・ If you need a copy of this manual in another language, ask

your authorised KATO dealer.

218711

Table of Contents

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Summary of Contents for Kato PREMIUM CITYRANGE CR-200RF

Page 1 Keep it in the crane so it will be available to anybody who needs it. ・ If you need a copy of this manual in another language, ask your authorised KATO dealer. 218711...
Page 2 背厚 14.5 mm　（中）...
Page 3 Cautions on setting outriggers Inadequate setting of the outriggers or an error in setting the outrigger status to the ACS could result in the crane tipping over. So be sure to check the following before starting work. ① Has the strength of the ground where the outriggers will be set been suﬀciently discussed with the work supervisor ? ②...
Page 4 All operations in accordance with lifting capacity chart Make sure that all crane operations are in accordance with the lifting capacity chart for the crane. Accidents such as the crane tipping over or damage to the boom etc. cannot be attributed but to operation beyond the lifting capacity of the crane.
Page 5 Don't use the crane to lift the planet !! If you use the crane to pull up or break oﬀ objects which have been driven into the ground or buried ( sheet piles, H-beams, posts, pipes etc. ) , or if you try to drag a load toward the crane by raising the boom, you place a strong diagonal load on the boom which may exceed rated lifting capacity by many times.
Page 6 Absolutely avoid releasing !! Working with the ACS emergency switch and the overhoisting emergency switch turned to the release positions risks causing accidents. Before you start work, always check that both switches are positioned correctly. ( 0099-0099-0E ) [ 4 ]...
Page 7 Attachments not designated by KATO may impair safety or performance. They may cause tip-over accidents or have an adverse eﬀect on the lifespan of the crane. KATO bears no responsibility for accidents or malfunctions which arise as a result of the ﬁtting of unauthorised attachments. ( 0099-0100-0E ) AdBlue®...
Page 8: How To Use This Manual
Indicates warnings concerning potential risks of injury or major damage to the crane. ( 0099-0050-0E ) ・ If this manual is lost or seriously damaged, please order a replacement immediately from your authorised KATO dealer. ・ When the user changes through resale or other circumstances, the instruction manuals must be transferred together with the crane.
Page 9: Inspection And Servicing
Serial number nameplate ( 0099-0221-0E ) When you order parts or repairs from your authorised KATO dealer, please help to ensure smooth processing by quoting the model and serial number of the crane at the same time. When you take delivery of the crane, make a record of its serial number, engine serial number and delivery date.
Page 10 Speciﬁcation of CR-200Rf Speciﬁcation of CR-200Rf ( T218351-003-0E ) 1. Crane Speciﬁcation ( T218351-004-0E ) Maximum lifting capacity : 20 ton×2.5m : 6.5m － 28.0m ( 6 section ) Boom length : 4.0m, 5.8m ( 2 section, oﬀset 7° － 60° ) Jib length Searcher hook ( option ) 1.0m ( High position and Low position ) Boom derricking angle : -9.5°...
Page 11 Accessory socket ( 24V ) USB socket ( output 5V-2.4A×2 ) Floor mat Entry key system K･COR ( KATO Crane Operation Recorder ) : Working light ( LED ) on boom, table and cab Standard equipment Winch view camera Hook for 20 ton Hook for 3.2 ton...
Page 12 Speciﬁcation of CR-200Rf 2. Carrier Speciﬁcation ( T218351-005-0E ) Drive system : 4×2, 4×4 Maximum traveling speed : 55km/h Grade ability ( tanθ ) : 60% ( computed at G.V.W.=19755kg ) : 4.7m ( 4 wheel steer ) Minimum turning radius ( center of extreme outer tire ) 8.0m ( 2 wheel steer ) Engine Maker...
Page 13 Speciﬁcation of CR-200Rf Safety devices : Emergency steering device Rear wheel steering lock system ( automatic ) Brake ﬂuid leak warning device Service brake lock Suspension lock Engine overspeed alarm Electrically retractable side view mirrors Left front view camera Rear view camera Clearance sonar system Radiator coolant level warning device Air ﬁlter service warning device...
Page 14 Speciﬁcation of CR-200Rf 4. Dimensions ( T217591-021-0E ) [ 12 ]...
Page 15: Recorded Data
Disclosure of data KATO, and agents of KATO, will not disclose or supply the data obtained to a third-party, except in any of the following cases. ・ The owner or user of the machine agreed to disclose the data.
Page 16 MEMO [ 14 ]...
Page 17: Table Of Contents
Table of Contents ( T218711-001-0E ) Introduction ………………………………………………………………………………………… [ 5 ] How to use this manual …………………………………………………………………………… [ 6 ] Inspection and servicing …………………………………………………………………………… [ 7 ] Serial number nameplate ………………………………………………………………………… [ 7 ] Operation qualiﬁcations …………………………………………………………………………… [ 7 ] Speciﬁcation of CR-200Ri ………………………………………………………………………… [ 8 ] Recorded data ……………………………………………………………………………………...
Page 18 Crane operation 218711 19. For safe operation ………………………………………………………………………… 171 20. How to read the capacity charts …………………………………………………………… 201 21. Crane operation devices …………………………………………………………………… 208 22. Crane operation when the outriggers are used ………………………………………… 224 23. Crane operation without outriggers ……………………………………………………… 251 24.
Page 19 List of illustrations Switches inside the cab Side panel 1 Roof window wiper/washer switch 6 Overhoisting emergency switch Working lamp switch 7 Boom extension/retraction emergency switch 3 Slewing warning lamp switch 8 Seat bypass switch 9 Loudspeaker system ( optional ) Winch lighting switch 10 Combustion type air heater ( optional ) 5 Slewing free/lock switch...
Page 20 Front panel 1 Information display 13 Parking brake switch 2 Entry key system authentication area 14 Left/right mirror selection switch 3 Hazard warning switch 15 Side-view mirror extension/stowage switch 4 USB power supply port 16 Slewing brake switch 17 Mirror heater switch ( optional ) Turn signal indicator lamp 6 Cluster meter panel 18 Suspension control switch...
Page 21 Information display ( initial screen display ) 1 Rear steering central position indicator lamp 12 Temperature/voltage conﬁrmation and fuel consumption display screen mode switch 2 Suspension operation OK indicator lamp 13 SCR cleaning cancel indicator lamp 3 Suspension locked indicator lamp 14 Outrigger operation screen select switch 4 Rear steering lock release conﬁrmation 15 Exhaust temperature warning lamp indicator lamp...
Page 22 Information display ( temperature/voltage conﬁrmation and fuel consumption display screen ) 1 Trip setting switch A, B for fuel consumption 7 KEY ON-OFF select display switch during driving 2 Maintenance alarm setting screen display 8 Display of battery voltage switch 3 Initial screen display switch 9 SCR cleaning cancel switch 4 Level gauge conﬁrmation screen switch 10 Display of hydraulic oil temperature 5 Brightness adjustment mode switch...
Page 23 Switches outside the cab Lower control switches 6 Extension/retraction switch ( self-reset type ) 1 Right-rear outrigger operation switch All-outrigger operation switch 7 Horizontal/vertical selection switch 3 Right-front outrigger operation switch 8 Left-rear outrigger operation switch 4 Outrigger control panel lamp switch 9 Left-front outrigger operation switch 5 Outrigger emergency switch [ 21 ]...
Page 24 MEMO [ 22 ]...
Page 25: General Devices ( For Driving And Crane )
( T218711-002-0E ) General devices 218711 ( for driving and crane ) 1. Part names and terms ………………………………………………………………………… 1 Part names …………………………………………………………………………………………………… 1 Terms ………………………………………………………………………………………………………… 2 2. For safe operation …………………………………………………………………………… 5 General precautions ………………………………………………………………………………………… 5 3. General operation devices …………………………………………………………………… 11 Inside the cab …………………………………………………………………………………………………...
Page 26 10. Entry key system ……………………………………………………………………………… 73 10-1 System components ………………………………………………………………………………………… 73 Registration mode ( Registering additional tags ) ……………………………………………………………… 74 10-2 10-3 Startup mode ………………………………………………………………………………………………… 76 Registration mode ( Unregistering tags ) ……………………………………………………………………… 77 10-4 10-5 Standby mode ………………………………………………………………………………………………… 80 10-6 Tag reader speciﬁcations ……………………………………………………………………………………...
Page 27: Part Names And Terms
1. Part names and terms 1. Part names and terms ( 541A-0019-0E ) 1-1 Part names ( 541A-0020-0E ) 1-1-1 Exterior ( 541A-0268-0E ) - 1 -...
Page 28: Terms
1. Part names and terms 1-2 Terms ( T218351-087-0E ) The following names and terms are used frequently in this manual and they are deﬁned as follows. ・ Boom…………………………… The box-shaped structure element which bears the load through the sheave, hoisting rope etc.
Page 29 1. Part names and terms ・ Pick and carry operation………… Driving with the suspension cylinders locked and a lifting load held ( without crane operation ) . ・ Boom angle ……………………… The angle between the boom center line and the horizontal. The lifting capacity for jib use is based on the boom angle.
Page 30 MEMO - 4 -...
Page 31: For Safe Operation
WARNING 2. For safe operation　 2. For safe operation ( 0099-0104-1E ) ・ This section lists precautions you should observe when operating this crane. ・ Make sure you fully understand these points before you start operation and observe them to operate safely. ・...
Page 32 Refer to the parts list on the crane and order a new sign from your authorised KATO dealer to replace the safety sign. ・ When you replace a safety sign, always check that it is identical to the original.
Page 33 WARNING 2. For safe operation　 ( 8 ) Keep the area of the operator's seat clean and tidy Do not leave parts, tools or other objects in the area of the operator's seat. These can cause unexpected accidents while you are working.
Page 34 WARNING　 2. For safe operation ( 12 ) Precautions when starting the engine indoors If you need to start the engine indoors, open doors and windows to ensure good ventilation. ( 13 ) Keep the surroundings of the engine clean and tidy Do not leave tools, rags etc.
Page 35 WARNING 2. For safe operation　 ( 16 ) Sound the horn before you start the engine ・ Before you board the crane, check that there is nobody nearby. ・ When you are about to start the engine, sound the horn to warn people nearby.
Page 36 MEMO - 10 -...
Page 37: General Operation Devices
3. General operation devices 3. General operation devices ( 061A-0003-0E ) ( 1 ) Inside the cab - 11 -...
Page 38 3. General operation devices ( 2 ) Outside the cab - 12 -...
Page 39: Inside The Cab
3. General operation devices 3-1 Inside the cab ( T218351-009-0E ) ( 1 ) Door The door can be opened with a starter key. After you ﬁnish work, turn the starter switch to the oﬀ position and always lock the door. The key should be kept by the operator. ・...
Page 40 3. General operation devices ( 2 ) Operator's seat Adjust it to the easiest position for you to operate the controls. It is dangerous to adjust the seat while you are driving or operating the crane. ( T218351-011-0E ) 1 ) Headrest Sit in the seat and adjust the height of the headrest.
Page 41 3. General operation devices 3 ) Front and rear height levers You can adjust the height of the front or rear of the seat base independently. Pull the front or rear height lever and use your body weight to raise or lower the front or rear of the seat base. ①...
Page 42 3. General operation devices 7 ) Pocket Documents etc. can be kept here. Check that the operator's seat is ﬁxed securely after adjustment. ( T217921-130-0E ) 8 ) Seat switch The seat is equipped with a seat switch that detects when the operator is sitting in the seat.
Page 43 3. General operation devices ② Sit in the seat and insert the tang into the buckle and push until it clicks. ③ Pull the seatbelt as far as your hip and adjust the fastening pulling the belt end through the tang. 2 ) How to remove and tow the seatbelt Press the removal button on the buckle once and remove the tang from the buckle.
Page 44 3. General operation devices ( 5 ) Windows 1 ) Rear window 2 ) Left window Grip and pull out the lock to slide open the window. * This window can be opened only 50mm. ・ After you ﬁnish work, close the window ﬁrmly until it locks. ・...
Page 45 3. General operation devices ( 7 ) Fuse box If a fuse blows, investigate and repair the cause before replacing the fuse with a spare fuse from inside the fuse box. ・ If a fuse blows, investigate the cause with the starter switch in the "OFF" position. After checking that there are no short circuits in the wiring, replace the blown fuse with a spare fuse of the same capacity.
Page 46 3. General operation devices ( 9 ) Keys ( 10 ) Hanger hook ( 11 ) Loudspeaker system ( optional ) For more information, see the attached instruction manual. - 20 -...
Page 47 3. General operation devices ( 12 ) Step lamp switch If this switch is set to the "ON" position, the step lamp will turn on whenever the door is open. Switch it "OFF" if the crane will not be used for a long period or if nobody gets into or out of the cab at night or in darkness.
Page 48: Front Panel
3. General operation devices 3-2 Front panel ( T218151-004-0E ) ( 1 ) Power window switch ( self-reset type ) When the starter switch is set to the "ON" position and the door is shut, this switch can be used to open and close the door window. The window will move in the corresponding direction for as long as the switch is pressed.
Page 49 3. General operation devices The engine is running in this position. ・ Do not leave the key in this position for a long time when the engine is not running as this can run down the battery. ・ When the starter switch is turned to the "ON" position, the lamps on the cluster meter panel will all light for three seconds.
Page 50 Make sure the device is compatible before using the ports, such as by checking the device instruction manual. ・ KATO will not provide warranty repairs for malfunctions/failures to devices used or for damage or data loss. ・ Do not insert metal or other objects into the ports. Also make sure no water or other liquids get inside the ports.
Page 51: Side Panel
3. General operation devices 3-3 Side panel ( T218351-031-0E ) ( 1 ) Roof window wiper/washer switch Set this switch to "ON" to have the roof window wiper work continuously and "INT" for intermittent action. Press the center of the switch to spray cleaning fluid from the washer tank through the nozzle.
Page 52: Outside The Cab
3. General operation devices 3-4 Outside the cab ( T218351-013-0E ) ( 1 ) Power window auxiliary switch If you have forgotten to shut the door window, use this switch to close the window from the outside. The door window will rise ( close ) for as long as the switch is pressed.
Page 53 3. General operation devices ( 3 ) Service switch This switch is used exclusively for servicing the engine and is set for normal operation when shipped from KATO. The service switch is used exclusively for servicing. Never disturb this switch unless instructed to do so by your authorised KATO dealer or KATO service representative.
Page 54 3. General operation devices ( 5 ) Engine cover 1 ) Opening and closing the engine cover ① To open the engine cover, grip the engine cover open/close handle and release the locks, then open the cover toward the rear. ・...
Page 55: During Driving
3. General operation devices ( 6 ) Toolbox ・ Do not place aerosol cans, paint thinner, or other dangerous flammable items in the toolbox. They could cause a ﬁre. ・ Be sure the toolbox is closed and locked during driving. Leaving the lid open during driving could cause items stored in the toolbox to fall out and damage the toolbox or machine, or cause a traﬃc disturbance.
Page 56 3. General operation devices ( 8 ) Fuse box If a fuse blows, investigate and repair the cause before replacing the fuse with a spare fuse from inside the fuse box. ・ If a fuse blows, investigate the cause with the starter switch in the "OFF" position. After checking that there are no short circuits in the wiring, replace the blown fuse with a spare fuse of the same capacity.
Page 57 3. General operation devices ( 10 ) ACS outside indicator The ACS outside indicator is available for this crane, which lets people other than the crane operator know the load status of the crane as ACS safety level, such as the rigger or safety supervisor. ・...
Page 58 3. General operation devices ( 13 ) Way side lamp ( optional ) The lamp is lit when the way side lamp switch is pressed with the lighting switch in the position of ( 14 ) Side marker lamps ( optional ) ( 15 ) Heated mirrors ( optional ) - 32 -...
Page 59 3. General operation devices (16) Storage box (optional) An electric wiring is arranged near the storage box, so be careful when taking it in and out. Also, do not put things that protrude extensively from the storage box. (T217051-039-0E) (17) Outrigger plate stowage brackets (optional) Make sure the outrigger plates are stowed securely with stoppers installed and locked in the correct positions to prevent the plates from falling out.
Page 60 MEMO - 34 -...
Page 61: Safety Signs
・ If it is not possible to remove the dirt or if a safety sign is damaged or peeling, replace the safety sign with new. Refer to the parts list on the crane and order a new sign from your authorised KATO dealer to replace the safety sign.
Page 62 WARNING 　4. Safety signs [ 6 ] Content: Notes for the lifting capacity chart Location: Inside the cab Part No.: 44A-75106001 [ 6 ] Content: Notes for crane operation Location: Inside the cab Part No.: 44A-75106001 - 36 -...
Page 63 Be sure to read the instruction manuals carefully and familiarize yourself with the contents before operating the crane. If you cannot understand how to manipulate or deal with the crane, contact your authorised KATO dealer. Location: Inside the cab Part No.: 001-81332001 - 37 -...
Page 64 WARNING 　4. Safety signs [ 60 ] Content: Warning when tilting the seat forward while operating the crane Location: Inside the cab Part No.: 521-75116000 [ 61 ] Content: Warning of suspension lock release with the outriggers extended Location: Inside the cab Part No.: 371-75118001 [ 62 ] Content:...
Page 65 WARNING 4. Safety signs　 [ 70 ] Meaning: Operation prohibiton Part No.: 707-75118001 [ 81 ] Meaning: Beware of falling. Location: Left side of the slewing table Part No.: 001-81302010 [ 82 ] Meaning: Do not allow anybody, even other site workers, to enter the rear slewing radius.
Page 66 WARNING 　4. Safety signs [ 86 ] Content: Precautions for the slewing range Location: Inside the cab Part No.: 899-81430492 [ 87 ] Content: Precautions f or the boom angle when swinging the jib out or stowing the jib Location: Inside the cab Part No.: 899-81421572 [ 94 ] Content:...
Page 67 WARNING 4. Safety signs　 ( 2 ) Boom and jib [ 1 ] Content: How to connect the connector for overhoisting detector Location: Right side of the boom top Part No.: 44A-75801001 - 41 -...
Page 68 WARNING 　4. Safety signs [ 14 ] Content: Note for the rope guide Location: Right side of the jib Part No.: 899-81410292 [ 20 ] Content: How to connect the connector for overhoisting detector Location: Right side of the jib Part No.: 581-75602000 [ 21 ] Meaning: Do not allow anybody, even other site...
Page 69 WARNING 4. Safety signs　 [ 31 ] Content: When operating the crane, detach the boom guard. Location: Front of the boom guard Part No.: 899-81422512 [ 86 ] Content: Note when lowering the boom Location: Inside the cab Part No.: 899-81430492 [ 87 ] Meaning: Note for the boom angle when swinging out or stowing the jib...
Page 70 WARNING 　4. Safety signs ( 3 ) Lower structure [ 5 ] Content: Precautions for fuel to be used Location: Near the fuel ﬁller port Part No.: 899-81421082 [ 6 ] Content: Check the DEF ( AdBlue® ) level. Location: Near the fuel ﬁller port Part No.: 44A-75506000 [ 15 ] Meaning: Do not touch the engine, its surrounding, the...
Page 71 WARNING 4. Safety signs　 [ 16 ] Meaning: Never bring any ﬂame or source of ignition near the fuel tank. Location: Near the fuel filler port, and side of the oil reservoir Part No.: 001-81332005 [ 17 ] Meaning: The coolant will be hot while the engine is running or immediately after it has stopped.
Page 72 WARNING 　4. Safety signs [ 36 ] Meaning: Climbing prohibition Location: Top surfaces of the engine cover ( 2 places ) and the air cleaner Part No.: 001-81332011 [ 42 ] Content: Precautions on handling the battery Location: Side of the batteries Part No.: 707-75122001 [ 44 ] Content: Prohibition of high pressure cleaning...
Page 73 If you cannot understand how to manipulate or deal with the machine, contact your authorised KATO dealer. Location: Inside the cover of the outrigger control panel Part No.: 001-81332001 [ 101 ]...
Page 74 MEMO - 48 -...
Page 75: Precautions On Getting On And Off The Machine
5. Precautions on getting on and oﬀ the machine 5. Precautions on getting on and oﬀ the machine ( 541A-0042-0E ) ・ When you get on and oﬀ the machine, face toward it and use the hand grips and steps to support yourself. Keep at least three points of support at all times on the hand grips and steps. Do not use the control levers to hold on to.
Page 76: Precautions When Filling With Fuel
6. Precautions when ﬁlling with fuel 6. Precautions when ﬁlling with fuel ( T218351-016-0E ) Strictly observe the following precautions when ﬁlling with fuel. ・ Do not carry any other fuel or fuel container than the fuel tank. ・ Always ﬁll with speciﬁed fuel. If you use a non-recommended fuel, performance will be impaired and a major accident could result.
Page 77 Using anything other than the speciﬁed fuel is not covered by the warranty, of course, but also could cause a major malfunction. In addition, the appropriate fuel ﬁlter element for this engine has been speciﬁed as well, so it is important to use genuine KATO fuel elements. ( 2 ) Fuel 1 ) Selecting fuel Diesel engine fuel should satisfy the following criteria.
Page 78: Air Conditioner
7. Air conditioner 7. Air conditioner ( 541A-0046-0E ) When the engine is running, the operating mode can be switched between cooling, heating, or dehumidifying/heating modes, or the air outlet mode can be switched between upper body, lower body, or defrost modes. 7-1 Function of each switch ( T217921-015-0E ) ①...
Page 79: Temperature Setting Values And Corresponding Display
7. Air conditioner 7-2 Temperature setting values and corresponding display ( T217921-016-0E ) ( 1 ) The indicator displayed for each temperature setting is shown below. ( 2 ) How to change the temperature With each recognized press of the [ temperature setting UP arrow ] switch, the temperature setting value is increased by one level ( towards HOT ) .
Page 80: Fan Speed Setting Values And Corresponding Display
7. Air conditioner 7-4 Fan speed setting values and corresponding display ( T217921-018-0E ) ( 1 ) The indicator displayed for each fan speed setting is shown below. ( 2 ) How to change the fan speed With each recognized press of the [ fan speed UP arrow ] switch, the fan speed increases by one level, in the sequence Lo →...
Page 81 7. Air conditioner 2 ) After the oil temperature increases from the state described in 1 ) and reaches the prescribed temperature, the fan speed remains ﬁxed at Lo for three minutes. During that period, the fan indicator and Lo speed bar indicator ﬂash, and the fan speed bar indicators other than for Lo speed ( the prescribed value ) are lit.
Page 82: Display When Errors Are Detected
7. Air conditioner 7-6 Display when errors are detected ( T217921-020-0E ) - 56 -...
Page 83: Color Monitor
8. Color monitor 8. Color monitor ( T217051-069-1E ) 8-1 Part names ( T218351-017-0E ) ( 1 ) Color monitor/Remote control Never operate the monitor while driving. ( T217921-106-0E ) ( 2 ) Left-forward view camera ( color ) - 57 -...
Page 84 8. Color monitor ( 3 ) Rear view camera ( color ) Precautions for models equipped with the rear view camera The screen image automatically switches to the rear view camera image whenever the shift lever is shifted to the "R" position, regardless of the camera mode button status. Shifting the shift lever to any gear position restores the image displayed before shifting to the "R"...
Page 85 8. Color monitor ( 5 ) Wireless rear view camera ( optional ) The wireless rear view camera is installed at the same time as the regular rear view camera included standard on the slewing upper structure. The rear view camera mode switch on the front panel is used to switch between displaying either the image from the slewing upper structure rear view camera or the image from the wireless rear view camera on the color monitor.
Page 86 8. Color monitor 8-1-1 Description of functions ( T217481-009-1E ) ( 1 ) POWER /STANDBY button When the POWER/STANDBY button is pressed, the lamp is unlit and power is turned on. When the POWER/STANDBY button is pressed again, the lamp is lit and power is turned oﬀ. ( 2 ) VOL +/-: Volume control button ( volume control ) Volume can be controlled by holding down the ▲/▼...
Page 87 8. Color monitor ( 4 ) Screen switching When the MODE button on the monitor is pressed, the screen is switched. Split screen buttons on the remote control enable to switch to other split screens. ( 5 ) Splitting method switching When the ▲/▼...
Page 88 8. Color monitor 2 ) External input switching When the AV button is pressed, the screen is switched to the external input ( AUX ) screen. When the AV button is pressed again, the previous screen is restored. 3 ) Split screen setting When the MENU button on the monitor or the SETUP button on the remote control is pressed under a split screen status, the split screen setting screen appears.
Page 89 8. Color monitor ③ Example of setting of quad split screen NOTE In case of quad split screen by any other method, the setting method is the same. （7 ) Signal input screen switching 1 ) Camera images during signal input can be set. The factory default setting is "VIDEO SWITCH 1".
Page 90 8. Color monitor ③ When signal inputs 2 to 4 are entered, image can be displayed on a split screen, too. Factory default is "FULL SCREEN " . NOTE For the trigger image for the camera 3 or 4, the setting method is the same. 3 ) When "...
Page 91 8. Color monitor ② When the signal input 2 ( left turn signal ) or the signal input 3 ( right turn signal ) is entered, image can be displayed on a split screen, too. This function allows checking the rearward simultaneously when turning left ( or right ) . When the signal input 2 ( or 3 ) is entered, the images of the camera 2 ( or 3 ) and camera 1 are displayed on the split screen irrespective of the previous screen.
Page 92 8. Color monitor ⑤ When a number of signals are entered, the image is displayed in the following order. When a signal is entered in STAND BY ( standby ) status, the power of the monitor is turned on and the camera image is displayed.
Page 93 8. Color monitor 8-1-2 Change of setting ( T218001-041-0E ) ( 1 ) Dimmer setting Dimmer function adjusts brightness of the screen. Adjustment of daytime / night / auto is available. The factory default setting is "AUTO". ① When the MENU button on the monitor or the SETUP button on the remote control is pressed three times, "PICTURE SETUP"...
Page 94 8. Color monitor ( 4 ) Initialization of setting All settings can be initialized to the factory default setting. ① When the MENU button on the monitor or the SETUP button on the remote control is pressed three times, "PICTURE SETUP" menu appears. ②...
Page 95 8. Color monitor ( 8 ) Setting of marker indication 1 ) While the camera 1 is displayed in full screen mode, press the MENU button on the monitor or the SETUP button on the remote control. 2 ) Press the MODE button on the monitor or ▲/▼ button on the remote control to select "ON"...
Page 96 8. Color monitor ( 10 ) MARKER ADJUST ( Adjustment of vehicle bumper position ) 1 ) Press the MENU button on the monitor or the SETUP button on the remote control ﬁve times to select the MARKER ADJUST menu. 2 ) Press the MODE button on the monitor or ▲/▼...
Page 97: Radio
9. Radio 9. Radio ( T218351-018-0E ) 9-1 Names of buttons ( T218351-019-0E ) Name Function [ PWR ] button Switches the radio ON or OFF [ AM/FM ] button Switches between AM, FM1, and FM2 bands [ VOL+ ] [ VOL- ] buttons Adjusts the volume up or down [ UP ] [ DOWN ] buttons Used to switch frequencies, adjust steps for adjusting the sound, and adjust the clock [ PRESET ] buttons Recalls or registers preset frequencies...
Page 98: Operating Buttons
9. Radio 9-3 Operating buttons ( T218351-062-0E ) ( 1 ) Operations with the power "ON" Radio ON ( Normal status ) Clock adjustment Short press Switches power OFF ( clock display ) Switches power OFF [ PWR ] Long press ─ ─...
Page 99: Entry Key System
10. Entry key system 10. Entry key system ( T218111-009-0E ) This is a theft prevention system that uses IC tags. When it is activated, it prevents starting the engine with anything except the registered startup tag. ・ Do not bend or apply strong impacts to tags during use or storage. ・...
Page 100: Registration Mode ( Registering Additional Tags )
・ Lost or damaged registration tags can be reissued, but a fee is charged. To reissue a registration tag, contact an authorised KATO dealer. ( T217201-015-0E ) ( 1 ) To register a startup tag, touch the registration tag against the tag reader area.
Page 101 10. Entry key system ( 3 ) Move the registration tag away from the reader and lightly touch the startup tag to be registered against the reader. When the startup tag touches the reader, one long alarm sound is emitted. ( 4 ) After moving the startup tag away from the reader, turn the starter switch to the "OFF"...
Page 102: Startup Mode
10. Entry key system 10-3 Startup mode ( T218351-065-0E ) ( 1 ) To use a registered startup tag to start the engine, touch the startup tag against the tag reader area. With the starter switch in the "OFF" position and the tag reader ﬂashing red, lightly touch the startup tag against the tag reader, so that the alarm sounds once and the tag reader changes from flashing red to steady blue illumination and the engine starts.
Page 103: Registration Mode ( Unregistering Tags )
10. Entry key system 10-4 Registration mode ( Unregistering tags ) ( T218351-066-0E ) ( 1 ) To unregister a startup tag, touch the registration tag against the tag reader. When the registration tag touches the tag reader, an alarm sounds once and the reader illuminates purple. If the registration tag is separated from the reader before the starter switch is turned to the "ON"...
Page 104 10. Entry key system ( 3 ) Move the registration tag away from the reader and then use one of the following methods to unregister the startup tag. 1 ) To unregister a speciﬁc startup tag B, touch tag B against the tag reader.
Page 105 10. Entry key system ( 4 ) After touching the startup tag or registration tag against the reader, turn the starter switch to the "OFF" position. When the starter switch is turned to the "OFF" position, the tag reader will change from purple to the following state.
Page 106: Standby Mode
10. Entry key system 10-5 Standby mode ( T218111-020-0E ) ・ Standby mode ( 1 ) When the entry key system is OFF ( No startup tags registered ) * In this state, the starter switch can be turned either to the "ON" or "START" position. ( 2 ) When the entry key system is ON ( Locked ) * If the starter switch is turned to the "ON"...
Page 107: Characteristics Of The Tags
10. Entry key system 10-7 Characteristics of the tags ( T218111-130-0E ) ( 1 ) Startup tag 1 ) Case 1: Where plural startup tags are used to start up a machine Two startup tags are standardly provided with each machine, but the number of tags can be increased by purchasing separately.
Page 108: Starting And Stopping The Engine
If no problem is detected, all warning lamps will go out. If all warning lamps continue to light or all warning lamps do not light, stop the engine start procedure and contact your authorised KATO dealer. ( 121A-0077-2E )
Page 109 11. Starting and stopping the engine ( 6 ) Warm-up running Once the engine has started, warm the engine and the torque converter adequately. This warm-up time can be used for going through the after-starting tests. Raising the engine speed without doing warm-up running for the engine and torque converter could cause a seizure, fast wear, damage etc.
Page 110: Stopping And Parking
11. Starting and stopping the engine 11-2 Stopping and parking ( T217051-017-0E ) ( 1 ) Always apply the parking brake when parking the machine. On slopes etc., place chocks in front of the wheels if necessary. ( 541A-0060-2E ) ( 2 ) When you stop the machine, bring it to a stop, lift your foot from the accelerator pedal and leave the engine idling for about ﬁve minutes to cool down.
Page 111: Handling The Machine In Winter And Summer
( 2 ) Engine oil Use an engine oil recommended by KATO or speciﬁed by Cummins ( Cummins Premium Blue ) . Using an oil other than the type recommended by KATO or speciﬁed by Cummins could cause engine malfunction/failure.
Page 112: Handling In Summer
12. Handling the machine in winter and summer ( 4 ) Long Life Coolant To prevent the engine coolant freezing during the shipping period between leaving the factory and arriving at the point of delivery, the cooling system is ﬁlled with Long Life Coolant as shown below, regardless of the season. ・...
Page 113: Scr System
13. SCR system 13. SCR system ( T218351-020-0E ) This machine is equipped with an SCR ( Selective Catalytic Reduction ) system for reducing the level of toxic NOx gases in exhaust emissions. The SCR system sprays exhaust gases with the DEF ( Diesel Exhaust Fluid ) to convert the toxic NOx gases into harmless water and nitrogen.
Page 114 13. SCR system ・ Only use the DEF in accordance with ISO 22241-1. Do not use any DEF other than the brand speciﬁed. ・ Do not dilute the DEF or add any additives. Doing so could not only result in worse gas emissions, but also could cause the machine to fail.
Page 115: Clearance Sonar System
14. Clearance sonar system 14. Clearance sonar system ( T218301-010-0E ) 14-1 Description ( T218351-051-0E ) The clearance sonar system uses ultrasonic obstacle sensors to detect obstacles in areas around the crane and emits a corresponding alarm to reduce accidents involving contact or collisions with obstacles. The sensors are installed in four locations ( left-front, left-front wheel, rear, and left-rear corner areas ) .
Page 116 However, be careful to prevent getting the connector areas wet with water. If foreign matter becomes adhered to a sensor and cannot be removed, promptly contact your authorised KATO dealer.
Page 117: System Configuration
14. Clearance sonar system 14-3 System conﬁguration ( T218301-018-0E ) The clearance sonar system includes the following components. ( 1 ) Ultrasonic obstacle sensors Four sensors are installed on the machine. ( 2 ) Indicators - 91 -...
Page 118 14. Clearance sonar system 1 ) Power lamp Lights ( blue ) when power is supplied. Changes to ﬂashing after the cancel switch is pressed and the alarm stops sounding. 2 ) Alarm sound cancel switch The alarm sound can be stopped by pressing this switch ( each sensor lamp will remain displayed ) . After the alarm sound is canceled, the power lamp will ﬂash ( blue ) .
Page 119: How To Use The System
If the following symptoms occur, the clearance sonar system may not be functioning properly, due to an obstacle sensor malfunction or other problem. If so, contact your authorised KATO dealer. ・ The power lamp does not light even when the starter switch is turned to the ON position.
Page 120 MEMO - 94 -...
Page 121: Driving Operation 218711
( T218711-003-0E ) Driving operation 218711 15. Driving safely …………………………………………………………………………………… 95 16. What to do when the machine breaks down …………………………………………… 103 16-1 Cautions on breakdown …………………………………………………………………………………… 103 16-2 Emergency power steering ………………………………………………………………………………… 104 16-3 Handling a malfunction in the automatic transmission system …………………………………………… 105 16-4 Dealing with breakdowns …………………………………………………………………………………...
Page 122: Driving Safely
WARNING 15. Driving safely　 15. Driving safely ( T218351-022-0E ) In addition to the precautions listed below, always drive safely and carefully, observing basic precautions and driving etiquette. ( 1 ) Do not keep anything other than the standard equipment on the body of the machine when driving normally.
Page 123 WARNING 　15. Driving safely ( 5 ) Keep the working lamps oﬀ when driving on the roads Keep all working lamps and other lamps on the crane switched off when driving on the roads at night. Use of these lamps disturbs other drivers, and it may be forbidden by law.
Page 124 WARNING 15. Driving safely　 ( 9 ) Have another worker guide you through narrow openings or place with poor visibility. This guidance will help to avoid scrapes or impacts with obstacles, people or machines etc. ( 10 ) Take care around train power cables and bridge spans When driving, pay close attention to the distance from the machine in front, machine height and width and distance to any obstacles.
Page 125 WARNING 　15. Driving safely ( 13 ) Brake operation 1 ) Check that air pressure is normal, then release the parking brake. If you try to release the parking brake when the compressed air pressure is below the rated pressure, the buzzer will sound to warn of inadequate air pressure.
Page 126 WARNING 15. Driving safely　 5 ) If the machine was stopped after heavy brake use or after applying the emergency brake, be sure to confirm brake performance by depressing the brake pedal before starting to move again. If a heat-soak phenomenon occurs, the brakes may not function properly after starting to move again.
Page 127 WARNING 　15. Driving safely ( 15 ) During driving on public roads, use mirrors or other means to carefully check for bicycles, motorcycles, or other vehicles that may be hidden behind the boom. Carefully check mirrors and so on before starting to move. ( 16 ) Precautions about the SCR system 1 ) Engine intake/exhaust system cannot be modified because exhaust gas aftertreatment system failure or engine stop may...
Page 128 SCR system and engine. 6 ) Use low-ash engine oil, "E9 standard." Use an engine oil recommended by KATO or specified by Cummins ( Cummins Premium Blue ) . Using an oil other than the type recommended by KATO or speciﬁed by Cummins could cause engine malfunction/failure.
Page 129 MEMO - 102 -...
Page 130: What To Do When The Machine Breaks Down
If the breakdown occurs in a tunnel, even a simple repair can be dangerous and can lead to serious secondary damage, so never attempt any repair within a tunnel. ( 5 ) If you cannot repair the breakdown, contact your authorised KATO dealer to order a repair. - 103 -...
Page 131: Emergency Power Steering
16. What to do when the machine breaks down 16-2 Emergency power steering ( 541A-0075-1E ) This machine is equipped with an emergency steering pump connected directly to the transmission to enable power steering in the event of sudden engine failure or steering pump breakdown while in motion. Moving the machine backward during evasive maneuvers can cause sudden highly dangerous failure of the emergency power steering.
Page 132: Handling A Malfunction In The Automatic Transmission System
16. What to do when the machine breaks down 16-3 Handling a malfunction in the automatic transmission system ( 471A-0018-1E ) If a malfunction occurs in the automatic transmission, the AT/M malfunction warning lamp on the cluster meter panel in the cab will light to alert the driver. Depending on the cause of the malfunction, the automatic shift control may not function, in which case it will be impossible to go on driving.
Page 133 ・ If the AT/M malfunction warning lamp lights, park the machine in a safe place immediately. After stopping in a safe place, stop the engine then start it again. If the AT/M malfunction warning lamp is still lit, leave the machine where it is and contact your authorised KATO dealer for instructions.
Page 134: Dealing With Breakdowns
( 4 ) Once the engine starts, disconnect the booster cables in the reverse order from the connection order above. Have the battery completely recharged or replaced by a gas station or your authorised KATO dealer as soon as possible.
Page 135 Investigate the cause of the breakdown. If you consider it impossible to repair on site, have the machine towed away for repairs. In this case follow the procedure below. ・ Contact your authorised KATO dealer to have it make the necessary preparations for towing, then proceed cautiously with towing.
Page 136 16. What to do when the machine breaks down ( 1 ) If the cause of the breakdown is not the engine and the engine may be used without causing problems: 1 ) Shift lever………………………… "N" 2 ) Start the engine. 3 ) Hazard warning switch …………...
Page 137: Drive Operation Devices
17. Drive operation devices 17. Drive operation devices ( 061A-0012-0E ) Familiarize yourself with the names and operation methods of the devices such as levers, meters, switches etc. before you start to drive. ( 1 ) Inside the cab - 110 -...
Page 138 17. Drive operation devices - 111 -...
Page 139 17. Drive operation devices - 112 -...
Page 140: Cluster Meter Panel
17. Drive operation devices 17-1 Cluster meter panel ( 541A-0086-0E ) 17-1-1 Meter section ( T218351-025-0E ) ( 1 ) Speedometer Indicates the speed at which the machine is driving. 1 ) Indication switching between km/h and km/h-MPH on the cluster meter panel ①...
Page 141 17. Drive operation devices ③ If the KEY ON-OFF select display switch during driving, trip setting switch A for fuel consumption during driving, or trip setting switch B for fuel consumption during driving is pressed when the km/h-MPH display is selected, the odometer/trip meter indications are also displayed in both miles and km on the cluster meter panel.
Page 142 5 or below, check that it climbs back to the 5 ― 9 range when the engine is running. If the air pressure climbs above 9, stop the engine immediately and contact your authorised KATO dealer. ( 9 ) DEF level meter Indicates how much DEF is remaining.
Page 143 AT/M controller, sensors or switches etc. A pop-up window for error occurrence display also appears on the information display. When the AT/M malfunction warning lamp ﬂashes or lights, stop the machine in a safe place and contact your authorised KATO dealer quickly. ( 541A-0089-1E ) - 116 -...
Page 144 If the machine is driven when pressure is below the rated pressure, the clutch for the transmission will wear away, so stop the machine immediately and contact your authorised KATO dealer. If any of the problem listed below occur, stop the machine immediately and contact your authorised KATO dealer.
Page 145 17. Drive operation devices ( 12 ) Preheat indicator lamp When you turn the starter switch to the "ON" position, engine preheating starts automatically if necessary and this indicator lamp lights. When the preheating is completed, the indicator lamp goes out. Then turn the starter switch to the "START"...
Page 146 After air pressure has been raised above the rated level, release the parking brake and move oﬀ. If any of the problems listed below occurs, stop the machine immediately and contact your authorised KATO dealer. If there is a problem with sensors or wiring, the warning lamp ﬂashes. ( 541A-0091-1E ) ( 17 ) Battery charge indicator lamp This lamp lights when the starter switch is turned to the "ON"...
Page 147 This lamp lights while the rear steering lock is released. If this lamp lights or ﬂashes while you are driving on the roads, stop the machine immediately and contact your authorised KATO dealer. ・ When the rear steering emergency switch has been switched …… Rapid ﬂashing ( 0.5 seconds intervals )
Page 148 DEF. The warning will be canceled once the speciﬁed DEF is replenished. 2 ) SCR system error warning This is displayed if a problem is detected with a component in the SCR system. If this warning is displayed, promptly inspect the system and contact your authorised KATO dealer. - 121 -...
Page 149 DEF. The warning will be canceled once the speciﬁed DEF is replaced. If replacing the ﬂuid does not deactivate the warning, contact your authorised KATO dealer. If machine usage restrictions are applied due to an SCR system error or DEF quality error, the waning is canceled, and another warning with a lower warning level than the warning at point B in the ﬁgure below is displayed again within 40 minutes after canceling the previous warning,...
Page 150 ( engine torque and speed ) will be restricted. If this warning is displayed, promptly inspect the system and contact your authorised KATO dealer. - 123 -...
Page 151 17. Drive operation devices ( 23 ) Rear steering angle display NOTE The rear steering angle is displayed with numbers from 0 to 9 like the conventional rear steering angle display. ・ When the rear steering lock has been released The rear wheels steering angle will be displayed.
Page 152 17. Drive operation devices ( 27 ) Fuel display The display diﬀers depending on whether the PTO switch is ON or OFF. Fuel consumption is displayed in terms of liters per hour ( L/h ) when the PTO switch is ON and kilometers per liter ( km/L ) when the PTO switch is OFF.
Page 153 17. Drive operation devices - 126 -...
Page 154 17. Drive operation devices - 127 -...
Page 155: Information Display
( 1 second intervals ) . If this lamp ﬂashes, stop the engine immediately and contact your authorised KATO dealer. ( 2 ) Outrigger operation OK indicator lamp ・ This lamp lights when the PTO switch is "ON" and the front area switch is "ON", or when there is an ACS system error.
Page 156 17. Drive operation devices ( 4 ) Suspension operation OK indicator lamp This lamp lights when the following conditions for suspension operation are satisﬁed. ・ Boom angle ………………………… 50° or less ・ Boom length ………………………… Fully retracted ・ Slewing upper structure position …… Within front 0° ±5° Within rear 180°...
Page 157 17. Drive operation devices ( 6 ) Suspension locked indicator lamp This lamp lights when the suspension is locked. If the machine runs at an excessive speed with the suspension locked, the warning buzzer sounds continuously. If an invalid suspension operation is performed by moving the shift lever to any position other than "N", the warning buzzer sounds continuously.
Page 158 17. Drive operation devices 17-2-2 Switch section ( T218351-081-0E ) When a switch operation registers, it makes a "pip" tone and the color of the switch changes. If there is some misoperation, the conditions for the operation have not been met, or for any other reason the switch operation does not register, the misoperation warning buzzer "pip pip"...
Page 159: Display Of Battery Voltage
17. Drive operation devices 1 ) Display of hydraulic oil temperature Hydraulic oil temperature 39℃ or lower ( blue ) From 40℃ to 90℃ ( green ) 91℃ or higher ( red ) Temperature of 14℃ or lower is "- - -℃." ・...
Page 160: Scr Cleaning Cancel Switch
17. Drive operation devices ・ When the PTO is "OFF" ( for driving on roads ) When the battery voltage falls below the rated voltage ( 20V ) , the current voltage is displayed in red, the battery charge indicator lamp on the cluster meter panel starts to ﬂash and the warning buzzer sounds. At the same time, the battery voltage indicator lamp lights.
Page 161 17. Drive operation devices 2 ) To shift to two-wheel drive, press the switch while the two/four wheel drive switch lights in green. The conﬁrmation buzzer "pip" will sound and the two/four wheel drive switch will ﬂash in green and blue ( mode shifting ) and light in blue steadily, indicating that the machine is in two-wheel drive mode.
Page 162 17. Drive operation devices ( 5 ) Brake lock switch The brake lock switch applies the brakes on the front and rear wheels independently of the brake pedal. This is a "working auxiliary braking device" which can be used together with the parking brake while setting the outriggers or during stationary crane-on-rubber operation.
Page 163 17. Drive operation devices NOTE Refer to the crane operation section for the outrigger operation screen mode switch. ( 6 ) Idling level switch Normally leave this set to OFF. During engine warm-up, for example, press the up-arrow button to increase the engine speed in 100 min increments.
Page 164 17. Drive operation devices 17-2-3 SCR system cleaning ( T218151-029-0E ) Cleaning involves minimizing the amount of DEF deposits within the SCR system and then cleaning out the remaining deposits by generating heat with a diesel oxidation catalyst ( DOC ) using a small amount of fuel aftertreatment spray. There are three cleaning modes for Cummins engines.
Page 165 17. Drive operation devices Do not clean the SCR system manually in a garage or other poorly ventilated area. Gas emissions could cause carbon monoxide poisoning, particularly in garages or other enclosed indoor spaces. ( T218151-030-0E ) Do not clean the SCR system manually in the following locations. If unavoidable, use the SCR cleaning cancel switch.
Page 166: Key On-Off Select Display Switch
17. Drive operation devices 17-2-4 Fuel consumption display switch section ( T218001-036-0E ) ( 1 ) Display of fuel consumption during driving 1 ) KEY ON-OFF select display switch It displays fuel consumption from the time when the key switch is turned ON to the time when it is turned OFF. 2 ) Select switch for display screen of fuel consumption during driving The color of switch is green: The screen has been selected.
Page 167 17. Drive operation devices 17-2-5 Adjusting the display brightness level ( T217921-034-0E ) ( 1 ) Adjusting the cluster meter/COR display brightness There are ﬁve brightness level settings for both when the lighting switch is ON or OFF. NOTE ・ Turning the lighting switch automatically switches between daytime and nighttime brightness setting screens.
Page 168 17. Drive operation devices ( 1 ) Press either the ① switch for returning to previous alarm setting or the ③ switch for advancing to next alarm setting to display the setting screen for desired maintenance item. ( 2 ) The maintenance alarm display can be switched OFF by pressing the ④ alarm display mode selection switch, so that the ⑤...
Page 169 17. Drive operation devices Default settings Maintenance alarm display timing Maintenance item Display Driving distance Operating hours Engine oil 500h ○ － Crankcase breather 2000h ○ － Engine oil ﬁlter element 500h ○ － DEF pump ﬁlter 4500h ○ － Fuel ﬁlter element 500h ○...
Page 170: Front And Side Panel Switches
17. Drive operation devices 17-3 Front and side panel switches ( 541A-0103-0E ) 17-3-1 Front panel switches ( T218151-035-0E ) ( 1 ) Left/right mirror selection switch Used to select the left mirror, right mirror, or both mirrors. ( 2 ) Side-view mirror extension/stowage switch If the left/right mirror selection switch is in the neutral position, this switch extends or stows both mirrors.
Page 171 17. Drive operation devices NOTE This device includes a fuse to protect its electrical circuits. If the side-view mirror cannot be extended or stowed, such as due to an overcurrent event or other situation that causes the fuse to fail, inspect the fuses in the fuse box. ( 3 ) Suspension control switch The suspension control switch is used to retract, lock, or unlock ( driving position unlocked ) the suspension depending on the crane operation status.
Page 172 17. Drive operation devices The following conditions must be satisﬁed before the suspension can be locked or unlocked. Suspension operations are possible only when the "suspension operation OK indicator lamp" is lit. 1 ) Retracting the suspension When the suspension lock is released, operating the suspension control switch towards "suspension retraction"...
Page 173 17. Drive operation devices 3 ) Releasing the suspension lock Move the suspension control switch to the "suspension lock release" side while the suspension is locked. The suspension lock will be released, the suspension cylinders will return to the driving position and the suspension locked indicator lamp will go out.
Page 174 17. Drive operation devices ・ Lock the rear steering before you stop the engine. ・ Lock the rear steering for driving on roads. ・ Check that there is nobody near the rear wheels before you lock the rear steering. ・ As a rule, the machine should be at rest for rear steering locking/releasing. ・...
Page 175 17. Drive operation devices ( 6 ) Hazard warning switch All turn signal lamps ﬂash simultaneously to indicate a hazard. Only use this switch in an emergency. This switch functions even when the starter switch is "OFF". ( 7 ) Mirror heater switch ( optional ) ・...
Page 176 17. Drive operation devices ・ Guideline for speed change and range Position Shift range Speed range Speed 1 0－18km/h Speed 1⇔2 0－27km/h Speed 1⇔2⇔3 0－39km/h Speed 1⇔2⇔3⇔4 0－55/h Reverse speed 1 0－27km/h ( T218351-079-0E ) ・ If you move the shift lever to any position other than "N" while the machine is at rest, it may start to move even if you are not pressing the accelerator pedal.
Page 177: Accelerator And Brake Pedals
17. Drive operation devices 17-4 Accelerator and brake pedals ( T217161-026-0E ) ( 1 ) Accelerator pedal This pedal controls the engine speed and therefore the speed of the machine in motion. Sudden acceleration while driving is dangerous. Always work the accelerator smoothly and steadily.
Page 178: Steering Column
Press the horn switch in the center of the steering wheel to sound the horn. When the horn does not sound even if the switch is pressed, contact your authorised KATO dealer to order a repair before starting to drive. - 151 -...
Page 179 17. Drive operation devices 17-5-2 Combination switch ( T218151-037-0E ) The combination switch is mounted on the steering column. The steering column incorporates the following switches. ( 1 ) Combination switch The combination switch has the following switching functions. ・ Windscreen wiper switch ・...
Page 180 17. Drive operation devices 3 ) Auxiliary brake lever switch Use the auxiliary brake to increase the eﬀect of engine braking while driving down a long slope. Move the lever switch to the "ON" position and take your foot oﬀ the accelerator pedal to activate the auxiliary brake. The auxiliary brake will disengage when you depress the accelerator pedal again with the lever switch set to the "ON"...
Page 181 17. Drive operation devices 2 ) Lighting switch The knob on the end of the lever is the lighting switch. Turn the knob clockwise to light the lamps as described below according to the switch position. Switch position Clearance lamps Tail lamps License plate lamp Oﬀ...
Page 182: Lower Control Switch Panel
17. Drive operation devices 17-6 Lower control switch panel ( T218151-039-0E ) ( 1 ) AT/M emergency switch If there is a malfunction indicated by the AT/M malfunction warning lamp on the cluster meter panel and you cannot continue driving in "D" range, turn this switch to the "emergency" position. You may now continue driving using manual transmission.
Page 183 ・ If the AT/M malfunction warning lamp lights, park the machine in a safe place immediately. After stopping in a safe place, stop the engine then start it again. If the AT/M malfunction warning lamp is still lit, leave the machine where it is and contact your authorised KATO dealer for instructions.
Page 184 17. Drive operation devices During normal driving the rear steering emergency switch should be in the "neutral" position. Do not drive with it in the "release" position. ( 541A-0025-0E ) When the rear steering mode is switched to "Automatic" by setting the rear steering emergency switch back to "neutral”...
Page 185: Driving The Machine
18. Driving the machine 18. Driving the machine ( 371A-0038-0E ) Check the relevant safety regulations and laws in the country concerned before you drive this machine on the road. 18-1 Preparations for driving on the roads ( T218351-029-0E ) The machine must always be in the position shown below for road driving.
Page 186 18. Driving the machine ( 12 ) Return the suspension from locked to free state. The procedure for returning the suspension to the free state is as follows. ① Move the shift lever to the "N" position. ② Check that the suspension operation OK indicator lamp is lit. ③...
Page 187 18. Driving the machine ( 13 ) Check that the "specialized driving" indicator lamp is not lit. ( 14 ) Check that no warning lamps are lit. ( 15 ) Check that the turn signal lamps ﬂash correctly. ( 16 ) Check that the foot brake operates and that the brake lamps lights. ( 17 ) Check that the crane working lamps are not lit.
Page 188: General Driving
18. Driving the machine 18-2 General driving ( T218151-042-0E ) ( 1 ) Normal driving Move the shift lever to the "D" position and press the accelerator pedal. As the machine accelerates, the computer will read its changing speed and automatically change from speed 1 to speed 4 in response to the machine speed.
Page 189 18. Driving the machine ( 2 ) Driving on slopes 1 ) When climbing a slope, move the shift lever to D, 3, 2 or 1 depending on the gradient. 2 ) When driving down a slope, take great care not to deplete the foot brake force because loss of brake force is extremely dangerous.
Page 190: Specialized Driving
18. Driving the machine 18-3 Specialized driving ( 321A-0038-3E ) This machine features three specialized driving modes ― low range driving, rear steering, and four-wheel drive modes. When a specialized driving mode is selected, the specialized driving indicator lamp lights on the cluster meter panel. Make sure the specialized driving indicator lamp is not lit before drive on a public road.
Page 191 18. Driving the machine 2 ) Switching from low range to high range ・ Stop the machine before switching between high and low ranges. ・ If you switch between ranges when the machine is moving at 3km/h or more, the range gear could be broken or damaged and the engine could overrun.
Page 192 18. Driving the machine 18-3-2 Rear steering ( T218151-044-0E ) ( 1 ) Releasing the rear steering lock 1 ) Stop the machine. 2 ) In order to release the rear steering lock, set the rear steering lock/release switch to the release side. While it is releasing, a buzzer sounds and the rear steering lock release conﬁrmation indicator lamp ﬂashes rapidly.
Page 193 18. Driving the machine ( 2 ) Rear steering 1 ) Release the rear steering lock ( the rear steering lock release confirmation indicator lamp is lit ) and the rear steering ( rear wheels ) can be done to the left and right using the rear steering switch on the side panel.
Page 194 18. Driving the machine ( 3 ) Locking the rear steering 1 ) Stop the machine. 2 ) In order to lock the rear steering, set the rear steering lock/release switch to the lock side. While it is locking, a buzzer sounds and the rear steering lock release conﬁrmation indicator lamp ﬂashes slowly. When the buzzer stops and the rear steering lock release confirmation indicator lamp goes out, the locking process is complete.
Page 195 18. Driving the machine 18-3-3 Two/four wheel drive selection ( 121A-0074-0E ) ( 1 ) Use two-wheel drive for normal drive and switch to four-wheel drive for driving on particularly steep roads or even or soft ground, or for pick and carry operation. ( 2 ) If you are using four-wheel drive when you come to a road that could be traversed without using four-wheel drive, stop the machine immediately and switch to two-wheel drive.
Page 196 18. Driving the machine NOTE The followings are the available combinations of high/low range with two/four wheel drive. 　・High range + two-wheel drive ( normal driving ) 　・High range + four-wheel drive 　・Low range + four-wheel drive ( automatic switching ) While switching between two-wheel drive and four-wheel drive, the lamp flashes to indicate mode shifting in process.
Page 197: Boom Guard
18. Driving the machine 18-4 Boom guard ( T217591-005-0E ) 18-4-1 Removing the boom guard ( T217591-014-1E ) ( 1 ) Extract pin [ A ] and stow it in place. ( 2 ) Extract pin [ B ] and stow it in place. Remove the boom guard. ・...
Page 198 ( T218711-004-0E ) Crane operation 218711 19. For safe operation ………………………………………………………………………… 171 19-1 General precautions ……………………………………………………………………………………… 171 19-2 Precautions during operation ……………………………………………………………………………… 179 19-3 Precautions after operation ………………………………………………………………………………… 199 20. How to read the capacity charts …………………………………………………………… 201 20-1 How to read the working area chart ……………………………………………………………………… 201 20-2 How to read the lifting capacity chart ……………………………………………………………………...
Page 199 25. Changing the wire rope number of parts ………………………………………………… 281 25-1 Wire rope standard number of parts ……………………………………………………………………… 281 25-2 Changing the wire rope number of parts ………………………………………………………………… 282...
Page 200: For Safe Operation
WARNING 19. For safe operation　 19. For safe operation ( 0099-0104-1E ) ・ This section lists precautions you should observe when operating this crane. ・ Make sure you fully understand these points before you start operation and observe them to operate safely. ・...
Page 201 WARNING 　19. For safe operation ( 4 ) Keeping good visibility 1 ) When you need to slew or reverse in areas of restricted visibility, place a guide and a signaler and do as they instruct you. 2 ) Always keep the cab windows, mirrors, wipers and working lamps clean.
Page 202 WARNING 19. For safe operation　 ( 5 ) Precautions on working in the public road Position a guide in the road and erect fences etc. to ensure the safety of passing vehicles and pedestrians. Further observe the safety regulations and laws of the country where the crane is used.
Page 203 3. The cut power transmission cable cannot be detached from the crane structure. 4. Other emergent conditions 5 ) Be sure to use the machine involved in such an accident only after being inspected at your authorized KATO dealer. - 174 -...
Page 204 WARNING 19. For safe operation　 ( 8 ) Precautions when operating the crane near high-power electromagnetic wave emitters High voltages with painful and dangerous consequences can be induced in the vicinity of radio and television transmitters and radar stations. Contact the relevant authority before starting work.
Page 205 2. The crane is damaged and inoperable. 3. Other emergent conditions 4 ) Be sure to use the machine involved in such an accident only after being inspected at your authorised KATO dealer. ( 10 ) Work according to signals Choose one person to be the signaler.
Page 206 WARNING 19. For safe operation　 19-1-2 Precautions before you start work ( T218351-033-0E ) ( 1 ) Keep the area of the operator's seat clean and tidy Do not leave parts, tools or other objects in the area of the operator's seat.
Page 207 WARNING 　19. For safe operation ( 5 ) Check ACS operation Check the operation of the ACS according to the ACS preoperational check procedure which should always be kept in the cab. ( 6 ) Check safety devices In addition to the ACS, the crane is ﬁtted with an overhoisting detector and other safety devices which you should check before starting work.
Page 208: Precautions During Operation
WARNING 19. For safe operation　 19-2 Precautions during operation ( 0099-0012-0E ) 19-2-1 Precautions when starting the engine ( T218351-034-0E ) ( 1 ) Precautions when starting the engine indoors If you need to start the engine indoors, open doors and windows to ensure good ventilation or get exhaust gas out of doors with the additional exhaust pipe connected.
Page 209 WARNING 　19. For safe operation ( 5 ) Sound the horn before you start the engine ・ Before you board the crane, check that there is nobody nearby. ・ When you are about to start the engine, sound the horn to warn people nearby.
Page 210 WARNING 19. For safe operation　・ Brick or cobbled road surfaces ・ Areas where soil under the road paving has been eroded by water to leave a void ・ Areas where the soil is very dry but soft ・ Road shoulders or near construction excavations Set the crane level with full consideration for the above points.
Page 211 WARNING 　19. For safe operation ( 4 ) Before setting outriggers, check to conﬁrm that the suspension cylinders are completely retracted ( suspension locked ) . ( 5 ) Check outrigger extension width Before starting work, check that the outriggers are extended to the width speciﬁed in the lifting capacity chart.
Page 212 WARNING 19. For safe operation　 ( 7 ) Set up the crane level A leaning crane compromises stability and strength. This reduces the eﬀective lifting capacity and can cause the crane to tip over. Use the level gauge to make sure the crane is level. ( 8 ) Check the state of outrigger setting If the outriggers are not set properly, the crane's lifting capacity will be reduced and the crane may be caused to tip over.
Page 213 WARNING 　19. For safe operation 19-2-3 Precautions on operation ( T218351-036-0-0E ) ( 1 ) Do not lift loads in excess of the lifting capacity If you lift loads in excess of the lifting capacity, an excessive load acts on the crane which could cause it to break or tip over. Before you start work, always conﬁrm lifting capacity from the lifting capacity chart.
Page 214 WARNING 19. For safe operation　 ( 5 ) Use utmost care to crane up objects from under the water ・ When drawing up an object from under the water, the crane can be subjected to almost the same load as when drawing it out of the ground.
Page 215 WARNING 　19. For safe operation ( 9 ) No careless crane operation If you are careless in operating the crane, the slightest slip or inattention can result in a major accident. Be constantly alert to ensure that the boom or the suspended load do not collide with people or buildings and that the load does not collide with the boom or outriggers.
Page 216 WARNING 19. For safe operation　 ( 13 ) Arrange slings securely If the slings are not ﬁtted securely, the load can fall oﬀ or slip out of the slings and fall down. Arrange slings securely with attention to the following points. ・...
Page 217 WARNING 　19. For safe operation ( 16 ) Consider deﬂection of the boom when hoisting a load When a load is lifted, the boom deﬂects, increasing the working radius. Particularly when working with a very heavy load or a long boom, allow an extra margin below the rated lifting capacity to allow for alteration of the working radius due to boom deﬂection under the load.
Page 218 WARNING 19. For safe operation　 ( 20 ) Do not move the suspended load above people's heads Never pass a suspended load or hook over the heads of other workers as this endangers their safety. ( 21 ) Beware of contact and collision with obstacles When you hoist or slew the load or hook and the wire rope becomes entangled with any obstacle, disentangle it carefully without hoisting or slewing it further by force and then resume...
Page 219 WARNING 　19. For safe operation ( 24 ) Never drag a load sideways, hoist it diagonally or drag it toward the crane Using boom lowering and derricking or winch operation to drag the load sideways or hoist it diagonally causes a bending force to act on the boom and can lead to damage of the boom and the slewing mechanism or tipping the crane over.
Page 220 WARNING 19. For safe operation　 19-2-4 Boom derricking and lowering ( 0099-0016-3E ) ( 1 ) When you derrick and lower the boom, the working radius increases as the angle of the boom decreases, increasing the risk of tip over. ( 2 ) Beware of overhoisting the hook When the boom is lowered or extended, the hook is wound up, possibly causing overhoisting and damage when the hook block...
Page 221 WARNING 　19. For safe operation ( 3 ) Do not unwind the winch so far that the hook touches the ground If you continue unwinding operation even after the hook touches the ground, the wire rope can be tangled. ( 4 ) Never use the main and the auxiliary winches at the same time If the main winch hook and the auxiliary winch hook are each carrying one individual load, the boom and jib can be damaged and the crane may tip over.
Page 222 WARNING 19. For safe operation　 19-2-6 Boom extension and retraction ( 0099-0018-3E ) ( 1 ) Lower the hook suﬃciently before you extend the boom. Extending the boom can put the hook into an overhoisted condition which causes an automatic stop. ( 2 ) Be careful when extending and retracting the boom with a load suspended on it.
Page 223 WARNING 　19. For safe operation 19-2-7 Slewing ( T217161-039-0E ) ( 1 ) Check that the slewing area is free of obstructions before slewing. ( 2 ) Sound the horn before slewing. ( 3 ) After you have completed slewing, always apply the slewing brake.
Page 224 WARNING 19. For safe operation　 ( 5 ) Beware of centrifugal force when slewing Slewing at high speed with a hoisted load causes centrifugal force to act on the load which in turn increases the working radius and can cause an overload with the risk of tip over. If you stop slewing abruptly, the load will swing uncontrollably imposing a further overload on the boom.
Page 225 WARNING 　19. For safe operation 19-2-9 Handling the searcher hook ( optional ) ( T218351-083-0E ) ( 1 ) Before you start to mount or remove the searcher hook, refer to the separate instruction manual to conﬁrm the correct procedure. If you do not follow the right procedure, the crane could be damaged or the searcher hook could drop oﬀ.
Page 226 WARNING 19. For safe operation　 ( 3 ) Lifting operation through combined use of jib and boom hooks 1 ) Perform this kind of lifting operation within the range where the lifting capacity of the jib is not exceeded. 2 ) Set the boom condition menu mode of ACS to the "Jib operation".
Page 227 WARNING 　19. For safe operation 19-2-12 Pick and carry operation ( 0099-0257-0E ) ( 1 ) Strictly follow the cautionary instructions given in the operation manual. ( 2 ) Attempt neither to load the crane to its full capacity nor to lift up loads unnecessarily high.
Page 228: Precautions After Operation
WARNING 19. For safe operation　 19-3 Precautions after operation ( 0099-0171-2E ) ( 1 ) Stow the boom ( jib ) away after you have ﬁnished work Leaving the crane in its working position can inadvertently cause accidents. At the end of work, stow the boom ( jib ) and lock it.
Page 229 ( 5 ) Inspection after the end of crane operation After you have ﬁnished operating the crane, check all its parts and add lubricants and fuel as required. If you find any defective parts, repair them immediately. ( 6 ) Check the crane for safety before you leave it When you leave the crane, set it to the driving position, stop the engine and lock the door.
Page 230: How To Read The Capacity Charts
20. How to read the capacity charts 20. How to read the capacity charts ( 541A-0145-0E ) 20-1 How to read the working area chart ( 541A-0146-2E ) The working area chart indicates the relationship between the working radius and height above the ground for each combination of the boom length, jib length, boom angle and jib oﬀset angle.
Page 231: How To Read The Lifting Capacity Chart
20. How to read the capacity charts 20-2 How to read the lifting capacity chart ( 541A-0147-2E ) The lifting capacity chart printed here is an extract from those which are attached to the crane. Before you start work, check the entire chart. ( 541A-0148-1E ) ( 1 ) When you are going to operate the crane, ﬁnd the outrigger status on the lifting capacity chart.
Page 232: Precautions On Crane Operation
20. How to read the capacity charts 20-3 Precautions on crane operation ( 541A-0149-3E ) Familiarize yourself with the following points before you start to operate the crane. There is a safety sign of the lifting capacity chart inside the cab on which the summary of these same points is also given. Always read them before you start to operate the crane.
Page 233 20. How to read the capacity charts ( 10 ) The lifting load with which you can extend or retracted the boom during searcher hook operation may become smaller then the lifting capacity depending on the conditions such as the oil pressure, boom angle, lubricating state to the boom, etc.
Page 234 20. How to read the capacity charts ( 10 ) If the boom length, boom angle and/or working radius exceeds the rated value, use the lifting capacity for the rated value or for the next one, whichever gives the smaller lifting capacity. ( 11 ) In whatever working conditions the corresponding boom critical angle is shown in the chart.
Page 235 ( 14 ) If any error code No. or error message is displayed during crane operation or preoperational checks, or if the problem occurs in the communication signal or circuit between the carrier and crane, stop work immediately and contact your authorised KATO dealer to ask for advice. - 206 -...
Page 236 ・ Always stow the ACS display panel when you leave the crane operation cab. ( 061K-0002-0E ) ( 16 ) If any breakdown or accident occurs as a result of the operator's failure to observe the above points, KATO will bear no responsibility.
Page 237: Crane Operation Devices
21. Crane operation devices 21. Crane operation devices ( 061A-0005-0E ) ( 1 ) Inside the cab - 208 -...
Page 238 21. Crane operation devices - 209 -...
Page 239 21. Crane operation devices ( 2 ) Outside the cab - 210 -...
Page 240: Front Panel
21. Crane operation devices 21-1 Front panel ( T218351-028-0E ) ( 1 ) PTO ( Power Take Oﬀ ) switch When the PTO switch is set to the "ON" position, the pump is driven, power is supplied to the ACS and the slewing stop circuit is released.
Page 241 21. Crane operation devices ( 2 ) ACS emergency switch ( self-reset type ) In an emergency such as a malfunction in ACS-related devices or crane stop etc. has occurred due to overload, set this switch to the "release" position to take appropriate emergency actions regardless of the ACS.
Page 242 ・ If the engine does not stop when the starter switch is turned to the "ACC" position, contact your authorised KATO dealer immediately. ・ After the engine has stopped, release the lock by pulling out the switch or turning it to the right.
Page 243: Side Panel
21. Crane operation devices 21-2 Side panel ( T218351-039-0E ) ( 1 ) Boom extension/retraction emergency switch ( self-reset type ) Use this switch if boom sections 4, 5 and 6 cannot extend or retract due to trouble in the boom sequential extension/retraction circuit, or when greasing boom sections 4, 5 and 6.
Page 244 21. Crane operation devices ( 6 ) Winch lighting switch Switching this switch ON lights the pilot lamp and the lamp for the winch drum monitor camera. ( 7 ) ACS display panel The angle of the ACS display panel is adjustable so position it at the angle which gives you the best view of the screen.
Page 245: Control Levers And Pedals
21. Crane operation devices 21-3 Control levers and pedals ( T217321-163-0E ) ( 1 ) Slewing lever : Push the slewing lever forward to slew the crane left. : Pull the slewing lever backward to slew the crane right. ( 2 ) Slewing alarm button Press the button to sound the horn before starting the engine or slewing operation to warn those nearby.
Page 246 21. Crane operation devices ( 4 ) Power jib derricking/lowering lever lock This is used to lock the power jib derricking/lowering lever when it is not operated, for preventing incorrect operation. The power jib derricking/lowering lever is operable when the knob is pulled. It is ﬁxed when the knob is returned. Apply the power jib derricking/lowering lever lock only when the lever is in the neutral position.
Page 247 21. Crane operation devices ( 7 ) Boom extension/retraction pedal : Depress the boom extension/retraction pedal forward to extend the boom. : Depress the boom extension/retraction pedal backward to retract the boom. To extend and retract boom sections 4, 5 and 6 work the pedal while pressing the boom sections 4, 5, 6 extension/retraction button.
Page 248 21. Crane operation devices ( 12 ) Main winch high-speed lowering switch ( 13 ) Auxiliary winch high-speed lowering switch When you set the winch high-speed lowering switch to the "ON" position and move the winch lever to the lowering side while a load is not suspended, the winch is lowered at a high speed.
Page 249 21. Crane operation devices ( 17 ) Tilt lever If the control levers obstruct your way to take or leave the operator seat, pull the tilt lever toward you ( rearward ) , and all the control levers ( boom derricking/lowering lever and winch levers ) will be folded down rearward as a unit.
Page 250: K-Cor
21. Crane operation devices 21-4 K-COR ( T217671-076-0E ) ( 1 ) Refer to the K-COR instruction manual for details. 21-5 Lower control switch panel ( T218351-040-0E ) ( 1 ) Outrigger control panel Refer to the "Outrigger operation" section. ・...
Page 251 21. Crane operation devices ( 2 ) Outrigger emergency switch ( self-rest type ) If the switches on the outrigger control panel fail to move the outriggers ( when the multiplex communication error warning lamp flashes etc. ) , switch the outrigger emergency switch to the "emergency" position then use the switches on the outrigger control panel of the carrier as a temporary measure to stow the outriggers.
Page 252 21. Crane operation devices ( 4 ) Bridging device key switch ( self-reset type ) In an emergency such as a malfunction in ACS-related devices or crane stop etc. has occurred due to overload, set the operation switch to the "release" position to take appropriate emergency actions regardless of the ACS.
Page 253: Crane Operation When The Outriggers Are Used
22. Crane operation when the outriggers are used 22. Crane operation when the outriggers are used ( 541A-0171-1E ) ( 1 ) Preparations for crane operation Before starting crane operation, always follow the procedure below to change the machine's position from driving condition to a position suitable for crane operation.
Page 254 22. Crane operation when the outriggers are used ( 2 ) After crane operation Before driving on the roads, always follow the procedure below to change the machine's position from crane operation condition to a position suitable for driving. Always follow the speciﬁed procedure and precautions strictly to set the machine in its driving conﬁguration before you drive on the roads.
Page 255: Suspension Operation
22. Crane operation when the outriggers are used 22-1 Suspension operation ( 541A-0373-0E ) Any one of the faults below could cause the crane to tip over, so strictly observe all the relevant precautions. ・ If you operate the crane without ﬁrst locking the suspension, the crane could tip over, causing a major accident.
Page 256 22. Crane operation when the outriggers are used 22-1-1 Suspension retraction procedure ( 541A-0294-2E ) ( 1 ) Set the crane to the following conditions. ・ Fully retract the boom and lower it to a boom angle of at least 50°. ・...
Page 257 22. Crane operation when the outriggers are used 22-1-2 Suspension lock release procedure ( 541A-0295-2E ) Do not operate the suspension while the outriggers are extended. When the suspension lock is released, there is some risk that the axles could drop oﬀ. ( 541A-0175-0E ) ・...
Page 258: Pto Switch Operation
22. Crane operation when the outriggers are used 22-2 PTO switch operation ( T218001-046-0E ) After locking the suspension, hold the engine at idling speed and move the PTO switch on the left side of the front panel to the "ON" position. At this time the PTO pilot lamp on the switch and the PTO indicator lamp on the information display will light.
Page 259 22. Crane operation when the outriggers are used - 230 -...
Page 260: Precautions On Setting The Outriggers
22. Crane operation when the outriggers are used 22-3 Precautions on setting the outriggers ( T218351-044-0E ) The outrigger control switches are located on the side of the carrier body and inside the cab. As a general rule, the outrigger control panel inside the cab should be used. Only use the outrigger control panel on the side of the carrier in an emergency.
Page 261 22. Crane operation when the outriggers are used ( 1 ) Outrigger reaction forces Never operate the crane on soft ground. The ground must be reinforced appropriately for supporting the crane ( such as by using steel plates to increase the supportable load ) . In order to properly reinforce the ground to ensure the crane can be operated safely, it is necessary to determine how much force the ground can support.
Page 262 22. Crane operation when the outriggers are used ( 4 ) Check that the suspension lock cylinders are fully retracted ( suspension locked ) before you set the outriggers. ( 5 ) As a rule, all four outriggers should be extended fully. If you have no alternative but to use any outrigger at intermediate extension or full retraction or if the outriggers cannot be used at all, you must first obtain the permission of the site foreman and then proceed slowly and cautiously with safety as your prime concern.
Page 263: Outrigger Control Panel
22. Crane operation when the outriggers are used 22-4 Outrigger control panel ( T218351-045-0E ) ( 1 ) Outrigger control switches inside the operation cab 1 ) Press the outrigger operation screen select switch on the information display to display the outrigger operation screen.
Page 264 22. Crane operation when the outriggers are used ・ If one or more outrigger selection switches are not selected, the horizontal selection switch or vertical selection switch is black indicating that selection is unavailable. If one or more outrigger selection switches are selected, the horizontal selection switch or vertical selection switch is white indicating that selection is available.
Page 265: Horizontal/Vertical Selection Switch
22. Crane operation when the outriggers are used 4 ) Horizontal/vertical selection switches Use these switches to select horizontal or vertical outrigger operation. When you press the outrigger position selection switch, a "pip" conﬁrmation buzzer sounds and the indicator lamp of horizontal/vertical selection switch lights in white indicting that selection is available. If you press the horizontal or vertical selection switch, the indicator lamp lights steadily in yellow during operation.
Page 266 22. Crane operation when the outriggers are used 5 ) Leveling assist switch The leveling assist switch is enabled by selecting all of the front, rear, left, and right outrigger selection switches and then selecting the vertical selection switch. To level the machine using the leveling assist direction switch, select whether to extend or retract the outriggers.
Page 267 22. Crane operation when the outriggers are used 6 ) Outrigger extension/retraction switch When you press either the extension switch or the retraction switch, of which color is white, while the outrigger selection switch and horizontal/vertical selection switch have been set, a "pip"...
Page 268: Right-Rear Outrigger Operation Switch
22. Crane operation when the outriggers are used ( 2 ) Control panel on the side of the lower structure 1 ) Extension/retraction switch ( self-reset type ) This switch allows extending or retracting the horizontal or vertical cylinders. 2 ) Horizontal/vertical selection switch This selects which cylinder is actuated by the extension/retraction switch for the outrigger ( s ) selected using the individual or all-outrigger operation switches.
Page 269: Outrigger Setting And Stowage Procedures
22. Crane operation when the outriggers are used 22-5 Outrigger setting and stowage procedures ( 061A-0085-0E ) 22-5-1 Outrigger setting procedure ( 061A-0086-3E ) ( 1 ) Check that the outrigger operation OK indicator lamp is lit. Conditions for lighting ・...
Page 270 22. Crane operation when the outriggers are used 2 ) Insert the stopper pin into each outrigger and confirm the extension length. NOTE If you cannot insert the stopper pin properly, use the extension/ retraction switch to "extend" or "retract" the outriggers repeatedly until the pin has been inserted ﬁrmly.
Page 271 22. Crane operation when the outriggers are used ・ After you extend the vertical cylinders, check that there are no dangers such as sinking of the outrigger ﬂoats or crumbling of the road shoulder. ・ After you extend the vertical cylinders, return all switches to their neutral positions to avoid accidentally retracting the outrigger beams.
Page 272 22. Crane operation when the outriggers are used 22-5-2 Outrigger stowage procedure ( T218351-046-0E ) When you are going to stow the outriggers, always set the slewing upper structure to the driving position as shown in the diagram below. ( T217921-140-0E ) ( 1 ) Check that the outrigger operation OK indicator lamp is lit.
Page 273 22. Crane operation when the outriggers are used ( 3 ) Vertical cylinder retraction Move the selection switch to the vertical side and the extension/retraction switch to the "retraction" side to retract the vertical cylinders fully. Do not retract the outrigger beam while the vertical cylinder is extended. ( 541A-0183-2E ) - 244 -...
Page 274 22. Crane operation when the outriggers are used ( 4 ) Outrigger beam retraction 1 ) Check that the vertical cylinders are fully retracted, then move the selection switch to the horizontal side. 2 ) Move the extension/retraction switch to the "retraction" side to retract the outrigger beams fully. 3 ) Check that all outrigger beams are fully retracted.
Page 275: Releasing And Stowing The Hooks
22. Crane operation when the outriggers are used 22-6 Releasing and stowing the hooks ( T218351-047-0E ) While driving the machine, always stow the main hook and the auxiliary hook into the brackets. If you drive the machine without stowing a hook ( with a hook suspended ) , the hook may swing, which results in obstructing other driving vehicles and causing a possible accident.
Page 276 22. Crane operation when the outriggers are used ( 5 ) Raise the boom to an angle of about 10 degrees. If you raise the boom to an angle of 13 degrees or higher, the "hook stowage mode" will be canceled.
Page 277 22. Crane operation when the outriggers are used 22-6-2 Hook stowing procedure ( T217321-027-0E ) ( 1 ) Make the crane face forward, fully retract the boom and set the boom to an angle of 10 degrees. If the main hook is conﬁgured with other than four parts of line, change it to four parts of line. ( T217321-042-0E ) ( 2 ) Set the "hook stowage mode"...
Page 278 22. Crane operation when the outriggers are used 3 ) Press the hook stowage mode selection switch ( green ) to set the "hook stowage mode" . When the "hook stowage mode" is selected, the color of the hook stowage mode selection switch is changed from green to yellow.
Page 279 22. Crane operation when the outriggers are used ( 4 ) Lower the boom and stow it on the boom rest. Be careful not to let the auxiliary hook touch the ground. ( 061A-0056-0E ) If the automatic stop function works when lowering the boom, lower the wire rope to cancel the automatic stop function.
Page 280: Crane Operation Without Outriggers
23. Crane operation without outriggers 23. Crane operation without outriggers ( 541A-0193-1E ) Preparations for crane operation Before starting crane operation, always follow the procedure below to change the machine's position from driving condition to a position suitable for crane operation. The ACS preoperational check should be conducted when all outriggers are fully extended for maximum safety.
Page 281: Precautions On Crane Operation Without Outriggers
23. Crane operation without outriggers 23-1 Precautions on crane operation without outriggers ( T217321-086-0E ) In addition to normal crane operation with the outriggers set, this machine can perform some lifting tasks ( stationary crane-on-rubber operation and pick and carry operation ) without using the outriggers. When the crane works without the outriggers, the tires must serve a substitute for the outriggers.
Page 282: Stationary Crane-On-Rubber Operation
23. Crane operation without outriggers 23-2 Stationary crane-on-rubber operation ( T217321-028-1E ) ( 1 ) Conditions for stationary crane-on-rubber operation 1 ) Maximum boom length: 19.6m 2 ) Suspension locked mode ( The suspension lock cylinder is fully retracted. ) 3 ) Tire pressure: 900kPa ( 9.00kgf/cm ) ( same pressure as for driving ) 4 ) Determine the boom status, working area and lifting capacity with reference to the lifting capacity chart for...
Page 283 23. Crane operation without outriggers ( 2 ) Procedure for stationary crane-on-rubber operation 1 ) Recheck the working area. Check again that the ground in the area where you are going to perform stationary crane-on-rubber operation is ﬁrm and level. If the ground is crumbly or muddy, stationary crane-on-rubber operation will not be possible there.
Page 284: Pick And Carry Operation
23. Crane operation without outriggers 23-3 Pick and carry operation ( T217321-059-0E ) ( 1 ) Conditions for pick and carry operation ( 2 ) Procedure for pick and carry operation Pick and carry operation involves traveling around a site while a load is suspended from the crane. The surface you travel on can change and cause instability which is highly hazardous.
Page 285 23. Crane operation without outriggers 1 ) Recheck the working area. Check again that the ground in the area where you are going to perform pick and carry operation is ﬁrm and level. If the ground is crumbly or muddy, pick and carry operation will not be possible there. 2 ) Recheck the lifting capacity chart.
Page 286: On-Site Moving
23. Crane operation without outriggers 23-4 On-site moving ( T217321-060-0E ) Always observe the following points when moving within a site to change working positions. Driving on public roads is not permitted when the machine is conﬁgured for on-site moving. Return the machine to the on-road moving conﬁguration before driving on public roads.
Page 287: Crane Operation
24. Crane operation 24. Crane operation ( 1610-0030-1E ) This crane is reasonably simple to operate, but even small slips can cause major accidents, so always work steadily one step at a time. 24-1 Preparations for crane operation ( 4210-3246-0E ) 24-1-1 Preparations before operating the crane ( T218151-060-0E ) ( 1 ) Move the crane to the ﬁrm, level ground.
Page 288 24. Crane operation ( 6 ) Conﬁrming that the keys are removed from the ACS emergency switch and bridging device key switch Conﬁrm that the keys are not in the ACS emergency switch on the front panel and bridging device key switch on the front of the left machine compartment.
Page 289: Level Gauge Confirmation Screen Switch
24. Crane operation ( 9 ) Display screen of fuel consumption during crane operation 1 ) Display of fuel consumption during crane operation As soon as the residual amount of fuel is exhausted, "0" is displayed as the possible crane operation time. 2 ) Select switch for display screen of fuel consumption during crane operation The color of switch is green: Selected The color of switch is black: Unselected...
Page 290 ( 3 ) If an error number is displayed in the display window on the ACS screen, inspect the corresponding problem. If the problem cannot be resolved, immediately contact your authorised KATO dealer. ( 4 ) Always follow the ACS precautions indicated in 20-3-3.
Page 291: Boom Derricking And Lowering
24. Crane operation 24-2 Boom derricking and lowering ( 541A-0209-0E ) : Tilt the boom derricking/lowering lever forward to lower the boom. : Tilt the boom derricking/lowering lever rearward to derrick the boom. Precautions regarding derricking the boom without using outriggers If derricking the boom without using outriggers, make sure the correct outrigger status is selected in the ACS working status setting screen.
Page 292 24. Crane operation ・ The boom can be fully lowered only in the forward area ( in the driving position ) or the side area ( as indicated in the ﬁgure below ) . If the boom is lowered below horizontal in the forward area ( in the driving position ) , be especially careful to prevent it from contacting the boom rest.
Page 293 24. Crane operation Precautions on derricking and lowering the boom ・ Work the lever gently. Sudden lever operation causes strong shocks in the structure of the crane, particularly when a load is suspended, so work with care. ・ The working radius increases as the boom lowers, possibly causing an overload which could tip the crane, so proceed with caution.
Page 294: Hoisting And Lowering
24. Crane operation 24-3 Hoisting and lowering ( T218151-061-0E ) : Move down the winch lever forward, and the winch will reel out the wire rope. : Move the lever rearward, and the winch will reel up the wire rope. ( 1 ) Operate the winch lever to accomplish the desired reel-up/reel-out operations.
Page 295 24. Crane operation ( 4 ) Hook displacement display setting buttons/ACS working status setting switching buttons 1 ) Pressing ( or holding down ) the button on either the main or auxiliary winch lever displays the hook movement distance for the corresponding lever. Pressing ( or holding down ) the other button switches to displaying the distance for the other hook, whereas pressing ( or holding down ) the same button cancels the hook displacement display mode.
Page 296: Boom Extension And Retraction
24. Crane operation 24-4 Boom extension and retraction ( 321A-1063-0E ) The boom of this machine is 6-section telescoping type. It is operated using the boom extension/retraction lever and the boom sections 4, 5 and 6 extension/retraction button. If it is not possible to extend or retract the boom sections 4, 5 and 6, move the boom extension/retraction emergency switch to the "release"...
Page 297 24. Crane operation 24-4-2 Extension and retraction of boom sections 4, 5 and 6 ( T217321-032-0E ) Perform operations with boom sections 2 and 3 fully extended. Extend: Push the lever forward while pressing the boom sections 4, 5 and 6 extension/retraction button. Stop: Return the lever to the neutral position.
Page 298 24. Crane operation Before extending the boom sections 4, 5 and 6, make sure that the boom sections 2 and 3 are fully extended. If you extend the only boom sections 4, 5 and 6 and proceed to lift a load, the boom could break. When you extend the only boom sections 4, 5 and 6 for periodical inspection such as greasing the boom etc., do so with the outriggers fully extended and no suspended load.
Page 299 24. Crane operation NOTE Extension/retraction sequence for each boom length - 270 -...
Page 300: Slewing
24. Crane operation 24-5 Slewing ( T217221-033-0E ) : Tilt the slewing lever forward to slew the crane to the left. : Pull the slewing lever rearward to slew the crane to the right. ( 1 ) Set the slewing warning lamp switch to the "ON" position. ( 2 ) Set the slewing brake switch to the "release"...
Page 301 24. Crane operation ・ If you slew the crane when the boom is lowered, be especially careful not to damage the engine cover, mirror, fender, or other parts. ・ If you slew the crane when the boom is lowered down to a low angle, warning is given with sound "pip"...
Page 302: Function Of The "Slewing Stop System
24. Crane operation 24-6 Function of the "slewing stop system" ( T217161-058-0E ) When the outriggers are not fully extended, the "slewing stop system" functions by using the ACS to predict how much the crane load will increase as it slews and when the crane is about to enter a region speciﬁed in the ACS as restricted from slewing, then gently slowing the slewing movement and automatically stopping slewing before it causes a dangerous situation, such as the crane becoming overloaded or entering a restricted region.
Page 303 24. Crane operation If the voice warning message "Caution when slewing" is emitted and slewing begins automatically decelerating, try to stop slewing manually by operating the slewing lever in the opposite direction, while paying attention to the movement of the load. Waiting for slewing to stop automatically could result in not stopping properly and overrunning the overload point, if the machine is not level or if there is a strong wind.
Page 304 24. Crane operation 24-6-2 Slewing control when a "slew-restricted region" is speciﬁed in the ACS ( 511A-0032-1E ) If a certain slewing region is speciﬁed as restricted in the ACS, such as to avoid hitting obstructions when operating on sites with limited working space or avoiding electrocution from nearby power lines, the "slewing stop system" will function in the follow sequence to avoid an accident.
Page 305 If the "slewing stop system" malfunctions and slewing is not automatically stopped correctly, follow the guidelines below and promptly contact your authorised KATO dealer and request repair. Even if the "slewing stop system" is functioning normally, slewing may stop automatically under the conditions indicated below, such as an unlevel machine or strong winds.
Page 306 ( 511A-1131-0E ) Always obtain permission from the site safety manager before turning the ACS emergency switch to "release" for slewing in an emergency. Furthermore, contact your authorised KATO dealer to request repair. ( 511A-1132-0E ) NOTE Even if the ACS emergency switch is turned to "release", the ACS will continue to emit the voice warnings "Caution...
Page 307 24. Crane operation Never slew the crane when the safety level bar graph indicator is in the red zone, indicating the crane is overloaded. If outriggers are extended to different lengths, crane capacity can vary signiﬁcantly depending on the slewing position. Forgetting this point and slewing the crane even when the safety level bar graph indicator is in the red zone can result in the crane tipping over and causing a major accident.
Page 308 24. Crane operation Slewing Slewing % of load Warning sound Voice warning ( or emergency sound ) operation position capacity "Danger maximum lifting Continuing Point D 100% "DING DONG DANG DONG,…" capacity" ( 1 time ) to slew in same Region E Less than 110% "DING DONG DANG DONG,…"...
Page 309: Power Jib Derricking/Lowering Operation
24. Crane operation 24-7 Power jib derricking/lowering operation ( 581A-0051-0E ) ( 1 ) ：Push the power jib derricking/lowering lever forward to lower the power jib. ：Pull the power jib derricking/lowering lever backward to derrick the power jib. Precautions on derricking and lowering the power jib ・...
Page 310: Changing The Wire Rope Number Of Parts
25. Changing the wire rope number of parts 25. Changing the wire rope number of parts ( 541A-0245-0E ) 25-1 Wire rope standard number of parts ( T21732-034-0E ) The standard hook and number of parts of line for each boom length are as shown in the table below. If you use a non- standard number of parts of line, observe a limit of 28.4kN ( 2900kg ) on each part of wire rope.
Page 311 25. Changing the wire rope number of parts 25-2 Changing the wire rope number of parts ( T218351-084-0E ) ( 1 ) Set the outriggers. Then retract and lower the boom fully and slew it to the side or front. ( 2 ) Remove the rope retaining bracket located at the segment on the left side of the boom top.
Page 312 25. Changing the wire rope number of parts 1 ) Insert the wire rope from the front side of the hook. 2 ) Insert the wire guide to raise the wire rope for position adjustment. 3 ) Change the insertion position of the wire guide to route the wire rope.
Page 313 25. Changing the wire rope number of parts ・ If the length of the wire rope is not enough when you are changing the wire rope number of parts, lower the rope further while it is pulled out by hand, taking care that it does not become tangled on the drum.
Page 314: Preoperational Checks/Pre-Drive Checks
( T218711-005-0E ) Preoperational checks/ 218711 Pre-drive checks 26. Preoperational checks/Pre-drive checks ………………………………………………… 285 26-1 Pre-drive checks …………………………………………………………………………………………… 286 26-2 Preoperational checks ……………………………………………………………………………………… 293...
Page 315 ・ The inspection intervals for this machine are based on standard operations and working conditions. Under severe conditions, the inspection and replacement intervals should be shortened accordingly. ・ If any method or interval of inspection and servicing is unclear, contact your authorised KATO dealer. ( 541A-0259-0E ) - 285 -...
Page 316 Air pressure increase ○ back to the 5 ― 9 range when the engine is running. If the air pressure climbs above 9, stop the engine immediately and contact your authorised KATO dealer. Excluding machines Pedal stroke length equipped with air ○...
Page 317 26. Preoperational checks/Pre-drive checks Daily Inspection/servicing item inspection Inspection procedure Notes Before After Inspection location Inspection item start start ・ After starting the engine, depress the accelerator pedal and check the following. If you notice anything abnormal, stop the engine immediately and investigate the cause.
Page 318 26. Preoperational checks/Pre-drive checks Daily Inspection/servicing item inspection Inspection procedure Notes Before After Inspection location Inspection item start start Condensation in the air Air compressor ○ tank When sitting in the cab, always adjust the mirror Rear view mirrors and reﬂectors Image status positions and clean them if necessary to get an adequate ○...
Page 319 26. Preoperational checks/Pre-drive checks 26-1-2 Points for pre-drive checks ( 511A-0076-0E ) - 289 -...
Page 320 26. Preoperational checks/Pre-drive checks - 290 -...
Page 321 26. Preoperational checks/Pre-drive checks - 291 -...
Page 322 26. Preoperational checks/Pre-drive checks - 292 -...
Page 323 26. Preoperational checks/Pre-drive checks 26-2 Preoperational checks ( 511A-0077-0E ) 26-2-1 Preoperational check sheet ( 511A-0078-0E ) Engine Inspection location Part Task Inspection procedure Notes and service task Before After start start Dents and other ○ Before starting the day's work, make a habit of Cover etc.
Page 324 26. Preoperational checks/Pre-drive checks Engine Inspection location Part Task Inspection procedure Notes and service task Before After start start ・ Af ter starting the engine, depress the accelerator pedal and check the following. If you notice anything abnormal, stop the engine immediately and investigate the cause.
Page 325 26. Preoperational checks/Pre-drive checks Engine Inspection location Part Task Inspection procedure Notes and service task Before After start start Heater Inspect ○ Cooling Inspect ○ Heating Inspect ○ Use the air outlet switch to set the air outlet Defroster Inspect indicator to the "DEF"...
Page 326 26. Preoperational checks/Pre-drive checks Engine Inspection location Part Task Inspection procedure Notes and service task Before After start start The battery electrolyte level should be between Check the "UPPER" and "LOWER" levels. Battery electrolyte If the level is at "LOWER" or below, top it up to ○...
Page 327 26. Preoperational checks/Pre-drive checks Engine Inspection location Part Task Inspection procedure Notes and service task Before After start start Check the gear status at each shift lever position. D: Shifts automatically between 4 gears - 1st, 2nd, 3rd, and 4th 1: Only 1st gear Shift lever Gear change...
Page 328 26. Preoperational checks/Pre-drive checks 26-2-2 Points for preoperational checks ( T217221-051-0E ) - 298 -...
Page 329 26. Preoperational checks/Pre-drive checks - 299 -...
Page 330 26. Preoperational checks/Pre-drive checks - 300 -...
Page 331 26. Preoperational checks/Pre-drive checks - 301 -...
Page 332 MEMO - 302 -...
Page 333: Index 218711
( T218711-006-0E ) Index 218711 Accelerator pedal ………………………………………………………………………………………… 150, 213 Accessory socket …………………………………………………………………………………………………… 23 ACS display panel ……………………………………………………………………………………………… 215 ACS emergency switch ( self-reset type ) ………………………………………………………………………… 212 ACS outside indicator ……………………………………………………………………………………………… 31 ACS working status setting switching buttons ………………………………………………………………… 218 Air cleaner blockage warning indicator lamp ……………………………………………………………………...
Page 334 Clearance lamp indicator lamp ………………………………………………………………………………… 125 Clearance sonar system …………………………………………………………………………………………… 89 Cluster meter panel ……………………………………………………………………………………………… 113 Color monitor/Remote control …………………………………………………………………………………… 57 Combination switch …………………………………………………………………………………………… 152 Combustion type air heater ( optional ) ……………………………………………………………………………… 25 Control panel on the side of the lower structure ………………………………………………………………… 239 DEF level meter …………………………………………………………………………………………………...
Page 335 Front and rear height levers………………………………………………………………………………………… 15 Front panel …………………………………………………………………………………………………… 22, 211 Front panel switches …………………………………………………………………………………………… 143 Fuel consumption display switch section ……………………………………………………………………… 139 Fuel display ……………………………………………………………………………………………………… 125 Fuel gauge ……………………………………………………………………………………………………… 115 Fuel level warning lamp ………………………………………………………………………………………… 117 Fuse box ………………………………………………………………………………………………… 19, 30, 144 Hanger hook ………………………………………………………………………………………………………...
Page 336 Left/right mirror selection switch ……………………………………………………………………………… 143 Left-forward view camera ( color ) …………………………………………………………………………… 29, 57 Level gauge ……………………………………………………………………………………………………… 212 Level gauge conﬁrmation screen switch ………………………………………………………………………… 260 Leveling assist direction switch ………………………………………………………………………………… 237 Leveling assist switch …………………………………………………………………………………………… 237 Lighting switch ………………………………………………………………………………………………… 154 Loudspeaker system ( optional ) ……………………………………………………………………………………...
Page 337 Parking brake indicator lamp …………………………………………………………………………………… 119 Parking brake switch …………………………………………………………………………………………… 147 Pocket ……………………………………………………………………………………………………………… 16 Power jib derricking/lowering lever …………………………………………………………………………… 216 Power jib derricking/lowering lever lock ……………………………………………………………………… 217 Power steering pressure warning lamp ………………………………………………………………………… 130 Power window auxiliary switch …………………………………………………………………………………… 26 Power window switch ( self-reset type ) ……………………………………………………………………………...
Page 338 Side-view mirror extension/stowage switch …………………………………………………………………… 143 Slewing alarm button …………………………………………………………………………………………… 216 Slewing brake switch …………………………………………………………………………………………… 212 Slewing free/lock switch ………………………………………………………………………………………… 214 Slewing lever …………………………………………………………………………………………………… 216 Slewing warning lamp switch …………………………………………………………………………………… 214 Slide lever ………………………………………………………………………………………………………… 15 Specialized driving indicator lamp ……………………………………………………………………………… 118 Speedometer ……………………………………………………………………………………………………...
Page 339 Washer tank………………………………………………………………………………………………………… 26 Way side lamp ( optional ) ………………………………………………………………………………………… 32 Way side lamp switch …………………………………………………………………………………………… 131 Weight adjustment dial …………………………………………………………………………………………… 15 Wheel chocks ( optional ) …………………………………………………………………………………………… 31 Winch camera ( color ) ＋Winch light ……………………………………………………………………………… 58 Winch lever lock ………………………………………………………………………………………………… 220 Winch lighting switch ……………………………………………………………………………………………...
Page 340 MEMO - 310 -...
Page 341 9-37, Higashi-ohi 1-chome, Shinagawa-ku, Tokyo 140-0011 Japan. Tel. : Head Office Tokyo ( 03 ) 3458-1111 Tokyo ( 03 ) 3458-1115 Overseas Marketing Department Fax. : Tokyo ( 03 ) 3458-1163 http://www.kato-works.co.jp 180213TI 7.2018-50 （GD） 1 4.2019-10 （GD） 1-1-1...
Page 342 899-92187110...

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