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

2. Precautions on inspection and servicing DANGER
- 3 -
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.
2-1 Information marked "DANGER" (T217941-093-0E)
(1)Lower the lifting load and work device to the ground before
inspection and servicing.

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WARNING 2. Precautions on inspection and servicing
2-2 Information marked "WARNING" (T218371-002-0E)
(1)Repair of broken or malfunctioning parts
If you discover a breakdown or malfunction during an
independent inspection or preoperational check, it must be
repaired immediately. Operation with such problems unrepaired
is highly dangerous.
Never start work before all repairs are complete.
(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.
(4)Always place signs to indicate that the crane is being inspected
and serviced
During inspection and servicing, stop the engine and take the
key out.

- 5 -
Precautions on inspection and servicing
2. Precautions on inspection and servicing WARNING
(5)Repairs to the boom and jib require special techniques.
Contact your authorised KATO dealer.
(6)Do not allow water to enter when you top up with oils
When you are topping up with fuel or hydraulic oil or replacing
hydraulic oil, take care to avoid the entry of water or other
materials.
If water does get in, it will cause corrosion and breakdowns.
(7)Cautions when removing the radiator cap:
・Removing the radiator cap while the coolant in the radiator is
hot may cause the hot coolant splash out, resulting in a burn
injury.
・Before removing the radiator cap, make sure the temperature of
the coolant is lowered and release the pressure by slowly
loosening the cap. The coolant must be replenished from the
reservoir tank.
(8) Use genuine KATO or KATO-approved lubricants and filters.
・When you top up with or replace lubricants or replace parts
such as filters etc., always use genuine 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.

- 6 -
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.
・Waste oil is environmentally harmful. Never allow it to pour
onto the ground or dump it in streams, rivers or wetlands.
・Follow the relevant regulations when you dispose of oil, fuel,
coolant, AdBlue®/DEF, brake fluid, solvents, filters, batteries or
any other hazardous or potentially hazardous materials.
(10)Keep the hydraulic equipment, engine, and the electric and
electronic parts clean.
The hydraulic equipment, engine, and the electric and electronic
parts have been precisely adjusted. Make a habit of keeping
them clean.
(11)Precautions when washing the crane
・While washing the crane, you may lose your footing and fall
down, so wear slip-resistant boots while washing the crane. If
you are using high-pressure steam for cleaning, the jet can cut
your skin and mud etc. can splash back into your eyes. Wear all
appropriate protective equipment when using high-pressure
steam.
・ If you spray water on electrical equipment during washing, it
could short and malfunction, so work carefully to avoid wetting
the electrical equipment.
(12)Precautions when working in high places
・When you are working in high places, take precautions to avoid
falling off.
Keep the area you are standing on tidy (no tools scattered
around)and clean (wipe off any spilled oil or grease), and walk
carefully to avoid slipping.
・When climbing and descending, use the hand grips and
platforms and always keep yourself adequately supported on at
least three points at any time. Wear a safety harness and other
safety equipment as necessary.

- 7 -
Precautions on inspection and servicing
2. Precautions on inspection and servicing WARNING
(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.
・The operator should keep the key for safety.
(14) Servicing with the engine running is a job for two people
・Avoid servicing the crane while it is working if at all possible.
・ If it is unavoidable, work with at least two people. One of you
must be in the operator's seat to be able to stop the engine at any
time and all those involved must be in constant contact.
・ If you work near rotating parts, take care not to be trapped or
dragged in.
(15)Precautions when welding
・ There is a risk of fire when welding due to generation of gas
from hot paint.
・Employ a qualified welder for the job and carry it out in a
properly equipped place.
・ Sparks from welding can damage electrical parts, hoses, or
other parts. Be sure to always protect the surrounding area when
welding.
(16)The following are basic precautions before welding.
・Turn the starter switch to OFF.
・Disconnect the negative side of the battery cable from the
terminal.
・Cut away the paint from the area to be welded so that it cannot
produce gas.
・Attach an earth connection within one meter of the weld point
with no O-rings or bearings between the weld and earth points.
・Always wear protective equipment and make sure the
ventilation is adequate.
・Remove flammable materials and place a fire extinguisher
nearby.
・ If you don't turn the starter switch to OFF and disconnect the
negative side of the battery cable from the terminal before
welding, the electrical equipment could malfunction or the
batteries could explode dangerously.

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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. The battery electrolyte is dilute
sulfuric acid which will burn skin on contact.
・Damage to the batteries is extremely dangerous, so always
remove either of the battery cables before servicing any part of
the electrical system or welding.
(Always disconnect the battery cable from the negative
terminal.)
・Before disconnecting the battery cable, turn the starter switch to
OFF and wait for at least 30 seconds. Never disconnect the
battery cable when the starter switch is turned to ON.
If the battery cable is disconnected when the engine is running
or 30 seconds do not elapse after the starter switch is turned to
OFF, the engine control computer will not memory the engine
operating information normally, causing a problem in the engine
control system etc.
(18)The equipments are hot immediately after the engine stops
・The equipments are hot immediately after the engine stops, so
you could be burned if you touch them. In particular the engine,
silencer, exhaust pipe, oil reservoir, coolant, radiator, sliding
parts, hydraulic equipment, pipes etc. will be very hot.
・Wait for all parts to cool before you begin inspection and
servicing.
(19) Illumination
・ If you are working in poor light, you cannot see well enough
what you are doing, so you could injure yourself.
Before operation, prepare illumination enough to light the
working place.
・ Do not use a lighter or other flame in place of a lamp to light
dark places. You could start a fire or cause an explosion by
igniting gas generated by the battery.
・ Use an explosion-preventive type of lamp when looking at the
battery or fuel.

- 9 -
Precautions on inspection and servicing
2. Precautions on inspection and servicing WARNING
(20)Do not heat hydraulic equipment or pipes
・ If you heat hydraulic equipment or pipes or areas near them, it
could generate and ignite flammable vapour or smoke.
Avoid welding, soldering or heating with a torch near hydraulic
equipment or pipes.
・ If you directly heat pressurised pipes or rubber hoses, they may
rupture suddenly. Cover them with a fire-resistant material.
(21) Have the tires serviced at the qualified service factory.
・ 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.
・When you open an inspection cover or cab door, always use the
lock bar (if it is provided)to lock it securely in the fully open
position.
When there is a strong wind, do not open the door or covers.
(23)You must not use inadequate wire ropes
・ The operator must not use any wire ropes which are defined by
law as inadequate slings during crane operation.
Inspect any wire rope to be used in crane operation (including
slings)to see if they fail on even one of the replacement criteria.
・We recommend that you periodically replace or switch the drum
and hook sides of the winch wire rope.

- 10 -
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.
Do not dilute the AdBlue®/DEF or add any additives. Doing
so could not only result in worse gas emissions, but also could
cause the machine to fail.
3
) Use low-sulfur diesel fuel with sulfur content of 15 ppm or
less. If not, engine stop may be caused. Do not use any type
of water remover.
4
) Exhaust gases become significantly hotter during SCR system
cleaning than conventional machines. Therefore, be careful
not to park near flammable substances. Also be careful not to
get burned.
If the SCR system is cleaned near a painted wall, the hot
exhaust gases could discolor the wall.

- 11 -
Precautions on inspection and servicing
2. Precautions on inspection and servicing WARNING
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.
Depending on the content of the work, also wear a safety belt,
protective gloves, protective eyewear, a dust mask, ear
protection, or other protective gear, as appropriate.
(26)Precautions for ventilation during inspection or service work
indoors
When performing inspection or service work indoors or in any
other poorly ventilated area, ventilate the area appropriately to
prevent gas poisoning from exhaust gas emissions, fuel,
cleaning solutions, paints, and so on, such as by extending the
exhaust pipe and opening a door or window to let in plenty of
fresh air or by installing a ventilation fan.

- 12 -
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. Also, notify other
workers in the surrounding area before performing inspection
or service work under the machine.
Do not perform inspection or service work under the machine if
the machine is not securely supported.
(28) Precautions for high-temperature or high-pressure oils etc.
Fuels, coolant, engine oils, hydraulic oils, and other solutions
may be very hot and under high pressure. Wear protective
eyewear and gloves before inspecting leaks, for example.
Before removing the cap, hoses, hydraulic lines, filters, or other
such parts, confirm that the hydraulic oil has cooled adequately
and then relieve the internal pressure of the hydraulic system,
for example. If anyone contacts a high-temperature or high-
pressure oil etc., immediately have the person examined by a
physician.