SR-300L Im (E)
SR-300L Im (E)
SR-300L Im (E)
SR-300L
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.
214521
11.5 mm
SR-300L
214521
[1]
(0099-0001-1E)
(0099-0002-0E)
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.
(0099-0003-1E)
[2]
(0099-0099-0E)
[3]
MEMO
[4]
Introduction
(0099-0045-0E)
(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)
[5]
(0099-0101-1E)
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", "
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 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.
[6]
(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.
(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.
Serial number
Engine serial number
Delivery date
(0099-0053-0E)
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)
[7]
MEMO
[8]
Table of Contents
(611A-0001-0E)
Introduction
How to use this manual
Inspection and servicing
Serial number nameplate
Operation qualifications
General devices
(for driving and crane)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
55
61
69
94
214521
1
11
17
37
46
47
49
52
214521
Driving safely
What to do when the machine breaks down
Drive operation devices
Driving the machine
Crane operation
13.
14.
15.
16.
17.
18.
19.
214521
Driving operation
[5]
[6]
[7]
[7]
[7]
105
129
137
147
168
175
192
Preoperational checks/
Pre-drive checks
214521
Index
214521
Index 211
Separate
manual
214531
Separate
manual
214541
[10]
(611A-0002-0E)
General devices
(for driving and crane)
214521
Part names 1
1-2
Terms
General precautions 11
17
3-2
Front panel 24
3-3
Side panel 26
3-4
Radio (optional)
3-5
3-6
27
4. Safety signs 37
5. Precautions on getting on and off the machine 46
6. Precautions when filling with fuel 47
7. Starting and stopping the engine 49
7-1
49
7-2
Handling in winter
52
8-2
Handling in summer 53
(541A-0019-0E)
-1-
MEMO
-2-
3-1
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
3-2
1.
2.
3.
4.
Front panel
Lighter
Ashtray
Starter switch
Idle speed knob
3-3
1.
2.
3.
4.
Side panel
Roof window wiper/washer switch
Fan switch (optional)
Defroster switch
Heater switch (optional)
Fuse box
Holders for the rated lifting capacity
chart and instruction manual
11. Keys
12. Fire extinguisher (optional)
13. Emergency kit
14. Rear window
-3-
-4-
11-1-2
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
Indicator section
Turn signal indicator lamp (left)
Turn signal indicator lamp (right)
11-2-2
1.
2.
3.
4.
Switch section
Torque converter oil temperature display switch
Two/four wheel drive switch
High/low speed switch
Brake lock switch
11-3
11-3-1
1.
2.
3.
4.
5.
6.
11-4
11-5
11-5-1
1.
2.
11-2
11-2-1
1.
2.
3.
4.
5.
6.
7.
8.
9.
Switch panel
Indicator section
Multiplex communication error warning lamp
PTO indicator lamp
Working lamp indicator lamp
Outrigger operation OK indicator lamp
Hydraulic oil warning lamp
Suspension locked indicator lamp
Power steering pressure warning lamp
Suspension operation OK indicator lamp
Rear steering lock release confirmation indicator
lamp
10. Rear steering central position indicator lamp
11. Digital display
Steering column
Steering wheel
Height and angle adjustment lock lever
Horn switch
-5-
-6-
Front panel
PTO switch
ACS emergency switch (self-reset type)
Level gauge
Crane operation switch
Slewing brake switch
Main winch switch
Auxiliary winch switch
Boom extension/retraction switch
Side panel
1. Overhoisting emergency switch
(self-reset type)
2. Boom extension/retraction emergency switch
(self-reset type)
3. Jib side-lifting switch (self-reset type)
4. Slewing free/lock switch
5. Drum rotation detector switch
6. Working lamp switch
15-3
1.
2.
3.
4.
5.
6.
7.
16-4
-7-
-8-
The box-shaped structural element which bears the load through the sheave,
hoisting rope etc. and varies the working radius by derricking, lowering,
extending and retracting. It is composed of the boom base, boom sections 2, 3
and 4 which, except the boom base, extend and retract.
Jib
An auxiliary component mounted on the top of the boom to increase its length
for lifting comparatively light loads to higher places.
Rooster sheave
The auxiliary sheave mounted on the top of the boom. Used within the area
reached by the boom to hoist comparatively light loads on a single part of line.
Winch
This device hoists and lowers the load via the hoisting rope. There are winches
for the main winding and the auxiliary winding and their drums are driven by
hydraulic motors.
Counterweight
A weight provided to counterbalance the moment due to the load (lifted load
weight working radius).
Outriggers
Used to level the machine. They extend sideways from four locations on the
carrier body and support the machine.
Lifting the load and pausing briefly when the load is slightly clear off the ground.
The boom top with the machine in the driving configuration is defined as the
front. Rear, left and right are determined accordingly.
Crane operation carried out with the outriggers extended to the specified width
and the machine set up horizontally.
Suspension lock
The status where the suspension cylinders are fully retracted and the suspension
function is disabled.
Always lock the suspension cylinders during crane operation (including the
operation without load lifting).
Suspension free
The status where the suspension cylinders freely extend or retract according to
the bumpy road and the suspension function is operated.
When driving on the road, always release the suspension lock. (Release the
suspension lock when the crane operation is over).
Crane operation with the suspension cylinders locked and the outriggers not
extended. The term refers to any crane operation in this condition, regardless of
whether any load is lifted.
Pick and carry operation Driving with the suspension cylinders locked and a lifting load held (without
crane operation).
-9-
Boom angle The angle between the boom center line and the horizontal.
The rated lifting capacity for jib use is based on the boom angle.
Jib offset angle The angle between the boom center line and the jib center line.
Working radius The horizontal displacement between the slewing center and the center line of
the hook. If the working radius changes so does the rated lifting capacity value
(except the rated lifting capacity for jib use).
The value on the rated lifting capacity chart indicates the actual working radius
under load including deflection of the boom.
Hoisting direction The direction of the boom top in the driving configuration is defined as the front
and the right, left and rear are determined accordingly.
The actual rated lifting capacity may vary depending on the hoisting direction,
even if all the other various crane parameters are identical, such as whether or
not outriggers are used (stationary crane-on-rubber operation, pick and carry
operation).
The capacity will also vary depending on how far outriggers are extended in
each hoisting region.
NOTE
Refer to the separate ACS instruction manual for slewing position display on the ACS.
- 10 -
WARNING
(0099-0104-1E)
This section lists precautions you should observe when operating this crane.
Make sure you fully understand these points before you start operation and observe them to operate safely.
In this section, pictures which illustrate dangerous situations or working practices are marked with a large "" .
The illustrations in this section are intended to attract attention and supplement the main text.
They do not give a full and detailed account of the content of the text.
Further precautions may be necessary due to the attachments in use or the conditions of the site.
Observe the safety regulations and laws of the country where the crane is used.
- 11 -
WARNING
(4) Follow instructions and warnings
This instruction manual and the safety signs mounted on the
crane contain instructions and warnings which are necessary for
safe operation. Read them first. If you ignore instructions or
warnings, you risk injury or fatal accident. If there is something
you do not understand, have it explained to you. If the manual
is lost or a safety sign is illegible, you should immediately order
a replacement from your authorised KATO dealer.
(5) We urge you to carry a fire extinguisher and first aid kit
Fit a fire extinguisher to guard against fire and read its
instructions on the label before you need it.
You are advised to carry a first aid kit.
- 12 -
WARNING
(8) Keep the area of the operator's seat clean and tidy
Do not leave parts, tools or other objects in the area of the
operator's seat. These can cause unexpected accidents while you
are working.
Do not put aerosol spray cans, paint thinner, or other dangerous
combustibles in the cab. They could cause a fire.
- 13 -
WARNING
(12) Precautions when starting the engine indoors
If you need to start the engine indoors, open doors and windows
to ensure good ventilation.
- 14 -
WARNING
(16) Sound the horn before you start the engine
Before you board the crane, check that there is nobody nearby.
When you are about to start the engine, sound the horn to warn
people nearby.
(17) Before you start the engine, check that all the levers, pedals and
switches are in their neutral or OFF positions.
- 15 -
MEMO
- 16 -
(061A-0003-1E)
Do not put your hands or head out through the door or windows while the crane is working.
If you operate the crane with the door open, open it all the way back until it engages on the
door lock. If you operate the crane with the lock not engaged, the door could slam dangerously
during slewing operation. Also take care not to put your hands or head out through the open
door during crane operation.
Always shut and lock the door while driving on roads.
Do not hang on to the door when getting on or off the cab.
(4210-0003-1E)
- 17 -
(2) Seat
Adjust it to the easiest position for you to operate the controls.
It is dangerous to adjust the seat while you are operating the crane.
(8210-0021-0E)
1) Headrest
Sit in the seat and adjust the height of the headrest.
Press the knob while adjusting for height.
2) Reclining lever
Sit in the seat and adjust the reclining angle of the seat-back.
Pull the reclining lever and adjust using your body weight until
the angle is right.
- 18 -
6) Pocket
Documents etc. can be kept here.
- 19 -
(3) Seatbelt
Always fasten the seatbelt for safety while driving the machine.
1) How to put on the seatbelt
Press the removal button on the buckle to remove the tang
from the buckle.
Sit in the seat and insert the tang into the buckle and push
until it clicks.
Pull the seatbelt as far as your hip and adjust the fastening
pulling the belt end through the tang.
- 20 -
After you finish work, close the window firmly until it locks.
If you slide the window very rapidly, you could break the lock, so slide it slowly.
If you open the window during crane operation, do not put your hands, head etc. through the
open window.
Your hands, head etc. could be caught in the derrick cylinder or boom.
(541A-0027-0E)
(7) Sunshade
When using the sunshade, make sure that it does not come out of
its rails. Also, make sure that the locking mechanism is fully
latched.
- 21 -
If a fuse blows, investigate the cause with the starter switch in the "OFF" position. After
checking that there are no short circuits in the wiring, replace the blown fuse with a spare fuse
of the same capacity.
Never use a fuse with a higher capacity than specified or a wire, etc.
(8230-0025-0E)
(10) Holders for the rated lifting capacity chart and instruction manual
- 22 -
(11) Keys
- 23 -
NOTE
The lighter operates on 24V.
Do not use the socket as a power source for anything other than the lighter.
The metallic part of the lighter becomes hot, so do not touch the metallic part when lighting a
cigarette.
(541A-0032-1E)
(2) Ashtray
When cleaning it, pull it toward you with pressing down the
stopper and remove.
OFF;
In this position, the key may be inserted and withdrawn and the power to the radio etc. is cut off.
If you leave the operator's seat, take the key out.
When you turn the key to OFF to stop the engine, it takes 4 5 seconds for the indicator lamps
to go out, even if the engine has stopped. This is for circuit protection and is quite normal.
(541A-0033-2E)
- 24 -
ACC;
The engine stops in this position. You can use the radio etc.
If you use the radio or other accessories for long periods while the engine is stopped, the battery
will run down. Do not use the radio etc. for long periods.
(541A-0034-1E)
ON;
Do not leave the key in this position for a long time when the engine is not running as this can
run down the battery.
When the starter switch is turned to the "ON" position, the lamps on the cluster meter panel
and on the switch panel will all light for three seconds and a buzzer will sound. This indicates
that the duplex communications system check is running. If no problem is detected, normal
operation will begin automatically, but if an error code is displayed, refer to the "inspection
and servicing section" to find what the error code means. In particular check that there are no
error messages displayed before you start the engine.
(541A-0035-2E)
START;
You can start the engine in this position. Once the engine has started, let go of the key.
It will return to the "ON" position automatically. (The engine starts only when the shift lever is in the
"N" position.)
- 25 -
Do not press the washer switch for more than 15 seconds continuously at one time. If you keep
pressing the switch for a long time, the pump could break down. Do not press the switch if the
washer tank is empty as this could burn out the pump.
(591A-0081-0E)
NOTE
Use the lever on the fan to turn oscillation on and off.
(3) Defroster switch
Use this switch to defrost the windscreen and side windows.
- 26 -
- 27 -
5) To turn the radio OFF, turn the "VOL" knob to the left until it
clicks.
- 28 -
Pressing the "AST" button for less than 2 seconds will cause the
radio to play each preset station for 5 seconds each. Pressing the
button again returns it to the normal mode (Preset scan function).
- 29 -
- 30 -
Be sure to ventilate by opening a window before operating the air conditioner while parked in
hot weather.
(611A-0011-0E)
- 31 -
If the air inside the cab becomes dirty, such as with cigarette smoke, open the window.
If the temperature controller is set to "Max" and the fan controller to "Low", when the
compressor rpm is high or humidity is high, frost may form on the cooling system and reduce
the air flow.
If this occurs, moving the temperature controller to the lowest setting (while maintaining air
flow) will remove the frost.
(611A-0012-0E)
- 32 -
If a fuse blows, investigate the cause with the starter switch in the "OFF" position. After
checking that there are no short circuits in the wiring, replace the blown fuse with a spare fuse
of the same capacity.
Never use a fuse with a higher capacity than specified or a wire, etc.
(8230-0025-0E)
- 33 -
Diagnostic indicator
Engine control
lamp
warning lamp
Lights
Flashes rapidly
(every 0.5 seconds)
Buzzer
Rapid intervals
(every 0.5 seconds)
No sound
(491A-0036-0E)
Do not operate the machine when the red diagnostic indicator lamp is lit.
When the orange diagnostic indicator lamp is lit, it is possible to drive in the backup mode,
but it cannot be controlled properly. Therefore, only drive for emergency purposes.
Then contact your authorised KATO dealer for instructions as soon as possible.
(491A-0005-0E)
Due to the danger of rotating parts, such as the cooling fan and belts, only open the engine
cover when the engine is stopped.
When opening the engine cover, be careful of being burned by a hot engine cover, engine, or
muffler cover. The engine cover itself may become very hot immediately after operating the
engine.
Therefore, make sure the engine has cooled down sufficiently before opening the engine cover
to inspect the engine.
Leaving the engine cover open can be dangerous as it may close unexpectedly from wind
gusts or other causes.
When opening the engine cover, open it completely without stopping part way.
Do not open the engine cover in strong winds.
(591A-0083-1E)
Close and lock the engine cover before driving or operating the crane.
Be careful not to pinch hands or other body parts when closing the cover.
(541A-0039-1E)
- 35 -
Due to the danger of rotating parts, such as the cooling fan and belts, only open the engine
cover when the engine is stopped.
When opening the engine cover, be careful of being burned by a hot engine cover, engine, or
muffler cover. The engine cover itself may become very hot immediately after operating the
engine.
Therefore, make sure the engine has cooled down sufficiently before opening the engine cover
to inspect the engine.
Leaving the engine cover open can be dangerous as it may close unexpectedly from wind
gusts or other causes.
When opening the engine cover, open it completely without stopping part way.
Do not open the engine cover in strong winds.
(591A-0083-1E)
Before driving or operating the crane, tighten the attachment screws of the engine inspection
cover securely.
(491A-0007-0E)
- 36 -
WARNING
4. Safety signs
(611A-0015-0E)
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)
(1) Superstructure
- 37 -
WARNING
[5]
Content: Notes for the rated lifting capacity chart
Location: Inside the cab
Part No.: 611-75105001
[6-1]
Content: Notes for crane operation
Location: Inside the cab
Part No.: 611-75106000
- 38 -
WARNING
[2]
Content: How to connect the overhoisting detector
wiring connector
Location: Left side of the boom top
Part No.: 421-75710000
[6-2]
Content: Attaching the safety rope for stowing jib
Location: Right side of the boom base
Part No.: 899-81405772
[8]
Content: Precautions when driving and handling the
brake lock
Location: Inside the cab
Part No.: 611-75108000
[9]
Meaning: Do not allow anybody, even other site workers,
to pass under the suspended load.
Location: Underside of the boom base
Part No.: 161-74815001
- 39 -
WARNING
[10]
Content: How to connect the overhoisting detector
wiring connector (for the jib)
Location: Left side of the jib top
Part No.: 899-81600782
[13]
Content: Exhaust gas hazard
Location: Inside the cab
Part No.: 611-75113000
[16]
Content: Check list for outrigger setting
Location: Inside the cab
Part No.: 611-75116001
[21]
Content: Note for the rope retaining pin
Location: Left side of the rooster sheave
Part No.: 899-81405812
- 40 -
WARNING
[23]
Content: Insert the jib offset pin from the inside to the
outside and fasten it with the quick pin.
Location: Left side of the jib top
Part No.: 161-75115001
[32]
Meaning: Take care not to trap fingers, arms, head or
any other parts of the body in the sheave.
Location: Top surface of the table
Part No.: 161-74814001
[39]
Content: Warning of suspension lock release with the
outriggers extended
Location: Inside the cab
Part No.: 371-75118001
[40]
Content: Pr eca u t ion w hen goi ng d ow n hill a nd
overrunning
Location: Inside the cab
Part No.: 371-75119001
[55]
Content: Warning when handling the accumulator
Location: Near the accumulator
Part No.: 707-75109001
- 41 -
WARNING
[56]
Meaning: Operation prohibition
Part No.: 707-75118001
[62]
Meaning: Beware of falling. Climb up and down with
care.
Location: Left and right sides of the table
Part No.: 001-81302010
[63]
Meaning: Always keep the instruction manuals in the
cab and check their contents frequently.
Be sure to read the instruction manuals carefully
and familiarise yourself with the contents before
operating the crane.
When you cannot understand how to manipulate
or deal with the crane during working, check
and read the instruction manuals repeatedly.
Location: In the crane operation cab where the instruction
manuals are kept
Part No.: 001-81332001
[64]
Meaning: Do not allow anybody, even other site workers,
to enter the rear slewing radius.
Location: Left and right sides on the rear of the superstructure
Part No.: 001-81352015
- 42 -
WARNING
(2) Lower structure
[10]
Meaning: Do not touch the engine, its surrounding, the
fan belt or the rotating parts of the fan while
the engine is running or immediately after it
has stopped.
Location: Inside the engine cover
Part No.: 001-81332019
[11]
Meaning: Never bring any flame or source of ignition
near the fuel tank and the oil reservoir.
Location: Side of the fuel tank and inside surface of the
oil reservoir cover
Part No.: 001-81332005
- 43 -
WARNING
[12]
Meaning: The coolant will be hot while the engine is
running or immediately after it has stopped.
Do not open the radiator cap before the coolant
has had time to cool.
Location: Inside the engine cover
Part No.: 001-81332002
[13]
Meaning: Beware of high temperature.
If touched carelessly, you will get burned or
serious injury.
Location: Near the exhaust pipe
Part No.: 001-81332003
[16]
Content: Prohibition of high pressure cleaning
Location: Front side of the relay box
Part No.: 453-75006001
[30]
Content: Precaution when operating the outriggers
Location: Inside the cover of the outrigger control panel
Part No: 233-75111001
[31]
Meaning: Climbing prohibition
Location: Top surface of the engine cover
Part No.: 001-81332011
- 44 -
WARNING
[38]
Content: Precautions on handling the battery
Location: Top surface of the batteries
Part No.: 707-75122001
[41]
Meaning: Do not use the outriggers to climb onto or off
the machine, or climb onto or off the outriggers
themselves.
Location: Side of each outrigger beam
Part No: 161-74806001
[42]
Meaning: Beware of falling. Climb up and down with
care.
Location: Both sides of the lower structre
Part No.: 161-74809001
- 45 -
WARNING
(541A-0042-0E)
When you get on and off the machine, face toward it and use the hand grips and steps to
support yourself.
Keep at least three points of support at all times on the hand grips and steps.
Do not use the control levers to hold on to.
Jumping onto or off the machine can cause injury.
It is also dangerous to get on or off the machine while it is in motion.
The hand grips, steps, etc. are slippery when they have mud or oil on them, so wipe them
clean before you get on or off the machine.
If attachment bolts of hand grips or steps are loose, tighten them securely before you get on of
off the machine.
(541A-0043-2E)
- 46 -
WARNING
(611A-0059-0E)
Do not carry any other fuel or fuel container than the fuel tank.
Always fill with specified fuel.
If you use a non-recommended fuel, performance will be impaired and a major accident could
result.
Stop the engine and turn the starter switch to OFF before you start filling.
Stop the engine in a well ventilated place and check that there is nobody inside before you
start filling.
Do not allow any fire or source of ignition nearby.
Take care not to spill fuel on hot areas.
If any fuel spills, wipe it up immediately.
As soon as you finish filling, close the filler cap.
(611A-0078-0E)
NOTE
Fuel for fillingDiesel fuel
Fuel tank capacity 300L
- 47 -
WARNING
(1) Engine fuel and filter maintenance
Only use specified fuel.
Using anything other than the specified fuel is not covered by the warranty, of course, but also could cause a major
malfunction. In addition, the appropriate fuel filter element for this engine has been specified as well, so it is
important to use genuine KATO fuel elements.
(2) Fuel
1) Selecting fuel
Diesel engine fuel should satisfy the following criteria.
Does not contain even fine dust
Has adequate viscosity
Has a high cetane number
Has good low-temperature flowability
Has low sulfur content
Has low carbon residue
Use standard automotive diesel fuels (JIS K 2204, EN590, ASTM D975, GOST R52368, GB252) that meet the
requirements above.
Never use diesel fuel that does not meet the requirements. Doing so may prevent maximizing the
functionality and performance of the engine and may cause engine malfunction or failure.
Any malfunction or failure resulting from using non-specified fuel is not covered by the
warranty.
(611A-0080-0E)
- 48 -
(541A-0054-0E)
If the buzzer continues to sound with all warning lamps lit or all warning lamps do not light with
no buzzer, stop the engine start procedure and contact your authorised KATO dealer.
(121A-0077-0E)
If the engine has trouble starting in cold weather etc., do not run the starter motor for more than
15 seconds continuously as it could burn out.
If the engine does not start within 15 second, release the key and wait for at least 20 seconds
before trying again.
(541A-0057-0E)
2) In cold weather
To improve starting performance in cold weather, turn the starter switch to the "ON" position. The preheat
indicator lamp will light and engine preheating will start. When the indicator lamp goes out ( after
approximately 10 seconds), the engine is ready to start.
If the engine does not start, turn the key beck to the "OFF" position and wait for about one minute before
trying the procedure in above.
- 49 -
Raising the engine speed without doing warm-up running for the engine and torque converter
could cause a seizure, fast wear, damage etc. due to poor lubrication (from high oil viscosity).
Properly perform warm-up running and confirm that the needle of the engine water temperature
gauge is above point "C", then start to drive or set the PTO switch to the "ON" position.
(541A-0058-0E)
- 50 -
(2) When you stop the machine, bring it to a stop, lift your foot from the accelerator pedal and leave the engine idling
for about five minutes to cool down.
If you switch the engine off immediately after bringing the machine to a stop, the temperature of
coolant will rise, possibly causing seizure of pistons and other sliding parts in the engine and
further seizure in the turbocharger bearing because the supply of lubricating oil to the
turbocharger stops.
(541A-0061-0E)
(3) Turn the starter switch to the "ACC" position to stop the engine.
Once the engine has completely stopped, turn the starter switch to the "OFF" position and take the key out.
NOTE
If the machine is going to the left parked for a long time, the area of the tire in contact with the ground will
become flattened, creating what is known as a "flat spot". This can cause uncomfortable vibration during later
driving, but the tire will regain its original shape after driving for some distance, so there is cause for concern.
The formation of flat spots can be avoided by using the outriggers to jack up the machine so that the tires are off
the ground.
- 51 -
(541A-0062-0E)
Use of a non-recommended fuel will reduce performance and could cause a major accident.
Such problems are not subject to guarantee.
(541A-0065-1E)
Outside air
temperature at
start time
Oil viscosity
20
C 40
C
10
C 40
C
SAE 10W-30
SAE 20W-40
(541A-0066-0E)
Outside air
temperature
SAE No.
20 30
C
0 50
C
90
140
(8230-0166-0E)
- 52 -
(5) Batteries
Normally battery electrolyte does not freeze in cold weather, but if the battery charge is low, some freezing is
possible. A battery which has frozen is permanently unusable, so take precautions to maintain the battery
temperature.
- 53 -
MEMO
- 54 -
(611A-0016-0E)
Driving operation
9. Driving safely
214521
55
Cautions on breakdown 61
10-2
10-3
10-4
10-5
63
11-2
Switch panel 75
11-3
11-4
11-5
Steering column 88
11-6
87
94
12-1
94
12-2
General driving 96
12-3
Specialized driving 98
WARNING
9. Driving safely
(0099-0227-0E)
In addition to the precautions listed below, always drive safely and carefully, observing basic precautions and driving
etiquette.
(1) Do not keep anything other than the standard equipment on the
body of the machine when driving on the roads.
Additional objects on the machine could cause accidents or
damage, so keep to the standard driving position and equipment.
(2) Set the "PTO switch" to the "OFF" position and return the
machine to the driving position before driving on the roads.
Never operate the crane in any way when driving on the roads.
- 55 -
WARNING
(5) Do not allow extra passengers on the machine
Never allow more people in the cab while driving than the
number described in the machine specifications.
Driving with excess people in the machine can cause accidents.
(6) Keep the working lamps off when driving on the roads
Keep all working lamps and other lamps on the crane switched
off when driving on the roads at night. Use of these lamps
disturbs other drivers, and it may be forbidden by law. Follow
the relevant safety regulations and laws in the country of use.
(7) Coasting with the engine turned off is hazardous and should
never be attempted.
If the engine is switched off, the steering will be inoperable and
the compressed air tank will not be charged with air, which can
disable the brakes dangerously.
- 56 -
WARNING
(9) Pay attention to road surface conditions
Drive slowly and cautiously for maximum safety on snowcovered or icy roads, irregular road surfaces, inclined ground,
roads sloping up and down etc.
Check the road surface before you drive over it, and if
necessary, fit tire chains or improve the road surface.
(11) Take care around train power cables and bridge spans
When driving, pay close attention to the distance from the
machine in front, machine height and width and distance to any
obstacles.
In particular, check the height and width of the opening in
advance when driving under power cables or bridges.
- 57 -
WARNING
(13) Steering control
This machine is equipped with fully hydraulic power steering.
This makes the steering wheel lighter to turn, but means that it
does not return to the center when released. After turning the
steering wheel to either side, return it to the center position by
hand. Do not keep the steering wheel at either full lock for long
periods.
- 58 -
WARNING
4) While driving, keep checking the air pressure gauge which
displays the air pressure for the foot brake.
Reduced air pressure leads to a large reduction in braking
capacity, so close observation is required. If the low air
pressure warning lamp lights and an intermittent buzzer
sounds while the machine is in motion, bring the machine to
rest in the nearest available safe place and inspect the air pipe
system.
5) Do not drive with your foot resting on the brake pedal. Doing
so could increase the brake and brake fluid temperature and
result in "fading or vapor lock", which could cause an
accident.
6) Braking on a downhill
Be particularly careful braking when going downhill.
Excessive braking can reduce the air pressure and cause the
brakes to stop working. Reduce speed adequately by
downshifting or using the exhaust brake. When downshifting,
downshift one gear at a time. Downshifting 2 or 3 gears at
once could damage the engine, transmission or other drive
equipment.
- 59 -
MEMO
- 60 -
(541A-0072-0E)
(3) You must place blocks etc. as chocks in front of the wheels.
(4) Investigate the cause of the breakdown and repair it if you are able to do so yourself. While doing so, always pay
attention to your surroundings and particularly to passage of traffic to safeguard yourself.
If the breakdown occurs in a tunnel, even a simple repair can be dangerous and can lead to serious secondary
damage, so never attempt any repair within a tunnel.
(5) If you cannot repair the breakdown, contact your authorised KATO dealer to order a repair.
- 61 -
(3) Ignite the flare by removing the end cap and rubbing the igniter
material on the cap against the tip of the flare, being careful to
hold them as far away as possible. When ignited, the flare will
emit a flame about 15 cm long.
Be sure to read the instructions indicated on the label affixed to the flare case before using a
flare.
The flare should be used within 4 years. Be sure to replace the flare with a new flare by the
"use by" date indicated on the label affixed to the flare case.
When igniting a flare, keep it away from your body, anyone nearby, and flammable materials.
When the flare ignites, it will emit a flame about 15 cm long.
Place the ignited flare away from flammable materials and at a location that provides other
motorists a safe stopping distance.
Do not use the flare inside a tunnel or other enclosed location. The smoke may impair
visibility.
Never let children or other unauthorized people touch the flare.
Only use the flare when necessary.
(541A-0074-0E)
NOTE
Use adequate caution when using the flare.
The flare is mounted on the left side of the operation cab.
- 62 -
Violent operation of the shift lever or the starter switch during evasive maneuvers can cause
sudden highly dangerous failure of the emergency power steering.
(541A-0274-0E)
NOTE
If you move the shift lever to "N" during evasive maneuvers, the emergency power steering will be disabled. Be
sure to move the shift lever to any position other than "N".
(2) After bringing the machine to a stop, move the shift lever to "N", apply the parking brake and move the starter
switch to "OFF". If you have to park by the roadside, put out signs etc. to indicate to other drivers that the machine
has broken down.
- 63 -
- 64 -
If the AT/M malfunction warning lamp lights, park the machine in a safe place immediately.
After stopping in a safe place, stop the engine then start it again. If the AT/M malfunction
warning lamp is still lit, leave the machine where it is and contact your authorised KATO
dealer for instructions.
When the AT/M emergency switch is switched to the "emergency" side to continue to drive
unavoidably, normal driving with the shift lever in the "D" range (automatic gear change) is
impossible, so use manual gear change to continue driving. You must choose the optimum
gear for the speed range you are driving in at any time.
(It is impossible to use manual gear change in the low range.)
Manual shift position guidelines for machine speeds (high range)
Position
Speed range
0 18km/h
1826km/h
2638km/h
3849km/h
(121A-0012-1E)
- 65 -
(2) After making the above connections, increase the speed of the assisting machine engine slightly.
(3) Refer to the section "Starting the engine" for details of engine starting.
(4) Once the engine starts, disconnect the booster cables in the reverse order from the connection order above. Have
the battery completely recharged or replaced by a gas station or your authorised KATO dealer as soon as possible.
If you make a mistake in connecting the booster cables, the following problems could result, so
work with care.
Serial connection with an assisting machine using 24V
Voltage will exceed 24V, which will burn out the starter motor and could cause a fire.
(541A-0080-1E)
When you have the engine idling and open the engine cover, take care to avoid burns from the
engine cover which could be very hot. Also take care to keep your fingers clear of the rotating
section on the V-belt, fan belt etc. which could trap them.
(541A-0081-0E)
- 66 -
Do not try to fill the radiator with coolant before the water already in the radiator has had time
to cool. Sudden cooling due to the addition of coolant can crack the engine block.
The inside of the radiator is under pressure. If you open the cap carelessly, steam and hot
water could spurt out, causing serious burns. To avoid spurting steam etc., allow the radiator to
cool and cover the cap with a cloth etc. before you open it.
(541A-0082-1E)
Contact your authorised KATO dealer to have it make the necessary preparations for towing,
then proceed cautiously with towing according to the applicable laws.
Exercise extreme caution when towing, keeping your speed low and constant.
Sudden change of speed could break the "tow bar" or the "wire rope".
If the engine has broken down, remove the propeller shaft between the transmission and the
axle before towing the machine. If the propeller shaft remains in place, towing could damage
the torque converter.
Pay careful attention to the air tank pressure when towing. If the pressure is low, the braking
effect will be lost or the parking brake will be applied suddenly.
(541A-0083-1E)
(1) If the cause of the breakdown is not the engine and the engine may
be used without causing problems:
1) Shift lever "N"
2) Start the engine.
3) Hazard warning switch "ON"
4) Allow an adequate distance between the towed and towing
machines and join the machines with a strong "wire rope" or
"tow bar" etc.
5) Attach a red flag etc. to the front and back of the broken-down
machine to show other drivers that this machine is under tow.
6) Position a guide machine in front of the towing machine and a
supervising machine behind the towed machine.
7) "Release" the parking brake and remove the "chocks" in front of
the wheels.
8) Begin towing.
- 67 -
Then take the same actions as 4) 8) described in (1) above " If the cause of the breakdown is not the engine and the
engine may be used without causing problems".
If you do not provide the broken-down machine with compressed air, the parking brake cannot
be released and the foot brake will not work during towing.
Supply compressed air until the "low air pressure warning lamp" goes out and remains unlit.
Be sure the compressed air supply hose does not get caught in the tires or touch the ground.
If the engine breaks down, the alternator will no longer supply the battery with electricity. Be
sure the battery has an adequate charge.
If the battery voltage is too low, the parking brake cannot be released. If the low-voltage
warning buzzer sounds while being towed, immediately stop towing the machine before the
parking brake is applied.
(541A-0084-2E)
- 68 -
(061A-0012-0E)
Familiarize yourself with the names and operation methods of the devices such as levers, meters, switches etc. before
you start to drive.
(2) Tachometer
Indicates the engine revolutions per minute.
- 69 -
When the needle is pointing 0kPa (0kg/cm2) or below, stop the engine and contact your
authorised KATO dealer.
(541A-0087-1E)
- 70 -
If there is any problem with the engine oil pressure sensor or its wiring, the lamp will flash.
(541A-0088-0E)
When the AT/M malfunction warning lamp flashes or lights, stop the machine in a safe place and
contact your authorised KATO dealer quickly.
(541A-0089-1E)
- 71 -
When the warning lamp flashes at 0.5 seconds intervals, drain water from the fuel filter.
If there is a problem with sensors or wiring, the warning lamp flashes. (1 second intervals)
(511A-0012-0E)
- 72 -
If the indicator lamp lights, clean or replace the air cleaner filter element.
(541A-0093-0E)
Lights
Warning buzzer
Rapid intervals
(every 0.5 seconds)
No sound
If the engine control warning lamp lights or flashes, immediately move to a safe place and stop
the machine, then call the closest authorised KATO dealer and follow their instructions.
If the lamp flashes, driving is still possible in the backup mode, but the engine is not being
controlled properly, so operate the machine very carefully and only for emergency purposes.
If you continue to drive with the lamp lit, the engine could be damaged.
(491A-0018-0E)
If the warning lamp is ignored and the machine continues to be operated in the overrun state, a
warning buzzer sounds to indicate the condition.
Ignoring the warning buzzer and operating the machine in the overrun state could result in
engine, propeller shaft, or other drivetrain component damage or brake lining wear and could
cause a serious accident. Therefore, if the warning lamp lights, slow down promptly.
(541A-0095-2E)
- 73 -
If the volume of brake fluid has decreased without any external leakage, the pads of the disk
brakes may be excessively worn, so check the pads as well as adding the brake fluid.
(491A-0019-0E)
If the brake fluid level is appropriate, this lamp lights while the parking brake is engaged. If you move the shift
lever to any position other than "N" while the parking brake is engaged, the lamp flashes slowly at 1 second
intervals and the continuous warning buzzer sounds.
(18) Rear steering lock release indicator lamp
This lamp lights while the rear steering lock is released.
If this lamp lights or flashes while you are driving on the roads,
stop the continuous machine immediately and contact your
authorised KATO dealer.
When the rear steering emergency switch has been switched Rapid flashing
(0.5 seconds intervals)
When a malfunction occurs in rear steering-related devices Slow flashing
(1 second intervals)
(541A-0096-0E)
- 74 -
- 75 -
- 76 -
When no error is displayed or the torque converter oil temperature is not displayed, press the outrigger extension
and retraction switches simultaneously for two seconds or more to display the current hydraulic oil temperature
irrespective of any alarms.
2) When the PTO is "OFF" (for driving on roads)
When the battery voltage falls below the rated voltage (20V), the battery charge indicator lamp on the cluster
meter panel starts to flash and the warning buzzer sounds.
At the same time, the current value is displayed and the battery voltage indicator lamp lights.
When no error is displayed or the torque converter oil temperature is not displayed, press the outrigger extension
and retraction switches simultaneously for two seconds or more to display the current battery voltage irrespective
of any alarms.
- 77 -
--- .
NOTE
When the maximum steering angle "9" is displayed, it will flash at 1 second intervals.
- 78 -
1) If the four-wheel drive indicator lamp is not lit, the machine is in two-wheel drive mode. Press the switch to
switch to four-wheel drive. When you press the switch, the confirmation tone "pip" will sound and the fourwheel drive indicator lamp will flash (mode shifting) and light steadily, indicating that the machine is in fourwheel drive mode.
2) To shift to two-wheel drive, press the switch while the four-wheel drive indicator lamp is lit. The confirmation
tone "pip" will sound and the four-wheel drive indicator lamp will flash (mode shifting) and go out, indicating
that the machine is back in two-wheel drive mode.
NOTE
When low range has been selected, two-wheel drive is unavailable. If you try to use two-wheel drive in low
range, the misoperation warning buzzer will sound.
- 79 -
1) When the low range indicator lamp is unlit, the transmission is in high range. Press this switch in this state to
switch to low range. The confirmation tone "pip" will sound and the low range indicator lamp will flash (mode
shifting) and then light steadily, indicating that the machine is in low range.
2) Press the switch while the low range indicator lamp is lit to switch to high range.
The confirmation tone "pip" will sound and the low range indicator lamp will flash (mode shifting) and go out,
indicating that the machine is in high range.
NOTE
If you switch the high/low speed switch to low range while the machine is in two-wheel drive, it will
automatically switch to four-wheel drive.
- 80 -
The brake lock must not be used as a substitute for the parking brake.
The brake lock can only be used while the engine is running and the parking brake is engaged.
(541A-0100-0E)
If air pressure inside the compressed air tank drops while the brake lock is engaged, the
warning buzzer sounds. Raise the engine revolutions to increase pressure in the compressed
air tank.
When the engine is switched off, air is not supplied to the compressed air tank. If the pressure
inside the compressed air tank falls for some reason or other, the brake lock may release itself.
Do not leave the machine unattended while the brake lock is engaged.
(541A-0101-1E)
If you release the parking brake while the brake lock is engaged, the brake lock indicator lamp
will flash.
Release the brake lock first and then proceed to release the parking brake.
(541A-0102-1E)
- 81 -
When you lock or release the suspension, the following conditions must be satisfied.
Suspension control is only possible when thesuspension operation OK indicator lampis lit.
- 82 -
1) Suspension lock
Set the suspension lock/release switch to the "suspension lock"
side and use the suspension retraction switch to retract the
suspension cylinders fully. When you release the switch, the
suspension cylinders will be held at that position and the
suspension locked indicator lamp will light.
The suspension lock cylinders will only be locked if they are fully retracted.
(541A-0108-1E)
If you set the PTO switch to the "ON" position while the suspension lock is released (for the
driving position), the suspension cylinders will be locked at that position.
Even if you set the PTO switch to the "OFF" position at this status, the suspension lock will not
be released.
At this time the suspension locked indicator lamp will flash rapidly.
Move the suspension lock/release switch to the "suspension lock" position and then move it to
the "suspension lock release" side to release the suspension lock.
(611A-0060-0E)
- 83 -
- 84 -
If the compressed air pressure is below the rated pressure, the parking brake will not release
even if the switch is moved to the release position.
If you try to drive while the parking brake id engaged, the parking brake indicator lamp will
flash and the warning buzzer will sound.
(541A-0111-0E)
Speed range
Speed 1
018km/h
Speed 1 2
026km/h
Speed 1 2 3
038km/h
Speed 1 2 3 4
049km/h
Reverse speed 1
026km/h
(511A-0016-0E)
- 85 -
If you move the shift lever to any position other than "N" while the machine is at rest, it may
start to move even if you are not pressing the accelerator pedal. Always keep the brake pedal
pressed down when changing gear while the machine is at rest.
When the machine is lifted off the ground on the outriggers and the parking brake is engaged,
the shift lever should only be in the "N" position.
Changing to any other position could break the differential gear.
Only change gear while all wheels are on the ground.
(541A-0115-1E)
NOTE
If you move the shift lever to any position other than "N" while the parking brake is engaged, the warning
buzzer will sound.
NOTE
If you shift down but do not reduce speed to a suitable level for that gear, the transmission will not shift down to
the lower position. Also on downhill slopes with speeds 1, 2 or 3 selected when the driving speed exceeds the
speed range for the selected gear, the transmission will automatically shift up one position. In this case, the effect
of engine brake will be lost. Take care to keep the machine's speed within the range for the selected shift
position.
NOTE
If the AT/M malfunction warning lamp lights or flashes, the shift lever will change over to manual shift by
switching the AT/M emergency switch to the "emergency" side. Refer to the section "Handling a malfunction in
the automatic transmission system".
(2) Rear steering switch (self-reset type)
When the rear steering lock is released (the rear steering lock
release confirmation indicator lamp is lit), moving the rear steering
switch will steer the rear wheels in the direction the switch is
moved for as long as it is held in that direction.
NOTE
If you try to move the rear steering switch while the rear steering
is locked, misoperation warning buzzer will sound.
- 86 -
Before operating the accelerator pedal, confirm that the needle of the engine water temperature
gauge is above point "C".
Operating the accelerator pedal while the engine coolant temperature is low could cause a
seizure, fast wear, damage etc. due to poor lubrication (from high oil viscosity) of the engine and
torque converter.
Properly perform warm-up running.
(541A-0158-2E)
If the air pressure in the foot brake circuit falls below the rated pressure (500900kPa (59kgf/
cm2)), the available braking force will be inadequate. Use the air pressure gauge on the cluster
meter panel to check the compressed air pressure while driving. When driving down a long slope,
use the engine brake and the exhaust brake and avoid overusing the foot brake.
If air pressure in the foot brake circuit falls below 500kPa (5kgf/cm2), the "low air pressure
warning lamp" on the cluster meter panel will light and an intermittent buzzer will sound to alert
the driver to the danger of brake failure. Stop the machine and raise the air pressure to within the
rated range before driving on.
(611A-0068-0E)
- 87 -
Only adjust the steering wheel position while the machine is at rest.
Always fasten the lock lever securely after adjusting the angle and height of the steering
wheel. If the lever is loose, the steering wheel could move unpredictably while the machine is
in motion and cause an accident.
(541A-0120-1E)
- 88 -
Wiper action
OFF
Stop
INT
Intermittent
LO
Slow
HI
Fast
(541A-0121-1E)
Do not press the washer switch for more than 15 seconds continuously at one time. If you keep
pressing the switch for a long time, the pump could break down. Do not press the switch if the
washer tank is empty as this could burn out the pump.
(591A-0081-0E)
- 89 -
The exhaust brake will not act when the shift lever is in the "N" position.
(541A-0122-0E)
NOTE
The exhaust brake acts when the machine is driving at 10km/h or more.
NOTE
When the exhaust brake acts, the "exhaust brake indicator lamp" on the cluster meter panel will light.
(2) Turn signal and dimmer switch
This switch incorporates the following switching functions.
Turn signal switch
Lighting switch
Dimmer switch
- 90 -
2) Lighting switch
The knob on the end of the lever is the lighting switch.
Turn the knob counterclockwise to light the lamps as described
below according to the switch position.
Lamp
Switch position
Clearance lamps
Tail lamps
License plate lamp
Cluster meter panel lamp
Switch panel
Night illumination of driving switches
Headlamps
OFF
Off
Lit
Off
Lit
(611A-0170-0E)
3) Dimmer switch
Move the lever forward and backward to work the dimmer
switch.
High beam Move the lever forward with the lighting
switch in position 2 to turn the headlamps to
high beam. The high beam indicator lamp
(
- 91 -
NOTE
It is impossible to use manual gear change in the low range.
If the AT/M malfunction warning lamp lights, park the machine in a safe place immediately.
After stopping in a safe place, stop the engine then start it again. If the AT/M malfunction
warning lamp is still lit, leave the machine where it is and contact your authorised KATO
dealer for instructions.
When the AT/M emergency switch is switched to the "emergency" side to continue to drive
unavoidably, normal driving with the shift lever in the "D" range (automatic gear change) is
impossible, so use manual gear change to continue driving. You must choose to optimum gear
for the speed range you are driving in at any time.
(It is impossible to use manual gear change in the low range.)
Manual shift position guidelines for machine speeds (high range)
Position
Speed range
0 18km/h
1826km/h
2638km/h
3849km/h
(121A-0012-1E)
(541A-0077-3E)
- 92 -
During normal driving the rear steering emergency switch should be in the "central" position. Do
not drive with it in the "release" position.
(541A-0025-0E)
When you return the rear steering emergency switch back to its central position (to cancel
emergency operation) and return to automatic, the rear steering lock release indicator lamp may
continue flashing on the cluster meter panel if the rear steering lock/release switch and the lock
release condition do not match. Set the rear steering lock/release switch again. If in emergency
mode lock and release cannot be confirmed when the rear steering emergency switch is returned
to its central position, error No. 2412 will be displayed.
(611A-0061-0E)
When using the rear steering emergency switch, the rear steering lock release indicator lamp
on the cluster meter panel inside the cab will flash rapidly (every 0.5 seconds) to indicate that
"rear steering emergency mode" is in effect.
The "rear steering emergency mode" will remain in effect for two seconds after the rear
steering emergency switch is returned to its central position.
Steering with the machine parked is impossible while you are using the rear steering
emergency switch.
Do not use the rear steering switch while the rear steering lock is engaged.
(541A-0127-1E)
NOTE
The "rear steering locked lamp" on the rear steering emergency switch panel can be used to check the condition
of the rear steering lock pin.
Unlit:
Lock confirmed
Release confirmed
(371A-0038-0E)
Check the relevant safety regulations and laws in the country concerned before you drive this machine on the road.
- 94 -
(11) Return the suspension from locked to free state. The procedure for returning the suspension to the free state is as
follows.
Move the shift lever to the "N" position.
Check that the suspension operation OK indicator lamp is lit.
Push the suspension lock/release switch to the lock release side to extend the suspension cylinders to the
position required for driving.
The machine should be on the firm level ground for suspension operation.
(541A-0130-0E)
Do not return the shift lever to the "N" position while the machine is in motion.
(541A-0134-0E)
NOTE
If you move the shift lever to a lower position before decelerating to the shift down speed, the transmission will
not shift until the speed has reduced sufficiently.
(2) Driving on slopes
1) When climbing a slope, move the shift lever to D, 3, 2 or 1 depending on the gradient.
2) When driving down a slope, take great care not to deplete the foot brake force because loss of brake force is
extremely dangerous. Use the foot brake effectively in short bursts as necessary to minimize heating. At the
same time, shift down to take advantage of engine braking and use the exhaust brake for efficient speed
reduction. If you drive with your foot resting constantly on the brake pedal, an accident is only a matter of time.
- 96 -
- 97 -
Before driving on the road, check that the lamps on the high/low speed switch and rear steering
lock/release switch and two/four wheel drive switch are not lit.
(611A-0027-0E)
- 98 -
Stop the machine before changing between high and low range.
If you change between ranges when the machine is moving at 3km/h or more, the range gear
could be broken or damaged and the engine could overrun.
While switching between high and low range, the lamp flashes to indicate mode shifting in
process. Never start the machine moving while the lamp is still flashing as the gear could be
broken as a result.
(061A-0028-0E)
NOTE
The following are the available combinations of high/low range with two/four wheel drive.
High range + two-wheel drive
High range + four-wheel drive
Low range + four-wheel drive (automatic switching)
- 99 -
- 100 -
2) Steer the rear wheels by operating the rear steering switch in the direction you would like to turn. The rear
steering will function as long as the switch is held in that direction.
3) The direction of the rear wheels can be seen from the digital display on the switch panel.
When you drive, be especially careful that the direction in which you will drive is safe, and always be careful of
which way the rear wheels are pointed.
NOTE
Steering examples
- 101 -
- 102 -
NOTE
If the rear steering lock/release switch does not lock or release the rear steering automatically or the rear steering
switch does not move the rear wheels, use the rear steering emergency switch on the lower control panel of the
lower structure to temporarily switch the rear steering control to manual so that you can continue working.
(Refer to the section "Rear steering emergency switch".)
- 103 -
NOTE
The following are the available combinations of high/low range with two/four wheel drive.
High range + two-wheel drive
High range + four-wheel drive
Low range + four-wheel drive (automatic switching)
While switching between four-wheel drive and two-wheel drive, the lamp flashes to indicate
mode shifting in process.
Never start the machine moving while the lamp is flashing as the gear could be broken as a result.
(061A-0030-0E)
Stop the machine to change between four-wheel drive and two-wheel drive.
If it is difficult to switch, do so while driving at extremely low speed.
Changeover is not possible if the machine is moving at 3km/h or more. If you do so at 3km/h
or more, the misoperation warning buzzer will sound.
Four-wheel drive is provided for driving on unusual surfaces which are impassable when
using two-wheel drive.
Driving on roads for long periods using four-wheel drive imposes an excessive load on the
transmission and the axle reduction gear, causing increased tire wear and possibly breakdown
in the transmission and the axle reduction gear.
(061A-0031-1E)
- 104 -
(611A-0028-0E)
Crane operation
214521
13-2
13-3
129
14-1
14-2
14-3
137
15-1
15-2
15-3
15-4
16-2
16-3
16-4
16-5
16-6
152
17-2
17-3
17-4
170
172
18-2
18-3
18-4
18-5
Slewing 184
18-6
19-2
WARNING
(0099-0104-1E)
This section lists precautions you should observe when operating this crane.
Make sure you fully understand these points before you start operation and observe them to operate safely.
In this section, pictures which illustrate dangerous situations or working practices are marked with a large "" .
The illustrations in this section are intended to attract attention and supplement the main text.
They do not give a full and detailed account of the content of the text.
Further precautions may be necessary due to the attachments in use or the conditions of the site.
Observe the safety regulations and laws of the country where the crane is used.
(2) Check for the working position, roads and the presence of
obstructions
Finally before the operator starts work, he should check the
safety of the area with his own eyes.
- 105 -
WARNING
(4) Keeping good visibility
1) When you need to slew or reverse in areas of restricted
visibility, place a guide and a signaler and do as they instruct
you.
- 106 -
WARNING
(5) Precautions on working in the public road
Position a guide in the road and erect fences etc. to ensure the
safety of passing vehicles and pedestrians.
Further observe the safety regulations and laws of the country
where the crane is used.
(6) Maintain a good work site and environment for the crane.
If people or other machines enter the working area, they could
cause collisions or personal injury.
Before you start work, always check that your working area is
free of people and obstructions. Keep the working area a no
entry zone by placing fences or posting a supervisor.
- 107 -
WARNING
(8) Precautions when operating the crane near high-power
electromagnetic wave emitters
High voltages with painful and dangerous consequences can be
induced in the vicinity of radio and television transmitters and
radar stations. Contact the relevant authority before starting
work.
- 108 -
WARNING
(12) Stop work in strong winds
Loads of high volume or side area and long booms are subject
to strong wind loads due to wind pressure.
If the wind is strong and is received from behind the crane, the
wind load is added to the suspended load mass which can cause
the crane to tip over.
If a long boom derricked to a high angle is subjected to a strong
wind from the front, the crane can be tipped over.
If the wind has a gust speed of 10m/s or more, stop work
immediately, retract the boom and lower the load. If you are
working with a long boom or large load, stop work even if the
wind does not reach 10m/s.
- 109 -
WARNING
(4) Do not put flammable items in the toolbox
Do not put aerosol spray cans, paint thinner, or other dangerous
combustibles in the toolbox.
They could cause a fire.
- 110 -
WARNING
- 111 -
WARNING
(5) Sound the horn before you start the engine
Before you board the crane, check that there is nobody nearby.
When you are about to start the engine, sound the horn to warn
people nearby.
(6) Before you start the engine, check that all the levers, pedals and
switches are in their neutral or OFF positions.
Areas where soil under the road paving has been eroded by
water to leave a void
Areas where the soil is very dry but soft
Road shoulders or near construction excavations
Set the crane level with full consideration for the above points.
- 112 -
WARNING
2) Beware of buried objects
Before you start work, check with the firm in charge of the
site for the existence and location of buried objects such as
water and gas mains and high-voltage cable ducts.
- 113 -
WARNING
(3) Lock the suspension with the lock pins before setting the
outriggers.
- 114 -
WARNING
(7) Before beginning crane operation, lift the load off the ground to
gauge the working condition and confirm that the ground
supports the outriggers adequately. If an outrigger supervisor is
appointed to observe outriggers during operation, safety will be
enhanced.
- 115 -
WARNING
(3) Start and stop any lever operation gradually
Sudden starting, acceleration and stopping and other sudden or
violent operations are dangerous as they reduce the stability of
the load and cause the crane to break. Always operate the levers
and pedals smoothly and securely.
- 116 -
WARNING
(7) Never remove the jib
Operating the crane with the jib removed compromises the
safety factor and could cause the crane to tip over. The rated
lifting capacity chart for boom operations is based on the
assumption that the jib is stowed on the boom. Therefore, never
operate the crane with the jib removed.
(9) Only operate the crane while seated in the operator's seat.
Operating the crane by reaching in through the door or window
rather than while seated in the operator's seat is dangerous and
can cause accidents and personal injury. Always sit in the
operator's seat before you begin any operation.
- 117 -
WARNING
(11) Confirmation before lifting the load
Failure to check the following points could result in major
accidents such as dropping the load, damage to the boom or the
crane, or crane tip over.
Is the total mass of the load, the slings and the hook to be lifted
below the rated lifting capacity?
Is the number of parts of line on the main winding wire rope a
standard number according to the rated lifting capacity chart ?
Are the sling wire ropes placed correctly to hoist from above
the load center of gravity ?
Is the main winding wire rope hanging vertically ?
After the load leaves the ground, pause until it has stopped any
swinging and confirm that it is stable before you continue to
hoist.
(12) Arrange slings securely
If the slings are not fitted securely, the load can fall off or slip
out of the slings and fall down. Arrange slings securely with
attention to the following points.
The sling wire ropes or chains used to suspend the load from
the hook should be the right size and undamaged. Damaged
slings could break and drop the load. Arrange the slings so that
they do not interfere or tangle with each other.
- 118 -
WARNING
(14) Lift the load off the ground carefully
When the load is lifted, deflection of the boom increases the
working radius, which can result in overload. Hoist the load
vertically and pause briefly when the load is about 10
centimeters from the ground to confirm its sling and that there
is no overload. Then carry on hoisting.
(15) Never lift the load off the ground by derricking or extending the
boom
Do not hoist the load by derricking or extending the boom until
it is a few centimeters off the ground.
(16) Apply the drum lock when you hold the load suspended
If the load is held aloft for a long period by the brake alone, the
braking force can fade, allowing the load to fall. Apply the
drum lock to prevent the load from descending.
(17) Before moving your load sideways, check the safety of your
surroundings
People under the load or in contact with the superstructure
could be killed and other serious accidents could result.
While you are working, there should be a fence around the
slewing area and nobody else should be allowed into this area.
- 119 -
WARNING
(18) Do not move the suspended load above people's heads
Never pass a suspended load or hook over the heads of other
workers as this endangers their safety.
- 120 -
WARNING
(22) Never drag a load sideways, hoist it diagonally or drag it toward
the crane
Using boom lowering and derricking or winch operation to drag
the load sideways or hoist it diagonally causes a bending force
to act on the boom and can lead to damage of the boom and the
slewing mechanism or tipping the crane over.
Follow the appropriate instructions of the signaler to hoist the
load vertically.
- 121 -
WARNING
(2) Beware of overhoisting the hook
When the boom is lowered or extended, the hook is wound up,
possibly causing overhoisting and damage when the hook block
hits the boom top. Normally the overhoisting detector will act to
prevent this, but if the detector is inoperative and overhoisting
occurs, lower the hook to the proper position.
When a lifting load is overhoisted, the distance between the
load and the boom is reduced and the load can hit the boom and
damage it.
The size of the lifting load must also be taken into account.
(2) When lifting the load, pause briefly when it has just left the
ground to check for safety and then continue the operation.
(3) Do not unwind the winch so far that the hook touches the
ground
If you continue unwinding operation even after the hook
touches the ground, the wire rope can be tangled.
- 122 -
WARNING
(4) Never use the main and the auxiliary winches at the same time
If the main winch hook and the auxiliary winch hook are each
carrying one individual load, the boom and jib can be damaged
and the crane may tip over. Never attempt this operation.
(5) If the wire rope has become twisted causing the hook to rotate,
untwist the rope before starting work.
(2) Be careful when extending and retracting the boom with a load
suspended on it.
(3) Confirm the boom extension/retraction sequence
Confirm the boom extension/retraction sequence and always
control boom extension/retraction in the correct sequence. The
figures in the rated lifting capacity chart are set based on the
condition that the boom is extended and retracted in the correct
sequence.
Lifting a load with the boom extended in an improper sequence
is forbidden.
- 123 -
WARNING
(4) Never use the boom to push or pull objects
If you use the top of the boom to push cargo along a truck bed
or push objects around the construction site, you will damage
the boom top. If you push or pull objects by slewing the boom,
you could bend the boom.
To move objects, you must completely hoist them clear of the
ground even if this seems time consuming. Alternatively use a
forklift or other specialist cargo handling machine. Do not use
the crane for purposes it was not designed for.
(3) After you have completed slewing, always apply the slewing
brake.
- 124 -
WARNING
(4) Check the position of the slewing free/lock switch
When the switch is in the free position, beware of slewing drift
due to wind or inertia.
- 125 -
WARNING
(2) Set the working configuration setting of the ACS correctly
according to the actual work to be done.
- 126 -
WARNING
- 127 -
WARNING
(5) Inspection after the end of crane operation
After you have finished operating the crane, check all its parts
and add lubricants and fuel as required. If you find any
defective parts, repair them immediately.
- 128 -
(541A-0145-0E)
(541A-0146-2E)
The working area chart indicates the relationship between the working radius and height above the ground for each
combination of the boom length, jib length, boom angle and jib offset angle.
(1) The working area chart does not include deflection of the boom and jib.
With a load suspended, the working radius will increase slightly due to deflection under the load.
(2) The working area chart is for the crane with all outriggers fully
extended (all round).
(3) Points A and B are at the same working radius, but point A
indicates the boom angle and point B indicates the height above
the ground.
- 129 -
The rated lifting capacity chart printed here is an extract from those which are attached to the
crane. Before you start work, check the entire chart.
(541A-0148-1E)
(1) When you are going to operate the crane, find the outrigger status on the rated lifting capacity chart.
(2) Look at the column for the boom length with which you will be working.
(3) Find the rated lifting capacity (load mass + hook mass + mass of slings) for the distance to the position where the
load hangs, which is the working radius allowing for the deflection. The working radius available for the actual
working condition can be found on the rated lifting capacity chart.
NOTE
For jib use, find the rated lifting capacity from the boom angle and the jib offset angle.
- 130 -
Intermediate
extension (6.0m)
Intermediate
extension (5.0m)
Intermediate
extension (3.8m)
35
30
20
Full
retraction
3
(511A-0050-0E)
(8) After setting the outriggers, you must insert the stopper pins into the outriggers and check the extension width.
Also check carefully that all four tires are clear of the ground, that all floats are firmly in contact with the ground
and that the ground on which the outrigger floats are resting is sufficiently strong.
(9) Set the "outrigger status" and "boom operation status" that will be used next on the ACS working status setting
screen correctly. If you will not be able to fully extend all outriggers in the actual work site, move the crane to a
more spacious area first, extend the outriggers fully and perform the ACS preoperational checks.
- 131 -
(10) Check that the key of the ACS emergency switch has been extracted.
(11) If you work with the rooster sheave, subtract the mass of the 30 ton hook (250kg) from the figure in the boom
rated lifting capacity chart, with an upper limit of 4,000kg.
[Hook for use with rooster sheave: 4 ton hook (mass: 80kg), parts of line: 1]
(12) If you are working with a different boom length other than in the rated lifting capacity chart, refer to the next
longest and next shortest boom lengths and work at whichever rated lifting capacity is lower.
(13) If you are working with the boom while the jib is rigged, subtract 2,200kg from the boom rated lifting capacity as
well as subtracting the mass of the hook and slings etc. with an upper limit of 14 tons.
When the jib is rigged, never operate the rooster sheave and operate the boom with the outriggers extended to the
minimum extension width.
(14) The standard number of parts of line for each boom length are as indicated in the lifting capacity chart.
If you work with a non-standard number of parts of line, take 37.2kN (3.8tf) as the maximum load on any part of
the wire rope.
(15) Raise the boom especially slowly near the maximum raised position when using the jib.
(16) The boom can tip over if the boom is lowered below the critical angle in the rated lifting capacity chart even if
unloaded.
(17) If instantaneous wind speeds are expected to exceed 10 meters per second, immediately stop operating the crane. If
a hoisted load swings sideways in the wind, it could not only damage the crane, but is extremely dangerous for
workers as well. Be sure to stay aware of conditions and stop operations early.
The higher the height, the faster the wind speed. Therefore, be especially careful of the increased danger.
(18) If you work with a load in excess of the rated lifting capacity or use incorrect working procedures, you are risking
damaging the crane or tipping it over. In such cases, the machine will not be guaranteed.
- 132 -
(6) The rated lifting capacity differs between the front area capacity and the full range capacity. When slewing from
the front to the side, it could be overloaded, so take special care.
Crane operation
Area
(061A-0038-0E)
(7) If you work with the rooster sheave, subtract the mass of the 30 ton hook (250kg) from the figure in the boom
rated lifting capacity chart, with an upper limit of 4,000kg.
The value includes the mass of all other slings.
[Hook for use with rooster sheave: 4 ton hook (mass: 80kg), parts of line: 1]
(8) Boom operation beyond a boom length of 23.45m and jib operation are prohibited.
(9) For stationary crane-on-rubber operation, the wheels must all be completely immobilized by the parking brake and
brake lock.
(10) For pick and carry operation, apply the slewing brake, switch the high/low speed switch to "ON" (low range) and
set the shift lever to speed 1.
(11) If the suspended load starts to swing during pick and carry operation, it is highly dangerous. If you feel that the
load is about to start swaying, immediately lower the load to just above the ground and keep your speed strictly
below 2km/h.
Avoid any sudden actions such as starting, steering, accelerating and decelerating.
(12) Never operate the crane during pick and carry operation.
If crane operation is absolutely necessary, stop the machine first.
(13) If you are working with a different boom length or working radius other than in the rated lifting capacity chart,
refer to the next longest and next shortest boom lengths or working radii and work at whichever rated lifting
capacity is lower.
(14) The critical angle for each working status is indicated in the chart. The boom can tip over if the boom is lowered
below the critical angle even if unloaded.
(15) The standard number of parts of line for each boom length are as indicated in the chart. If you work with a nonstandard number of parts of line, take 37.2kN (3.8tf) as the maximum load on any part of the wire rope.
(16) Crane operation is permissible up to a wind speed of 10m/s. Even in relatively light wind conditions, extra care
should be taken when handling loads presenting large wind catching areas.
(17) If you work with a load in excess of the rated lifting capacity or use incorrect working procedures, you are risking
damaging the crane or tipping it over. In such cases, the machine will not be guaranteed.
- 133 -
2) Press the switch and release it once the "pip" sounds. This sound means that the ACS has accepted the setting. If
the "pip" does not sound when you press the switch, it means that the setting was not registered. Release the
switch and press it again.
3) Always press switches one at a time to set the ACS and be sure that each press has registered. If you press two or
more switches at the same time, the ACS will not be set correctly.
(5) To clean the display panel, use a soft cloth or cotton wool moistened with a neutral detergent or ethanol to wipe it
gently. If wiping causes static electrical build-up in the display, it will not function correctly.
(6) The ACS body, display panel and sensors are accurately adjusted and equipped with protective measures against
temperature fluctuations. If humidity or dust enters these parts, they could cause the ACS to malfunction, so never
open the case.
(7) Perform the ACS preoperational checks before you start work. The ACS preoperational checks can be performed
only when all outriggers are extended fully. If you will not be able to fully extend all outriggers in the actual work
site, move the crane to a more spacious area first, extend the outriggers fully and perform the ACS preoperational
checks.
(8) Set the actual "outrigger status" on the ACS correctly.
Insert the stopper pins and check the extension width of each outrigger.
Check that the ACS outrigger configuration display matches the stopper pin positions and that the outrigger color
marks (right: green, left: red) match the left/right outrigger configuration on the ACS display.
Incorrect setting of the working status setting screen risks crane damage or tipover. After you
insert the outrigger stopper pins to confirm the outrigger extension width and check that the ACS
display matches the actual outrigger status, set the "boom operation status" you are planning to
use correctly.
- 134 -
(611A-0062-0E)
(9) When you use the outrigger control switches, the crane operation status previously set to the ACS will be canceled.
When you change the outrigger status, you must rest the new crane operation status to the ACS. The crane will not
work until the new setting on the ACS is complete.
(10) Set the "boom operation status" you are planning to use on the ACS working status setting screen correctly.
Set the "boom operation status" you are planning to use on the ACS working status setting screen
correctly. Incorrect setting can result in an exaggerated lifting capacity setting which risks crane
damage or tipover.
An unnecessarily small capacity setting could also result, which limits the crane's effectiveness
and is uneconomic.
(511A-0064-0E)
(11) Before you start work, check that the key of the ACS emergency switch has been extracted. Also check that the
overhoisting emergency switch is in the "working position" (OFF).
(12) If you perform slewing operation, hoist in a zone of smaller capacity (with shorter outrigger extension width) and
slew to a zone of larger lifting capacity. If the ACS announces "Danger maximum lifting capacity" and the crane
automatic stop works with the continuous chime alarm, immediately stop operation and take emergency action
such as derricking and retracting the boom or lowering the lifted load to the ground while watching the safety level
bar graph on the display to return it to the green zone before you continue work.
The rated lifting capacity varies greatly according to the outrigger extension configuration and
the slewing direction. Therefore when you are going to slew from a zone of larger rated lifting
capacity to a zone of smaller capacity, work throughout within the lower capacity.
(881A-0066-0E)
(13) If any error code No. or error message is displayed during crane operation or preoperational checks, or if the
problem occurs in the communication signal or circuit between the carrier and crane, stop work immediately and
contact your authorised KATO dealer to ask for advice.
(14) Always move the PTO switch to the "OFF" position when you drive on the road, with the exception of pick and
carry operation and on-site moving.
Always stow the ACS display panel when you drive on the road. Driving without stowing the
ACS display panel is dangerous.
Always stow the ACS display panel when you leave the crane operation cab.
(061K-0002-0E)
(15) If any breakdown or accident occurs as a result of the operator's failure to observe the above points, KATO will
bear no responsibility.
- 135 -
- 136 -
(061A-0005-0E)
Lock the suspension before you turn the PTO switch "ON".
If you turn the PTO switch "ON" without locking the suspension, the suspension lock
cylinders will lock where they are at different stages of extension.
If you lock the suspension lock cylinders without fully retracting them and attempt any crane
operations without the outriggers, the body will not be level and the crane will tip over.
Fully retract and lock the suspension cylinders regardless of whether or not the outriggers will
be used to turn the PTO switch "ON" before you start crane operation.
(541A-0155-2E)
Before you set the PTO switch to the "ON" position, confirm that the needle of the engine
water temperature gauge is above point "C". Setting the PTO switch to the "ON" position
while the engine coolant temperature is low could cause a seizure, fast wear, damage etc. due
to poor lubrication (from high oil viscosity) of the engine and torque converter.
Before you work the PTO switch, take your foot off the accelerator pedal so that the engine is
idling.
When the PTO switch is switched "OFF", the brake will be applied automatically to
immobilize the superstructure regardless of the slewing brake switch position.
Before you drive on the road, move the superstructure to the driving position, engage the
slewing lock, stow the outriggers and set the PTO switch to the "OFF" position to return the
suspension to the driving position (suspension free state).
(541A-0246-0E)
- 137 -
The ACS emergency switch is only used to take emergency action to avoid a serious accident.
Before crane operation, take the key off the switch and it must be kept by the safety supervisor.
If the ACS emergency switch is set to the"release" position intentionally when operating the
crane, the crane tipping over or other serious accident can be caused.
(541A-0157-0E)
When you get out of the operator's seat, set this switch to the "OFF" position.
(611A-0072-0E)
- 138 -
- 139 -
The overhoisting emergency switch is provided to avoid danger in an emergency. Crane operation
with this switch pressed can cause the wire rope to snap or other major accidents.
(4210-0011-0E)
- 140 -
- 141 -
- 142 -
- 143 -
Before operating the accelerator pedal, confirm that the needle of the engine water temperature
gauge is above point "C".
Operating the accelerator pedal while the engine coolant temperature is low could cause a
seizure, fast wear, damage etc. due to poor lubrication (from high oil viscosity) of the engine and
torque converter.
Properly perform warm-up running.
(541A-0158-2E)
NOTE
When the PTO switch is set to the "ON" position, the engine speed is controlled between about 670min-1
(670r.p.m.) and 1820min-1 (1820r.p.m.).
- 144 -
Do not use the console lock lever as a hand grip when getting on or off the cab.
When you lower the console, push down on the console lock lever or the console unit to lock
it. Do not use the left control lever to lower the console, which is extremely dangerous.
(4210-3256-0E)
The crane is automatically stopped when the left console is tilted (raised), so there will be no
response to movement of the crane control levers, pedals etc.
(611A-0073-0E)
(7) Armrest
Adjust the armrest to the easiest height for you to operate.
- 145 -
When you operate the switches on the outrigger control panel, the ACS outrigger setting status
will be canceled and the ACS will switch to the "working status setting screen".
When you have used the outrigger control switches, insert the outrigger stopper pins and
check the outrigger extension widths and check that all four outriggers are in the positions
indicated on the ACS display, then press the ACS setting switch to rest the outrigger extension
widths.
If it is not reset on the ACS, the crane cannot be operated.
(491A-0043-1E)
When you use the outrigger emergency switch to stow the outriggers, always set the crane to the
driving position.
(121A-0079-0E)
- 146 -
(541A-0171-0E)
Always follow the specified procedure and precautions strictly to set the machine in its working
configuration before you start crane operation.
Crane operation with the crane in an incorrect position could cause severe accidents.
(541A-0172-0E)
- 147 -
Always follow the specified procedure and precautions strictly to set the machine in its driving
configuration before you drive on the roads.
Driving on the roads with the crane in an incorrect position could cause severe accidents.
(541A-0173-0E)
- 148 -
Any one of the faults below could cause the crane to tip over, so strictly observe all the relevant
precautions.
If you operate the crane without first locking the suspension, the crane could tip over, causing
a major accident.
When you operate the crane, fully retract the suspension lock cylinders to lock them.
If you lock the suspension while the suspension lock cylinders are not fully retracted, the tires
could be contact with the ground, causing a major accident.
Do not release the suspension lock until all crane operations are complete and you are about to
move the machine on the road.
Push the suspension retraction switch to the "suspension retraction" side for about at least four
seconds. When the suspension cylinders are fully retracted and locked, check that the
suspension locked indicator lamp has lit.
Only retract and lock the suspension when the machine is on firm, level ground with the
outriggers stowed.
Keep the suspension locked when moving around the site between working positions.
Never drive on the road with the suspension locked.
Always release the suspension lock before you move the machine onto the road.
(611A-0035-0E)
- 149 -
- 150 -
Release the suspension lock and return the machine to the driving position before you move
the machine onto the road.
Never drive on the road with the suspension lock cylinders retracted.
Only retract and lock the suspension when the machine is on firm, level ground with the
outriggers stowed.
(541A-0176-2E)
- 151 -
Lock the suspension before you turn the PTO switch "ON".
If you turn the PTO switch "ON" without locking the suspension, the suspension lock
cylinders will lock where they are at different stages of extension.
If you lock the suspension lock cylinders without fully retracting them and attempt any crane
operations without the outriggers, the body will not be level and the crane will tip over.
Fully retract and lock the suspension cylinders regardless of whether or not the outriggers will
be used to turn the PTO switch "ON" before you start crane operation.
(541A-0155-2E)
Before you work the PTO switch, take your foot off the accelerator pedal so that the engine is
idling.
When the PTO switch is switched "OFF", the brake will be applied automatically to
immobilize the superstructure regardless of the slewing brake switch position.
Before you drive on the road, move the superstructure to the driving position, stow the
outriggers, set the PTO switch to the "OFF" position and release the suspension lock to return
the suspension lock cylinders to the "driving position".
(541A-0178-2E)
Work the PTO switch with the idle speed knob set to "AUTO".
(611A-0079-0E)
- 152 -
ON
OFF
- 153 -
When the outriggers are used, the load values in the rated lifting capacity chart are based on the assumption that the
crane is supported on the level by the outriggers. Therefore the strength of the ground where the outriggers are set is
one of the most important factors for safety.
In some working positions, as much as 80% of the total mass of the crane plus the suspended load may act through a
single outrigger, creating an enormous surface pressure under the outrigger float. If this happens, ground conditions
below the surface can cause the float to sink into the ground, even in ground which appears to be level and firm at first
sight.
Therefore always watch for the following points.
- 154 -
(1) Improve the ground surface as far as possible if it is soft, crumbly, uneven or sloping. Use wooden blocks etc. if
necessary to produce a flat surface and then set the outriggers on steel plates etc. of adequate areas and rigidity to
reduce surface pressure further.
(2) Ground which appears to be strong can have dangerously inadequate strength due to ground conditions below the
surface. Avoid areas which are likely to suffer such problems as listed below, and set the outrigger floats on steel
plates etc. of adequate areas and rigidity to guard against potentially weak soil.
Surfaces paved with plain asphalt
Surfaces paved with thin concrete
Brick or cobbled road surfaces
Areas where soil under the road paving has been eroded by water to leave a void
Areas where the soil is very dry but soft
Road shoulders or near construction excavations
Set the crane level with full consideration for the above points.
If the crane is not set level, the reduction in the crane's lifting capacity can be unexpectedly
severe. If you use the crane without noticing and correcting the inclination, it could tip over or
the boom could be broken even if the load is well below the rated lifting capacity.
(541A-0180-1E)
(3) Check that the suspension lock cylinders are fully retracted (suspension locked) before you set the outriggers.
(4) As a rule, all four outriggers should be extended fully. If you have no alternative but to use any outrigger at
intermediate extension or full retraction or if the outriggers cannot be used at all, you must first obtain the
permission of the site foreman and then proceed slowly and cautiously with safety as your prime concern.
(5) Check that nobody is near the outriggers and under the machine before you set the outriggers.
(6) While driving or when you set the outriggers, always check that the stopper pins are inserted to fasten the
outriggers securely in the correct positions.
- 155 -
(7) After you have finished setting the outriggers, check that the tires
are off the ground. If any tire is touching the ground, a reactive
force will act which will impair stability.
If site conditions are such that any of tires are still in contact with
the ground when the outrigger vertical cylinders are fully
extended, place plates etc. under the outrigger floats until all tires
are off the ground.
(8) After you have finished setting the outriggers, check that each outrigger float is in contact with the ground.
Also check that the ground is not deformed, the floats have not sunk down and the road shoulder is not crumbling.
(9) Set the "outrigger status" and "boom status" that will be used next on the ACS working status setting screen
correctly. If you will not be able to fully extend all outriggers in the actual work site, move the crane to a more
spacious area first, extend the outriggers fully and perform the ACS preoperational checks. The ACS preoperational
checks can be performed only when all outriggers are extended fully.
(Refer to the ACS instruction manual for details.)
(10) At the start of lifting, lift the load just clear of the ground to gauge the working condition and confirm that the
ground supports the outriggers adequately. If an outrigger supervisor is appointed to observe the outriggers during
operation, safety will be enhanced.
(11) This machine is equipped with control switches for outrigger operation on the side of the carrier and inside the cab.
Whichever switches you start moving, the ACS will automatically switch to the working status setting screen.
Reset the ACS if you have changed the outrigger configuration.
- 156 -
When you operate the switches on the outrigger control panel, the ACS outrigger setting status
will be canceled and the ACS will switch to the "working status setting screen".
When you have used the outrigger control switches, insert the outrigger stopper pins and
check the outrigger extension widths and check that all four outriggers are in the positions
indicated on the ACS display, then press the ACS setting switch to reset the outrigger
extension widths.
If it is not reset on the ACS, the crane cannot be operated.
(511A-0080-0E)
- 157 -
- 158 -
If you try to operate the outriggers while the PTO switch is turned "OFF", the misoperation
warning buzzer will sound and the outriggers will not move.
If you try to use extension/retraction switch before you have set both the position selection
and horizontal/vertical selection switches, the misoperation warning buzzer will sound.
When you extend or retract the outriggers, the ACS outrigger setting status will be canceled
and the ACS will switch to the "working status setting screen".
When you have used the outrigger control switches, insert the outrigger stopper pins and
check the outrigger extension widths and check that all four outriggers are in the positions
indicated on the ACS display, then press the ACS setting switch to reset the outrigger
extension widths.
If it is not reset on the ACS, the crane cannot be operated.
(511A-0065-0E)
- 159 -
1) Extend the outrigger beams as far as the marks for the desired length (full or intermediate extension). When each
outrigger beam reaches the desired length, release the extension/retraction switch.
2) Insert the stopper pin into each outrigger and confirm the
extension length.
NOTE
If you cannot insert the stopper pin properly, use the extension/
retraction switch to "extend" or "retract" the outriggers
repeatedly until the pin has been inserted firmly.
NOTE
When you operate the outriggers from the operator's seat, adjust the engine speed with the accelerator pedal to
keep a suitable speed of operation.
3) Place the outrigger floats on the plates.
- 160 -
After you extend the vertical cylinders, check that there are no dangers such as sinking of the
outrigger floats or crumbling of the road shoulder.
After you extend the vertical cylinders, return all switches to their neutral positions to avoid
accidentally retracting the outrigger beams.
Check that four tires are not touching the ground.
(491A-0048-1E)
The data for each outrigger extension widths is set to the ACS automatically, but always insert
the stopper pin into each outrigger beam and check the extension widths.
Check that the positions of the stopper pins match the outrigger status shown on the ACS
display, then set the "outrigger status" on the "working status setting screen".
(511A-0052-0E)
- 161 -
If you cannot take an outrigger stopper pin out, retract the vertical cylinder first. Once it is fully
retracted, extend (or retract) the outrigger beam until you can take the pin out.
(591A-0089-1E)
- 162 -
Do not retract the outrigger beam while the vertical cylinder is extended.
(541A-0183-1E)
(5) After you have confirmed that the outriggers are fully retracted,
insert all four stopper pins.
- 163 -
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.
(541A-0189-1E)
- 164 -
(4) Set the main winch switch to the "ON" position and move the right
control lever to the "derricking" side and "lowering" side
simultaneously to derrick the boom so that the hook can be
released from the hook fixing ring.
When lowering the main winch, take care not to lower the wire rope further than necessary.
The wire rope could get tangled on the drum.
When derricking the boom, take care that the wire rope does not get too tightened.
(491A-0054-0E)
(5) Release the main hook from the fixing ring and stow the ring.
- 165 -
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.
(541A-0189-1E)
(3) Fully retract the boom and move the hook so it is directly above
the fixing ring.
(4) Lower the winch so that the hook can be hooked into the fixing ring.
Take care that the hook does not touch the cab.
(491A-0057-0E)
- 166 -
(6) Set the main winch switch to the "ON" position and move the right control lever to the "hoisting" side and
"lowering" side simultaneously to lower the boom to the level.
Take care that the wire rope does not get tangled on the drum.
At this time, take care that the wire rope does not get too tightened.
If excessive tension is applied to the wire rope, the automatic function will work.
(541A-0192-1E)
(7) Before driving on the roads after stowing the hook, set the machine in the driving position.
(8) Stow the four outriggers and insert the stopper pins to check that the outriggers are stowed completely.
(9) Set the PTO switch to the "OFF" position.
- 167 -
(541A-0193-0E)
The ACS preoperational check should be conducted when all outriggers are fully extended for
maximum safety. If you will not be able to fully extend the outriggers in the actual work site,
move to a more spacious area first, extend the outriggers fully and conduct the ACS
preoperational check.
(491A-0078-1E)
Always follow the specified procedure and precautions strictly to set the machine in its working
configuration before you start crane operation.
Crane operation with the crane in an incorrect position could cause severe accidents.
- 168 -
(541A-0172-0E)
When the crane works without the outriggers, the tires must serve a substitute for the outriggers. However if the
suspension lock cylinders which support the tires are not fully retracted (suspension locked) or if the tire pressure is
below the rated value (900kPa (9kgf/cm2)), they will not function adequately in place of the outriggers and crane
operation without outriggers will not be possible.
If the outriggers are not used, the working area or the lifting capacity differs greatly from those when the outriggers
are used. Check the relevant rated lifting capacity chart before you start work.
The crane's lifting capacity depends on the crane body being level, even when the outriggers are not used. However
it is difficult to keep the body level without the outriggers, so be sure to choose a working area which is firm and
level.
When the outriggers are not in use, any of the faults listed below can cause the crane to lose
stability and tip over during any kind of operation, even if there is no suspended load.
If the suspension lock cylinders are not locked.
If the tire pressure is below the rated pressure in any tire.
If the body is not level.
If the crane moves beyond its specified range of operation.
If the boom status is not as specified.
If the ACS is not set correctly.
(541A-0195-0E)
- 169 -
When the pressure in the compressed air tank falls while the brake lock is in use and the foot
brake cannot operate, a buzzer will sound. Before you are going to use the foot brake again,
you must raise the engine speed to recharge pressure in the tank to the rated level.
Do not use the brake lock when the engine is not running or when the crane is not in use and
in any case never use it for more than one hour. Do not leave the machine unattended while
the brake lock is in use.
(541A-0197-1E)
- 170 -
In stationary crane-on-rubber operation in contrast to other operations which use the outriggers,
the body of the crane is supported by the tires. This increases the amount of deflection and
distortion, making this an unstable and hazardous operation. Observe the specified conditions
strictly and work slowly and cautiously.
(541A-0198-1E)
- 171 -
Choose a path for pick and carry operation which is firm, level and without major
irregularities.
Never change the direction during pick and carry operation.
Choose a path which will allow you to move in a continuous straight line.
Keep the load close to the ground.
All crane operations are forbidden during traveling.
Always bring the machine to a complete stop before making any crane operations.
Sudden braking and sharp steering while in motion will cause the suspended load to swing
dangerously.
(541A-0200-2E)
- 172 -
Crane operation while in motion is forbidden. If you must lift the load just off the ground and
clear any irregularities on the ground surface, stop the crane, apply the parking brake and hoist
the load sufficiently to avoid any obstacles.
If this operation leaves the load hoisted a long distance above the ground, lower it back down
close to the ground as soon as possible.
(541A-0201-2E)
- 173 -
Driving on public roads is not permitted when the machine is configured for on-site moving.
Return the machine to the on-road moving configuration before driving on public roads.
(541A-0203-1E)
(1) Crane status: Driving mode (boom fully retracted, lowered and facing within 1of the front, and outriggers
stowed)
(2) Suspension:
Moving within a site to change working positions is within the scope of crane operations.
Therefore, even if it involves driving, leave the suspension locked and the PTO switch "ON"
as well.
If the machine is moved with the suspension unlocked (on-road driving) or the PTO switch
"OFF", the operator may forget to fully retract the suspension at the next working position.
Therefore, be sure to lock the suspension in the fully retracted position before starting work at
the next position.
(541A-0204-1E)
- 174 -
(1610-0030-1E)
This crane is reasonably simple to operate, but even small slips can cause major accidents, so always work steadily one
step at a time.
- 175 -
(6) Confirming that the key is removed from the ACS emergency switch
Confirm that the key is not in the ACS emergency switch on the front panel. This switch is provided to avert
possible danger in an emergency of the ACS system. Therefore, give the key to the safety supervisor when on the
work site.
The ACS emergency switch is only used to take emergency action to avoid a serious accident.
Before crane operation, take the key off the switch and it must be kept by the safety supervisor.
If the ACS emergency switch is set to the"release" position intentionally when operating the
crane, the crane tipping over or other serious accident can be caused.
(541A-0157-0E)
The crane is automatically stopped when the left console is tilted (raised), so there will be no
response to movement of the crane control levers, prdals etc.
(611A-0073-0E)
- 176 -
- 177 -
When the boom is long or the jib fitted, the crane will tip over if the boom is lowered below the
critical angle even if there is no suspended load. Refer to Service data to find the critical angle.
(4210-0039-1E)
(4210-0040-0E)
- 178 -
When the wire rope number of parts does not correspond to the boom length, the hook will
not reach the ground and the winch drum can wind up the wire rope in reverse, which can
cause the wire rope to be damaged or the crane to tip over.
When hoisting from below the ground or working with a long boom, refer to the table for wire
rope standard number of parts and use the adequate number of parts for the boom length with
which you are working.
(4210-3249-0E)
- 179 -
(611A-0042-0E)
NOTE
Using the flow control system, you can hoist or lower the load at a constant speed regardless of the weight of the
load.
- 180 -
- 181 -
If the boom section 2 is not fully extended, the boom sections 3 and 4 cannot extend even if the
boom extension/retraction switch is set to the boom sections 3 and 4 side.
(611A-0045-0E)
- 182 -
If you extend or derrick the boom while the hydraulic oil is hot and then leave it to rest, the
extended cylinder may retract as the oil cools. This is because the volume of oil has reduced
and is not a malfunction.
The degree of cylinder retraction depends on the amount of change in the oil temperature and
the cylinder stroke position and can be as much as several percent of the cylinder's stroke. This
phenomenon is most pronounced in the long telescopic cylinder or derrick cylinder and can
lower the hook position, so take care to avoid problems due to this effect. Take necessary
precautions in the following situations.
(1) If you wait with a load suspended from a long boom, avoid extending the boom further than
necessary and correct the boom length (extend it) from time to time.
(2) If the boom angle is low and the load is close to the rated lifting capacity, correct the boom
angle (by derricking) before the ACS alerts you to danger.
When extending the boom, make sure the hooks are far enough below the boom top to avoid
overhoisting.
If it is not possible to retract the boom sections 3 and 4, move the boom extension/retraction
emergency switch to the "release" position, set the boom extension/retraction switch to the
boom sections 3 and 4 side and depress the boom extension/retraction pedal backward to
retract the boom sections 3 and 4.
(611A-0075-0E)
NOTE
Extension sequence for each boom length
- 183 -
NOTE
During "inching" and other fine positioning movements, the slewing free/lock switch should be set to "lock", but
if "lock" is in use and the slewing lever is returned suddenly to neutral, the superstructure stops suddenly,
causing the load to swing and affecting the structure of the crane adversely, so work carefully in this case.
- 184 -
Remarks
Slewing will
automatically stop
: Slewing may overrun and not stop at the correct position in strong winds.
(611A-0081-0E)
When the crane is operated in the stationary crane-on-rubber or pick and carry modes, the front
working area will become narrow. If the lever is operated suddenly, slewing may overrun.
Consequently, if working in these modes, pay attention to the ACS safety level bar graph display
and warnings and be careful to never overload the crane. Failing to use adequate caution and
continuing to slew the machine when overloaded could cause the crane to tip over and result in
tragic consequences.
(611A-0082-0E)
If the voice warning message "Caution when slewing" is emitted and slewing begins
automatically decelerating, try to stop slewing manually by operating the slewing lever in the
opposite direction, while paying attention to the movement of the load. Waiting for slewing to
stop automatically could result in not stopping properly and overrunning the overload point, if
the machine is not level or if there is a strong wind.
(611A-0047-0E)
Slewing position
(slewing angle)
Voice warning
Warning sound
Start
Operator
determined speed
Automatic
deceleration
Slewing status
B-C
C-D
Automatic
deceleration
Automatic
Display
stop
: If the machine is not level or there is a strong wind, slewing may not stop at the correct position and overrun the
overload point.
(611A-0048-0E)
- 186 -
18-6-2 Slewing control when a "slew-restricted region" is specified in the ACS (611A-0049-0E)
If a certain slewing region is specified as restricted in the ACS, such as to avoid hitting obstructions when operating on
sites with limited working space or avoiding electrocution from nearby power lines, the "slewing stop system" will
function in the follow sequence to avoid an accident.
(1) Deceleration warning and corresponding slewing position
When slewing reaches the warning point, which is back-calculated from the slew-restricted point (angle), a voice
warning message "Caution when slewing" is emitted (1 time ) to warn the operator that slewing will be
automatically decelerated.
(2) Slewing deceleration and corresponding warning sound
After the voice warning, slewing is decelerated. Then when slewing approaches the restricted region, a warning
chime ("DING DONG", "DING DONG", ) is emitted (intermittently) to notify the operator that the stopping
system is functioning.
If the control lever is moved in the opposite direction while slewing decelerates (before automatically stopping),
slewing will stop, then when the slew position starts moving away from the restricted region, the warning sound
will stop.
If the voice warning message "Caution when slewing" is emitted and slewing begins
automatically slowing down, try to stop slewing manually before reach reaching the slewrestricted region by operating the slewing lever in the opposite direction, while paying attention
to the movement of the load.
Waiting for slewing to stop automatically could result in not stopping properly and overrunning
the overload point if the machine is not level or if there is a strong wind, which could cause the
crane to hit obstructions or electrocution.
(611A-0050-0E)
- 187 -
Slewing position
(slewing angle)
Voice warning
Warning sound
Start
Operator
determined speed
Automatic
deceleration
B-C
C-D
Slewing status
Automatic
deceleration
Automatic
Display
stop
: If the machine is not level or there is a strong wind, slewing may not stop at the correct position and overrun the
restricted region.
(611A-0051-0E)
Only use the ACS emergency switch in emergency situations, such as when the "slewing stop
system" malfunctions and does not allow slewing within the rated load range or slewing within
the permitted slewing region. Furthermore, even in such situations, slew very cautiously, making
sure to continuously monitor the safety level bar graph and ACS display for restricted slewing
regions to confirm safety.
(611A-0064-0E)
Always obtain permission from the site safety manager before turning the ACS emergency
switch to "release" for slewing in an emergency. Furthermore, contact your authorised KATO
dealer to request repair.
(611A-0065-0E)
NOTE
Even if the ACS emergency switch is turned to "release", the ACS will continue to emit the voice warnings "Caution
when slewing", "Danger maximum lifting capacity", "Slewing limit reached", and "Danger overload", chime
warnings, and emergency two-tone beep warnings (assuming the ACS is functioning normally).
NOTE
If the ACS emergency switch is used to disable the "slewing stop system", inertial slewing drift is controlled
based on the "slewing free/lock switch" position, located on the side panel.
(2) If slewing does not stop when overloaded
If the crane is level and yet slewing does not automatically
decelerate when the safety level bar graph approaches the yellow
zone and does not stop even after reaching the red zone, use the
following procedure to operate the crane and avoid danger.
1) If slewing does not automatically decelerate when the safety
level bar graph approaches the yellow zone, move the slewing
control lever to the neutral position, while keeping a close watch
on the load movement, and let the engine idle.
2) If slewing doe not decelerate adequately and appears as though the safety level bar graph indicator will not stop
within the yellow zone, forcibly stop the slewing motion by operating the lever in the opposite direction, being
careful not to let the load swing.
3) If it is necessary to keep slewing in the same direction, keep slewing stopped and raise or retract the boom until
the safety level bar graph enters the green zone, then use the independent slewing controls to slowly and
cautiously slew the crane to the desired position, while carefully monitoring the safety level bar graph indicator.
Never slew the crane when the safety level bar graph indicator is in the red zone, indicating the
crane is overloaded. If outriggers are extended to different lengths, crane capacity can vary
significantly depending on the slewing position. Forgetting this point and slewing the crane even
when the safety level bar graph indicator is in the red zone can result in the crane tipping over and
causing a major accident. If the voice warning message "Danger maximum lifting capacity" is
emitted and the safety level bar graph is in the red zone, stop slewing as quickly as possible, while
being careful of load swing.
- 189 -
(611A-0052-0E)
(3) If slewing does not stop even after slewing into the slew-restricted region
If the crane is level and a "slew-restricted region" has been specified in the ACS, yet slewing does not automatically
decelerate when approaching the restricted region and does not stop when slewing reaches the restricted region,
use the following procedure to operate the crane and avoid danger.
1) If slewing does not automatically slow down as it approaches the "slew-restricted regions" indicated on the ACS
screen, move the slewing control lever to the neutral position, while keeping a close watch on the load
movement, and let the engine idle.
2) If slewing doe not decelerate adequately and appears as though slewing will not stop before entering the
restricted region, forcibly stop the slewing motion by operating the lever in the opposite direction, being careful
not to let the load swing.
3) If it is necessary to slew close to the restricted region, double-check the distance to any obstructions and slowly
and cautiously slew the crane to the desired position.
(4) Warning sounds and voice warnings emitted when slewing while overloaded or within a restricted region
If the associated danger is ignored and the crane is slewed when overloaded or into a restricted region, a voice
warning, warning chime or emergency sound is emitted depending on how overloaded the crane is or how far it
has slewed into the restricted region, to warn the operator of the extremely dangerous state.
1) Voice warning, warning chime or emergency sound emitted
depending on extent of overload
If slewing does not stop automatically at the correct position, but
overruns the overload point, due to a "slewing stop system"
malfunction, unlevel machine or strong winds, a voice warning,
warning chime or emergency sound is emitted, according to how
overloaded the crane is, to notify the operator of the danger.
In addition, even if slewing is reversed to escape the danger, the
warning sound will continue until the crane is no longer
overloaded.
Slewing
operation
Continuing
to slew in
same
direction
Reverse
slewing
Slewing
position
% of load
capacity
Point D
105%
Region E
Region E
Up to point D
Point D and
beyond
Voice warning
"Danger maximum lifting
capacity" (1 time)
Warning sound
(or emergency sound)
"DING DONG DANG DONG,"
110% or more
110% or more
(611A-0053-0E)
- 190 -
Slewing operation
Continuing to slew
in same direction
Restart slewing in
same direction
Reverse slewing
Slewing position
Point D and beyond
Region E
Voice warning
Warning sound
"DING DONG", "DING DONG",
(611A-0054-0E)
Be sure to always park and level the machine on firm ground before operating the crane. If not
level, the slewing will not automatically stop at the correct position even if the "slewing stop
system" is functioning normally. This can cause the crane to tip over, hit obstructions,
electrocution or other accidents.
(541A-0241-1E)
Always leave the key for the ACS emergency switch with the site safety manager before starting
crane operations.
If it becomes necessary to switch the ACS emergency switch to "release", due to the "slewing
stop system" or "ACS system" malfunctioning, always report the situation to the safety manager
and obtain their permission.
(611A-0055-0E)
- 191 -
(541A-0245-0E)
Attach the overhoisting detector weight in the position shown in the "method of reeving" of
the "table for wire rope standard number of parts" above.
If the work site is below the ground, the length of the winch wire rope may become inadequate
for the boom length used. In that case, reduce the number of parts of line so that at least three
turns of the wire rope remain on the winch drum.
When hoisting from below the ground, the length of the wire rope required is equal to the
number of parts of line multiplied by the distance below the ground.
Inadequate parts of line for a given boom length can result in the hook not reaching the
desired below-ground level, which could cause the rope to start winding up on the drum in the
opposite direction and damage the wire rope, or cause the crane to tip over.
Always wear strong working gloves for jobs such as detaching and reeving the wire rope.
(541A-0247-3E)
- 192 -
(2) Remove the rope retaining pins from the boom top.
- 193 -
If the length of the wire rope is not enough when you are changing the wire rope number of
parts, lower the rope further while it is pulled out by hand, taking care that it does not become
tangled on the drum.
The rope socket should be attached in the orientation shown below.
(541A-0249-2E)
Base the wire rope standard number of parts on the table for the wire rope standard number of
parts.
Take care not to tangle the wire rope.
The rope socket and clip should be attached as shown in the diagram below.
(541A-0250-1E)
Refer to "Wire rope handling" in the inspection and servicing section for the replacement criteria.
(541A-0251-1E)
- 194 -
(611A-0056-0E)
Preoperational checks/
Pre-drive checks
214521
20-2
(511A-0040-0E)
The purpose of preoperational checks and pre-drive checks is to ensure safe and efficient work.
Before you start driving machine or operating the crane, make the following items of inspections.
Record the crane condition you observe in the course of the checks in the "Inspection sheet".
If you discover any problems or points which require lubrication, refer to the sections on "Greasing" and "Inspection
and servicing of each part" for periodic inspection tasks.
The intervals stated in the inspection and servicing table are based on the elapsed time
indicated by the hour meter.
Follow both the passage of dates and of hours of operation and carry out each inspection item
when one of the times is reached, whichever occurs sooner.
If you discover any damage, breakdown or malfunction, repair it immediately. Do not leave it
for later and do not start work before it is repaired.
For the inspection and replacement methods for the engine, refer to the separate engine
manual.
The inspection intervals for this machine are based on standard operations and working
conditions.
Under severe conditions, the inspection and replacement intervals should be shortened
accordingly.
If any method or interval of inspection and servicing is unclear, contact your authorised KATO
dealer.
(541A-0259-0E)
- 195 -
Steering
system
Inspection location
Steering wheel
Others
Inspection item
Braking system
Machine equipped
with autogreaster
Excluding machines
equipped with air
brakes
Braking effect
Reserve tank
Air pressure
Abnormal wear
wheels
Suspension
Electrical
system
Hydraulic suspension
Battery
or bolts
Leveling and other
functionality
Tires
Wheels
Notes
Brake pedal
Parking brake
Inspection procedure
Before After
start start
Steerability
Lubrication using
autogreaster and grease
quantity
Drive system
Daily
inspection
- 196 -
Tightening torque:
568627Nm
(5864kgfm)
Inspection/servicing item
Inspection location
Prime mover
Main unit
Inspection item
Daily
inspection
Deceleration and
acceleration status
Lubrication system
Oil level
Fuel system
Cooling system
Water level in radiator
and other parts of the
cooling system
Inspection procedure
Before After
start start
Notes
Remove water
properly.
tank
of the chassis
(511A-0075-2E)
- 197 -
- 198 -
- 199 -
- 200 -
- 201 -
Part
Exterior
Cover etc.
Inspection location
and service task
Engine
Before
start
After
start
Inspect
Oil leakage
Inspect
Air leakage
Inspect
External damage
Inspect
Inspect
Hose etc.
Device and
equipment
Engine and
engine
mountings
Inspect
Abnormal noise on
starting, running or
stopping
Inspect
Stopping behavior
Inspect
Inspect
Oil pan
Engine oil
Water separator
Notes
Inspect
Check oil
level
Inspect
Check
water level
Inspect
Inspect
Check oil
level
Check for
water
content
Drain
water
Inspection procedure
Radiator
Fuel system
Engine-related
Task
When
defective
- 202 -
Hydraulic system-related
Slewing-related
Winch-related
Inspect
Engine
Before
start
Accelerator
Inspect
When
defective
Task
Oil leakage
Inspect
Responsivity
Inspect
Oil leakage
Inspect
Abnormal noise
Inspect
Oil cooler
Oil leakage
Inspect
Rotary seal
Oil leakage
Inspect
Inspect
Inspect
Cylinder
Hydraulic pump
Bearing
Abnormal noise on
slewing
Hook
Notes
Hydraulic oil
Inspection procedure
After
start
Check oil
level
Oil reservoir
Boom-related
Inspection location
and service task
Slewing
gear
Engine-related
Part
Inspect
Attachment bolt
Inspect
Bearing play
Inspect
Sheave wear
Inspect
Inspect
Hook
Inspect
Inspect
Wire rope
Inspect
Drum lock
Inspect
Inspect
Inspect
Sheave
Inspect
30 ton hook
Operate the winch drum lock lever to check that
the lock device has locked securely.
- 203 -
Air conditioner
Heater
Air conditioner
Inspection location
and service task
Task
Engine
Before
start
Inspect
Cooling
Inspect
Heating
Inspect
Defroster
Inspect
Refrigerant gas
Inspect
Belt tension
Inspect
Condenser
Clean
Clean and
inspect
Replace
Inspect
Crack, damage,
abnormal wear
Inspect
Lodged metal
fragments, stones
etc.
Inspect
Inspect
Depression distance
Inspect
Braking effect
Inspect
Brake fluid
Inspect
Braking effect
Inspect
Tires
Brake-related
Foot brake
Parking brake
Water
extraction
Air tank
Inspect
Air drier
Inspect
Drain water
Notes
Air pressure
Wheel nut
Inspection procedure
After
start
Oil
Filter
Drive-related
When
defective
Part
- 204 -
Tightening torque:
568627Nm
(5864kgfm)
Inspection location
and service task
Electrical system
Engine
Before
start
Check
electrolyte
volume
Warning horn
Check
action
Wiper
Check
action
Lamp
Inspect
Inspect
Ease of steering
Inspect
Battery
Mirrors
Adjust
Side-view mirror
Inspect
Underside mirror
Inspect
Door mirror
Inspect
Inspect
Seatbelt
Shift lever
Gear change
Inspect
Control lever
and pedal
Inspect
Inspect
Inspection procedure
After
start
Steering wheel
Task
When
defective
Part
- 205 -
Notes
Inspection location
and service task
Task
When
defective
Part
Engine
Before
start
After
start
Inspect
Switch panel
Check
action
Inspect
ACS
Inspect
Buzzer
Inspect
Automatic stop
Inspect
Overhoisting
detector
Inspection procedure
Notes
- 206 -
- 207 -
- 208 -
- 209 -
- 210 -
(611A-0058-0E)
Index
214521
A
Accelerator pedal 87
Accelerator pedal 144
ACS emergency switch (self-reset type) 138
Air cleaner blockage warning indicator lamp 73
Air pressure gauge 70
Armrest 145
Ashtray 24
AT/M (automatic transmission) malfunction warning lamp 71
AT/M emergency switch 92
Auxiliary winch switch 139
B
Battery charge indicator lamp 74
Boom extension/retraction emergency switch(self-reset type) 140
Boom extension/retraction pedal 143
Boom extension/retraction switch 139
Brake lock switch 81
Brake pedal 87
C
Cabin air conditioner 31
Combination switch 89
Windscreen wiper switch 89
Windscreen washer switch 89
Exhaust brake lever 90
Console lock lever 145
Crane operation switch 138
D
Defroster switch 26
Diagnostic indicator lamps 34
Digital display 77
Door 17
Drum rotation detector switch 141
- 211 -
E
Emergency kit 23
Engine control warning lamp 73
Engine cover 35
Engine inspection cover 36
Engine oil pressure gauge 70
Engine trouble warning lamp 71
Engine water temperature gauge 70
Exhaust brake indicator lamp 72
F
Fan switch (optional) 26
Fire extinguisher (optional) 23
Flare 22
Fuel gauge 70
Fuel level warning lamp 72
Fuse box 2233
H
Hazard warning switch 85
Heater switch (optional) 26
Height and angle adjustment lock lever 88
High beam indicator lamp 70
High/low speed switch 80
Holders for the rated lifting capacity chart and instruction manual 22
Horn switch 88
Hour meter 69
Hydraulic oil warning lamp 75
I
Idle speed knob 25
Interior lamp 21
J
Jib side-lifting switch (self-reset type) 140
K
Keys 23
L
Left control lever 142
Left window 21
Level gauge 138
Lighter 24
Low air pressure warning lamp 74
- 212 -
M
Main winch switch 139
Multiplex communication error warning lamp 75
O
Odometer/trip meter 69
Odometer/trip meter switch 69
Outrigger control panel 146157
Outrigger emergency switch (self-reset type) 146
Outrigger operation OK indicator lamp 75
Overhoisting emergency switch(self-reset type) 140
Overrun warning lamp 73
P
Parking brake switch 84
Parking brake/brake fluid level warning lamp 74
Power steering pressure warning lamp 75
Preheat indicator lamp 72
PTO indicator lamp 75
PTO switch 137
R
Radiator coolant level warning lamp 71
Radio (optional) 27
Radio aerial (optional) 36
Rear steering central position indicator lamp 76
Rear steering emergency switch 93
Rear steering lock release confirmation indicator lamp 76
Rear steering lock release indicator lamp 74
Rear steering lock/release switch 84
Rear steering switch (self-reset type) 86
Rear window 23
Revolving warning lamp switch (optional) 85
Right control lever 143
Roof window wiper/washer switch 26
- 213 -
S
Seat 18
Seatbelt 20
Service switches 34
Shift lever 85
Shift position indicator lamp 71
Slewing alarm button 142
Slewing brake switch 138
Slewing free/lock switch 140
Speedometer 69
Starter switch 24
Sun visor 21
Sunshade 21
Suspension lock/release switch 82
Suspension locked indicator lamp 75
Suspension operation OK indicator lamp 76
Suspension retraction switch 83
T
Tachometer 69
Turn signal and dimmer switch 90
Turn signal switch 90
Dimmer switch 91
Lighting switch 91
Torque converter oil temperature display switch 78
Torque converter trouble warning lamp 72
Turn signal indicator lamp (left) 70
Turn signal indicator lamp (right) 70
Two/four wheel drive switch 79
W
Washer tank 33
Working lamp indicator lamp 75
Working lamp switch 141
- 214 -
140-0011 1-9-37
03(3458)1111
140-0011 1-9-37
03(3458)1123
140-0011 1-9-37
03(3458)1112
003-0807 7 2-7-1
011(837)5211
080-0010 11-18-1
0155(25)7211
980-0802 3-10
022(222)4896
020-0021 3-3-26
019(652)1191
010-0951 2-1-60
018(863)5001
963-8004 1-22
024(932)1811
331-0814 1-497MJ
048(651)1135
950-0912 1-1-54
025(247)8326
370-0811 1-182
027(325)1311
262-0033 1-2-24
043(296)0005
310-0063 1-3-34
029(227)5051
221-0844 1-2 2
045(311)7992
422-8042 1-1-46
054(286)3141
461-0004 3-23-3 14
052(934)0588
930-0046 1-3-6()
076(493)1833
532-0011 2-3-20
06(6303)1131
520-0801 2-1-48
077(524)8001
733-0035 7-16-15
082(295)0300
700-0927 71-1
086(231)1291
760-0023 2-2-10(JPR )
087(822)7731
812-0007 3-12-16
092(474)0122
870-0034 1-1-1
097(536)6650
890-0052 24-2
099(258)3326
900-0016 3-1-156
098(868)9461
HEAD OFFICE :
(OVERSEAS MARKETING DEPT.)
Telephone :
Telex Number :
Cable Address :
080424TI