Kato PREMIUM CITYRANGE CR-200RF User manual

WARNING
・You must read and understand this manual before operating
or servicing this crane.
If you do not do so, you may cause serious injury or death
including damage to the equipment etc.
・All people who come into contact with this crane must read
and be familiar with the contents of this manual. Keep it in
the crane so it will be available to anybody who needs it.
・If you need a copy of this manual in another language, ask
your authorised KATO dealer.
218731
Applicable serial No.: 0051－
Inspection and Servicing Section

218731
背厚 6.5 mm （極小）

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Introduction(T218351-002-0E)
Thank you for choosing KATO.
Correct operation and handling of the crane is essential for maximum safety and performance and will help to improve
working efficiency and work rate.
We have prepared this manual to help you to do just that. Do not start using the crane before you have read this manual
thoroughly and understood its contents.
All industrial products, including cranes, have a given expected service life that depends on the conditions and
frequency of use.
With respect to expected service life, this crane is classified in ISO 4301-1 and ISO 4301-2 standards with a "class of
utilization" of U2 and a "state of loading" of Q2, and the overall crane with a "group classification" of A1.
The "maximum number of operating cycles" varies depending on loading conditions. In particular, using the crane in an
unintended manner, such as indicated in the examples below, will shorten the expected service life.
・Operating the crane with safety systems not functioning properly
・Frequently hoisting loads that are at or near the rated load capacity
・Operating the crane only in a limited number of working positions
・ Using operations that subject the crane to shock, such as suddenly winding up or stopping winches
・Operating the crane when it has not been inspected or maintained properly
・Operating the crane in harsh environments
(1) Modifications
If you modify this crane from the state in which it left our factory, you may impair its safety
or performance.
KATO bears no responsibility for accidents or malfunctions which arise as a result of
unauthorised modifications.
(2)Optional parts and attachments
Refer to the instruction manuals provided when you install genuine optional parts or
designated attachments. 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® is a registered trademark of VDA (Verband der Automobilindustrie).
Introduction

[2]
How to use this manual(0099-0101-2E)
・You must read this manual fully and understand its contents before
you operate, inspect or service this crane.
This manual is intended to be a guide to safe operation and regular
servicing so it should be kept in the designated place inside the cab
available to all those who use the crane.
・The sections in this manual and safety signs on this crane include
safety information.
The labels " DANGER", " WARNING" and " CAUTION"
are used in this manual and safety signs on this crane, so that you
can understand the important items for safety operations and
procedures.
Read them fully and understand them before you operate, inspect or
service this crane.
Indicates warnings concerning direct risks of serious injury or death.
(0099-0048-0E)
Indicates warnings concerning potential risks of serious injury or death.
(0099-0049-0E)
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.
・ This manual has been written as a standard for general handling in specified operations.
Before attempting any operations not covered by this manual or when you are unsure of any aspect of its contents,
contact your authorised KATO dealer.
・Any operations which do not conform to the contents of this manual are at the operator's own risk and responsibility.
KATO will bear no responsibility for any accident or damage which occurs as a result.
・ In addition to the contents of this manual, further safety information and requirements are to be found on the safety
signs on the crane and are contained in laws, regulations, ordinances, insurance conditions and other sources. You
must also adhere to these conditions.
Further observe the safety regulations and laws of the country where the crane is used.
・Please also refer to the separate instruction manuals.
How to use this manual

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Inspection and servicing(0099-0102-0E)
The inspection and servicing operations listed in this manual are a guide for extending the lifespan of the crane and
improving its work rate. Carry out the regular inspection and servicing tasks on the basis of this manual and regulations
of the country where the crane is used without fail.
This manual details the procedures for preoperational, monthly and annual inspection and servicing. Record the results
of each inspection and servicing measures taken in the separate "Inspection Sheet".
Refer to the separate "Service Manual" for servicing procedures for breakdowns and disassembly.
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.
Model CR-200Rf
Serial number
Engine serial number
Delivery date
(T218351-001-0E)
Operationqualifications(0099-0054-0E)
・Before operating this machine, make sure you have obtained all necessary qualifications
following the regulations and law of the country where the machine is used.
・ You must not operate without these qualifications.
(0099-0225-0E)
Inspection and servicing

[4]
MEMO

(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. Part names …………………………………………………………………………………… 1
2. Precautions on inspection and servicing …………………………………………………… 3
2-1 Information marked "DANGER" …………………………………………………………………………… 3
2-2 Information marked "WARNING" ………………………………………………………………………… 4
2-3 Information marked "CAUTION" …………………………………………………………………………… 13
3. Inspection and servicing table ……………………………………………………………… 15
3-1 Drive-related ………………………………………………………………………………………………… 16
3-2 Crane-related ………………………………………………………………………………………………… 22
4. Lubrication ……………………………………………………………………………………… 26
4-1 Precautions on lubrication …………………………………………………………………………………… 26
4-2 Oils that have been filled upon shipment from our factory ………………………………………………… 28
4-3 Recommended lubricants table ……………………………………………………………………………… 30
4-4 Greasing chart ……………………………………………………………………………………………… 31
4-5 Oil chart ……………………………………………………………………………………………………… 41
5. Inspection and servicing of each part ……………………………………………………… 42
5-1 Engine-related ……………………………………………………………………………………………… 42
5-2 Power transmission system ………………………………………………………………………………… 54
5-3 Drive system ………………………………………………………………………………………………… 58
5-4 Braking system ……………………………………………………………………………………………… 63
5-5 Steering system ……………………………………………………………………………………………… 70
5-6 Shock absorbers ……………………………………………………………………………………………… 71
5-7 Hydraulic system-related …………………………………………………………………………………… 72
5-8 Boom-related ………………………………………………………………………………………………… 84
5-9 Winch-related………………………………………………………………………………………………… 91
5-10 Slewing-related ……………………………………………………………………………………………… 98
5-11 Air conditioner-related …………………………………………………………………………………… 100
5-12 Electrical system-related ………………………………………………………………………………… 107
5-13 Crane safety devices ……………………………………………………………………………………… 113

6. Parts to be replaced periodically for safety ……………………………………………… 114
6-1 Drive-related parts ………………………………………………………………………………………… 114
6-2 Crane-related parts ………………………………………………………………………………………… 116
 7. Datafile ……………………………………………………………………………………… 117
7-1 Dimensions ……………………………………………………………………………………………… 117
7-2 Tightening torque table …………………………………………………………………………………… 120
7-3 Error display ……………………………………………………………………………………………… 126
7-4 Consumable parts guide …………………………………………………………………………………… 129

Part names
1. Part names
- 1 -
1. Part names(541A-0020-1E)

- 2 -
MEMO