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. 218731...
Page 2 背厚 6.5 mm　（極小）...
Page 3: Introduction
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 4: 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 5: 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 6 MEMO [ 4 ]...
Page 7: Table Of Contents
( T218731-001-0E ) Table of contents 218731 Introduction ………………………………………………………………………………………… [ 1 ] How to use this manual …………………………………………………………………………… [ 2 ] Inspection and servicing …………………………………………………………………………… [ 3 ] Serial number nameplate ………………………………………………………………………… [ 3 ] Operation qualiﬁcations …………………………………………………………………………… [ 3 ] 1.
Page 8 6. Parts to be replaced periodically for safety ……………………………………………… 114 Drive-related parts ………………………………………………………………………………………… 114 Crane-related parts ………………………………………………………………………………………… 116 7. Data ﬁle ……………………………………………………………………………………… 117 Dimensions ……………………………………………………………………………………………… 117 Tightening torque table …………………………………………………………………………………… 120 Error display ……………………………………………………………………………………………… 126 Consumable parts guide …………………………………………………………………………………… 129...
Page 9: Part Names
1. Part names 1. Part names ( 541A-0020-1E ) - 1 -...
Page 10 MEMO - 2 -...
Page 11: Precautions On Inspection And Servicing
DANGER 2. Precautions on inspection and servicing　 2. Precautions on inspection and servicing ( T217941-051-0E ) Inspection and servicing are as important as lubrication as they have a great inﬂuence on the lifespan of the crane and are highly significant in maintaining safety. Inspect and service the crane regularly to keep yourself aware of its condition and preserve its safety and economic performance.
Page 12: Information Marked "Warning
( 2 ) Each piece of equipment is rigorously tested and tuned before shipping. Tuning outside your authorised KATO dealer is forbidden. ( 3 ) Park on level ground for inspection and servicing, put the parking brake on and place chocks in front of the tires.
Page 13 KATO or KATO- approved products. ・ If you use any products which are not made or approved by KATO, we will not be in any way liable for resultant accidents or breakdowns. - 5 -...
Page 14 WARNING 　2. Precautions on inspection and servicing ( 9 ) Dispose of waste oil carefully ・ If you dispose of waste oil, used ﬁlters and other waste products of the crane carelessly, you will cause environmental pollution. ・ When you drain waste oil from the hydraulic equipment or oil reservoir, catch it in a proper container.
Page 15 WARNING 2. Precautions on inspection and servicing　 ( 13 ) Stop the engine before inspection and servicing ・ It is dangerous to inspect and service the crane while it is moving. ・ Be sure to stop the engine and take the key out before you start work unless the task you are about to perform needs the crane to be moving.
Page 16 WARNING 　2. Precautions on inspection and servicing ( 17 ) Detach the battery cable ・ When servicing any part of the electrical system or when welding, there is the risk that a short circuit could occur and place load on the batteries. The batteries generate ﬂammable gas causing the risk of an explosion.
Page 17 ・ Service of the tires needs expertise, and inappropriate servicing may cause not only machine failure but also human hazard. ・ Ask a KATO service agent to service the tires. ( 22 ) Lock all inspection covers ・ If you leave the inspection covers open, they can swing shut suddenly when the wind blows and trap ﬁngers etc.
Page 18 WARNING 　2. Precautions on inspection and servicing ( 24 ) Precautions about the SCR system 1 ) Engine intake/exhaust system cannot be modified because exhaust gas aftertreatment system failure or engine stop may be caused. 2 ) Only use the AdBlue®/DEF in accordance with ISO 22241-1. Do not use any AdBlue®/DEF other than the brand speciﬁed.
Page 19 WARNING 2. Precautions on inspection and servicing　 5 ) Since no soot generates in exhaust gas, a spark arrester is not necessary. Do not install a spark arrester because it adversely aﬀects the SCR system and engine. 6 ) Use low-ash engine oil, "E9 standard." ( 25 ) Wear protective gear Always wear a hard hat and safety shoes when performing inspection or service work.
Page 20 WARNING 　2. Precautions on inspection and servicing ( 27 ) Precautions for inspection or service work under the machine To prevent being crushed under the machine when performing inspection or service work under the machine, securely support the machine, such as by inserting support columns or wood blocks under the outriggers, for example.
Page 21: Information Marked "Caution
CAUTION 2. Precautions on inspection and servicing　 2-3 Information marked "CAUTION" ( T217941-095-0E ) ( 1 ) Use appropriate tools When performing inspection or service work, use tools that are appropriate for the given application. - 13 -...
Page 22 MEMO - 14 -...
Page 23: Inspection And Servicing Table
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. ・ The intervals for inspection and servicing in this section are based on standard crane operating conditions.
Page 24: Drive-Related
3. Inspection and servicing table 3-1 Drive-related ( T218371-004-0E ) ○ ……… indicates the procedure designated by KATO Symbols of lubricants for replacements ◇ ……… indicates the procedure designated by KATO EO ……… Engine oil ( when used under more harsh operational conditions. ) BF ………...
Page 25 3. Inspection and servicing table Inspection/servicing item Timings for inspection and service Reference section Inspection Part to Notes Machine Before Every 3 Every 12 Inspection location Inspection item Others Monthly change servicing running months months section section Air pressure gauge Air pressure increase 26-1 ○...
Page 26 3. Inspection and servicing table Inspection/servicing item Timings for inspection and service Reference section Inspection Part to Notes Machine Before Every 3 Every 12 Inspection location Inspection item Others Monthly change servicing running months months section section Air pressure 26-1 5-3-1 ○...
Page 27 3. Inspection and servicing table Inspection/servicing item Timings for inspection and service Reference section Inspection Part to Notes Machine Before Every 3 Every 12 Inspection location Inspection item Others Monthly change servicing running months months section section Leveling and other functions ○...
Page 28 3. Inspection and servicing table Inspection/servicing item Timings for inspection and service Reference section Inspection Part to Notes Machine Before Every 3 Every 12 Inspection location Inspection item Others Monthly change servicing running months months section section Low speed and acceleration states 26-1 ＊...
Page 29 3. Inspection and servicing table Inspection/servicing item Timings for inspection and service Reference section Inspection Part to Notes Machine Before Every 3 Every 12 Inspection location Inspection item Others Monthly change servicing running months months section section Looseness and damages on the 5-1-2 ◆...
Page 30: Crane-Related
＊5 ……… When the receiver drier is replaced BG ……… Extreme-pressure boom grease ＊6 ……… Every 250 hours ＊7 ……… Every 4 years after the previous replacement ＊8 ……… KATO ’ s designated hydraulic oil: every 4,000 hours or every 4 years Reference section Every 45...
Page 31 3. Inspection and servicing table Reference section Every 45 Every 3 Every 6 Every 2 Inspection location Inspection Weekly Monthly Yearly or Part Task Daily Part to Machine days or months months or years or and service task or 50h or 100h 1000h change...
Page 32 3. Inspection and servicing table Reference section Every 45 Every 3 Every 6 Every 2 Inspection location Inspection Weekly Monthly Yearly or Part Task Daily Part to Machine days or months months or years or and service task or 50h or 100h 1000h change...
Page 33 3. Inspection and servicing table Reference section Every 45 Every 3 Every 6 Every 2 Inspection location Inspection Weekly Monthly Yearly or Part Task Daily Part to Machine days or months months or years or and service task or 50h or 100h 1000h change...
Page 34: Lubrication
( 4 ) Select a clean place to perform lubrication to avoid dirt and/or moisture from entering the lubricant or the machine. ( 5 ) Failures caused by using such lubricants that are not recommended by KATO or do not meet the speciﬁed selection criteria, or by not observing the speciﬁed lubrication timings shall not be covered by the warranty.
Page 35 4. Lubrication ( 7 ) When greasing the slewing bearing gear, use a brush etc. to apply grease while turning the slewing upper structure slowly for a full turn. When greasing while the slewing upper structure is being slewed, take special cautions not to get your hand, ﬁngers, or any thing such as brush caught in the structure.
Page 36: Oils That Have Been Filled Upon Shipment From Our Factory
4. Lubrication 4-2 Oils that have been ﬁlled upon shipment from our factory ( T217241-035-0E ) ( 1 ) Hydraulic oil Hydraulic oil based on the agreement has been ﬁlled upon shipment from our factory. The brand and ISO VG number of the ﬁlled hydraulic oil are indicated on the plate on the side of the hydraulic oil reservoir. ( 2 ) Engine oil Refer to the separate engine instruction manual.
Page 37 ( 7 ) Heater oil Name Symbol Standard Oil ﬁlled upon shipment from our factory Heater oil Genuine KATO heater oil ( 511D-0043-0E ) ( 8 ) Greases Following greases have been ﬁlled upon shipment from our factory. Symbol Greasing Grease ﬁlled upon shipment from our factory...
Page 38: Recommended Lubricants Table
4. Lubrication 4-3 Recommended lubricants table T218371-020-0E ( 1 ) Hydraulic oil Hydraulic oil must be selected in consideration of the ambient air temperature at the operating site and the upper limit of the hydraulic oil usage temperature. The upper limit of the temperature range is the operating limit temperature while the lower limit is the minimum ambient air temperature.
Page 39: Greasing Chart
4. Lubrication 4-4 Greasing chart ( 541D-0018-1E ) - 31 -...
Page 40 4. Lubrication - 32 -...
Page 41 4. Lubrication 4-4-1 Greasing via the central lubrication ports ( T217941-063-0E ) Grease the following components via the central lubrication ports. ( Both in the front and rear ) ・ Axle kingpins, top and bottom ( Both in the front and rear ) ・...
Page 42 Weekly or every 50 hours of operation, apply "extreme-pressure boom grease ( BG ) ", with superior sliding ability and extreme-pressure resistance speciﬁed by KATO, to each boom section ( grease traps on top of the boom ( accessed via nipples on the side surfaces ) and upper and lower curved surfaces of the boom ) .
Page 43 4. Lubrication ( 1 ) Lump greasing ( with the boom fully extended to 28m ) 1 ) Preparing for greasing ① Secure a space for greasing with the boom fully extended ( 28m ) below horizontal. ② On ﬁrm level ground, fully extend all outriggers and install the machine body on the level. ③...
Page 44 4. Lubrication ② Use a rubber spatula or other tool to apply a thin layer of grease to the sliding surfaces. NOTE The load on the lower curved sliding surfaces of the boom is the greatest on the boom section 2 and the smallest at the front end.
Page 45 4. Lubrication 2 ) Greasing the boom sections 4, 5 and 6 ① Upon completion of greasing the boom sections 2 and 3, retract these sections to the extent that the lubrication ports on the side surfaces of the boom section 3 are not covered. ②...
Page 46 4. Lubrication ⑦ Release the boom extension/retraction emergency switch and boom sections 4, 5 and 6 extension/retraction button and move the boom extension/retraction lever to the "retraction" side to retract the boom sections 2 and 3 fully. ・ Observe the specified intervals for greasing the boom. Otherwise, the boom's extension/ retraction ability is deteriorated and rust may be generated on the sliding section, increasing wear on the sliding plate and adversely aﬀecting working eﬃciency.
Page 47 4. Lubrication 4-4-4 Greasing procedure for the boom extension/retraction wire ropes ( T217341-037-1E ) The boom extension/retraction wire ropes wear and corrode with use and the passage of time. Apply rope grease periodically to prevent the ropes from wearing and getting corroded. Apply grease to the wire ropes in the following procedure.
Page 48 4. Lubrication ( 4 ) Scrape oﬀ any sands and/or old grease on the surfaces of the boom extension/retraction wire ropes and clean the wire ropes with a wire brush or cloth. ( 5 ) Use spray-type rope grease to apply an even and appropriate amount of rope grease to the rope surfaces. ( 6 ) Upon completion of greasing the boom extension/retraction wire ropes, press the boom sections 4, 5 and 6 extension/retraction button to retract the boom sections 4, 5 and 6 fully while keeping the boom extension/ retraction emergency switch switched to the "release"...
Page 49: Oil Chart
4. Lubrication 4-5 Oil chart ( 511D-0004-0E ) - 41 -...
Page 50: Inspection And Servicing Of Each Part
5. Inspection and servicing of each part 5. Inspection and servicing of each part ( 541D-0034-1E ) 5-1 Engine-related ( 541D-0035-0E ) 5-1-1 Inspection and servicing of the engine ( T217321-102-0E ) ( 1 ) For engine-related inspection items, refer to "Inspection and servicing table". ( 2 ) For inspection method, refer to the instruction manual for your installed engine.
Page 51 5. Inspection and servicing of each part 2 ) To close the engine cover, grip the handle and close the engine cover toward the front, conﬁrming it is fully locked. ・ Close and lock the engine cover before driving or operating the crane. ・...
Page 52 5. Inspection and servicing of each part ( 3 ) Replenishment procedure of the DEF ( AdBlue® ) 1 ) Remove the ﬁller cap. 2 ) Replenish the speciﬁed DEF ( AdBlue® ) . 3 ) Close the ﬁller cap securely. ( 4 ) Replacement procedure of the DEF ( AdBlue®...
Page 53 3 ) Check that the ﬁxing clips for the tubes and hoses are not loosened. ( Refer to the pre -drive checks. ) *If there is any crack, damage, or bending on the tubes, hoses, or connectors, have them inspected or serviced by your authorised KATO dealer. Do not inspect for DEF or cooling water leakage immediately after driving. The exhaust pipe, muﬄer, and cooling water could be very hot.
Page 54 5. Inspection and servicing of each part ( 7 ) Cleaning the DEF tank strainer 1 ) Cleaning interval……As needed 2 ) Using the DEF tank strainer ① If the strainer is removed when ﬁlling the DEF tank with the DEF, debris or other matter could enter the DEF tank via the ﬁller port, which could cause the SCR system to malfunction.
Page 55 ・ When the machine is used under harsh conditions, the intervals for replacement must be shortened. ・ Use the genuine KATO or KATO-approved elements only. ・ When the machine is moved through any dusty places, shorten the replacement intervals as required.
Page 56 5. Inspection and servicing of each part 1 ) Removing the element ① Unlock and remove the cover. ② Remove the main element. ③ Wipe oﬀ the dust from the internal cover inside the case, such as by using a cloth. ④...
Page 57 Be sure to inspect the level of the coolant through the inspection window of the reservoir tank before starting the engine. If not, replenish the coolant. The machine uses KATO Diesel Long-life Coolant. When replenishing the coolant, make sure to add not only tap water but also KATO Diesel Long-life Coolant.
Page 58 5. Inspection and servicing of each part ・ Use only KATO genuine long-life coolant as an additive to coolant. Use of long-life coolant of another make may result in not only shortened engine service life but also damaged engine. ・ When replenishing the coolant after the level inspection or when repairing coolant leakage, be to measure the long-life coolant density.
Page 59 5. Inspection and servicing of each part 5-1-5 Fuel system ( T218171-017-0E ) ( 1 ) Procedure for draining water from the water separator 1 ) Stop the engine. 2 ) Open the drain valve by hand. 3 ) Drain the water/fuel until clean fuel appears. Do not overtighten the drain valve when closing it.
Page 60 ( 3 ) Replenishment and replacement of 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 61 5. Inspection and servicing of each part ( 4 ) Inspection and replacement intervals for engine oil Inspection interval……… At the time of pre-drive checks Oil leakage inspection … Monthly Replacement interval…… After ﬁrst 60 hours for the new machine and every 500 hours afterwards NOTE For oil replacement and replenishment procedures, refer to the instruction manual for your installed engine.
Page 62: Power Transmission System
5. Inspection and servicing of each part 5-2 Power transmission system ( 511D-0065-1E ) 5-2-1 Oil level inspection and replacement of torque converter oil, and washing of the strainer ( T218371-014-0E ) ( 1 ) Inspection of the oil level between the torque converter and the transmission Torque converter oil has two functions: transmitting the power to drive and lubricating the line between the torque converter and the transmission.
Page 63 5. Inspection and servicing of each part 5 ) Conﬁrm the torque converter trouble warning lamp on the cluster meter panel is not turned on. 6 ) If the status is normal, adjust so that the oil enters again through the ﬁller port into the area around the center of the level gauge with the engine idling.
Page 64 5. Inspection and servicing of each part 5-2-2 Replacement of the oil ﬁlter element for the torque converter ( T218021-007-0E ) ( 1 ) Replacement procedure 1 ) Provide an oil pan container under the cartridge to receive oil dripping from the removed cartridge. 2 ) Stop the engine. 3 ) Loosen the drain plug installed at the bottom of the oil ﬁlter to drain the torque converter oil out of the ﬁlter case.
Page 65 5. Inspection and servicing of each part 5-2-3 Inspection for the propeller shaft ( 511D-0066-0E ) ( 1 ) Inspection interval for the propeller shaft 1 ) Looseness on the coupling section …… Monthly 2 ) Plays on the joint section ……………… Every 12 months - 57 -...
Page 66: Drive System
5. Inspection and servicing of each part 5-3 Drive system ( 541D-0109-0E ) 5-3-1 Replacement of the tires ( T218171-006-0E ) ( 1 ) Precautions on tire replacement 1 ) Check out the standard of the installed tires. Be sure to use the tires of the same standard for replacement. 2 ) Replace the tires when: ・...
Page 67 5. Inspection and servicing of each part 5-3-2 Tire rotation ( 511D-0055-2E ) Wear of tires will vary depending on the road and brake operating conditions. To avoid biased wear, tires must be rotated for evenly distributed wear. ( 1 ) Precautions on tire rotation 1 ) Tires must be rotated so that the turning direction of the tires is reversed from the former installation.
Page 68 2 ) Clean the threads of the wheel bolts and wheel nuts as well as the disk wheel installation surfaces thoroughly. Never use the wheel bolts or wheel nuts with their threads worn out or the deformed or cracked disk wheels. Ask a KATO service agent to replace them. ( 541D-0113-1E ) 3 ) Reassemble the disk wheel to the axle.
Page 69 5. Inspection and servicing of each part ( 3 ) Inspection interval for the wheel nuts Installation state of the disk wheels ……At the time of pre-drive checks Looseness on the wheel nuts……………At the time of pre-drive checks Damage on the wheel nuts………………Every 12 months 5-3-4 Inspection of the disk wheels ( 511D-0068-1E ) Inspection interval for the disk wheels...
Page 70 5. Inspection and servicing of each part ( 2 ) Inspection and replacement intervals for axle gear oil, and amount of oiling Inspection interval …… Every 3 months Replacement interval … Yearly or every 10000 km After ﬁrst 1000 km or 100 hours of operation for a new machine Amount of oiling ………...
Page 71: Braking System
5. Inspection and servicing of each part 5-4 Braking system ( 541D-0085-0E ) 5-4-1 Inspection of the brake pedal ( 511D-0069-0E ) ( 1 ) Inspection interval for the brake pedal Inspection interval……Monthly 5-4-2 Inspection of the foot brake ( T218171-019-0E ) - 63 -...
Page 72 For safety running, be sure to perform periodical inspection of the brake pad thickness and if the brake pads reach the lower limit of the thickness, ask a KATO service agent to replace them. Brake pad thickness...
Page 73 5. Inspection and servicing of each part 2 ) Inspection interval Inspection interval……Every 3 months Make it habit to do voluntary inspections to ﬁnd any abnormalities and ask a KATO service agent to service them. ( 611D-0027-0E ) Before starting inspection, make sure the temperatures of the brake disk and the brake pad have been lowered.
Page 74 5. Inspection and servicing of each part 5-4-3 Replacement of the brake ﬂuid ( T217341-039-1E ) The brake ﬂuid tank is at the center to the left of the carrier. Conﬁrm the ﬂuid level is between LEVEL and MIN. If it is below LEVEL, replenish the ﬂuid. If the ﬂuid level is lowered even when any external ﬂuid leakage cannot be seen, the brake pads may have been worn out.
Page 75 5. Inspection and servicing of each part 6 ) Repeat the above procedure until no air bubble is recognized in the brake ﬂuid ﬂowing within the vinyl tube. During this operation, be sure to replenish the ﬂuid so that the brake ﬂuid tank will not become empty. 7 ) Each caliper has two bleeder screws.
Page 76 5. Inspection and servicing of each part ( 2 ) Adjustment procedure for the parking brake After setting the drum for free rotation, turn the drum until the adjusting screw can be seen through the drum hole. Extend the shoe until you feel resistance to the drum rotation, and then put back the adjusting screw by eight teeth to adjust the clearance to 0.23 mm.
Page 77 ・ When replacing the air drier, be sure to replace the O-rings and desiccant, too. ・ If water is drained from the air drier prematurely, replace the desiccant. ・ Do not use any substitutes for KATO's genuine products. ( 541D-0134-1E ) ( 3 ) Consumable part number Refer to the "Consumable parts guide".
Page 78: Steering System
5. Inspection and servicing of each part 5-5 Steering system ( 511D-0070-0E ) 5-5-1 Inspection of the steering system ( 511D-0071-1E ) ( 1 ) Inspection interval for the steering system 1 ) Cracks or damages on the dust boots ……………………………… Every 3 months 2 ) Cracks or installation state of the knuckle arms ……………………...
Page 79: Shock Absorbers
5. Inspection and servicing of each part 5-6 Shock absorbers ( 511D-0072-0E ) 5-6-1 Inspection of the shock absorber ( T217241-010-0E ) ( 1 ) Inspection interval for the shock absorber 1 ) Damages on the springs ……………………………………………………………………… Every 3 months 2 ) Looseness, play or damages on the spring installation section and the coupling section …...
Page 80: Hydraulic System-Related
・ Hydraulic pipes need to be handled with carefully. Incorrect handling can cause oil leakage, operation failure of the hydraulic equipment etc. When the pipes are disconnected, always contact your authorised KATO dealer. ・ Water, dirt and foreign material getting into the oil reservoir and pipes can lead to damage.
Page 81 5. Inspection and servicing of each part ( 1 ) Replacement procedure 1 ) Preparation for the replacement of hydraulic oil ① Park the machine on a level road surface with the crane in the drive posture. ② Prepare a container ( minimum capacity: 280 liters ) for hydraulic oil to be drained and an oil pan to receive the drained oil.
Page 82 These troubles shall not be covered by the warranty. ・ Hydraulic oil to be used for the crane must be of the ISO VG number based on the KATO's hydraulic oil selection criteria and of the brands recommended by KATO.
Page 83 ( 1 ) Structure of the KATO return ﬁlter The structure of the KATO return ﬁlter is as shown in the diagram to the right. The hydraulic oil ﬂows from the inside to the outside...
Page 84 5. Inspection and servicing of each part 2 ) Clean tray which is already washed: ( 300mm × 450mm or equivalent ) 3 ) Clean paper or cloth: with no nap 4 ) Hydraulic oil ( cleaning ﬂuid ) : the same new hydraulic oil as the crane is using 5 ) Ratchet wrench 6 ) 19mm box wrench 7 ) O-ring ( for the cover )
Page 85 5. Inspection and servicing of each part 4 ) Put the element assembly from which the oil is drained onto the tray. Use the washed tray. If the tray is dirty, it makes the lower part of the center bolt of the element assembly dirty.
Page 86 5. Inspection and servicing of each part 8 ) Remove the center bolt from the element, and separate the element and the retainer. ( 5 ) Cleaning and inspection 1 ) Thoroughly clean the component parts of the element assembly except the element using the new hydraulic oil which is prepared in advance.
Page 87 5. Inspection and servicing of each part 4 ) Attach the plate spring onto the safety valve. Tighten the castle nut to the center bolt to the regulation torque. Tightening torque: 10 ― 15N ・ m ( 1.0 ― 1.5kgf ・ m ) If the tightening force on the castle nut is insuﬃcient, the ﬁlter can not work eﬃciently.
Page 88 5. Inspection and servicing of each part 7 ) Check the O-ring for damage again. Then attach the O-ring in place and put the cover onto the ﬁlter case. 8 ) Attach the washers to the four bolts and tighten the cover to the ﬁlter case to the regulation torque.
Page 89 2 ) Stop the engine. 3 ) Remove the cartridge from the holder by using the dedicated tool. 4 ) Prepare unused KATO genuine spin ﬁlter cartridges and conﬁrm the gaskets have been properly seated on their seats. 5 ) Fill the cartridge with fresh oil that is the same brand as the oil in the hydraulic oil reservoir. Install the cartridge on the holder by manually turning the cartridge while taking care not to allow the gasket to be extruded.
Page 90 5. Inspection and servicing of each part ( 2 ) Cartridge replacement interval Replacement interval …… Every 500 hours or every 6 months After 100 operating hours or after one month when the new machine is used ( 3 ) Consumable part number Refer to the "Consumable parts guide".
Page 91 5. Inspection and servicing of each part 5-7-5 Mesh ﬁlter cleaning ( 511D-0054-1E ) ( 1 ) Cleaning procedure 1 ) Remove adapter [ 1 ] with the ﬁlter built in. Take special care not to damage O-ring [ 2 ] . 2 ) Clean the mesh-type ﬁlter element in the adapter with cleaning oil, then assemble it to its original position.
Page 92: Boom-Related
If any of the above problems arises, ﬁrst grease the boom and extend and retract it several times, and then check again. If abnormality still remains, ask your authorised KATO dealer to adjust the tension of the boom extension/retraction wire rope in the following procedure.
Page 93 5. Inspection and servicing of each part 6 ) Upon completion of adjusting the tension of the retraction wire ropes, lock the left and right RA. nuts-1 as follows. ① Lightly tighten the locknut against the RA. nut. ② Use a spanner to hold the locknut in the same position, and turn the adjuster nut RA.
Page 94 5. Inspection and servicing of each part 5 ) Check that the boom sections 4, 5 and 6 are fully retracted. If there is a gap ( portion not fully retracted ) , measure the gap. 6 ) Extend the boom section 4 about 1m and adjust RA. nuts depending on the gap measured in 5 ) above. ①...
Page 95 5. Inspection and servicing of each part 13 ) Upon completion of adjusting the tension of the boom extension/ retraction wire ropes of each boom section, lock each EA. nut and RA. nut as follows. ① Lightly tighten the locknut against the EA. nut or RA. nut. ②...
Page 96 Contact your authorised KATO dealer to have the slide plates inspected when you notice any such problem. ( 3 ) Consumable part number Refer to the "Consumable parts guide".
Page 97 5. Inspection and servicing of each part 5-8-3 Inspection and replacement criteria of the boom extension/retraction wire ropes ( 541D-0091-3E ) With use and the passage of time, the boom extension/retraction wire ropes become fatigued causing stretching and broken ﬁlaments. This deterioration can lead to severe accidents. In particular the extension wire rope needs periodic cleaning and greasing when the boom length is adjusted and at other times.
Page 98 5. Inspection and servicing of each part 5-8-4 Inspection of the boom foot pin attachment bolt ( T218171-021-0E ) ( 1 ) Inspection procedure 1 ) Looseness of the attachment bolt ( 2 ) Tightening torque and inspection interval Tightening torque and inspection interval …… 217N ・ m ( 22.1kgf ・ m ) Inspection interval ……………………………...
Page 99: Winch-Related
5. Inspection and servicing of each part 5-9 Winch-related ( 541D-0069-0E ) 5-9-1 Hook inspection ( 541D-0070-2E ) The hook is an essential component for daily operation. Grease it as regularly as you do the wire rope and inspect the bearings and the opening of the hook etc. following the items below.
Page 100 5. Inspection and servicing of each part 5-9-2 Wire rope handling ( 511D-0013-0E ) If dirt is constantly removed from the wire rope and grease applied periodically, corrosion can be prevented and use prolonged. Lifespan can be further extended by wire rope end rotation ( alternation of the rope ends at the drum end and the boom or hook end ) and rotation with a spare rope, so these are economical measures.
Page 101 5. Inspection and servicing of each part 3 ) When the wire rope has twisted into a kink. 4 ) When there is severe deformation so that the core rope protrudes, a birdcage shape is formed, or when there is corrosion. 5 ) When electricity or gas welding sparks have aﬀected the wire rope.
Page 102 5. Inspection and servicing of each part 5-9-3 Wire rope replacement procedure ( 591D-0021-2E ) ( 1 ) Wire rope removal 1 ) Set the outriggers correctly. 2 ) Place the boom on the level to the left or right direction. 3 ) After removing the wire clip, use a hammer and round bar with a diameter less than 10 mm to knock the rope wedge out of place, as shown in the diagram, and then separate the wire rope...
Page 103 5. Inspection and servicing of each part 3 ) Wind up the winch slowly. Watch out for disorderly winding of the wire rope. The wire rope must be wound evenly on the reel. Also, be sure to leave enough rope to wind on the hook. 4 ) Pass the rope through the overhoisting detector weight according to the standard number of parts of line.
Page 104 5. Inspection and servicing of each part ( 3 ) Handling of new wire ropes 1 ) When the new machine is used or after wire ropes are replaced, the wire ropes may be twisted during the operation with the extended boom, causing a dangerous situation of spinning of the suspended load by the force of the wire ropes that try to untwist.
Page 105 ・ The gear oil must be of a brand recommended by KATO and of an SAE No. chosen according to selection criteria set by KATO. Use of an inappropriate gear oil will shorten the lifespan of the reduction gear and could cause it to break down, making it out of use.
Page 106: Slewing-Related
5. Inspection and servicing of each part 5-10 Slewing-related ( 541D-0062-0E ) 5-10-1 Tightening of slewing bearing attachment bolts ( method and torque ) ( T218371-028-0E ) The slewing bearing attachment bolts are the only connections between the slewing upper structure ( crane ) and the lower structure ( carrier ) .
Page 107 These troubles shall not be covered by the warranty. ・ The gear oil must be of a brand recommended by KATO and of an SAE No. chosen according to selection criteria set by KATO. Use of an inappropriate gear oil will shorten the lifespan of the reduction gear and could cause it to break down, immobilizing the slewing upper structure.
Page 108: Air Conditioner-Related
Have the air conditioner system inspected and serviced regularly to maintain it at full perfomance. ・ If the air conditioner malfunctions, switch it OFF and contact your authorised KATO dealer. ・ Filling with regrigerant gas and other service tasks require special tools and instruments and should only be attempted in a properly equipped KATO dealer.
Page 109 5. Inspection and servicing of each part 5-11-1 Filter cleaning and replacement ( T218371-021-0E ) ( 1 ) Cleaning procedure The air intake ﬁlter is located in the ﬁlter holder behind the driver's seat in the cab. If this ﬁlter is blocked with grit etc. the air ﬂow will reduce and heating and cooling performance will decline as a result.
Page 110 ・ Filling with refrigerant gas and other service tasks require special tools and instruments and should only be attempted in a properly equipped KATO dealer. ( 541D-0098-1E ) ・...
Page 111 KATO dealer. ( 541D-0101-2E ) ( 2 ) Replacement procedure Contact your authorised KATO dealer. ( 3 ) Inspection and replacement intervals Inspection interval ……… Daily Replacement interval …… Yearly or every 1000 hours ( 4 ) Consumable parts Refer to the "Consumable parts guide".
Page 112 If the compressor belt is slack it will slip, reducing cooling performance. If the hydraulic pump belts are slack they will slip, reducing heating performance. ( 2 ) Adjustment procedure Contact your authorised KATO dealer. ( 3 ) Inspection interval Inspection interval ……… Every 6 months...
Page 113 5. Inspection and servicing of each part 5-11-6 Cartridge ﬁlter replacement ( T218371-018-0E ) ( 1 ) Remove Use a wrench ( ﬁlter size 80 mm, 15 faces ) to remove a cartridge ﬁlter. ( 2 ) Attachment Reverse the removal procedure. NOTE Tightening torque: 24.5 N ・...
Page 114 ・ Filling with refrigerant gas and other service tasks require special tools and instruments and should only be attempted in a properly equipped KATO dealer. ( 541D-0098-1E ) ・...
Page 115: Electrical System-Related
5. Inspection and servicing of each part 5-12 Electrical system-related ( 541D-0135-0E ) 5-12-1 Handling of the battery system ( T217941-028-0E ) ( 1 ) General precautions This machine has two 12V batteries connected in series, 24V negative grounded. When handling the battery system, observe the following precautions: 1 ) When handling the battery system, wear a protective eyewear, protective gloves, and long- sleeved working clothes.
Page 116 Do not charge the battery or use another power supply to start the engine when the battery electrolyte is frozen. NOTE An optional high capacity battery is available. If the temperature is expected to become －18 °C or lower, consult your authorised KATO dealer. - 108 -...
Page 117 Be sure to adjust the light beam after replacing headlamps. If you cannot avoid replacing the headlamp yourself, be sure to have it adjusted by your authorised KATO dealer. ( T218131-024-0E ) Always replace the bulb with that of the speciﬁed capacity. If you use the bulb in excess of the rated capacity, the excess power consumption will cause accidents by blowing the fuse or igniting electrical insulation.
Page 118 5. Inspection and servicing of each part 5-12-3 Fuse replacement ( T217241-054-1E ) Fuses are separated into two fuse boxes, one on the slewing upper structure ( inside the left panel at the rear of the cab ) and the other on the carrier ( inside the relay box and battery relay box on the left side of the carrier ) . If a fuse blows, investigate and repair the cause before replacing the fuse with a spare fuse from inside the fuse box.
Page 119 If the electric system will not operate even if the fuse is in normal state, the high current fuse may be burn out. Ask your authorised KATO dealer to ﬁnd and repair the failure, and to replace the high current fuse.
Page 120 5. Inspection and servicing of each part 5-12-5 Wiper blade inspection and replacement ( 541D-0145-3E ) Inspect the wiper blades and replace any that are worn or damaged. ( 1 ) Consumable part number Refer to the "Consumable parts guide". - 112 -...
Page 121: Crane Safety Devices
5. Inspection and servicing of each part 5-13 Crane safety devices ( 511D-0078-0E ) 5-13-1 Inspection and replacement of the overhoisting detector limit switch block ( overhoisting limit switch ) ( 031D-0042-2E ) Usually the crane is used without overhoisting ( the state the hook overhoisting detector weight is raised ) when hoisting the winch, or extending or lowering the boom.
Page 122: Parts To Be Replaced Periodically For Safety
6. Parts to be replaced periodically for safety ( 511D-0045-0E ) Parts that may lead to serious accidents if deteriorated must be replaced periodically. For the replacement of these parts, please ask your authorised KATO dealer. 6-1 Drive-related parts ( 511D-0046-0E )
Page 123 After ﬁrst 100 hours Diﬀerential gear oil 10000 After ﬁrst 100 hours Planetary hub gear oil 10000 After ﬁrst 100 hours KATO’s designated hydraulic Hydraulic oil 2000 oil: every 4 years or every 4,000 hours Hydrodynamic retarder oil Coolant ( long-life coolant )
Page 124: Crane-Related Parts
6. Parts to be replaced periodically for safety 6-2 Crane-related parts ( 511D-0049-0E ) Parts to be replaced periodically for safety Parts Location Replacement timing Boom extension/retraction wire rope On the boom Every 4 years Overhoisting detector limit switch block On the boom, the jib, and the rooster Every 4 years sheave...
Page 125: Data File
7. Data ﬁle 7. Data ﬁle ( 541D-0148-1E ) 7-1 Dimensions ( 541D-0149-1E ) - 117 -...
Page 126 7. Data ﬁle - 118 -...
Page 127 7. Data ﬁle - 119 -...
Page 128: Tightening Torque Table
7. Data ﬁle 7-2 Tightening torque table ( 0099-0237-0E ) 7-2-1 Tightening torque for meter screw standard bolt ( 0099-0238-0E ) [ Standard ] Units: N ・ m ( kgf ・ m ) [ Fine ] Units: N ・ m ( kgf ・ m ) Strength classiﬁcation Strength classiﬁcation Nominal...
Page 129 7. Data ﬁle 7-2-2 Tightening torques for hydraulic and pneumatic related joints ( T217941-033-0E ) ( 1 ) The tolerance for the torque values is ±10%. ( 2 ) The unit for the torque values is N ・ m ( kgf ・ m ) . ( 3 ) Never allow oil to adhere on the threads or the rotating section of the nut.
Page 130 7. Data ﬁle ( 7 ) Hose joint ( Type C, R ) Units: N ・ m ( kgf ・ m ) Screw size ( G ) 1 1/4 1 1/2 Width across faces ( H ) ( mm ) 55 ( 60 ) ( 3.5 ) ( 13.5 )
Page 131 7. Data ﬁle ( 9 ) Flare nut ( made of steel ) Units: N ・ m ( kgf ・ m ) Outer diameter of tube ( mm ) 4.76 6.35 10.0 12.0 Screw size ( d ) M10×1.0 M12×1.0 M14×1.5 M16×1.5 M20×1.5...
Page 132 7. Data ﬁle 2 ) SAE high pressure ( Type Ⅱ, Ⅲ ) Units: N ・ m ( kgf ・ m ) Inner diameter indication Hose size 1 1/4 1 1/2 Inner diameter of hose ( mm ) 12.7 19.0 25.4 31.8 38.1...
Page 133 7. Data ﬁle ( 12 ) Piping ﬂange Units: N ・ m ( kgf ・ m ) Bolt to be used M8×1.25 M10×1.5 M12×1.75 M16×2.0 ( 001-105 ) Tightening Steel ( 2.3 ) ( 6 ) ( 9 ) ( 17 ) torque ( Seating surface...
Page 134: Error Display
7. Data ﬁle 7-3 Error display ( T218371-029-0E ) ( 1 ) COR errors 1131 : WDT start error WDT start error ( FT ) 1132 : Program write error ( DI ) 2141 : Program write error ( FT ) 2142 : EEPROM format error ( DI ) 2151 :...
Page 135 7. Data ﬁle EEPROM memory data corruption ( DI ) 5111 : EEPROM addressing error ( FT ) 5112 : EEPROM addressing error ( DI ) 5121 : EEPROM memory data corruption ( FT ) 5122 : 5171 : Switch box connection conﬁrmation error 5181 : Switch box error 5210 :...
Page 136 7. Data ﬁle ( 2 ) AT errors AT speed sensor 1 error AT speed sensor 2 error AT accelerator sensor error AT shift switch error AT supply voltage error ATSOLA error ATSOLD-b error ATSOLC error ATSOLD-a error ATSOLE error ATSOLF error ATSOLL error ATSOLM error...
Page 137: Consumable Parts Guide
( 541D-0161-1E ) 7-4-1 List of genuine lubricants ( 511D-0050-0E ) ( 1 ) Greases Type Brand Part number Quantity 　 KATO YK-2 Grease 999-00000090 16kg Exterme-pressure boom grease ( BG ) KATO YK-2 Grease 999-00000100 2.5kg KATO YK-2 Grease 999-00000200 0.4kg...
Page 138 Hydraulic oil ( HO ) Hydraulic oil VG46 779-70520420 ( T218371-025-0E ) ( 3 ) Long life coolants Brand Part number Quantity 　 KATO Diesel Long Life Coolant 779-70301100 200L KATO Diesel Long Life Coolant 779-70301200 ( T218371-026-0E ) - 130 -...
Page 139 7. Data ﬁle ( 4 ) DEF ( AdBlue® ) Brand Part number Quantity 　 KATO recommended DEF ( AdBlue® ) 779-71100400 10L×2 ( T218371-027-0E ) - 131 -...
Page 140 7. Data ﬁle 7-4-2 Replacement parts ( 511D-0024-0E ) [ Section ref. ] 　5-1-1 [ Consumable part name ] 　V-belt [ Section ref. ] 　5-1-1 [ Consumable part name ] 　Crankcase breather ﬁlter element ( T217341-033-0E ) - 132 -...
Page 141 7. Data ﬁle [ Section ref. ] 　5-1-1 [ Consumable part name ] 　Oil ﬁlter [ Section ref. ] 　5-1-2 [ Consumable part name ] 　DEF pump ﬁlter ( T218171-011-0E ) - 133 -...
Page 142 7. Data ﬁle [ Section ref. ] 　5-1-3 [ Consumable part name ] 　Air cleaner element [ Section ref. ] 　5-1-4 [ Consumable part name ] 　Radiator cap ( T218171-012-0E ) - 134 -...
Page 143 7. Data ﬁle [ Section ref. ] 　5-1-5 [ Consumable part name ] 　Fuel ﬁlter [ Section ref. ] 　5-1-6 [ Consumable part name ] 　Water separator ( 581D-0008-0E ) - 135 -...
Page 144 7. Data ﬁle [ Section ref. ] 　5-2-2 [ Consumable part name ] 　Torque converter oil ﬁlter element [ Section ref. ] 　5-4-5 [ Consumable part name ] 　Air drier ( T217341-034-0E ) - 136 -...
Page 145 7. Data ﬁle [ Section ref. ] 　5-7-2 [ Consumable part name ] 　Return ﬁlter element [ Section ref. ] 　5-7-3 [ Consumable part name ] 　Spin ﬁlter cartridge ( 581D-0018-0E ) - 137 -...
Page 146 7. Data ﬁle [ Section ref. ] 　5-7-3 [ Consumable part name ] 　Spin ﬁlter cartridge [ Section ref. ] 　5-7-4 [ Consumable part name ] 　Steering oil ﬁlter element ( T217341-016-0E ) - 138 -...
Page 147 7. Data ﬁle [ Section ref. ] 　5-8-2 [ Consumable part name ] 　Slide plate ( 581D-0010-0E ) - 139 -...
Page 148 7. Data ﬁle [ Section ref. ] 　5-8-2 [ Consumable part name ] 　Slide plate ( 581D-0011-0E ) - 140 -...
Page 149 7. Data ﬁle ( 1 ) Front end lower boom slide plate ( plastic ) Thickness ( t ) Standard dimensions Attaching Ref. No. Part No. Q'ty position Recommended Limit of use replacement Boom base 701-48807000 Boom section 2 701-48808001 147 140 Boom section 3 701-48809000...
Page 150 7. Data ﬁle ( 5 ) Rear end lower and side boom slide plate ( plastic ) 　※1 Standard dimensions Thickness Attaching Ref. No. Part No. Q'ty position Recommended Length Width Limit of use Thickness replacement Boom section 2 511-41617000 Boom section 2 511-41661000 AR Boom section 3...
Page 151 7. Data ﬁle [ Section ref. ] 　5-9-2 [ Consumable part name ] 　Wire rope [ Section ref. ] 　5-11-2 [ Consumable part name ] 　Refrigerant ( 581D-0021-0E ) - 143 -...
Page 152 7. Data ﬁle [ Section ref. ] 　5-11-6 [ Consumable part name ] 　Air conditioner cartridge ﬁlter ( 581D-0038-0E ) - 144 -...
Page 153 7. Data ﬁle [ Section ref. ] 　5-12-2 [ Consumable part name ] 　Bulb ( 581D-0022-0E ) - 145 -...
Page 154 7. Data ﬁle [ Section ref. ] 　5-12-3 [ Consumable part name ] 　Fuse ( 581D-0023-0E ) - 146 -...
Page 155 7. Data ﬁle [ Section ref. ] 　5-12-5 [ Consumable part name ] 　Wiper blade ( 511D-0084-0E ) - 147 -...
Page 156 MEMO - 148 -...
Page 157 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 150206TI 7.2018-50 （GD） 1...
Page 158 899-92187310...

Kato PREMIUM CITYRANGE CR-200RF Instruction Manual

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