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.
218741
Applicable serial No.: 0051－
Searcher Hook Section

CR-200Rf 218741
背厚 2.0 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

(T218741-001-0E)
Table of Contents 218741
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 searcher hook ………………………………………………………………… 7
2-1 Summary …………………………………………………………………………………………………… 7
3. Mounting the searcher hook ………………………………………………………………… 11
4. Removing the searcher hook ………………………………………………………………… 27
 5. Changingtheoffsetangle …………………………………………………………………… 41

1
Safety signs
1. Safety signs WARNING
1. Safety signs(T218391-002-0E)
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 cleaner to remove the dirt. Do not use gasoline or organic solvents.
If it is not possible to remove the dirt, replace the safety sign with new.
・ If a safety sign is damaged or peeling
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.
・ Refer to the CR-200Rf instruction manuals (machine section, power jib section)for the safety
signs but for the searcher hook.
(T218391-003-0E)

2
WARNING 1. Safety signs
[1]
Content: Lifting capacity chart
Location: Inside the cab
Part No.: 44A-75701002

3
Safety signs
1. Safety signs WARNING
[2]
Content: Lifting capacity chart
Location: Inside the cab
Part No.: 44A-75702002

4
WARNING 1. Safety signs
[3]
Content: Notes for the lifting capacity chart
Location: Inside the cab
Part No.: 44A-75106001
[1]
Content: How to connect the connector for overhoisting
detector
Location: Side of the boom
Part No.: 44A-75801001
[3]
Content: Searcher hook weight: 46 kg
Location: Top surface of the arm
Part No.: 44A-76103000

5
Safety signs
1. Safety signs WARNING
[10]
Meaning: Do not get caught.
Location: Link
Part No.: 899-81328982

6
MEMO

7
Operating the searcher hook
2. Operating the searcher hook
2. Operating the searcher hook(371R-0004-0E)
2-1 Summary (T218391-004-0E)
When lifting medium loads to places having limitation in an upward space, the searcher hook is mounted on the front
end of the boom for use.
Also, refer to the separate "CR-200Rf instruction manual (machine section)" and "ACS instruction manual".
2-1-1 General precautions when working with the searcher hook (T218391-005-0E)
(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)Follow the procedures described in this manual when mounting and removing the searcher hook.
(3) Be sure to refer to the separate "ACS instruction manual" for ACS operation. Set the operation status on the ACS
correctly.
Select and set "jib setting" to mount or remove the searcher hook or change the offset angle.
However, in this state the ACS will not detect overhoisting. Therefore, be sure to set the "next boom operation
status" after mounting or removing the searcher hook or changing the offset angle.
(4)Work with the searcher hook according to the lifting capacity chart which is always available for reference in the
cab.
(5)The lifting load with which you can extend or retract the boom during searcher hook operation may become
smaller than the lifting capacity depending on the conditions such as the oil pressure, boom angle, lubricating state
to the boom, etc.
(6)Change over the overhoisting detector connectors correctly for searcher hook operation.
(7) If you work with the searcher hook, stow the main and auxiliary wire ropes. If you work with the searcher hook
while the main hook is mounted, the weight of the main hook is added to the actual load on the ACS screen.
(8)Lock the main and auxiliary winch levers for safety after stowing the main and auxiliary wire ropes. Do not
operate the winches.
(9) If you work with the searcher hook while the main hook is mounted, work with extra attention to the position of
the main hook to prevent overhoisting.
(10)Remove the searcher hook when driving on roads.
(11)When mounting or removing the searcher hook, it is necessary to work in high places, so always work safely using
a workbench, safety belt, etc. Always wear a safety belt when climbing on top of the machine compartment so that
you cannot fall off.
(12)When you lower the boom while mounting or removing the searcher hook or changing the offset angle, be
especially careful that the boom does not hit and damage the side-view mirror, fender, engine cover, or other parts.
(13) If you work with the boom while the searcher hook is mounted, subtract its load as noted in the lifting capacity
chart. Then set the operation status to "boom operation with the searcher hook" on the ACS.

8
2. Operating the searcher hook
(12) 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.

9
Operating the searcher hook
2. Operating the searcher hook
3
)Chain for the overhoisting detector weight
In this manual, occasions when you remove or attach a chain appear as shown below.
・Removal
・Attachment

10
2. Operating the searcher hook
2-1-2 Structure of the searcher hook and the name of its parts (T218391-006-0E)

11
Mounting the searcher hook
3. Mounting the searcher hook
3. Mounting the searcher hook (T218391-007-0E)
If you are going to work with the searcher hook, follow
the procedure below to mount it.
(The following describes the procedure for mounting
the searcher hook, starting in the driving mode.)
(1)Preparations for mounting the
searcher hook
1)Before you start mounting the searcher hook,
make sure there are no other workers in the
searcher hook movement area.
Never allow anyone into the searcher hook
movement area during searcher hook mounting as
this is extremely dangerous.
(T218391-008-0E)
2
) Check that there is at least 3 m of clear space in
front of the boom top. Fully extend all outriggers
on the firm, level ground to set the crane.
3
) After setting the outrigger status on the ACS, set
the boom operation status to "jib setting".
・ 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)
4
) Set the "hook stowage mode" to the ACS.
5
) Raise the boom to an angle of about 10 degrees.
3. Mounting the searcher hook 4. Removing the searcher hook 5.Changingtheoffsetangle

12
3. Mounting the searcher hook
6
) Slowly lower the auxiliary wire rope to release
the auxiliary hook.
Then slowly lower the main wire rope to release
the main hook.
(2)Extending the boom
1) Set the "boom operation" to the ACS.
2
) Extend the boom by about 1.2 m and set the
boom angle to 0 degrees.
NOTE
If you retract the vertical cylinders in the
mounting direction of the searcher hook, the
boom top will be lowered, which allows
mounting the searcher hook even if the boom is
fully retracted.
(3)Removing the main and auxiliary
wire ropes and overhoisting
detector weight
1) Set "jib setting" to the ACS again.
2
)Lower the main wire rope until the main hook
almost contacts the ground.
The overhoisting detector is disabled, so work with
extra attention to the position of the main hook.
(T218391-009-0E)
Be careful not to let the main hook touch the
ground. The main wire rope will become tangled
if the main hook touches the ground.
(T218391-010-0E)
3. Mounting the searcher hook 4. Removing the searcher hook 5.Changingtheoffsetangle

13
Mounting the searcher hook
3. Mounting the searcher hook
3
) Lower the boom to an angle of about -3 degrees
so that the main hook rests on the ground.
4
)Lower the auxiliary wire rope until the auxiliary
hook almost contacts the ground.
The overhoisting detector is disabled, so work
with extra attention to the position of the auxiliary
hook.
(T218391-030-0E)
Be careful not to let the auxiliary hook touch the
ground. The auxiliary wire rope will become
tangled if the auxiliary hook touches the ground.
(T218391-031-0E)
5
)Fully lower the boom so that the auxiliary hook
rests on the ground.
The boom can be fully lowered only in the
forward area (in the driving position)or the side
area (as indicated in the figure below). If the boom
is lowered below horizontal in the forward area (in
the driving position), be especially careful to
prevent it from contacting the boom rest. If the
boom is lowered below horizontal in any other
area than shown below, be especially careful not
to damage the engine cover, fender, or other parts.
(T217231-019-0E)
3. Mounting the searcher hook 4. Removing the searcher hook 5.Changingtheoffsetangle