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.
218721
Applicable serial No.: 0051－
Power Jib Section

CR-200Rf 218721
背厚 2.5 mm （極小）

[1]
Introduction(0099-0045-1E)
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)
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

[3]
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

(T218721-001-0E)
Table of Contents 218721
Introduction ………………………………………………………………………………………… [1]
How to use this manual …………………………………………………………………………… [2]
Inspection and servicing …………………………………………………………………………… [3]
Serial number nameplate ………………………………………………………………………… [3]
Operationqualifications …………………………………………………………………………… [3]
1. Safety signs …………………………………………………………………………………… 1
2. Operating the power jib ……………………………………………………………………… 5
2-1 Summary …………………………………………………………………………………………………… 5
3. Mounting the power jib ……………………………………………………………………… 11
3-1 Mounting procedure ………………………………………………………………………………………… 11
4. Stowing the power jib ………………………………………………………………………… 29
5. 2nd jib section ………………………………………………………………………………… 45
5-1 Extending the 2nd jib section ………………………………………………………………………………… 45
5-2 Retracting the 2nd jib section………………………………………………………………………………… 49

1
Safety signs
1. Safety signs WARNING
1. Safety signs(T218361-002-0E)
The safety signs are stuck on in the places shown in the diagram. Check all of them before you start to operate the
crane.
Keep the safety signs clean at all times so that they are clearly visible and easy to read.
・ If a safety sign is dirty, use water or a neutral cleaner to remove the dirt. Do not use gasoline
or organic solvents.
・ 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.
・When you replace a safety sign, always check that it is identical to the original.
(541A-0041-2E)

2
WARNING 1. Safety signs
[1]
Content: How to connect the connector for overhoisting
detector
Location: Right side of the boom top
Part No.: 44A-75801001
[14]
Content: Note for the rope guide
Location: Right side of the jib
Part No.: 899-81410292
[20]
Content: How to connect the connector for overhoisting
detector
Location: Right side of the jib
Part No.: 581-75602000
[21]
Meaning: Do not allow anybody, even other site workers,
to pass under the suspended load.
Location: Underside of the boom base
Part No.: 821-75022000

3
Safety signs
1. Safety signs WARNING
[22]
Content: Note for the rope retaining pin
Location: Left side of the auxiliary hook stowage
bracket
Part No.: 899-81320802
[31]
Content: When operating the crane, detach the boom
guard.
Location: Front of the boom guard
Part No.: 899-81422512
[86]
Content: Note when lowering the boom
Location: Inside the cab
Part No.: 899-81430492
[87]
Meaning: Note for the boom angle when swinging out
or stowing the jib
Location: Inside the cab
Part No.: 899-81421572

4
MEMO

5
Operating the power jib
2. Operating the power jib
2. Operating the power jib(541P-0016-0E)
2-1 Summary (T217331-004-0E)
When lifting a comparatively light load to a high place, the jib is mounted to the top of the boom for use. The offset
angle of the jib of this machine can be changed to an optional angle from 7° to 60°. When the jib is not in use, it is
stowed on the underside of the boom base. When it is used, it is easily swung forth and can be mounted to the top of the
boom.
Also refer to the separate "ACS instruction manual".
2-1-1 General precautions when working with the power jib (T217231-110-0E)
(1) Set the crane on a firm, level ground horizontally with the outriggers fully extended. Insert the outrigger stopper
pins and confirm that all outriggers are fully extended.
(2) As a general rule, the boom should be fully extended or the boom length should be 19.60m when working with the
jib.
(3)When mounting or stowing the jib, make sure that you have enough clear space to swing the jib. Also, do not allow
anyone else to enter the jib movement area.
(4)Follow the procedures described in this manual when mounting and stowing the jib.
(5) Select and set the ACS operation status correctly.
Select "jib setting" to mount or stow the jib or set the initial offset angle setting.
However, in this state the ACS will not detect overhoisting. Therefore, be sure to set the "next boom operation
status" after mounting or stowing the jib or setting the initial offset angle.
(6)Work with the jib according to the lifting capacity chart which is always available for reference in the cab.
(7)Change over the overhoisting detector connectors correctly for jib operation.
(8)When driving on roads, have the jib, main hook and auxiliary hook stowed in the proper places.
(9) When inevitably using the jib and the boom together to suspend one load, set the boom operation status to "jib" on
the ACS and take care that the lifting load does not exceed the rated lifting capacity of the jib.
(10) If you work with the boom while the jib is mounted, set the boom operation status to "boom operation with the jib"
on the ACS working status setting screen.
(11)When you lower the jib, the working radius will increase and the load limit could be exceeded or the wire rope
overhoisted. Be very careful of your working radius and auxiliary hook position.
(12)When mounting or stowing the jib, adjust the hoist height so that the main hook passes the jib foot.
(13)When you lower the boom while mounting or stowing the jib, be especially careful the boom or jib does not hit
and damage the side-view mirror, fender, engine cover, or other parts.
(14)Never use the jib and the rooster sheave together to suspend one load.

6
2. Operating the power jib
(15) Strictly observe the following notes on the handling of each pin.
1) Quick pin
In this manual, occasions when you remove or insert a quick pin appear as shown below.
・To remove the quick pin, disengage the lock then pull the pin out. Take care that the fastening pin does not drop
out once you remove the quick pin.
・ To fit the quick pin, insert it into the fastening pin and always turn the lock into position.
2
) Snap pin
・ To remove the snap pin, put your finger through the ring end or grip the pin with pliers or another convenient
tool to pull the pin out.
・To insert the snap pin, check that it is pushed far enough into the fastening pin.

7
Operating the power jib
2. Operating the power jib
3
)Chain for the overhoisting detector weight
In this manual, occasions when you remove or attach a chain appear as shown below.
・Removal
・Attachment

8
2. Operating the power jib
2-1-2 Structure of the power jib and the name of its parts (541P-0096-0E)

9
Operating the power jib
2. Operating the power jib
2-1-3 Power jib mounting and stowing procedure (511P-0009-1E)
(1)Power jib mounting procedure

10
2. Operating the power jib
(2)Power jib stowing procedure

11
Mounting the power jib
3. Mounting the power jib
3. Mounting the power jib
(121P-0004-0E)
3-1 Mounting procedure (T218361-003-0E)
If you are going to work with the jib, follow the procedure
below to mount it.
(The following describes the procedure for mounting
the jib, starting in the driving mode.)
(1)Preparations and conditions for
mounting the power jib
1)Before you start mounting the jib, make sure
there are no other workers in the jib movement
area.
Never allow anyone into the jib movement area
during jib mounting as this is extremely dangerous.
(T217061-087-0E)
2
) Check that there is at least about 10m of clear
space in front of the boom measured from the
slewing center. Fully extend all outriggers on the
firm, level ground.
3
) If the main hook is configured with seven parts
of line, change it to four parts of line.
If left configured with seven parts of line, there
may be not enough wire rope on the main winch
to allow extending the boom sufficiently.
(T217331-006-0E)
4
) Set "jib setting" to the ACS.
・ Always refer to the separate "ACS instruction
manual" for ACS operation.
・ When "jib setting" is set to the ACS, the
overhoisting detector is disabled, so work with
extra attention to the position of the hook.
(T217061-006-0E)
3. Mounting the power jib 4. Stowing the power jib 5-1 Extending the 2nd jib section 5-2 Retracting the 2nd jib section

12
3. Mounting the power jib
5) Set the "hook stowage mode" to the ACS.
6
)Raise the boom to an angle of about 5 degrees.
7
) Slowly lower the auxiliary wire rope until the
auxiliary hook is positioned about 30cm from the
overhoisting detector weight. Then slowly lower
the main wire rope until the main hook is
positioned about 30cm from the overhoisting
detector weight.
8
) Set the "boom operation" to the ACS.
9
) Extend and retract the boom by about 20cm and
confirm that the jib under-stow switch was
activated.
If the boom cannot be extended or retracted, the
jib under-stow switch has a bad connection or has
otherwise failed.
(T217331-013-0E)
3. Mounting the power jib 4. Stowing the power jib 5-1 Extending the 2nd jib section 5-2 Retracting the 2nd jib section

13
Mounting the power jib
3. Mounting the power jib
10) Set "jib setting" to the ACS again.
(2)Removing the auxiliary wire
rope and overhoisting detector
weight
1) Slowly hoist the auxiliary wire rope until the
auxiliary hook is positioned about 20cm from the
hook stowage bracket.
Then slowly hoist the main wire rope until the
main hook is positioned about 20cm from the
hook stowage bracket.
2
) Lower the boom to an angle of about -5 degrees.
3
)Disconnect the chains for the overhoisting
detector weight from the auxiliary hook stowage
bracket.
3. Mounting the power jib 4. Stowing the power jib 5-1 Extending the 2nd jib section 5-2 Retracting the 2nd jib section