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.
218711
Applicable serial No.: 0051－
Machine Section

218711
背厚 14.5 mm （中）

[1]
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 ?
②Is the crane set horizontal ?
③ Are the tires off the ground ?
④ Are the outriggers fully extended ?
⑤Are the outrigger stopper pins inserted ?
⑥ Has the outrigger extension width been correctly set to the ACS ?
(T217161-001-0E)

[2]
All operations in accordance with lifting capacity chart
Make sure that all crane operations are in accordance with the
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 lifting
capacity of the crane.
The 1st step toward safe operation is to set the crane level on firm
ground using the outriggers, and then operate according to the
lifting capacity chart.
Operation very close to or slightly in excess of the limits could
result in an accident.
Everyone including the crane operator and site supervisor must
perform work with a sufficient safety margin.
(0099-0002-1E)
Beware of wind !!
When operating with the boom extended or when hoisting/
lowering a large load, the wind could produce unexpected moment
against the crane and cause the boom to break or the crane to tip
over.
Be especially careful about wind striking the side of the boom or
when operating in the space between buildings.
(T217161-002-0E)

[3]
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. Pulling or
breaking off driven or buried objects by raising the boom is
recklessly dangerous as if you would use the crane to lift the
planet. Therefore raising the boom in any way that may apply
diagonal loads is forbidden. If you ignore the danger and the
warning of the ACS and continue such an operation, an excessive
load will act, possibly breaking the boom or the wire rope. Even if
there is no final collapse during operation, the crane will be
damaged resulting in progressive damage even when working
within lifting capacity and leading to sudden catastrophic failure.
(T217161-003-0E)
Absolutely avoid sudden release operation
This machine is designated for general hook duty.
Never operate the crane including sudden release of a lifting load
(with a grab bucket, lifting magnet etc.).
(T217591-026-0E)

[4]
Absolutely avoid releasing !!
Working with the ACS emergency switch and the overhoisting
emergency switch turned to the release positions risks causing
accidents. Before you start work, always check that both switches
are positioned correctly.
(0099-0099-0E)

[5]
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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

[6]
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

[7]
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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

[8]
SpecificationofCR-200Rf(T218351-003-0E)
1.CraneSpecification(T218351-004-0E)
Maximum lifting capacity : 20 ton×2.5m
Boom length : 6.5m － 28.0m (6 section)
Jib length : 4.0m, 5.8m (2 section, offset 7°－ 60°
)
Searcher hook (option)1.0m (High position and Low position)
Boom derricking angle : -9.5°－83°
*Boom derricking time : 35s/-9.5°－83°
*Boom extending speed : 6.5m － 28.0m/65s
*Hoisting line speed (winch up)
Main winch : 115m/min (at 5th layer)
Auxiliary winch : 104m/min (at 3rd layer)
*Hoisting hook speed (winch up)
Main winch (parts of line: 7): 16.4m/min (at 5th layer)
Auxiliary winch (parts of line: 1) : 104.0m/min (at 3rd layer)
*Slewing speed : 2.9min-1
*Speed/Time : Subject to no load
Wire rope for hoisting
Main winch;
Diameter : 14mm
Length : 155m
Auxiliary winch;
Diameter : 14mm
Length : 76m
Hydraulic system
Oil pump : 4 pumps, plunger and gear type
Hoisting motor : Axial plunger type
Slewing motor : Axial plunger type
Cylinder : Double acting type
Control valve : Double acting with integral check and relief valves
Oil reservoir capacity : 240L
SpecificationofCR-200Rf

[9]
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Winch system
Main winch
Auxiliary winch
: Driven by axial plunger type
hoisting motor through planetary gear reduction.
Controlled independently by 2-speed (high / low)
selection type respective operating lever.
Equipped with automatic brake.
Safety devices : ACS (Automatic Crane System with Voice alarm)
ACS outside indicator (LED)
Slewing automatic stop system
Working range limit mode
Outrigger status detector
Outrigger lock pins
Electronical horizontal detector
Boom derricking / telescoping holding valve
Jib derricking holding valve
Overhoist prevention device
Winch holding valve
Automatic winch brake
Winch drum roller
Winch drum turning indication device
Winch over unwinding device
Hydraulic safety valves
Hydraulic oil temperature warning device
Hydraulic oil return filter warning device
Slewing warning lamp
Seat switch
Operator's cab : All steel welded construction, 1 person
Rubber mounted
Adjustable steering wheel
Adjustable seat with suspension
Air conditioner
Power Window (external closing switch)
Front windscreen wiper & washer (2 speed wiper)
Roof window wiper & washer (2 speed wiper)
AM/FM Radio
Interior lamp (LED)
Step lamp (LED)
Accessory socket (24V)
USB socket (output 5V-2.4A×2)
Floor mat
Entry key system
K･COR (KATO Crane Operation Recorder)
Standard equipment : Working light (LED)on boom, table and cab
Winch view camera
Hook for 20 ton
Hook for 3.2 ton
Optional equipment : PA system
Door visor
Lunch table
Air heater
Searcher hook
SpecificationofCR-200Rf

[10]
2.CarrierSpecification(T218351-005-0E)
Drive system : 4×2, 4×4
Maximum traveling speed : 55km/h
Grade ability (tanθ): 60% (computed at G.V.W.=19755kg)
Minimum turning radius
(center of extreme outer tire)
: 4.7m (4 wheel steer)
8.0m (2 wheel steer)
Engine
Maker : Cummins
Model : QSB6.7 (EU Stage 4)
Type : 4 cycle, 6 cylinders, water cooled, direct injection
turbo-charged diesel engine with intercooling
Piston displacement : 6.690L
Max. power : 175kW at 2300min-1
Max. torque : 888N･m at 1500min-1
Torque converter : Engine mounted 3 elements
1 stage (with lock up clutch)
Transmission : Remote mounted full automatic
4 forward & 1 reverse speed
(with High-low selector)
Axles; Front & Rear : Planetary, drive/steer type
Suspension; Front & Rear : Taper-leaf spring
Hydraulic locking device with suspension cylinder
Steering Full hydraulic power steering
Completely independent front and rear steering
(with automatic rear wheel steering lock system)
Brake system; Service brake : Air-over hydraulic disk brake on 4 wheels
(front and rear independent circuit)
Parking brake : Spring applied, electrically air released parking
brake mounted on front axle, internal expanding
type
Auxiliary brake : Exhaust brake
Service brake lock
Electric system : 24V
Alternator : 24V － 70A
Batteries : (12V － 120AH)×2
Fuel tank capacity : 250L
Tire size Front & Rear : 325/95 R24 162/160K
SpecificationofCR-200Rf

[11]
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Safety devices : Emergency steering device
Rear wheel steering lock system (automatic)
Brake fluid leak warning device
Service brake lock
Suspension lock
Engine overspeed alarm
Electrically retractable side view mirrors
Left front view camera
Rear view camera
Clearance sonar system
Radiator coolant level warning device
Air filter service warning device
Low air warning device
Boom guard
Standard equipment : Hydraulic oil cooler
LED head lamp
Optional equipments : Wheel stopper
Way side lamp
Side marker lamp
Rear view camera (Wireless, mounted on carrier)
Storage box
Electrically retractable side view mirrors
with defroster
Aluminum outrigger plate and storage
3. General dimensions(T218351-006-0E)
Overall length : 8710mm
Overall width : 2290mm
Overall height : 3245mm
Wheel base : 3250mm
Treads; Front : 1920mm
Rear : 1920mm
Outriggers Type Hydraulic H-beam type
(with float and vertical cylinder in single unit)
Extension width : 5400mm (Fully extended)
: 4800mm (Intermediately extended)
: 4300mm (Intermediately extended)
: 3200mm (Intermediately extended)
: 1930mm (Completely retracted)
Gross vehicle weight : 19755kg (without Optional equipments)
Front axle : 9910 kg (without Optional equipments)
Rear axle : 9845kg (without Optional equipments)
SpecificationofCR-200Rf

[12]
4. Dimensions(T217591-021-0E)
SpecificationofCR-200Rf

[13]
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Recorded data(T217321-050-0E)
This machine includes an ACS system that immediately stops crane operations if the load exceeds the lifting capacity.
In addition to protecting the machine from damage or tipping over due to excessive loads, the ACS system also records
the following data whenever certain conditions are satisfied.
・ Date and time
・Operation mode
・Load value
・ Lifting capacity
・Load ratio
・Boom angle and length
・Jib angle and length
・Slewing angle
・Outrigger setting value
In some cases, KATO, or an authorized third-party agent of KATO, may obtain and utilize the recorded data for
technical diagnostic purposes or for mobile crane research and development.
Disclosure of data
KATO, and agents of KATO, will not disclose or supply the data obtained to a third-party, except in any of the
following cases.
・The owner or user of the machine agreed to disclose the data.
・ Disclosure is mandated by order of a court of law or other legal authority.
・ Disclosure is requested by a person in a position of responsibility with respect to crane operations performed by the
given crane.
・ Data is provided to a research institution, or other such organization, in a modified form that does not permit
identifying the user or machine, such as statistically processed data.
Recorded data

[14]
MEMO

[15]
Table of Contents (T218711-001-0E)
Introduction ………………………………………………………………………………………… [5]
How to use this manual …………………………………………………………………………… [6]
Inspection and servicing …………………………………………………………………………… [7]
Serial number nameplate ………………………………………………………………………… [7]
Operationqualifications …………………………………………………………………………… [7]
SpecificationofCR-200Ri ………………………………………………………………………… [8]
Recorded data …………………………………………………………………………………… [13]
General devices
(for driving and crane)218711
1. Part names and terms ………………………………………………………………………… 1
2. For safe operation …………………………………………………………………………… 5
3. General operation devices …………………………………………………………………… 11
4. Safety signs …………………………………………………………………………………… 35
 5. Precautionsongettingonandoffthemachine …………………………………………… 49
 6. Precautionswhenfillingwithfuel …………………………………………………………… 50
7. Air conditioner ………………………………………………………………………………… 52
8. Color monitor…………………………………………………………………………………… 57
9. Radio …………………………………………………………………………………………… 71
10. Entry key system ……………………………………………………………………………… 73
11. Starting and stopping the engine …………………………………………………………… 82
12. Handling the machine in winter and summer ……………………………………………… 85
13. SCR system …………………………………………………………………………………… 87
14. Clearance sonar system ……………………………………………………………………… 89
Driving operation 218711
15. Driving safely…………………………………………………………………………………… 95
16. What to do when the machine breaks down …………………………………………… 103
17. Drive operation devices …………………………………………………………………… 110
18. Driving the machine ………………………………………………………………………… 158

[16]
Crane operation 218711
19. For safe operation ………………………………………………………………………… 171
20. How to read the capacity charts…………………………………………………………… 201
21. Crane operation devices …………………………………………………………………… 208
22. Crane operation when the outriggers are used ………………………………………… 224
23. Crane operation without outriggers ……………………………………………………… 251
24. Crane operation …………………………………………………………………………… 258
25. Changing the wire rope number of parts ………………………………………………… 281
Preoperational checks/
Pre-drive checks 218711
26. Preoperational checks/Pre-drive checks ………………………………………………… 285
Index 218711
Index ……………………………………………………………………………………………… 303
Power Jib Section Separate
manual 218721
Inspection and Servicing Section Separate
manual 218731
Searcher Hook Section Separate
manual 218741
MS-250 Separate
manual 218751

[17]
List of illustrations
Switches inside the cab
Side panel
1Roof window wiper/washer switch 25 6Overhoisting emergency switch 214
2Working lamp switch 214 7Boom extension/retraction emergency switch 214
3Slewing warning lamp switch 214 8Seat bypass switch 215
4Winch lighting switch 215 9Loudspeaker system (optional)20
5Slewing free/lock switch 214 10 Combustion type air heater (optional)25

[18]
Front panel
1Information display 128 13 Parking brake switch 147
2Entry key system authentication area 24 14 Left/right mirror selection switch 143
3Hazard warning switch 148 15 Side-view mirror extension/stowage switch 143
4USB power supply port 24 16 Slewing brake switch 212
5Turn signal indicator lamp 115 17 Mirror heater switch (optional)148
6Cluster meter panel 113 18 Suspension control switch 144
7ACS emergency switch 212 19 Rear steering lock/release switch 146
8Accessory socket 23 20 Starter switch 22
9Color monitor 57 21 Air conditioner 52
10 PTO switch 2 11 22 Radio 71
11 Rear view camera mode switch (optional)59 23 Clearance sonar system indicator 91
12 Power window switch 22
Right console
1Hook displacement display setting buttons
(Auxiliary hook)
218 5Auxiliary winch high-speed lowering switch 219
2Hook displacement display setting buttons
(Main hook)
218 6Drum rotation detector switch 219
3Step lamp switch 21 7Rear steering switch 149
4Main winch high-speed lowering switch 219