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. 214521...
Page 2 背厚 11.5 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 rated lifting capacity chart Make sure that all crane operations are in accordance with the rated 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 rated 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.
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Page 7: 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 )
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.
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Page 11: Table Of Contents
Table of Contents ( 611A-0001-0E ) Introduction ………………………………………………………………………………………… [ 5 ] How to use this manual …………………………………………………………………………… [ 6 ] Inspection and servicing …………………………………………………………………………… [ 7 ] Serial number nameplate ………………………………………………………………………… [ 7 ] Operation qualifications …………………………………………………………………………… [ 7 ] General devices 214521 ( for driving and crane )
Page 12 Preoperational checks/ 214521 Pre-drive checks 20. Preoperational checks/Pre-drive checks ………………………………………………… 195 Index 214521 Index ……………………………………………………………………………………………… 211 Separate Manual Jib Section 214531 manual Separate Inspection and Servicing Section 214541 manual [ 10 ]...
Page 13: General Devices ( For Driving And Crane )
( 611A-0002-0E ) General devices 214521 ( for driving and crane ) 1. Part names and terms ………………………………………………………………………… 1 Part names …………………………………………………………………………………………………… 1 Terms ……………………………………………………………………………………………………… 9 2. For safe operation …………………………………………………………………………… 11 General precautions ………………………………………………………………………………………… 11 3. General operation devices …………………………………………………………………… 17 Inside the cab ………………………………………………………………………………………………...
Page 14: 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 -...
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Page 16 1-1-2 General operation devices ( 611A-0003-0E ) ( 1 ) Inside the cab 3-1 Inside the cab 1. Door 2. Seat 3. Seatbelt 4. Interior lamp 5. Left window 6. Sun visor 7. Sunshade 8. Flare ( optional ) 9. Fuse box 10.
Page 17 ( 2 ) Outside the cab For details of this page Refer to pages 33－36 - 4 -...
Page 18 1-1-3 Drive operation devices ( 611A-0004-0E ) ( 1 ) Inside the cab 11-1 Cluster meter panel 11-2-2 Switch section 11-1-1 Meter section 1. Torque converter oil temperature display switch 1. Speedometer 2. Two/four wheel drive switch 2. Tachometer 3. High/low speed switch 3.
Page 19 ( 2 ) Outside the cab For details of this page Refer to pages 92 and 93 - 6 -...
Page 20 1-1-4 Crane operation devices ( 611A-0005-0E ) ( 1 ) Inside the cab 15-1 Front panel 1. PTO switch 2. ACS emergency switch ( self-reset type ) 3. Level gauge 4. Crane operation switch 5. Slewing brake switch 6. Main winch switch 7.
Page 21 ( 2 ) Outside the cab For details of this page Refer to page 146 - 8 -...
Page 22: Terms
1-2 Terms ( 541A-0021-3E ) The following names and terms are used frequently in this manual and they are defined as follows. ・ Boom…………………………… The box-shaped structural element which bears the load through the sheave, hoisting rope etc. and varies the working radius by derricking, lowering, extending and retracting.
Page 23 ・ Boom angle ……………………… The angle between the boom center line and the horizontal. The rated lifting capacity for jib use is based on the boom angle. ・ Jib offset angle…………………… The angle between the boom center line and the jib center line. ・...
Page 24: For Safe Operation
WARNING 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. ・ In this section, pictures which illustrate dangerous situations or working practices are marked with a large "×" . ・...
Page 25 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 26 WARNING ( 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. Do not put aerosol spray cans, paint thinner, or other dangerous combustibles in the cab.
Page 27 WARNING ( 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. lying around in the engine compartment.
Page 28 WARNING ( 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. ( 17 ) Before you start the engine, check that all the levers, pedals and switches are in their neutral or OFF positions.
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Page 30: General Operation Devices
3. General operation devices ( 061A-0003-1E ) 3-1 Inside the cab ( 611A-0006-0E ) ( 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.
Page 31 ( 2 ) Seat Adjust it to the easiest position for you to operate the controls. It is dangerous to adjust the seat while you are operating the crane. ( 8210-0021-0E ) 1 ) Headrest Sit in the seat and adjust the height of the headrest. Press the knob while adjusting for height.
Page 32 3 ) Front and rear height levers You can adjust the height of the front or rear of the seat base independently. Operate either of the levers to raise or lower the seat base. ① Front height lever The front edge rises or lowers, pivoting about the rear of the seat.
Page 33 ( 3 ) Seatbelt Always fasten the seatbelt for safety while driving the machine. 1 ) How to put on the seatbelt ① Press the removal button on the buckle to remove the tang from the buckle. ② Sit in the seat and insert the tang into the buckle and push until it clicks.
Page 34 ( 4 ) Interior lamp ON ……… The lamp is switched on regardless of the door opening/ closing. DOOR…… The lamp is linked to the door to light when the door is open. OFF……… The lamp is switched off regardless of the door opening/ closing.
Page 35 ( 8 ) Flare ( optional ) A flare is stored in a holder on the left front side of the seat. It is intended for signaling in emergencies. The expiry date and method of use are indicated on the label affixed to the flare, so check them before using the flare.
Page 36 ( 11 ) Keys ( 12 ) Fire extinguisher ( optional ) Refer to the label on the fire extinguisher to check its instructions and limit of use. ( 13 ) Emergency kit ( 14 ) Rear window Grip and pull out the lock to slide open the window. - 23 -...
Page 37: Front Panel
3-2 Front panel ( 611A-0007-0E ) ( 1 ) Lighter Push it in and pull it out to use it once it springs out. NOTE The lighter operates on 24V. ・Do not use the socket as a power source for anything other than the lighter. ・The metallic part of the lighter becomes hot, so do not touch the metallic part when lighting a cigarette.
Page 38 ACC; The engine stops in this position. You can use the radio etc. If you use the radio or other accessories for long periods while the engine is stopped, the battery will run down. Do not use the radio etc. for long periods. ( 541A-0034-1E ) The engine is running in this position.
Page 39: Side Panel
3-3 Side panel ( 541A-0036-1E ) ( 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 40: Radio ( Optional )
3-4 Radio ( optional ) ( 591A-1098-0E ) ( 1 ) Name of each part 1 ) Power/volume knob ( VOL ) To switch the power ON, turn the knob to the right until it clicks. Keep turning it to the right to increase the volume. 2 ) Tone control knob ( TONE ) Turn the knob to the right to amplify high tone or to the left to reduce high tone.
Page 41 ( 2 ) Replacing fuses The radio is equipped with an internal fuse, which cannot be replaced. If a fuse failure is suspected, contact your authorised KATO dealer for service. Do not attempt to replace the fuse by disassembling the radio.
Page 42 ( 4 ) Using the "SEEK" button to search for stations ( automatically ) Pressing the "SEEK" button will cause the radio to automatically start increasing the frequency until it finds a station. Once it finds an available station, it will stop at that frequency. ( 5 ) Selecting stations by manual tuning Pressing the "up button ( ∧...
Page 43 ( 8 ) Automatic stereo/mono reception If the signal from an FM station becomes too weak, due to distance, mountains, or other reasons, reception will automatically switch from stereo to monaural modes to reduce undesired noise. If the signal becomes stronger again, the radio will automatically switch back to the stereo broadcast. ( 9 ) Setting the clock If the display is showing the frequency, press the "CLOCK"...
Page 44: Cabin Air Conditioner
3-5 Cabin air conditioner ( 611A-0008-0E ) 3-5-1 Name and function of control sliders ( 611A-0009-0E ) ( 1 ) Temperature controller Adjusts the air flow temperature. ・ Cooling increases the farther the slider is moved to the right ( toward "COOL"...
Page 45 ( 2 ) Normal operation To dehumidify the cab for increased comfort. ① Slide the temperature controller to the desired position. ② Slide the fan controller to the desired position. ・ If the air inside the cab becomes dirty, such as with cigarette smoke, open the window. ・...
Page 46: Outside The Cab
3-6 Outside the cab ( 611A-0014-0E ) ( 1 ) Washer tank The tank, which is located on the front end inside the right machine compartment, has a capacity of 2.2L. Use automobile cleaning fluid. NOTE This tank is used for both the front and roof wipers. ・...
Page 47 These switches are used exclusively for servicing the engine and automatic transmission and are set for normal operation when shipped from KATO. Service switches are used exclusively for servicing. Never disturb these switches unless instructed to do so by your authorised KATO dealer or KATO service representative. ( 491A-0004-0E )
Page 48 ( 5 ) Engine cover 1 ) Opening and closing the engine cover ① Opening the engine cover To open the engine cover, grip the handle on the front of the engine cover and press the button. ・ Due to the danger of rotating parts, such as the cooling fan and belts, only open the engine cover when the engine is stopped.
Page 49 ( 6 ) Engine inspection cover Remove this cover to check the engine oil level. ・ Due to the danger of rotating parts, such as the cooling fan and belts, only open the engine cover when the engine is stopped. ・...
Page 50: 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 51 WARNING [ 5 ] Content: Notes for the rated lifting capacity chart Location: Inside the cab Part No.: 611-75105001 [ 6-1 ] Content: Notes for crane operation Location: Inside the cab Part No.: 611-75106000 - 38 -...
Page 52 WARNING [ 2 ] Content: How to connect the overhoisting detector wiring connector Location: Left side of the boom top Part No.: 421-75710000 [ 6-2 ] Content: Attaching the safety rope for stowing jib Location: Right side of the boom base Part No.: 899-81405772 [ 8 ] Content: Precautions when driving and handling the...
Page 53 WARNING [ 10 ] Content: How to connect the overhoisting detector wiring connector ( for the jib ) Location: Left side of the jib top Part No.: 899-81600782 [ 13 ] Content: Exhaust gas hazard Location: Inside the cab Part No.: 611-75113000 [ 16 ] Content: Check list for outrigger setting...
Page 54 WARNING [ 23 ] Content: Insert the jib offset pin from the inside to the outside and fasten it with the quick pin. Location: Left side of the jib top Part No.: 161-75115001 [ 32 ] Meaning: Take care not to trap fingers, arms, head or any other parts of the body in the sheave.
Page 55 WARNING [ 56 ] Meaning: Operation prohibition Part No.: 707-75118001 [ 62 ] Meaning: Beware of falling. Climb up and down with care. Location: Left and right sides of the table Part No.: 001-81302010 [ 63 ] Meaning: Always keep the instruction manuals in the cab and check their contents frequently.
Page 56 WARNING ( 2 ) Lower structure [ 10 ] Meaning: Do not touch the engine, its surrounding, the fan belt or the rotating parts of the fan while the engine is running or immediately after it has stopped. Location: Inside the engine cover Part No.: 001-81332019 [ 11 ] Meaning: Never bring any flame or source of ignition...
Page 57 WARNING [ 12 ] Meaning: The coolant will be hot while the engine is running or immediately after it has stopped. Do not open the radiator cap before the coolant has had time to cool. Location: Inside the engine cover Part No.: 001-81332002 [ 13 ] Meaning: Beware of high temperature.
Page 58 WARNING [ 38 ] Content: Precautions on handling the battery Location: Top surface of the batteries Part No.: 707-75122001 [ 41 ] Meaning: Do not use the outriggers to climb onto or off the machine, or climb onto or off the outriggers themselves.
Page 59: Precautions On Getting On And Off The Machine
WARNING 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 60: Precautions When Filling With Fuel
WARNING 6. Precautions when filling with fuel ( 611A-0059-0E ) 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 61 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 62: Starting And Stopping The Engine
If the buzzer continues to sound with all warning lamps lit or all warning lamps do not light with no buzzer, stop the engine start procedure and contact your authorised KATO dealer. ( 121A-0077-0E )
Page 63 ( 5 ) Warm-up running Once the engine has started, set the idle speed knob to the "AUTO" position enough to warm the engine and the torque converter. This warm-up time can be used for going through the after-starting engine 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 64: Stopping And Parking
7-2 Stopping and parking ( 511A-0008-0E ) ( 1 ) Always apply the parking brake when parking the machine. On slopes etc., place chocks in front of the wheels if necessary. ( 541A-0060-1E ) ( 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 65: Handling The Machine In Winter And Summer
In areas which can get as cold as −20° C or below, adjust the concentration of Long Life Coolant before the onset of winter. If you are working at temperatures of −15° C or below, contact your authorised KATO dealer. ( 1 ) Fuel For fuel, use diesel fuel with a fluidity point at least −5°C below the minimum outside air temperature.
Page 66: Handling In 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. ・...
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Page 68: Driving Operation 214521
( 611A-0016-0E ) Driving operation 214521 9. Driving safely ………………………………………………………………………………… 55 10. What to do when the machine breaks down ……………………………………………… 61 10-1 Cautions on breakdown ……………………………………………………………………………………… 61 10-2 Using the flare ……………………………………………………………………………………………… 62 10-3 Emergency power steering ………………………………………………………………………………… 63 10-4 Handling a malfunction in the automatic transmission system ………………………………………………...
Page 69: Driving Safely
WARNING 9. Driving safely ( 0099-0227-0E ) 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 on the roads. Additional objects on the machine could cause accidents or damage, so keep to the standard driving position and equipment.
Page 70 WARNING ( 5 ) Do not allow extra passengers on the machine Never allow more people in the cab while driving than the number described in the machine specifications. Driving with excess people in the machine can cause accidents. ( 6 ) 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.
Page 71 WARNING ( 9 ) Pay attention to road surface conditions Drive slowly and cautiously for maximum safety on snow- covered or icy roads, irregular road surfaces, inclined ground, roads sloping up and down etc. Check the road surface before you drive over it, and if necessary, fit tire chains or improve the road surface.
Page 72 WARNING ( 13 ) Steering control This machine is equipped with fully hydraulic power steering. This makes the steering wheel lighter to turn, but means that it does not return to the center when released. After turning the steering wheel to either side, return it to the center position by hand.
Page 73 WARNING 4 ) While driving, keep checking the air pressure gauge which displays the air pressure for the foot brake. Reduced air pressure leads to a large reduction in braking capacity, so close observation is required. If the low air pressure warning lamp lights and an intermittent buzzer sounds while the machine is in motion, bring the machine to rest in the nearest available safe place and inspect the air pipe...
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Page 75: 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. - 61 -...
Page 76: Using The Flare
10-2 Using the flare ( 611A-0066-0E ) To use an emergency flare to signal danger in an emergency, such as when the machine breaks down on train tracks or roads and cannot be moved, follow the instructions below. ( 1 ) Remove the flare provided in the operation cab. ( 2 ) Take the flare outside and twist it as it is removed from its case, then insert it back into the case, facing the opposite direction.
Page 77: Emergency Power Steering
10-3 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. Violent operation of the shift lever or the starter switch during evasive maneuvers can cause sudden highly dangerous failure of the emergency power steering.
Page 78: Handling A Malfunction In The Automatic Transmission System
10-4 Handling a malfunction in the automatic transmission system ( 471A-0018-0E ) 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 79 ・ 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 80: 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 81 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 according to the applicable laws.
Page 82 ( 2 ) If the engine is the cause of the breakdown 1 ) Starter switch……………… "ON" 2 ) Shift lever ………………… "N" 3 ) Supply compressed air to the broken-down machine. Use a hose to connect the compressed air tank of the towing machine to that of the broken-down machine. The supply of compressed air to the broken-down machine can be provided through the coupler on the underside of the compressed air tank.
Page 83: Drive Operation Devices
11. 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. 11-1 Cluster meter panel ( 541A-0086-0E ) 11-1-1 Meter section ( 881A-0067-1E ) ( 1 ) Speedometer Indicates the speed at which the machine is driving.
Page 84 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 ) Engine oil pressure gauge Indicates the pressure of engine oil.
Page 85 This lamp flashes or lights when there is any malfunction in the AT/M controller, sensors or switches etc. 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 ) - 71 -...
Page 86 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 87 If the engine control warning lamp lights or flashes, immediately move to a safe place and stop the machine, then call the closest authorised KATO dealer and follow their instructions. If the lamp flashes, driving is still possible in the backup mode, but the engine is not being controlled properly, so operate the machine very carefully and only for emergency purposes.
Page 88 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 ) ( 16 ) Battery charge indicator lamp This lamp lights when the starter switch is turned to the "ON"...
Page 89: Switch Panel
( 1 second intervals ) . If this lamp flashes, stop the engine immediately and contact your authorised KATO dealer. ( 2 ) PTO indicator lamp This lamp lights when the PTO switch is "ON".
Page 90 ( 8 ) 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 ・ Superstructure position …… Within font 0° ± 5° Within rear 180°...
Page 91 ( 11 ) Digital display This display indicates the battery voltage, hydraulic oil and torque converter oil temperature, or rear steering angle. When an error occurs, the hydraulic oil temperature indicator lamp and the battery voltage indicator lamp go out and priority is given to the display of the corresponding error numbers on the digital display.
Page 92 3 ) When the torque converter oil temperature display switch is pressed When the "torque converter oil temperature display switch" on the switch panel is pressed to light the indicator lamp while the parking brake is engaged, both the battery voltage and hydraulic oil temperature indicator lamps will go out and the torque converter oil temperature will be displayed.
Page 93 ( 2 ) Two/four wheel drive switch Use this switch to choose the driven wheels. 1 ) If the four-wheel drive indicator lamp is not lit, the machine is in two-wheel drive mode. Press the switch to switch to four-wheel drive. When you press the switch, the confirmation tone "pip" will sound and the four- wheel drive indicator lamp will flash ( mode shifting ) and light steadily, indicating that the machine is in four- wheel drive mode.
Page 94 ( 3 ) High/low speed switch This switch selects high or low range transmission. ・ Press the switch firmly for at least 0.3 seconds. ・ Stop the machine before shifting between high and low range. If you attempt to shift while driving at 3km/h or more, the misoperation warning buzzer will sound.
Page 95 ( 4 ) Brake lock switch The brake lock switch applies the brakes on the front and rear wheels independently of the brake pedal. This is an "auxiliary braking device for use during crane operation" which can be used together with the parking brake while setting the outriggers or during stationary crane-on-rubber operation.
Page 96: Front And Side Panel Switches
11-3 Front and side panel switches ( 541A-0103-0E ) 11-3-1 Front panel switches ( 611A-0020-0E ) ( 1 ) Suspension lock/release switch This switch can be used to switch the suspension state between locked and free ( lock released in driving position ) to suit the task the crane is performing.
Page 97 1 ) Suspension lock Set the suspension lock/release switch to the "suspension lock" side and use the suspension retraction switch to retract the suspension cylinders fully. When you release the switch, the suspension cylinders will be held at that position and the suspension locked indicator lamp will light.
Page 98 ( 3 ) Rear steering lock/release switch This switch is used to lock or release the rear steering automatically. When you release the rear steering lock, set the switch to the release side while pressing the lock button. ・ Lock the rear steering before you stop the engine. ・...
Page 99 ・ If the compressed air pressure is below the rated pressure, the parking brake will not release even if the switch is moved to the release position. ・ If you try to drive while the parking brake id engaged, the parking brake indicator lamp will flash and the warning buzzer will sound.
Page 100 ・ 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. Always keep the brake pedal pressed down when changing gear while the machine is at rest. ・...
Page 101: Accelerator And Brake Pedals
11-4 Accelerator and brake pedals ( 541A-0117-0E ) ( 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. Before operating the accelerator pedal, confirm that the needle of the engine water temperature gauge is above point "C".
Page 102: Steering Column
Press the horn switch in the center of the steering wheel to sound the air 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. - 88 -...
Page 103 11-5-2 Combination switch ( 611A-0069-0E ) 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 ・ Windscreen washer switch ・...
Page 104 3 ) Exhaust brake lever Use the exhaust brake to increase the effect of engine braking while driving down a long slope. Move the lever to the "ON" position and take your foot off the accelerator pedal to activate the exhaust brake. The exhaust brake will disengage when you depress the accelerator pedal again.
Page 105 2 ) Lighting switch The knob on the end of the lever is the lighting switch. Turn the knob counterclockwise to light the lamps as described below according to the switch position. Switch position Clearance lamps Tail lamps License plate lamp Cluster meter panel lamp Switch panel Night illumination of driving switches...
Page 106: Lower Control Switches
・ 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 107 ( 2 ) Rear steering emergency switch ( for lower structure ) If the rear steering cannot be locked or released automatically by the action of the rear steering lock/release switch ( when the multiplex communication error warning lamp lights or when any rear-steering related device is malfunctioning etc.
Page 108: Driving The Machine
12. 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. 12-1 Preparations for driving on the roads ( 611A-0023-0E ) The machine must always be in the position shown below for road driving.
Page 109 ( 11 ) 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 110: General Driving
12-2 General driving ( 611A-0024-0E ) ( 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 111 Precautions when driving down a slope 1. Make a constant habit of testing your brakes before starting to move down a steep slope or a long gentle slope. If you notice during the descent that your brakes are weak, there is nothing you can do about it.
Page 112: Specialized Driving
12-3 Specialized driving ( 611A-0026-0E ) Before driving on the road, check that the lamps on the high/low speed switch and rear steering lock/release switch and two/four wheel drive switch are not lit. ( 611A-0027-0E ) 12-3-1 Low range drive ( 121A-0073-0E ) ( 1 ) Use high range for normal drive and switch to low range for driving on particularly steep roads or even or soft ground, or for pick and carry operation.
Page 113 2 ) Switching from low range to high range ・ Stop the machine before changing between high and low range. ・ If you change 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 114 12-3-2 Rear steering ( 611A-0070-0E ) ( 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 115 ( 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 116 ( 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 rapidly. When the buzzer stops and the rear steering lock release confirmation indicator lamp goes out, the locking process is complete.
Page 117 NOTE If the rear steering lock/release switch does not lock or release the rear steering automatically or the rear steering switch does not move the rear wheels, use the rear steering emergency switch on the lower control panel of the lower structure to temporarily switch the rear steering control to manual so that you can continue working.
Page 118 2 ) Switching from four-wheel drive to two-wheel drive This switching operation is only possible in high range. NOTE When low range has been selected, two-wheel drive is unavailable. NOTE The following are the available combinations of high/low range with two/four wheel drive. 　・High range + two-wheel drive 　・High range + four-wheel drive 　・Low range + four-wheel drive ( automatic switching )
Page 119: Crane Operation 214521
( 611A-0028-0E ) Crane operation 214521 13. For safe operation ………………………………………………………………………… 105 13-1 General precautions ……………………………………………………………………………………… 105 13-2 Precautions during operation ……………………………………………………………………………… 111 13-3 Precautions after operation ………………………………………………………………………………… 127 14. How to read the capacity charts ………………………………………………………… 129 14-1 How to read the working area chart ……………………………………………………………………… 129 14-2 How to read the rated lifting capacity chart ………………………………………………………………...
Page 120 19. Changing the wire rope number of parts ………………………………………………… 192 19-1 Wire rope standard number of parts ……………………………………………………………………… 192 19-2 Changing the wire rope number of parts ………………………………………………………………… 193...
Page 121: For Safe Operation
WARNING 13. 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. ・ In this section, pictures which illustrate dangerous situations or working practices are marked with a large "×" . ・...
Page 122 WARNING ( 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 123 WARNING ( 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 124 WARNING ( 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 125 WARNING ( 12 ) Stop work in strong winds Loads of high volume or side area and long booms are subject to strong wind loads due to wind pressure. If the wind is strong and is received from behind the crane, the wind load is added to the suspended load mass which can cause the crane to tip over.
Page 126 WARNING ( 4 ) Do not put flammable items in the toolbox Do not put aerosol spray cans, paint thinner, or other dangerous combustibles in the toolbox. They could cause a fire. ( 5 ) Precautions when you get on and off the crane ・...
Page 127: Precautions During Operation
WARNING 13-2 Precautions during operation ( 0099-0012-0E ) 13-2-1 Precautions when starting the engine ( 0099-0108-2E ) ( 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 128 WARNING ( 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. ( 6 ) Before you start the engine, check that all the levers, pedals and switches are in their neutral or OFF positions.
Page 129 WARNING 2 ) Beware of buried objects Before you start work, check with the firm in charge of the site for the existence and location of buried objects such as water and gas mains and high-voltage cable ducts. ( 2 ) Improving the ground surface for outrigger setting Improve the ground surface as far as possible if it is soft, crumbly, uneven or sloping.
Page 130 WARNING ( 3 ) Lock the suspension with the lock pins before setting the outriggers. ( 4 ) Check outrigger extension width Before starting work, check that the outriggers are extended to the width specified in the rated lifting capacity chart. ( 5 ) Set up the crane level A leaning crane compromises stability and strength.
Page 131 WARNING ( 7 ) Before beginning crane operation, lift the load off the ground to gauge the working condition and confirm that the ground supports the outriggers adequately. If an outrigger supervisor is appointed to observe outriggers during operation, safety will be enhanced.
Page 132 WARNING ( 3 ) Start and stop any lever operation gradually Sudden starting, acceleration and stopping and other sudden or violent operations are dangerous as they reduce the stability of the load and cause the crane to break. Always operate the levers and pedals smoothly and securely.
Page 133 WARNING ( 7 ) Never remove the jib Operating the crane with the jib removed compromises the safety factor and could cause the crane to tip over. The rated lifting capacity chart for boom operations is based on the assumption that the jib is stowed on the boom. Therefore, never operate the crane with the jib removed.
Page 134 WARNING ( 11 ) Confirmation before lifting the load Failure to check the following points could result in major accidents such as dropping the load, damage to the boom or the crane, or crane tip over. ・ Is the total mass of the load, the slings and the hook to be lifted below the rated lifting capacity? ・...
Page 135 WARNING ( 14 ) Lift the load off the ground carefully When the load is lifted, deflection of the boom increases the working radius, which can result in overload. Hoist the load vertically and pause briefly when the load is about 10 centimeters from the ground to confirm its sling and that there is no overload.
Page 136 WARNING ( 18 ) 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. ( 19 ) 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 137 WARNING ( 22 ) 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 138 WARNING ( 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 hits the boom top. Normally the overhoisting detector will act to prevent this, but if the detector is inoperative and overhoisting occurs, lower the hook to the proper position.
Page 139 WARNING ( 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. Never attempt this operation. ( 5 ) If the wire rope has become twisted causing the hook to rotate, untwist the rope before starting work.
Page 140 WARNING ( 4 ) Never use the boom to push or pull objects If you use the top of the boom to push cargo along a truck bed or push objects around the construction site, you will damage the boom top. If you push or pull objects by slewing the boom, you could bend the boom.
Page 141 WARNING ( 4 ) Check the position of the slewing free/lock switch When the switch is in the free position, beware of slewing drift due to wind or inertia. ( 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.
Page 142 WARNING ( 2 ) Set the working configuration setting of the ACS correctly according to the actual work to be done. ( 3 ) In jib operation, the rated lifting capacity is determined on the basis of the boom angle, not the working radius. 13-2-9 Precautions for special types of crane operation ( 0099-0037-0E ) ( 1 ) Tandem lifting...
Page 143: Precautions After Operation
WARNING 13-3 Precautions after operation ( 0099-0171-1E ) ( 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 144 WARNING ( 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 145: How To Read The Capacity Charts
14. How to read the capacity charts ( 541A-0145-0E ) 14-1 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. ( 1 ) The working area chart does not include deflection of the boom and jib.
Page 146: How To Read The Rated Lifting Capacity Chart
14-2 How to read the rated lifting capacity chart ( 541A-0147-2E ) The rated 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 rated lifting capacity chart.
Page 147: Precautions On Crane Operation
14-3 Precautions on crane operation ( 541A-0149-2E ) Familiarize yourself with the following points before you start to operate the crane. There is a safety sign of the rated 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 148 ( 10 ) Check that the key of the ACS emergency switch has been extracted. ( 11 ) If you work with the rooster sheave, subtract the mass of the 30 ton hook ( 250kg ) from the figure in the boom rated lifting capacity chart, with an upper limit of 4,000kg.
Page 149 ( 6 ) The rated lifting capacity differs between the front area capacity and the full range capacity. When slewing from the front to the side, it could be overloaded, so take special care. Crane operation Stationary crane-on-rubber operation Pick and carry operation Area α°...
Page 150 14-3-3 Precautions on using the ACS ( 611A-0071-0E ) If you use the ACS which monitors crane safety incorrectly, a major accident could result. Therefore read the separate ACS instruction manual and the following points thoroughly and operate the ACS correctly as described.
Page 151 ・ Always stow the ACS display panel when you leave the crane operation cab. ( 061K-0002-0E ) ( 15 ) 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 152 14-3-4 Crane performance tracks ( when using outriggers ) ( 541A-0293-0E ) - 136 -...
Page 153: Crane Operation Devices
15. Crane operation devices ( 061A-0005-0E ) 15-1 Front panel ( 611A-0031-0E ) ( 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 154 ( 2 ) ACS emergency switch ( self-reset type ) In an emergency such as a malfunction in ACS-related devices or crane stop etc. has occurred, set this switch to the "release" position to take appropriate emergency actions regardless of the ACS. The ACS emergency switch is only used to take emergency action to avoid a serious accident.
Page 155 ( 6 ) Main winch switch When operating the main winch, set this switch to the "ON" position. If the main winch is not in use, set this switch to the "OFF" position to prevent misoperation etc. ( 7 ) Auxiliary winch switch When operating the auxiliary winch, set this switch to the "ON"...
Page 156: Side Panel
15-2 Side panel ( 611A-0032-0E ) ( 1 ) Overhoisting emergency switch ( self-reset type ) In the event of a malfunction in the winch overhoisting detector or in a similar abnormal situation, press this switch to allow winch operation regardless of the condition of the overhoisting detector. The overhoisting emergency switch is provided to avoid danger in an emergency.
Page 157 ( 5 ) Drum rotation detector switch The rotation of the winch drum which is selected by this switch is detected during winch operation and a buzzer will sound to indicate that the winch drum is rotating. NOTE The buzzer sound is the same for hoisting and lowering. NOTE The buzzer sound becomes faster the faster the drum rotates.
Page 158: Control Levers And Pedals
15-3 Control levers and pedals ( 611A-0033-0E ) ( 1 ) Left control lever 1 ) Slewing operation Set the slewing brake switch to the "release" position before slewing operation. : Set the crane operation switch to the "ON" position and push the left control lever right to slew the crane right.
Page 159 ( 3 ) Right control lever 1 ) Boom derricking/lowering operation : Set the crane operation switch to the "ON" position and push the right control lever left to derrick the boom. : Set the crane operation switch to the "ON" position and push the right control lever right to lower the boom.
Page 160 ( 5 ) Accelerator pedal This pedal controls the operation speed during crane operation. Sudden acceleration during crane operation is dangerous. Always try to work the accelerator smoothly. Before operating the accelerator pedal, confirm that the needle of the engine water temperature gauge is above point "C".
Page 161 ( 6 ) Console lock lever Before starting work, check that the console lock lever is in the lock position. Pull the console lock lever toward you and raise the left console ( left control lever ) before you get out of your seat and leave the cab.
Page 162: Lower Control Switch Panel
15-4 Lower control switch panel ( 541A-0169-2E ) ( 1 ) Outrigger control panel Refer to the "Outrigger operation" section. ・ When you operate the switches on the outrigger control panel, the ACS outrigger setting status will be canceled and the ACS will switch to the "working status setting screen". ・...
Page 163: Crane Operation When The Outriggers Are Used
16. Crane operation when the outriggers are used ( 541A-0171-0E ) ( 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. Always follow the specified procedure and precautions strictly to set the machine in its working configuration before you start crane operation.
Page 164 ( 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 165: Suspension Operation
16-1 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 166 16-1-1 Suspension retraction procedure ( 611A-0036-0E ) ( 1 ) Set the crane to the following conditions. ・ Fully retract the boom and lower it to a boom angle of at least 50 ° ・ Check that the superstructure is within ±5° of the front or rear facing. ・...
Page 167 16-1-2 Suspension lock release procedure ( 611A-0037-0E ) 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 ) ・ Release the suspension lock and return the machine to the driving position before you move the machine onto the road.
Page 168: Pto Switch Operation
16-2 PTO switch operation ( 611A-0074-0E ) 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 indicator lamp on the switch panel will light. ・...
Page 169 - 153 -...
Page 170: Precautions On Setting The Outriggers
16-3 Precautions on setting the outriggers ( 511A-0051-1E ) The outrigger control switches are located on the side of the carrier body and inside the cab. As a general rule, the control switches on the carrier body should be used, but if you unavoidably have to operate the outriggers from the cab, ask another worker to insert the stopper pins and place the boards under the outrigger feet.
Page 171 ( 1 ) Improve the ground surface as far as possible if it is soft, crumbly, uneven or sloping. Use wooden blocks etc. if necessary to produce a flat surface and then set the outriggers on steel plates etc. of adequate areas and rigidity to reduce surface pressure further.
Page 172 ( 7 ) After you have finished setting the outriggers, check that the tires are off the ground. If any tire is touching the ground, a reactive force will act which will impair stability. If site conditions are such that any of tires are still in contact with the ground when the outrigger vertical cylinders are fully extended, place plates etc.
Page 173: Outrigger Control Panel
16-4 Outrigger control panel ( 121A-0027-0E ) ( 1 ) Control panel on the side of the lower structure 1 ) Extension/retraction switch ( self-reset type ) Use this switch to extend or retract the horizontal or vertical cylinders. 2 ) Horizontal/vertical combined selection switch Use to operate all the horizontal cylinders or all the vertical cylinders simultaneously.
Page 174 ( 2 ) Outrigger control switches inside the operation cab 1 ) Outrigger position selection switches Use these switches to specify which of the outriggers you will be operating. When you press a switch, a "pip" confirmation tone sounds and the indicator lamp for the selected position lights.
Page 175 2 ) Horizontal/vertical selection switches Use these switches to select horizontal or vertical outrigger operation. When you press the switch, a "pip" confirmation tone sounds and the indicator lamp for the selected operation lights. Press the same switch again or the other switch ( horizontal or vertical ) to cancel the selection.
Page 176: Outrigger Setting And Stowage Procedures
16-5 Outrigger setting and stowage procedures ( 061A-0085-0E ) 16-5-1 Outrigger setting procedure ( 061A-0086-3E ) ( 1 ) Check that the outrigger operation OK indicator lamp is lit. Conditions for lighting ・ If the crane position is in a boom length and boom angle as indicated on the capacity chart for pick and carry operation.
Page 177 ( 4 ) Vertical cylinder extension ・ 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 178 16-5-2 Outrigger stowage procedure ( 061A-0080-3E ) When you are going to stow the outriggers, always set the superstructure to the driving position as shown in the diagram below. ( 1 ) Check that the outrigger operation OK indicator lamp is lit. Conditions for lighting ・...
Page 179 ( 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-0183-1E ) ( 4 ) Outrigger beam retraction 1 ) Check that the vertical cylinders are fully retracted, then move the selection switch to the horizontal side.
Page 180: Stowing And Releasing The Main Hook
16-6 Stowing and releasing the main hook ( 541A-0188-1E ) Before driving, always stow the main hook on the frame. ( Driving on the roads is permitted only when the hook is in this state. ) If you drive with the hook hanging unstowed, you could cause an accident for the following reasons. ( 1 ) The swinging hook could obstruct another vehicle.
Page 181 ( 4 ) Set the main winch switch to the "ON" position and move the right control lever to the "derricking" side and "lowering" side simultaneously to derrick the boom so that the hook can be released from the hook fixing ring. ・...
Page 182 16-6-2 Hook stowing procedure ( 611A-0039-0E ) ( 1 ) Extend the four outriggers to the intermediate extension position or more and confirm that the ACS display matches the actual outrigger status. ( 2 ) Set the ACS working status to "jib setting". ・...
Page 183 ( 6 ) Set the main winch switch to the "ON" position and move the right control lever to the "hoisting" side and "lowering" side simultaneously to lower the boom to the level. ・ Take care that the wire rope does not get tangled on the drum. ・...
Page 184: Crane Operation Without Outriggers
17. Crane operation without outriggers ( 541A-0193-0E ) ( 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. The ACS preoperational check should be conducted when all outriggers are fully extended for maximum safety.
Page 185: Precautions On Crane Operation Without Outriggers
17-1 Precautions on crane operation without outriggers ( 541A-0194-1E ) 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 186: Stationary Crane-On-Rubber Operation
17-2 Stationary crane-on-rubber operation ( 511A-0028-0E ) ( 1 ) Conditions for stationary crane-on-rubber operation 1 ) Maximum boom length: 23.45m 2 ) Suspension locked ( suspension lock cylinders fully retracted ) 3 ) Tire pressure: 900kPa ( 9kgf/cm ) ( same pressure as for driving ) 4 ) Determine the boom status, working area and rated lifting capacity with reference to the rated lifting capacity chart for stationary crane-on-rubber operation.
Page 187 ( 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. 2 ) Recheck the rated lifting capacity chart.
Page 188: Pick And Carry Operation
17-3 Pick and carry operation ( 511A-0029-0E ) ( 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 189 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 rated lifting capacity chart.
Page 190: On-Site Moving
17-4 On-site moving ( 541A-0202-0E ) 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. ( 541A-0203-1E ) ( 1 ) Crane status: Driving mode ( boom fully retracted, lowered and facing within ±1°...
Page 191: Crane Operation
18. 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. 18-1 Preparations for crane operation ( 4210-3246-0E ) 18-1-1 Preparations before operating the crane ( 611A-0040-0E ) ( 1 ) Move the crane to the firm ground.
Page 192 ( 6 ) Confirming that the key is removed from the ACS emergency switch Confirm that the key is not in the ACS emergency switch on the front panel. This switch is provided to avert possible danger in an emergency of the ACS system. Therefore, give the key to the safety supervisor when on the work site.
Page 193 ( 3 ) If an error code is shown on the ACS auxiliary display, perform an inspection of the problem and contact your authorised KATO dealer if the error cannot be resolved. ( 4 ) Strictly observe the ACS operating precautions noted in the section 14-3-3.
Page 194: Boom Derricking And Lowering
18-2 Boom derricking and lowering ( 4210-3247-0E ) : Set the crane operation switch to the "ON" position and push the right control lever left to derrick the boom. : Set the crane operation switch to the "ON" position and push the right control lever right to lower the boom. When the boom is long or the jib fitted, the crane will tip over if the boom is lowered below the critical angle even if there is no suspended load.
Page 195: Hoisting And Lowering
18-3 Hoisting and lowering ( 611A-0077-0E ) : Set the crane operation switch and main or auxiliary winch switch to the "ON" positions and pull the right or left control lever backward to wind up the winch. : Set the crane operation switch and main or auxiliary winch switch to the "ON" positions and push the right or left control lever forward to lower the winch.
Page 196 Precautions on hoisting and lowering ・ Never drag a load sideways, pull it towards the crane or operate the lever violently as they are extremely dangerous to cause a serious accident. ・ Never continue lowering after the hook has reached the ground as this can cause the wire rope to tangle on the drum.
Page 197: Boom Extension And Retraction
18-4 Boom extension and retraction ( 4210-3251-0E ) Use the boom extension/retraction switch to select the boom extending or retracting sections. Extend : Set the crane operation switch to the "ON" position and depress the boom extension/retraction pedal forward to extend the boom. Retract : Set the crane operation switch to the "ON"...
Page 198 18-4-2 Extension and retraction of the boom sections 3 and 4 ( 611A-0044-0E ) Start these operations when the boom section 2 is fully extended switching the boom extension/retraction switch to the boom sections 3 and 4 side. Extend : Set the crane operation switch to the "ON" position and depress the boom extension/retraction pedal forward.
Page 199 When extending the boom, confirm that the boom sections 2 is fully extended before going on to extend the boom sections 3 and 4. If you extend the only boom sections 3 and 4 and proceed to lift a load, the boom could break. When you extend the only boom sections 3 and 4 for periodic inspection such as greasing the boom etc., do so with the outriggers fully extended and...
Page 200: Slewing
18-5 Slewing ( 4210-3254-0E ) : Set the crane operation switch to the "ON" position and push the left control lever left to slew the crane left. : Set the crane operation switch to the "ON" position and push the left control lever right to slew the crane right. ( 1 ) Set the crane operation switch to the "ON"...
Page 201: Function Of The "Slewing Stop System
18-6 Function of the "slewing stop system" ( 511A-0057-0E ) 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 202 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 203 18-6-2 Slewing control when a "slew-restricted region" is specified in the ACS ( 611A-0049-0E ) 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 204 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 205 ( 611A-0064-0E ) 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. ( 611A-0065-0E ) NOTE Even if the ACS emergency switch is turned to "release", the ACS will continue to emit the voice warnings "Caution...
Page 206 ( 3 ) If slewing does not stop even after slewing into the slew-restricted region If the crane is level and a "slew-restricted region" has been specified in the ACS, yet slewing does not automatically decelerate when approaching the restricted region and does not stop when slewing reaches the restricted region, use the following procedure to operate the crane and avoid danger.
Page 207 2 ) Voice warning, warning chime or emergency sound emitted depending on extent of entry into restricted region If slewing does not stop automatically immediately before the restricted region, but overruns into the region due to a "slewing stop system" malfunction, unlevel machine or strong winds, a voice warning, warning chime or emergency sound is emitted, according to how far it slewed into the restricted region, to notify the operator of the danger.
Page 208: Changing The Wire Rope Number Of Parts
19. Changing the wire rope number of parts ( 541A-0245-0E ) 19-1 Wire rope standard number of parts ( 511A-0054-0E ) 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 37.2kN ( 3.8tf ) on each part of wire rope.
Page 209 19-2 Changing the wire rope number of parts ( 511A-0037-1E ) ( 1 ) Set the outriggers. Then retract and lower the boom fully and slew it to the side or front. ( 2 ) Remove the rope retaining pins from the boom top. ( 3 ) Detach the rope socket.
Page 210 ・ 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 211 ( 611A-0056-0E ) Preoperational checks/ 214521 Pre-drive checks 20. Preoperational checks/Pre-drive checks ………………………………………………… 195 20-1 Pre-drive checks …………………………………………………………………………………………… 196 20-2 Preoperational checks ……………………………………………………………………………………… 202...
Page 212 ・ 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 ) - 195 -...
Page 213 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 214 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 215 20-1-2 Points for pre-drive checks ( 511A-0076-0E ) - 198 -...
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Page 219 20-2 Preoperational checks ( 511A-0077-0E ) 20-2-1 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 220 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. Pedal slack and play Inspect ○...
Page 221 Engine Inspection location Part Task Inspection procedure Notes and service task Before After start start Heater Inspect ○ Cooling Inspect ○ Heating Inspect ○ Defroster Inspect ○ Refrigerant gas Inspect ○ Air conditioner Belt tension Inspect ○ Condenser Clean ○ Clean and ○...
Page 222 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 223 If the multiplex communication error warning lamp flushes and an intermittent buzzer sounds, do not start the engine and contact your authorised KATO dealer. Action of the door and cover locks Inspect ○...
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Page 228 ( 611A-0058-0E ) Index 214521 Accelerator pedal ……………………………………………………………………………………………………… 87 Accelerator pedal …………………………………………………………………………………………………… 144 ACS emergency switch ( self-reset type ) …………………………………………………………………………… 138 Air cleaner blockage warning indicator lamp ………………………………………………………………………… 73 Air pressure gauge …………………………………………………………………………………………………… 70 Armrest …………………………………………………………………………………………………………… 145 Ashtray ……………………………………………………………………………………………………………… 24 AT/M ( automatic transmission ) malfunction warning lamp …………………………………………………………...
Page 229 Emergency kit ………………………………………………………………………………………………………… 23 Engine control warning lamp ………………………………………………………………………………………… 73 Engine cover ………………………………………………………………………………………………………… 35 Engine inspection cover ……………………………………………………………………………………………… 36 Engine oil pressure gauge …………………………………………………………………………………………… 70 Engine trouble warning lamp ………………………………………………………………………………………… 71 Engine water temperature gauge ……………………………………………………………………………………… 70 Exhaust brake indicator lamp ………………………………………………………………………………………… 72 Fan switch ( optional ) …………………………………………………………………………………………………...
Page 230 Main winch switch ………………………………………………………………………………………………… 139 Multiplex communication error warning lamp ……………………………………………………………………… 75 Odometer/trip meter ………………………………………………………………………………………………… 69 Odometer/trip meter switch …………………………………………………………………………………………… 69 Outrigger control panel ……………………………………………………………………………………… 146･157 Outrigger emergency switch ( self-reset type ) ……………………………………………………………………… 146 Outrigger operation OK indicator lamp ……………………………………………………………………………… 75 Overhoisting emergency switch ( self-reset type ) ……………………………………………………………………...
Page 231 Seat …………………………………………………………………………………………………………………… 18 Seatbelt ……………………………………………………………………………………………………………… 20 Service switches ……………………………………………………………………………………………………… 34 Shift lever …………………………………………………………………………………………………………… 85 Shift position indicator lamp ………………………………………………………………………………………… 71 Slewing alarm button ……………………………………………………………………………………………… 142 Slewing brake switch ……………………………………………………………………………………………… 138 Slewing free/lock switch …………………………………………………………………………………………… 140 Speedometer ………………………………………………………………………………………………………… 69 Starter switch ………………………………………………………………………………………………………… 24 Sun visor ………………………………………………………………………………………………………………...
Page 232 本社東京都品川区東大井 1-9-37 〒140-0011 03(3458)1111 番（大代表）（営業本部）関東ﾌﾞﾛｯｸ〒140-0011 東京都品川区東大井 1-9-37 03(3458)1123 番（代表）ｻﾎﾟｰﾄｾﾝﾀｰ東京支店〒140-0011 東京都品川区東大井 1-9-37 03(3458)1112 番（代表）札幌支店〒003-0807 札幌市白石区菊水 7 条 2-7-1 （札幌流通倉庫東ビル） 011(837)5211 番（代表）帯広営業所〒080-0010 帯広市大通南11-18-1 （明治安田生命帯広ビル） 0155(25)7211 番（代表）仙台支店〒980-0802 仙台市青葉区二日町 3-10 （グラン・シャリオビル） 022(222)4896 番（代表）...

Kato SR-300L Instruction Manual

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