KATO 50 Tonnes 217671E - SR-500L - (Serial No. 7110051)
KATO 50 Tonnes 217671E - SR-500L - (Serial No. 7110051)
KATO 50 Tonnes 217671E - SR-500L - (Serial No. 7110051)
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.
217671
背厚 11.5 mm (中)
217671
Cautions on setting outriggers
Inadequate setting of the outriggers or an error in setting the outrigger status to the ACS could result in the crane
tipping over. So be sure to check the following before starting work.
① Has the strength of the ground where the outriggers will be set been suffciently discussed with the work
supervisor ?
② Is the crane set horizontal ?
③ Are the tires off the ground ?
(0099-0001-1E)
[1]
All operations in accordance with lifting capacity chart
Make sure that all crane operations are in accordance with the
lifting capacity chart for the crane.
Accidents such as the crane tipping over or damage to the boom
etc. cannot be attributed but to operation beyond the lifting
capacity of the crane.
The 1st step toward safe operation is to set the crane level on firm
ground using the outriggers, and then operate according to the
lifting capacity chart.
Operation very close to or slightly in excess of the limits could
result in an accident.
Everyone including the crane operator and site supervisor must
perform work with a sufficient safety margin.
(0099-0002-1E)
Beware of wind !!
(0099-0003-1E)
[2]
Don't use the crane to lift the planet !!
If you use the crane to pull up or break off objects which have
been driven into the ground or buried (sheet piles, H-beams, posts,
pipes etc.), or if you try to drag a load toward the crane by raising
the boom, you place a strong diagonal load on the boom which
may exceed lifting capacity by many times. Pulling or breaking
off driven or buried objects by raising the boom is recklessly
dangerous as if you would use the crane to lift the planet.
Therefore raising the boom in any way that may apply diagonal
loads is forbidden. If you ignore the danger and the warning of
the ACS and continue such an operation, an excessive load will
act, possibly breaking the boom or the wire rope. Even if there is
no final collapse during operation, the crane will be damaged
resulting in progressive damage even when working within lifting
capacity and leading to sudden catastrophic failure.
(0099-0004-1E)
(T217591-026-0E)
[3]
Absolutely avoid releasing !!
(0099-0099-0E)
[4]
Introduction (0099-0045-1E)
All industrial products, including cranes, have a given expected service life that depends on the conditions and
frequency of use.
With respect to expected service life, this crane is classified in ISO 4301-1 and ISO 4301-2 standards with a "class of
utilization" of U2 and a "state of loading" of Q2, and the overall crane with a "group classification" of A1.
The "maximum number of operating cycles" varies depending on loading conditions. In particular, using the crane in an
unintended manner, such as indicated in the examples below, will shorten the expected service life.
・ Operating the crane with safety systems not functioning properly
・ Frequently hoisting loads that are at or near the rated load capacity
・ Operating the crane only in a limited number of working positions
・ Using operations that subject the crane to shock, such as suddenly winding up or stopping winches
・ Operating the crane when it has not been inspected or maintained properly
・ Operating the crane in harsh environments
(1) Modifications
If you modify this crane from the state in which it left our factory, you may impair its safety
or performance.
KATO bears no responsibility for accidents or malfunctions which arise as a result of
unauthorised modifications.
(2) Optional parts and attachments
Refer to the instruction manuals provided when you install genuine optional parts or
designated attachments. Attachments not designated by KATO may impair safety or
performance. They may cause tip-over accidents or have an adverse effect on the lifespan of
the crane.
KATO bears no responsibility for accidents or malfunctions which arise as a result of the
fitting of unauthorised attachments.
(0099-0100-0E)
[5]
How to use this manual (0099-0101-2E)
・ You must read this manual fully and understand its contents before
you operate, inspect or service this crane.
This manual is intended to be a guide to safe operation and regular
servicing so it should be kept in the designated place inside the cab
available to all those who use the crane.
・ The sections in this manual and safety signs on this crane include
safety information.
The labels " DANGER", " WARNING" and " CAUTION"
are used in this manual and safety signs on this crane, so that you
can understand the important items for safety operations and
procedures.
Read them fully and understand them before you operate, inspect or
service this crane.
Indicates warnings concerning 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]
Inspection and servicing (0099-0102-0E)
The inspection and servicing operations listed in this manual are a guide for extending the lifespan of the crane and
improving its work rate. Carry out the regular inspection and servicing tasks on the basis of this manual and regulations
of the country where the crane is used without fail.
This manual details the procedures for preoperational, monthly and annual inspection and servicing. Record the results
of each inspection and servicing measures taken in the separate "Inspection Sheet".
Refer to the separate "Service Manual" for servicing procedures for breakdowns and disassembly.
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)
・ 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]
Noise and vibration information (T217671-092-0E)
[8]
Recorded data (T217321-050-0E)
This machine includes an ACS system that immediately stops crane operations if the load exceeds the lifting capacity.
In addition to protecting the machine from damage or tipping over due to excessive loads, the ACS system also records
the following data whenever certain conditions are satisfied.
・ Date and time
・ Operation mode
・ Load value
・ Lifting capacity
・ Load ratio
・ Boom angle and length
・ Jib angle and length
・ Slewing angle
・ Outrigger setting value
In some cases, KATO, or an authorized third-party agent of KATO, may obtain and utilize the recorded data for
technical diagnostic purposes or for mobile crane research and development.
Disclosure of data
KATO, and agents of KATO, will not disclose or supply the data obtained to a third-party, except in any of the
following cases.
[9]
MEMO
[10]
Table of Contents (T217671-001-0E)
General devices
217671
(for driving and crane)
[11]
Crane operation 217671
Preoperational checks/
217671
Pre-drive checks
Index 217671
Separate
Manual Jib Section manual 217681
Separate
Inspection and Servicing Section manual 217691
Separate
ACS manual 217701
[12]
(T217671-002-0E)
General devices
217671
(for driving and crane)
-1-
1-1-2 General operation devices (T217321-003-0E) Refer to pages 17―32 for details of general operation devices.
-2-
(2) Outside the cab Refer to pages 33―36 for details of general operation devices.
-3-
1-1-3 Drive operation devices (T217321-004-0E) Refer to pages 77―83 and 92―102 for details of drive operation devices.
-4-
Refer to pages 84―91 for details of drive operation devices.
-5-
(2) Outside the cab Refer to pages 103―105 for details of drive operation devices.
-6-
1-1-4 Crane operation devices (T217321-005-0E) Refer to pages 155―165 for details of crane operation devices.
-7-
(2) Outside the cab Refer to pages 164 and 165 for details of crane operation devices.
-8-
1-2 Terms (T217671-003-0E)
The following names and terms are used frequently in this manual and they are defined as follows.
・Boom…………………………… 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.
・Load lifting off the ground …… Lifting the load and pausing briefly when the load is slightly clear off the ground.
・Front and rear, left and right…… The boom top with the machine in the driving configuration is defined as the
front. Rear, left and right are determined accordingly.
・Operation with outriggers……… 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 normally, always release the suspension lock. ( Release the
suspension lock when the crane operation is over).
・Stationary crane-on-rubber operation…… 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.
-9-
・Pick and carry operation………… Driving with the suspension cylinders locked and a lifting load held (without
crane operation).
・Boom angle ……………………… The angle between the boom center line and the horizontal.
The 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 lifting capacity value (except
the lifting capacity for jib use).
The value on the 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 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
・ 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 -
3. General operation devices (061A-0003-1E)
(1) Door
The door can be opened with a starter key. After you finish work, turn the starter switch to the off position and
always lock the door. The key should be kept by the operator.
Noise can be reduced by shutting the door during crane operation.
・ 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 normally.
・ Do not hang on to the door when getting on or off the cab.
(T217671-070-0E)
- 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 -
3) Front and rear height levers
You can adjust the height of the front or rear of the seat base
independently.
Operate either of the levers to raise or lower the seat base.
① Front height lever
The front edge rises or lowers, pivoting about the rear of the
seat.
② Rear height lever
The rear edge rises or lowers, pivoting about the front of the
seat.
4) Slide lever
You can adjust the position of the seat forward or backward.
Sit in the seat and adjust the seat position matching the
accelerator pedal.
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
① Press the removal button on the buckle to remove the tang
from the buckle.
② Sit in the seat and insert the tang into the buckle and push
until it clicks.
③ Pull the seatbelt as far as your hip and adjust the fastening
pulling the belt end through the tang.
- 20 -
(4) Interior lamp
ON ……… The lamp is switched on regardless of the door opening/
closing.
DOOR……The lamp is linked to the door to light when the door is
open.
OFF……… The lamp is switched off regardless of the door opening/
closing.
・ 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.
(T217671-005-0E)
(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 -
(8) Fuse box
If a fuse blows, investigate and repair the cause before replacing the fuse with a spare fuse from inside the fuse
box.
・ 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)
(9) Holders for the lifting capacity chart and instruction manual
- 22 -
(10) Keys
- 23 -
3-2 Front panel (T217671-006-0E)
(1) Starter switch
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)
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)
・ 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.)
- 24 -
(2) Idle speed knob
Normally leave idle speed set to "AUTO" .
Turning the knob clockwise about 30 degrees sets the idle speed to
"SLOW" for warm-up running. Turning it further clockwise sets it
to "FAST". Turning it back to "SLOW" reduces the engine
revolutions again.
If the door is left open for a long time in the half door position, the battery will run down.
(541A-0030-1E)
- 25 -
3-3 Side panel (T217671-007-0E)
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)
(2) Defroster switch
Use this switch to defrost the windscreen and side windows.
- 26 -
3-4 Radio (optional) (T217671-102-0E)
3) Display
Used to display the clock, radio frequency and operation mode.
- 27 -
7) Seek button (SEEK)
Pressing this button will automatically search for and stop at the
next available station.
5) To turn the radio OFF, turn the "VOL" knob to the left until it
clicks.
- 28 -
(4) Using the "SEEK" button to search for stations (automatically)
Pressing the "SEEK" button will cause the radio to automatically
start increasing the frequency until it finds a station. Once it finds
an available station, it will stop at that frequency.
2) Press the desired preset number, to which the current station will
be assigned, and hold it down for at least 2 seconds. When the
button number appears on the display, presetting is finished.
・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 -
(8) Automatic stereo/mono reception
If the signal from an FM station becomes too weak, due to distance, mountains, or other reasons, reception will
automatically switch from stereo to monaural modes to reduce undesired noise.
If the signal becomes stronger again, the radio will automatically switch back to the stereo broadcast.
- 30 -
3-5 Cabin air conditioner (611A-0008-0E)
Be sure to ventilate by opening a window before operating the air conditioner while parked in
hot weather.
(611A-0011-0E)
- 31 -
(2) Normal operation
To dehumidify the cab for increased comfort.
① Slide the temperature controller to the desired position.
② Slide the fan controller to the desired position.
・ 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 -
3-6 Outside the cab (T217671-008-0E)
・ 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 -
(3) Service switches
These switches are used exclusively for servicing the engine and automatic transmission and are set for normal
operation when shipped from KATO.
・ 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 remove the engine
cover when the engine is stopped.
・ When removing 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 removing the engine
cover to inspect the engine.
(T217671-009-0E)
・ Close and lock the engine cover firmly with the lock before you can start driving or operating
the crane.
・ Be careful not to pinch hands or other body parts when closing the cover.
(T217051-076-0E)
- 35 -
・ Due to the danger of rotating parts, such as the cooling fan and belts, only open the engine
inspection cover when the engine is stopped.
・ When opening the engine inspection cover, be careful of being burned by a hot engine
inspection cover, engine, or muffler cover. The engine inspection cover itself may become
very hot immediately after stopping the engine.
Therefore, make sure the engine has cooled down sufficiently before opening the engine
inspection cover to inspect the engine.
・ Leaving the engine inspection cover open can be dangerous as it may close unexpectedly from
wind gusts or other causes.
・ Do not open the engine inspection cover in strong winds.
(T217671-010-0E)
Securely tighten the engine inspection cover before driving or operating the crane.
(T217671-011-0E)
- 36 -
WARNING
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)
- 37 -
WARNING
[3]
Content: Notes for the lifting capacity chart
Location: Inside the cab
Part No.: 711-75103000
[3]
Content: Notes for crane operation
Location: Inside the cab
Part No.: 711-75103000
- 38 -
WARNING
[31]
Content: Precaution when changing the jib offset angle
Location: Inside the cab
Part No.: 899-81324512
[32]
Content: Lowering the left console and locking the
console lock lever when driving
Location: Front of the left control lever
Part No.: 899-81324712
[33]
Content: Note for the slewing range
Location: Inside the cab
Part No.: 899-81424892
- 39 -
WARNING
[34]
Content: Safety belt attachment point
Location: Hand grip on the left side of the slewing
upper structure
Part No.: 899-81503582
[49]
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
[53]
Content: Warning of suspension lock release with the
outriggers extended
Location: Inside the cab
Part No.: 371-75118001
[54]
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
- 40 -
WARNING
[67]
Content: Exhaust gas hazard
Location: Inside the cab
Part No.: 611-75113000
[69]
Content: Check list for outrigger setting
Location: Inside the cab
Part No.: 611-75116001
[73]
Content: Precautions when driving and handling the
brake lock
Location: Inside the cab
Part No.: 621-75109000
[74]
Content: Beware of tire slip.
Location: Inside the cab
Part No.: 621-75114000
[76]
Content: Warning when handling the accumulator
Location: Near the accumulator
Part No.: 707-75109001
- 41 -
WARNING
[77]
Meaning: Operation prohibition
Part No.: 707-75118001
[91]
Meaning: Beware of falling. Climb up and down with
care.
Location: Left side of the table
Part No.: 001-81302010
[92]
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
[93]
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 slewing
upper structure
Part No.: 001-81352015
- 42 -
WARNING
(2) Boom, jib
[11]
Content: Note for the guide fastening pin
Location: Right side of the rear end of the boom
Part No.: 899-81324382
- 43 -
WARNING
[12]
Content: Note for the jib fastening pin
Location: Right side of the rear end of the jib
Part No.: 899-81323582
[13]
Content: Note for the jib link pin
Location: Back side of the base bracket
Part No.: 899-81323682
[14]
Content: Note for the jib link pin
Location: Near the steps
Part No.: 899-81324612
- 44 -
WARNING
[15]
Meaning: Beware of the falling jib.
Location: Back side of the base bracket
Part No.: 899-81324082
[16]
Content: Precautions when stowing the tension rods
Location: Left side of the jib
Part No.: 899-81324182
[17]
Meaning: Beware not to pinch your hand or fingers.
Location: Left side of the jib
Part No.: 899-81324312
- 45 -
WARNING
[20]
Content: Safety belt attachment point
Location: Left and right sides of the boom top
Part No.: 899-81503582
[21]
Meaning: Read the instruction manual thoroughly
before operating the crane. When you cannot
understand how to manipulate the crane, read
the instruction manual repeatedly.
Location: Left and back sides of the jib, and right side
of the boom
Part No.: 001-81322001
[31]
Content: Note for the jib offset pin
Location: Left side of the jib
Part No.: 161-75115001
[32]
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
- 46 -
WARNING
[33]
Content: Note for the manual winch handle
Location: Right side of the rear end of the boom
Part No.: 921-75021001
[34]
Content: Watch your step.
Location: Top surface of the rear end of the boom, and
top surface of the jib
Part No.: 453-75010001
- 47 -
WARNING
(3) Lower structure
[4]
Meaning: Precaution when stowing the hook
Location: Beside the hook mount
Part No.: 711-75504000
[5]
Content: Warning when operating the outriggers
Location: Inside the cover of the outrigger control panel
Part No.: 711-75505000
- 48 -
WARNING
[14]
Content: Prohibition of high pressure cleaning
Location: Front and rear sides of the relay box
Part No.: 453-75006001
[20]
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
[21]
Meaning: Beware of falling. Climb up and down with
care.
Location: Near the steps
Part No.: 161-74809001
[33]
Content: Precautions on handling the battery
Location: Side of the battery cover
Part No.: 707-75122001
- 49 -
WARNING
[51]
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
[52]
Meaning: Beware of high temperature.
If touched carelessly, you will get burned or
serious injury.
Location: Near the exhaust pipe
Part No.: 001-81332003
[53]
Meaning: Never bring any flame or source of ignition
near the fuel tank and the oil reservoir.
Location: Side of the fuel tank and side of the oil
reservoir
Part No.: 001-81332005
[54]
Meaning: Climbing prohibition
Location: Top surface of the engine cover
Part No.: 001-81332011
[55]
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
- 50 -
WARNING
[56]
Meaning: Read the instruction manual thoroughly
before operating the crane. When you cannot
understand how to manipulate the crane, read
the instruction manual repeatedly.
Location: Inside of the control box
Part No.: 001-81322001
- 51 -
WARNING
・ 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 or
off the machine.
(541A-0043-3E)
- 52 -
WARNING
When working at elevated heights, wear a safety belt with the safety belt hook attached to an anchor point.
For details, refer to the safety belt manufacturer's instruction manual.
Connecting the safety belt hook to a location other than the anchor point could cause the person
wearing the belt to fall.
(T217681-051-0E)
- 53 -
WARNING
・ 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 filling…………Diesel fuel
Fuel tank capacity ……300L
- 54 -
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.
① Does not contain even fine dust
② Has adequate viscosity
③ Has a high cetane number
④ Has good low-temperature flowability
⑤ Has low sulfur content
⑥ Has low carbon residue
Use standard automotive diesel fuels (JIS K 2204, EN590, ASTM D975, GOST R52368, GB19147) 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)
- 55 -
MEMO
- 56 -
8. Starting and stopping the engine (541A-0054-0E)
Go through the "preoperational checks" before you start the engine then start it as described below.
(1) Check the position of the parking brake
Check that the parking brake switch is set to the "brake" side.
(2) Check the position of the shift lever
Always check that the shift lever is in the "N" position before you start the engine. The engine will not start if the
lever is in the wrong position.
(3) Check the status of the duplex communication system
When the starter switch is turned to the "ON" position, the status of the duplex communication system will be
checked for approximately 3 seconds. The buzzer will sound with all warning lamps lit. If no problem is detected,
the buzzer will stop and all warning lamps will go out.
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 seconds, release the key and wait for at least 20 seconds
before trying again.
(541A-0057-1E)
2) In cold weather
① 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.
② 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 ① above.
- 57 -
(5) Warm-up running
Once the engine has started, set the idle speed knob to the "AUTO" position enough to warm the engine and the
torque converter.
This warm-up time can be used for going through the after-starting engine tests.
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)
- 58 -
8-2 Stopping and parking (511A-0008-0E)
(1) Always apply the parking brake when parking the machine.
(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.
- 59 -
9. Handling the machine in winter and summer (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)
- 60 -
(4) Long Life Coolant
To prevent the engine coolant freezing during the shipping period between leaving the factory and arriving at the
point of delivery, the cooling system is filled with Long Life Coolant as shown below, regardless of the season.
(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.
Overheating can easily occur in summer, so pay attention to the following points.
(1) Cleaning and inspection of the cooling system
Overheating is more likely to occur when scale and corrosion build up in the cooling system.
Refer to "Cooling system" in the inspection and servicing section to clean the cooling system before summer starts.
Mud, dirt and insects etc. stuck to the core of the radiator will reduce its cooling performance, so make sure the
radiator is clean.
- 61 -
10. Transporting the machine on a trailer (T217671-093-0E)
If transporting the machine on a trailer, use the slinging rings indicated below. Fully lower the boom and stow the guard
rails and armrests.
・ Supporting the machine with only the tires can result in vertical oscillation that could damage
the machine due to excessive force on the derrick cylinder.
・ Supporting the machine with only the outriggers could result in inadequate friction between
the machine and trailer.
(T217671-101-0E)
・ Secure the hook to the top of the carrier frame.
・ Transporting the machine on a trailer with the boom raised could damage the derrick cylinder.
(T217671-094-0E)
- 62 -
(T217671-014-0E)
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 normally.
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 normally. Never
operate the crane in any way when driving normally.
- 63 -
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.
- 64 -
WARNING
(9) Pay attention to road surface conditions
Drive slowly and cautiously for maximum safety on snow-
covered 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.
- 65 -
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.
- 66 -
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.
- 67 -
MEMO
- 68 -
12. What to do when the machine breaks down (541A-0072-0E)
(1) If the machine breaks down, pay attention to following machines and traffic safety and start the machine's hazard
warning lamps flashing. Bring the machine gradually to a stop in a safe place.
(2) Post warnings to indicate that the machine has broken down. If you fail to post these warnings, following machines
could crash into the back of your machine. Always use one of the methods below to warn other drivers of the
breakdown.
(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.
- 69 -
12-2 Emergency power steering (541A-0075-1E)
This machine is equipped with an emergency steering pump connected directly to the transmission to enable power
steering in the event of sudden engine failure or steering pump breakdown while in motion.
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)
(1) If the "power steering pressure warning lamp" on the switch panel lights while the machine is in motion, leave
the starter switch "ON" and steer gently while checking the safety of your surroundings to roll to a stop in a safe
place.
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.
- 70 -
12-3 Handling a malfunction in the automatic transmission system (T217671-016-0E)
If a malfunction occurs in the automatic transmission, the AT/M malfunction warning lamp on the cluster meter panel
in the cab will light to alert the driver. Depending on the cause of the malfunction, the automatic shift control may not
function, in which case it will be impossible to go on driving. In this case, use the system switch (AT/M emergency
switch) which is located in the lower control panel on the right side of the lower structure. This will allow you to
continue driving using manual transmission.
- 71 -
・ 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.)
(541A-0077-3E)
- 72 -
12-4 Dealing with breakdowns (541A-0079-0E)
(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)
- 73 -
4) Display the "Do Not Operate" sign in a location easily visible
from the operator's seat.
・ 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.
・ 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.
(T217671-018-0E)
- 74 -
(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.
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".
- 75 -
・ 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)
- 76 -
13. Drive operation devices (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.
- 77 -
(6) Fuel gauge
Indicates how much fuel is remaining.
"F" indicates full and "E" indicates a small amount is remaining.
When the needle is pointing 0kPa (0kg/cm2) or below, stop the engine and contact your
authorised KATO dealer.
(541A-0087-1E)
- 78 -
(4) Shift position indicator lamp
The position lamp which corresponds to the position of the shift
lever lights.
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)
- 79 -
(8) Torque converter trouble warning lamp
This lamp lights when the pressure of oil supplied to the clutch
inside the torque converter goes below or above the rated pressure
or when the oil temperature inside the torque converter rises above
the rated temperature.
If the machine is driven when pressure is below the rated pressure,
the clutch for the transmission will wear away, so stop the machine
immediately and contact your authorised KATO dealer.
If any of the problem listed below occur, stop the machine
immediately and contact your authorised KATO dealer.
・ If pressure is above the rated pressure ……………… The warning lamp lights.
(The buzzer does not sound.)
・ If pressure is below the rated pressure……………… The buzzer sounds intermittently.
(0.5 seconds intervals)
・ If oil temperature is above the rated temperature … The buzzer sounds intermittently.
(1 second intervals)
・ If there is a problem with sensors or wiring………… The warning lamp flashes.
(541A-0090-0E)
(9) Exhaust brake indicator lamp
This lamp lights when the exhaust brake is operated.
The exhaust brake works when the accelerator is not operated
under the speed of 10km/h or more with the exhaust brake lever
being in the "ON".
・ 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)
- 80 -
Make sure the specialized driving indicator lamp is not lit before driving on public roads. If lit,
check the high/low speed switch, the steering mode switch, the two/four wheel drive switch and
the differential lock switch.
(T217671-020-0E)
If the indicator lamp lights, clean or replace the air cleaner filter element.
(541A-0093-0E)
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)
- 81 -
(15) Overrun warning lamp
When driving speed exceeds the rated speed or if the engine speed
exceeds the rated revolutions, this lamp lights and a slow
intermittent warning buzzer sounds. If this warning lamp lights,
you must apply the brakes to reduce speed and shift down to a
lower gear, then proceed at a safe speed.
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)
(16) Low air pressure warning lamp
This lamp lights when the compressed air pressure inside the air
tank falls below the rated level. If you release the parking brake
under this condition, an intermittent warning buzzer will sound.
After air pressure has been raised above the rated level, release the
parking brake and move off.
If any of the problems listed below occurs, stop the machine
immediately and contact your authorised KATO dealer.
- 82 -
(18) Parking brake/brake fluid level warning lamp
・This lamp lights and an intermittent buzzer sounds at 0.5 seconds
intervals irrespective of the condition of the parking brake when
the brake fluid level falls below the LOW level.
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.
・ 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)
- 83 -
13-2 Switch panel (541A-0097-0E)
- 84 -
(8) Suspension operation OK indicator lamp
This lamp lights when the following conditions for suspension
operation are satisfied.
・Boom angle ……………………… 50°
or less
・Boom length ……………………… Fully retracted
・Slewing upper structure position … Within front 0°
± 5°
Within rear 180°
± 5°
・PTO switch ……………………… OFF
・Shift lever ………………………… N (neutral) position
Suspension operation except suspension lock operation is only possible when the "suspension operation OK
indicator lamp" is lit.
- 85 -
(11) Digital display
This display indicates the battery voltage, hydraulic oil and torque
converter oil temperature, or rear steering angle. When an error
occurs, the hydraulic oil temperature indicator lamp and the battery
voltage indicator lamp go out and priority is given to the display of
the corresponding error numbers on the digital display.
When the voltage drops, the voltage is displayed irrespective of
PTO.
When the hydraulic oil is overheating, the temperature is displayed
irrespective of PTO.
1) When the PTO is "ON" (during crane operation)
When the hydraulic oil overheats, the hydraulic oil warning lamp lights on the switch panel and the current
value is displayed. The hydraulic oil temperature indicator lamp also 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 hydraulic oil temperature
irrespective of any alarms.
2) When the PTO is "OFF" (for driving normally)
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.
- 86 -
3) When the torque converter oil temperature display switch is pressed
When the "torque converter oil temperature display switch" on the switch panel is pressed to light the indicator
lamp while the parking brake is engaged, both the battery voltage and hydraulic oil temperature indicator lamps
will go out and the torque converter oil temperature will be displayed.
If the temperature is below 30℃, the display will be --- .
NOTE
When the maximum steering angle "9" is displayed, it will flash at 1 second intervals.
- 87 -
(2) Differential lock switch
This switch can be used to lock the differential gears, such as for
escaping from soft ground.
1) If you press this switch when the machine is stopped, the confirmation tone "pip" will sound and the differential
lock indicator lamp will flash (mode shifting) and light steadily, indicating that the front differential is locked.
The driving speed is also restricted to 15km/h.
2) If the two/four wheel drive switch is selected when the differential lock switch is selected, it will set the drive
mode to the four-wheel drive (4WD) mode and lock both the front and rear differentials.
3) If the drive mode is returned to the two-wheel drive mode, the rear differential is unlocked, so that only the front
differential remains locked.
If the differential lock switch is unlocked in the four-wheel drive (4WD) mode, the differential is unlocked and
the drive mode returns to the normal four-wheel drive (4WD) mode.
・ Use the differential lock in situations such as escaping from soft ground when the tires are
slipping.
・ Always leave the differential lock switched OFF during driving normally. Driving with the
differential locked for extended periods could cause mechanical damage.
・ Never use the steering when the differential is locked.
・ The differential may be difficult to lock after startup. Try locking the differential after the
machine has warmed up adequately.
If an unusual noise occurs when starting to move, try locking the differential again.
・ If the front or rear wheels start spinning freely, such as on soft ground, promptly engage the
differential lock.
Continuing to spin the wheels could cause the differential gears to seize up.
・ In general, the differential lock should only be used for slow straight driving on soft ground.
・ Never move the shift lever to any position except neutral when the outriggers are extended (with
the tires off the ground).
Letting the tires spin could damage the differential gears.
(T217671-023-0E)
- 88 -
(3) Two/four wheel drive switch
Use this switch to choose the driven wheels.
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 four-
wheel drive indicator lamp will flash (mode shifting) and light steadily, indicating that the machine is in four-
wheel drive mode.
2) If the differential lock switch is selected in the four-wheel drive (4WD) mode, it will lock both the front and rear
differentials. The driving speed is also restricted to 15km/h.
If the differential lock switch is unlocked, the differential is unlocked and the drive mode returns to the normal
four-wheel drive (4WD) mode.
・ Use the differential lock in situations such as escaping from soft ground when the tires are
slipping.
・ Always leave the differential lock switched OFF during driving normally. Driving with the
differential locked for extended periods could cause mechanical damage.
・ Never use the steering when the differential is locked.
・ The differential may be difficult to lock after startup. Try locking the differential after the
machine has warmed up adequately.
If an unusual noise occurs when starting to move, try locking the differential again.
・ If the front or rear wheels start spinning freely, such as on soft ground, promptly engage the
differential lock.
Continuing to spin the wheels could cause the differential gears to seize up.
・ In general, the differential lock should only be used for slow straight driving on soft ground.
・ Never move the shift lever to any position except neutral when the outriggers are extended (with
the tires off the ground).
Letting the tires spin could damage the differential gears.
(T217671-023-0E)
- 89 -
3) 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.
If the drive mode is returned to the two-wheel drive mode when the differential lock switch is selected, the rear
differential is unlocked, so that only the front differential remains locked.
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.
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.
- 90 -
(5) Brake lock switch
The brake lock switch applies the brakes on the front and rear wheels independently of the brake pedal.
This is an "auxiliary braking device for use during crane operation" which can be used together with the parking
brake while setting the outriggers or during stationary crane-on-rubber operation.
Before you use the brake lock, the engine must be running and the parking brake engaged. Press the brake lock
switch (ON) to activate the brake lock. The buzzer will sound until the brake lock is fully engaged. Once the brake
lock process is complete, the brake lock indicator lamp will light and the buzzer will stop.
The engine must keep running while the brake lock is engaged.
To release the brake lock, press the switch again while the parking brake is engaged to turn it back to the "OFF"
position.
When the indicator lamp goes out, the brake lock has disengaged.
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)
- 91 -
13-3 Front and side panel switches (541A-0103-0E)
When you lock or release the suspension, the following conditions must be satisfied.
Suspension control is only possible when the "suspension operation OK indicator lamp" is lit.
- 92 -
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 operation OK 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-0060-1E)
- 93 -
(3) Rear steering lock/release switch
This switch is used to lock or release the rear steering
automatically.
When you release the rear steering lock, set the switch to the
release side while pressing the lock button.
- 94 -
(4) Parking brake switch
Press the lock button and push the switch to "release" side to
release the parking brake.
・ 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 is engaged, the parking brake indicator lamp will
flash and the warning buzzer will sound.
(541A-0111-1E)
- 95 -
13-3-2 Side panel (611A-0021-0E)
(1) Shift lever
This lever shifts the transmission gear as follows.
R…… To drive the machine in reverse
N…… To start the engine and keep it running in neutral
D…… For normal driving
(Gear ratio varies automatically to suit all speeds from
moving off to high speed.)
3…… Use this setting to apply engine brake, fixing speed range to
a maximum of speed 3.
2…… Use this setting to apply engine brake, fixing speed range to
a maximum of speed 2.
1…… Use this setting to apply strong engine brake, fixing speed
range to a maximum of speed 1.
・ 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.
- 96 -
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".
- 97 -
13-4 Accelerator and brake pedals (541A-0117-0E)
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 (500-900kPa (5-9kgf/
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)
- 98 -
13-5 Steering column (541A-0119-0E)
・ 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)
- 99 -
13-5-2 Combination switch (611A-0069-0E)
The combination switch is mounted on the steering column. The steering column incorporates the following switches.
(1) Combination switch
The combination switch has the following switching functions.
・Windscreen wiper switch
・Windscreen washer switch
・Exhaust brake lever
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)
- 100 -
3) Exhaust brake lever
Use the exhaust brake to increase the effect of engine braking
while driving down a long slope.
Move the lever to the "ON" position and take your foot off the
accelerator pedal to activate the exhaust brake.
The exhaust brake will disengage when you depress the
accelerator pedal again.
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.
- 101 -
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.
Switch panel
Night illumination of driving switches
Headlamps Off Lit
(T217671-026-0E)
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
( ) on the cluster meter panel also lights.
・Passing …… Move the lever toward you in any lighting
switch position to turn the headlamps to high
beam only for as long as you lift the lever. The
high beam indicator lamp on the cluster meter
panel also lights while the headlamps are on
high beam. When you let go of the lever, it will
return to its central position and high beam
will be canceled.
- 102 -
13-6 Lower control switches (611A-0022-0E)
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
1 0 -16km/h
2 16-23km/h
3 23-34km/h
D 34-48km/h
(T217671-103-0E)
・ When the AT/M emergency switch is switched
to the "emergency" side, the lockup
mechanism is released, so engine braking will
not function.
Reduce the driving speed not to overuse the
brakes.
(541A-0077-3E)
- 103 -
(2) Rear steering emergency switch (for lower structure)
If the rear steering cannot be locked or released automatically by the action of the rear steering lock/release switch
(when the multiplex communication error warning lamp lights or when any rear-steering related device is
malfunctioning etc.), use the "rear steering emergency switch" located on the lower control panel on the side of the
lower structure to temporarily switch the steering manually so that you can continue working.
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)
- 104 -
・ 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
Slow flash (2 seconds): Mode shifting (Lock ⇔ Release)
Lit: Release confirmed
Fast flash (0.4 seconds): Error status
- 105 -
14. Driving the machine (371A-0038-0E)
Check the relevant safety regulations and laws in the country concerned before you drive this machine on the road.
The machine must always be in the position shown below for normal
driving.
(1) Fully retract the boom and stow the jib and rooster sheave.
(2) Stow the auxiliary hook in the specified position.
(3) Fasten the main hook in its stowage position on the front side of
the machine.
(4) Fully retract the derrick cylinder and face the boom forward with
respect to the machine.
(5) Engage the slewing brake and slewing lock to immobilized the
slewing upper structure.
(6) Fully retract the four vertical cylinders and the four horizontal
cylinders to stow the outriggers. Always insert the stopper pins and
check that the outriggers are completely stowed away.
(7) Always set the PTO switch to "OFF".
- 106 -
(10) Return the suspension from locked to free state. The procedure for returning the suspension to the free state is as
follows.
① Move the shift lever to the "N" position.
② Check that the suspension operation OK indicator lamp is lit.
③ 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)
(11) Check that the specialized driving indicator lamp is not lit.
(12) Check that no warning lamps are lit.
(13) Check that the turn signal lamps flash correctly.
(14) Check that the foot brake operates and that the brake lamps lights.
(15) Check that the crane working lamps are not lit.
(16) Check that each lamp etc. lights.
(17) Check that the needle of the engine water temperature gauge is above point "C".
(18) Check that the covers of the engine, toolbox and lower control switch panel are closed and locked.
(19) Check that the guard rails and winch view camera are stowed.
- 107 -
14-2 General driving (611A-0024-0E)
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.
- 108 -
Precautions when driving down a slope
1. Make a constant habit of testing your brakes before starting to move down a steep slope or a
long gentle slope. If you notice during the descent that your brakes are weak, there is nothing
you can do about it.
2. Do not use the foot brake excessively while driving.
Instead reduce speed by engine braking through appropriate down-shifting and use the exhaust
brake, supplementing these as necessary with short bursts of foot brake. Excessive use of the
foot brake risks overheating and reduced braking force as well as bubbling in the brake fluid
(vapor lock) which can completely disable the foot brake. Intermittent use of the foot brake
serves to minimize heating and allows adequate braking force. Use of the brake for long
periods with the pedal depressed half way leads to overheating which reduces braking force
and invites accidents.
3. After periods of parking or brief stops, depress the brake pedal to check brake function before
you move off again. For a short period after stopping the machine (5-20 minutes), the heat of
the brake is transmitted through the brake fluid, so the temperature of the brake fluid is higher
than it was while the machine was in motion. The brake fluid can become very hot after heavy
brake use on a long downhill or after a sudden stop. If the machine is at rest after that, bubbles
can form in the brake fluid, completely disabling the foot brake.
If you do not notice this situation until after you start driving, it is already too late. Instead
make a habit of applying the foot brake as you start to move the machine to gauge its strength.
4. Take care not to overrun the engine when driving downhill.
Excessive speed while driving downhill can cause the engine to overrun. If the engine
overruns, the overrun warning lamp lights and an intermittent buzzer sounds. If this happens,
use the foot brake immediately to reduce speed.
Engine overrun can cause seizure and ultimately destruction of the engine, so take care to
avoid it.
5. Before starting to descend a steep slope, choose the gear that you would use to climb that
slope and shift to that position.
6. Exercise caution when shifting down to descend a steep slope.
If shifting down does not reduce speed adequately, shifting down to another lower position
will not shift the transmission.
If you are driving down a slope with gear 1, 2 or 3 selected and the machine's speed exceeds
the allowable speed range for the gear you are using, the transmission will automatically shift
up to accommodate the machine's speed. In this case any engine braking effect will be lost.
Take great care to ensure that the machine's speed does not exceed the range for the shift
position you have chosen.
(611A-0025-1E)
- 109 -
14-3 Specialized driving (T217671-061-0E)
Check that the lamps on the high/low speed switch, rear steering lock/release switch, differential
lock switch and two/four wheel drive switch are not lit before driving normally.
(T217671-028-0E)
- 110 -
2) Switching from low range to high range
・ 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)
- 111 -
14-3-2 Rear steering (611A-0070-0E)
(1) Releasing the rear steering lock
1) Stop the machine.
2) In order to release the rear steering lock, set the rear steering lock/release switch to the release side. While it is
releasing, a buzzer sounds and the rear steering lock release confirmation indicator lamp flashes rapidly. When
the buzzer stops and the rear steering lock release confirmation indicator lamp lights steadily, the release process
is complete and rear steering is possible, independent of the front wheel steering.
- 112 -
(2) Rear steering
1) Release the rear steering lock (the rear steering lock release
confirmation indicator lamp is lit) and the rear steering (rear
wheels) can be done to the left and right using the rear steering
switch on the side panel.
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
- 113 -
(3) Locking the rear steering
1) Stop the machine.
2) In order to lock the rear steering, set the rear steering lock/release switch to the lock side.
While it is locking, a buzzer sounds and the rear steering lock release confirmation indicator lamp flashes rapidly.
When the buzzer stops and the rear steering lock release confirmation indicator lamp goes out, the locking
process is complete.
- 114 -
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".)
- 115 -
2) Switching from four-wheel drive to two-wheel drive
This switching operation is only possible in high range.
NOTE
When low range has been selected, two-wheel drive is unavailable.
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)
- 116 -
14-3-4 Locking the differential (T217671-072-0E)
Lock the differential gears, such as for escaping from soft ground.
(1) Setting the differential lock mode
Lock the differential gears, such as for escaping from soft ground where you cannot drive in the normal mode. Set
the differential lock switch to "ON" when the machine is stopped. The confirmation lamp will light and the driving
speed will be restricted to 15km/h.
・ Use the differential lock in situations such as escaping from soft ground when the tires are
slipping.
・ Always leave the differential lock switched OFF during driving on public roads. Driving with
the differential locked for extended periods could cause mechanical damage.
・ Never perform the steering or rear steering operation when the differential is locked.
If you do so, the warning buzzer will sound continuously.
・ The differential may be difficult to lock after startup. Try locking the differential after the
machine has warmed up adequately.
If an unusual noise occurs when starting to move, try locking the differential again.
・ If the front or rear wheels start spinning freely, such as on soft ground, promptly engage the
differential lock.
Continuing to spin the wheels could cause the differential gears to seize up.
・ In general, the differential lock should only be used for slow straight driving on soft ground.
・ Never move the shift lever to any position except neutral when the outriggers are extended (with
the tires off the ground).
Letting the tires spin could damage the differential gears.
(T217671-073-0E)
NOTE
If the four-wheel drive mode is selected when the differential is locked or the differential is locked when the
four-wheel drive mode is selected, both the front and rear differentials will be locked.
- 117 -
MEMO
- 118 -
(T217671-029-0E)
18. Crane operation when the outriggers are used ………………………………………… 166
18-1 Suspension operation ……………………………………………………………………………………… 168
18-2 PTO switch operation ……………………………………………………………………………………… 171
18-3 Precautions on setting the outriggers ……………………………………………………………………… 173
18-4 Outrigger control panel …………………………………………………………………………………… 176
18-5 Outrigger setting and stowage procedures ………………………………………………………………… 179
18-6 Stowing and releasing the main hook ……………………………………………………………………… 183
・ 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.
- 119 -
WARNING
(4) No entry into the working area
People, objects etc. should be absolutely prohibited from
entering into the crane working area. Always be aware of your
surroundings while you work.
- 120 -
WARNING
4) When visibility is bad due to fog, snow, rain or other
conditions, stop work and do not start again until conditions
have cleared enough to no longer reduce visibility.
(7) 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.
- 121 -
WARNING
1) Measures for safety
・Contact the managing company in advance and fit protective
devices such as tubular coverings and warning signs.
・Arrange appropriate guides at the necessary places to have
them watch the progress of the works.
・Keep a safe distance between the crane and the power cables.
Before you start work, the electricity company should be
consulted on the location and voltage of cables on the site and
the necessary isolation distance.
・Allow nobody to come near around the crane when you are
working in the neighborhood of power transmission lines.
3) Emergency measures
If it is an urgent need to rescue the operator injured by electric shock from the crane carrier cab being charged
with electricity, proceed as follow:
1. Move the crane to detach it from the current charging source such as a power transmission line. At this time,
pay attention to the power transmission line because it may be cut and fall down.
2. After the crane is moved out of the range under influence of the electric charge, check to confirm that the
crane carrier cab is not in charged condition. Then, rescue the operator injured with electric shock and take
the steps to transfer him to a hospital.
4) Escape from cab being charged with electricity
It is the best to stay in the cab until the electric power company stops the power transmission through the lines
with which the crane is or may come in contact. However, if it is not possible, operate the crane such that it is
brought out of the range under influence of electric charge and jump out of the cab.
- 122 -
WARNING
If the machine is in the following conditions, jump out of the cab as distant from the machine as possible
immediately after leaving the operator seat. Be careful that any part of your body does not come in contact with
the machine after landing. Contacting with the machine can lead to an electric shock.
1. The engine cannot be operated.
2. The crane is damaged and inoperable.
3. The cut power transmission cable cannot be detached from the crane structure.
4. Other emergent conditions
5) Be sure to use the machine involved in such an accident only after being inspected at your authorized KATO
dealer.
- 123 -
WARNING
2) Emergency measures
If it is an urgent need to rescue the operator injured by electric shock from the cab being charged with electricity,
proceed as follow:
1. Move the crane to detach it from the current charging source such as a power transmission line.
2. Confirm that the cab is not in charged condition. Then, rescue the operator injured with electric shock and
take the steps to transfer him to a hospital.
3) Escape from the cab being charged with electricity
If the machine is in the following conditions, jump out of the cab as distant from the machine as possible
immediately after leaving the operator’s seat. Be careful that any part of your body does not come in contact
with the machine after landing. Contacting with the machine can lead to an electric shock.
1. The engine cannot be operated.
2. The crane is damaged and inoperable.
3. Other emergent conditions
4) Be sure to use the machine involved in such an accident only after being inspected at your authorised KATO
dealer.
- 124 -
WARNING
(13) 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.
- 125 -
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.
- 126 -
WARNING
- 127 -
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.
- 128 -
WARNING
・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.
- 129 -
WARNING
(3) Lock the suspension with the suspension lock cylinders before
setting the outriggers.
(5) Avoid crane operations with any of four outriggers not extended
fully
If it is inevitable to operate the crane with outriggers extended
halfway, retracted to the minimum length or not used at all,
obtain permission of the worksite manager before beginning
with the work. Also, perform the operations more carefully and
slowly while bearing the motto "safety first" in mind.
- 130 -
WARNING
(6) Set up the crane level
A leaning crane compromises stability and strength. This
reduces the effective lifting capacity and can cause the crane to
tip over. Use the level gauge to make sure the crane is level.
(8) 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.
- 131 -
WARNING
15-2-3 Precautions on operation (T217671-031-0E)
(1) Do not lift loads in excess of the lifting capacity
If you lift loads in excess of the lifting capacity, an excessive
load acts on the crane which could cause it to break or tip over.
Before you start work, always confirm lifting capacity from the
lifting capacity chart. Lifting capacity varies with boom length
and working radius. Take care never to exceed the lifting
capacity under any circumstances.
- 132 -
WARNING
(5) Use utmost care to crane up objects from under the water
・When drawing up an object from under the water, the crane can
be subjected to almost the same load as when drawing it out of
the ground. Objects containing water may be far heavier than
estimated. When craning up an object from under water, always
perform it slowly so that the time for the water to escape from
the object will be left.
・Do not attempt to draw up the object without pause. It will
become heavier as soon as it is drawn out of water because any
buoyancy no longer acts on it.
- 133 -
WARNING
(9) No careless crane operation
If you are careless in operating the crane, the slightest slip or
inattention can result in a major accident. Be constantly alert to
ensure that the boom or the suspended load do not collide with
people or buildings and that the load does not collide with the
boom or outriggers.
(10) 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.
- 134 -
WARNING
(13) 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.
- 135 -
WARNING
(16) Consider deflection of the boom when hoisting a load
When a load is lifted, the boom deflects, increasing the working
radius. Particularly when working with a very heavy load or a
long boom, allow an extra margin below the lifting capacity to
allow for alteration of the working radius due to boom
deflection under the load.
(18) 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.
(19) Before moving your load sideways, check the safety of your
surroundings
People under the load or in contact with the slewing upper
structure 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.
- 136 -
WARNING
(20) 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.
- 137 -
WARNING
(24) 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.
- 138 -
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.
- 139 -
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.
- 140 -
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.
- 141 -
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.
- 142 -
WARNING
(2) Set the working configuration setting of the ACS correctly
according to the actual work to be done.
- 143 -
WARNING
15-2-10 Stationary crane-on-rubber operations (0099-0164-1E)
(1) Strictly follow the cautionary instructions given in the
instruction manual.
(2) The lifting capacity of the crane varies greatly from position to
position. Pay heed to this difference in particular when slewing
the boom.
(3) Select the "Stationary crane-on-rubber operation" as the
outrigger status on the ACS.
(4) Apply the suspension lock (with the suspension lock cylinders
fully retracted) and check that the "Suspension locked" lamp
comes to illuminate.
(5) Apply the parking brake.
(6) Inspect the tire inflation pressure and charge air if it is below the
specified value.
(7) Never perform such jobs as required to use the jib or to extend
the boom beyond the specified length.
(8) Perform the stationary crane-on-rubber operation while the
machine is placed on a level firm ground.
If you operate the crane without retracting the suspension cylinders fully, the machine could tip
over.
(T217671-065-0E)
- 144 -
WARNING
(1) Stow the boom (jib) away after you have finished work
Leaving the crane in its working position can inadvertently
cause accidents. At the end of work, stow the boom (jib) and
lock it.
- 145 -
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.
- 146 -
16. How to read the capacity charts (541A-0145-0E)
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.
- 147 -
16-2 How to read the lifting capacity chart (541A-0147-3E)
The 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-0148-2E)
(1) When you are going to operate the crane, find the outrigger status on the lifting capacity chart.
(2) Look at the column for the boom length with which you will be working.
(3) Find the 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 lifting capacity chart.
NOTE
For jib use, find the lifting capacity from the boom angle and the jib offset angle.
- 148 -
16-3 Precautions on crane operation (541A-0149-2E)
Familiarize yourself with the following points before you start to operate the crane. There is a safety sign of the lifting
capacity chart inside the cab on which the summary of these same points is also given. Always read them before you
start to operate the crane.
(7) The lifting capacity of the rooster sheave is the lifting capacity of the boom minus the mass of all attached hook,
slings etc. to the boom, with an upper limit of 5,000kg.
[The hook for use with the rooster sheave is the 5 ton hook (mass: 120kg) with one part of line.]
(8) If the boom length, boom angle and/or working radius exceeds the rated value, use the lifting capacity for the rated
value or for the next one, whichever gives the smaller lifting capacity.
(9) If you are working with the boom while the jib is rigged, subtract 3.0 ton plus the mass of all attached hook, slings
etc. to the boom from the each lifting capacity of the boom, with an upper limit of 18 ton.
Do not use the rooster sheave in this situation. And do not operate the boom while the jib is rigged, when the
outriggers are completely retracted.
(10) In whatever working conditions the corresponding boom critical angle is shown in the chart. The crane can tip over
if the boom is lowered below the critical angle even if unloaded. Therefore, never lower the boom below these
angles.
(11) If you work with 11 parts of line on the hook (with * marked in the lifting capacity chart), use the rooster sheave.
- 149 -
(12) The standard parts of line for each boom length are as indicated in the chart. If you work with a non-standard
number of parts of line, do not exceed 45.1 kN (4.6 tf) per wire rope respectively.
(13) High-speed winch operation should only be performed to allow descent of the hook alone. Avoid sudden lever
operation.
(14) 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.
Refer to the beaufort scale for wind conditions.
(15) Kato bears no liability whatsoever for damage, crane tipping or other accident caused by crane operations which
differ from the directions contained in the instruction manual and the warning labels.
Stationary crane-on-rubber
Crane operation Pick and carry operation
operation
Area α° 1 1
(T217671-091-0E)
(5) The lifting capacity of the rooster sheave is the lifting capacity of the boom minus the mass of all attached hook,
slings etc. to the boom, with an upper limit of 5,000kg.
[The hook for use with the rooster sheave is the 5 ton hook (mass: 120kg) with one part of line.]
(6) Do not work with the jib or with a boom length of more than 26.9m.
(7) For stationary crane-on-rubber operation, the parking brake and service brake lock device must be engaged.
(8) For pick and carry operation, the super-slow speed switch must be switched to "ON" and the shift lever set to
speed 1.
(9) For pick and carry operation, lower the load to just above the ground and keep your speed strictly below 2km/h to
avoid swinging the load. Take particular care to avoid sharp turns, sudden starts and stops.
(10) Never operate the crane during pick and carry operation. The slewing brake must be applied.
(11) If the boom length, boom angle and/or working radius exceeds the rated value, use the lifting capacity for the rated
value or for the next one, whichever gives the smaller lifting capacity.
- 150 -
(12) The standard parts of line for each boom length are as indicated in the chart. If you work with a non-standard
number of parts of line, do not exceed 45.1 kN (4.6 tf) per wire rope respectively.
(13) High-speed winch operation should only be performed to allow descent of the hook alone. Avoid sudden lever
operation.
(14) 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.
Refer to the beaufort scale for wind conditions.
NOTE
Beaufort scale
Beaufort Wind
Description Land conditions
number [m/s] [km/h]
0 Calm 0-0.2 1 Calm. Smoke rises vertically.
Smoke drift indicates wind direction. Leaves
1 Light air 0.3-1.5 1-5
and wind vanes are stationary.
Wind felt on exposed skin. Leaves rustle. Wind
2 Light breeze 1.6-3.3 6-11
vanes begin to move.
Leaves and small twigs constantly moving, light
3 Gentle breeze 3.4-5.4 12-19
flags extended.
Dust and loose paper raised. Small branches
4 Moderate breeze 5.5-7.9 20-28
begin to move.
Branches of a moderate size move. Small trees
5 Fresh breeze 8.0-10.7 29-38
in leaf begin to sway.
Large branches in motion. Whistling heard in
overhead wires.
6 Strong breeze 10.8-13.8 39-49
Umbrella use becomes difficult. Empty plastic
bins tip over.
High wind,
Whole trees in motion. Effort needed to walk
7 moderate gale, 13.9-17.1 50-61
against the wind.
near gale
Some twigs broken from trees. Cars veer on
8 Gale, fresh gale 17.2-20.7 62-74
road. Progress on foot is seriously impeded.
Some branches break off trees, and some small
trees blow over.
9 Strong/severs gale 20.8-24.4 75-88
Construction/temporary signs and barricades
blow over.
Trees are broken off or uprooted, structural
10 Storm, whole gale 24.5-28.4 89-102
damage likely.
Widespread vegetation and structural damage
11 Violent storm 28.5-32.6 103-117
likely.
Severe widespread damage to vegetation and
12 Hurricane force ≧32.7 ≧118 structures.
Debris and unsecured objects are hurled about.
(T217671-066-0E)
(15) Kato bears no liability whatsoever for damage, crane tipping or other accident caused by crane operations which
differ from the directions contained in the instruction manual and the warning labels.
- 151 -
16-3-3 Precautions on using the ACS (T217671-036-0E)
If you use the ACS which monitors crane safety incorrectly, a major accident could result.
Therefore read the separate ACS instruction manual and the following points thoroughly and operate the ACS correctly
as described. There is a safety sign permanently in the crane operation cab which gives these same points. Read them
before you start to operate the crane.
(1) The ACS will only work correctly provided you strictly adhere to the lifting capacity and the warnings and
provisions noted in the instruction manual and safety signs.
(2) Do not subject the ACS body, display panel and sensors to excessive shock.
(3) If the PTO switch is not set to the "ON" side, the outriggers cannot be moved and no settings to the ACS can be
made.
(4) Precautions on operating the ACS set switches
1) Press the switches lightly with an attached touch pen or your
finger. Do not use sharp objects such as a ballpoint pen or pencil.
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.
- 152 -
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.
(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 keys of the ACS emergency switch and bridging device key switch have
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 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 lifting capacity to
a zone of smaller capacity, work throughout within the lower capacity.
(881A-0066-1E)
(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 normally, with the exception of pick and carry
operation and on-site moving.
(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.
- 153 -
16-3-4 Crane performance tracks (when using outriggers) (541A-0293-0E)
- 154 -
17. Crane operation devices (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 slewing upper structure regardless of the slewing brake switch position.
・ Before you drive normally, move the slewing upper structure 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).
(T217671-074-0E)
- 155 -
(2) ACS emergency switch (self-reset type)
In an emergency such as a malfunction in ACS-related devices or
crane stop etc. has occurred, set this switch to the "release" position
to take appropriate emergency actions regardless of the ACS.
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)
(3) Level gauge
Use this gauge to confirm that the crane is level when supported
on the outriggers.
When you get out of the operator's seat, set this switch to the "OFF" position.
(611A-0072-0E)
(5) Slewing brake switch
If this switch is set to the "brake" position, the slewing brake will
be applied.
Setting this switch to the "release" position will disengage the
slewing brake.
- 156 -
(6) Main winch switch
When operating the main winch, set this switch to the "ON"
position.
If the main winch is not in use, set this switch to the "OFF"
position to prevent misoperation etc.
This switch is used to shut off the engine in an emergency if the engine does not stop when the starter switch is
turned to the "ACC" or "OFF" position.
Push this switch to shut off the engine and then release the lock by pulling out the switch or turning it to the right.
・ If the engine does not stop when the starter switch is turned to the "ACC" position, contact
your authorised KATO dealer immediately.
・ After the engine has stopped, release the lock by pulling out the switch or turning it to the
right. If you leave the starter key in the "ACC" or "ON" position with the engine stopped, the
battery will run down.
・ Never use the engine stop emergency switch to shut off the engine under normal conditions.
・ You can shut off the engine only when the shift lever is in the "N" position and the PTO
switch is in the "ON" position.
(T217671-038-0E)
- 157 -
17-2 Side panel (T217671-039-0E)
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)
・ Do not operate the winch at high speed when lifting a load. Doing so is dangerous.
・ Do not operate the winch lever suddenly. Doing so is dangerous.
(T217671-075-0E)
- 158 -
(6) Drum rotation detector switch
The rotation of the winch drum which is selected by this switch is
detected during winch operation and a buzzer will sound to
indicate that the winch drum is rotating.
NOTE
The buzzer sound is the same for hoisting and lowering.
NOTE
The buzzer sound becomes faster the faster the drum rotates.
When the drum speeds up f urther, the buzzer sounds
continuously and then dies away.
- 159 -
17-3 Control levers and pedals (T217671-040-0E)
(1) Left control lever
1) Slewing operation
Set the slewing brake switch to the "release" position before
slewing operation.
: Set the crane operation switch to the "ON" position and push
the left control lever right to slew the crane right.
: Set the crane operation switch to the "ON" position and push
the left control lever left to slew the crane left.
- 160 -
(3) Right control lever
1) Boom derricking/lowering operation
: Set the crane operation switch to the "ON" position and push
the right control lever left to derrick the boom.
: Set the crane operation switch to the "ON" position and push
the right control lever right to lower the boom.
- 161 -
(5) Accelerator pedal
This pedal controls the operation speed during crane operation.
Sudden acceleration during crane operation is dangerous. Always
try to work the accelerator smoothly.
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 2215min-1 (2215r.p.m.).
- 162 -
(6) Console lock lever
Before starting work, check that the console lock lever is in the lock position.
Pull the console lock lever toward you and raise the left console (left control lever) before you get out of your seat
and leave the cab.
・ 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.
- 163 -
17-4 K-COR (T217671-076-0E)
(1) Refer to the K-COR instruction manual for details.
The bridging device key 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 bridging device key switch is set to the "release" position intentionally when operating the
crane, the crane tipping over or other serious accident can be caused.
(T217671-042-0E)
- 164 -
17-6 Lower control switch panel (541A-0169-2E)
・ As a general rule, the outrigger control panel inside the cab should be used. Only use the
outrigger control panel on the side of the carrier in an emergency.
・ 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.
(T217671-077-0E)
When you use the outrigger emergency switch to stow the outriggers, always set the crane to the
driving position.
(121A-0079-0E)
- 165 -
18. Crane operation when the outriggers are used (T217671-043-0E)
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)
- 166 -
(2) After crane operation
Before driving normally, always follow the procedure below to change the machine's position from crane operation
condition to a position suitable for driving.
Always follow the specified procedure and precautions strictly to set the machine in its driving
configuration before you drive normally.
Normal driving with the crane in an incorrect position could cause severe accidents.
(T217671-044-0E)
- 167 -
18-1 Suspension operation (541A-0373-0E)
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 normally.
・ 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.
・ Never drive normally with the suspension locked.
Always release the suspension lock before you move the machine normally.
(T217671-045-0E)
- 168 -
18-1-1 Suspension retraction procedure (611A-0036-0E)
(1) Set the crane to the following conditions.
・Fully retract the boom and lower it to a boom angle of at least 50°
・Check that the slewing upper structure is within ±5°of the front or rear facing.
・Check that the PTO switch is in the "OFF" position.
・Check that the shift lever is in the "N" position.
・Check that the suspension operation OK indicator lamp is lit.
(2) Move the suspension lock/release switch to the "suspension lock" side.
(3) Move the suspension retraction switch to the "suspension retraction" side to retract the suspension.
(4) Once the suspension lock cylinders have retracted, release the suspension retraction switch.
(5) The suspension locked indicator lamp will light.
- 169 -
18-1-2 Suspension lock release procedure (611A-0037-0E)
・ Release the suspension lock and return the machine to the driving position before you move
the machine normally.
Never drive normally with the suspension lock cylinders retracted.
・ Only retract and lock the suspension when the machine is on firm, level ground with the
outriggers stowed.
(T217671-046-0E)
- 170 -
18-2 PTO switch operation (T217671-100-0E)
After locking the suspension, hold the engine at idling speed and move
the PTO switch on the right side of the front panel to the "ON" position.
At this time, the PTO indicator lamp on the switch panel will light.
・ 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 slewing upper structure regardless of the slewing brake switch position.
・ Before you drive normally, move the slewing upper structure 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".
(T217671-047-0E)
Work the PTO switch with the idle speed knob set to "AUTO".
(611A-0079-0E)
- 171 -
ON
OFF
- 172 -
18-3 Precautions on setting the outriggers (T217671-078-0E)
The outrigger control switches are located on the side of the carrier body and inside the cab. As a general rule, the
outrigger control panel inside the cab should be used. Only use the outrigger control panel on the side of the carrier in
an emergency.
When the outriggers are used, the load values in the 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.
- 173 -
(1) Outrigger reaction forces
Never operate the crane on soft ground. The ground must be
reinforced appropriately for supporting the crane (such as by
using steel plates to increase the supportable load).
In order to properly reinforce the ground to ensure the crane can
be operated safely, it is necessary to determine how much force
the ground can support. In other words, it requires calculating
the outrigger reaction force.
(2) 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.
(3) 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 lifting capacity.
(541A-0180-2E)
- 174 -
(4) Check that the suspension lock cylinders are fully retracted (suspension locked) before you set the outriggers.
(5) 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.
(6) Check that nobody is near the outriggers and under the machine before you set the outriggers.
(7) 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.
(8) 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.
(9) 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.
(10) 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.)
(11) 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.
(12) 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.
- 175 -
18-4 Outrigger control panel (T217671-048-0E)
- 176 -
2) Horizontal/vertical selection switches
Use these switches to select horizontal or vertical outrigger
operation.
When you press the switch, a "pip" confirmation tone sounds
and the indicator lamp for the selected operation lights. Press the
same switch again or the other switch (horizontal or vertical) to
cancel the selection.
The selected indicator lamp will go out to indicate that the
selection has been canceled.
・ 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)
- 177 -
(2) Control panel on the side of the lower structure
1) Extension/retraction switch (self-reset type)
Use this switch to extend or retract the horizontal or vertical cylinders.
2) Horizontal/vertical combined selection switch
Use to operate all the horizontal cylinders or all the vertical cylinders simultaneously. Move this switch to the
correct side for the cylinders you want to use.
When you select this switch and use the extension/retraction switch, the engine speed will increase automatically.
3) Horizontal/vertical individual selection switches
In order to operate each outrigger individually, select the relevant horizontal or vertical cylinder. When you
select the individual switch and use the extension/retraction switch, the engine speed will not increase.
1 Right-front horizontal/vertical selection switch
2 Left-front horizontal/vertical selection switch
3 Right-rear horizontal/vertical selection switch
4 Left-rear horizontal/vertical selection switch
・ Only use the outrigger control panel on the side of the lower structure in an emergency.
・ 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.
(T217671-079-0E)
- 178 -
18-5 Outrigger setting and stowage procedures (061A-0085-0E)
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.
- 179 -
(4) Vertical cylinder extension
・ 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)
- 180 -
18-5-2 Outrigger stowage procedure (061A-0080-4E)
When you are going to stow the outriggers, always set the slewing upper structure to the driving position as shown in
the diagram below.
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)
- 181 -
(3) Vertical cylinder retraction
Move the selection switch to the vertical side and the extension/retraction switch to the "retraction" side to retract
the vertical cylinders fully.
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.
- 182 -
18-6 Stowing and releasing the main hook (T217671-050-0E)
Before driving, always stow the main hook in front of the frame.
If you drive with the hook hanging unstowed, you could cause an accident for the following reasons.
(1) The swinging hook could obstruct another vehicle.
(2) If you stop the machine suddenly, the boom could be extended by inertia.
(3) If the hook is stowed on the top surface of the frame, follow Steps 1) and 2).
If the hook is stowed in front of the frame, follow Step 3).
・ 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)
- 183 -
1) Remove the hook fastening bracket.
2) 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 fastening
wire rope.
3) 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 fastening wire rope.
・ 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)
- 184 -
18-6-2 Hook stowing procedure (T217671-052-0E)
(1) Extend the four outriggers to the intermediate extension position
or more and confirm that the ACS display matches the actual
outrigger status.
(2) Set the ACS working status to "jib setting".
・ Always refer to the separate "ACS instruction manual" for ACS operation.
・ When "jib setting" is set to the ACS, the overhoisting detector is disabled, so work with extra
attention to the position of the hook.
(541A-0189-1E)
(3) If you stow the hook on the top surface of the frame, follow Steps 1)
to 4).
If you stow the hook in front of the frame, follow Step 5) to 7).
1) Fully retract the boom and move the hook so it is directly above
the hook fastening wire rope.
2) Lower the winch so that the hook can be hooked into the wire rope.
・ Take care that the hook does not touch the cab.
・ Stow the hook so that the hook part faces toward the cab.
(491A-0057-0E)
- 185 -
3) Hook the hook into the hook fastening wire rope.
NOTE
If the hook fastening wire rope is attached in front of the frame, replace the rope on the top surface of the frame.
4) 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.
When stowing the hook, always lay the hook block section to the left or right. If the boom is
lowered while the block section is still standing up, it could hit and damage the derrick cylinder.
(4210-0198-1E)
・ 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 machine could be damaged.
(T217671-067-0E)
- 186 -
5) Fully retract the boom and move the hook so it is directly above
the hook fastening wire rope in front of the frame.
6) Lower the winch so that the hook can be hooked into the hook fastening wire rope.
Take care that the hook does not touch the front bumper.
(T217671-080-0E)
NOTE
If the hook fastening wire rope is attached on the top surface of the frame, replace the rope in front of the frame.
At this time, take care that the wire rope does not get too tightened.
If excessive tension is applied to the wire rope, the machine could be damaged.
(T217671-081-0E)
(4) Before driving normally after stowing the hook, set the machine in the driving position.
(5) Stow the four outriggers and insert the stopper pins to check that the outriggers are stowed completely.
(6) Set the PTO switch to the "OFF" position.
- 187 -
19. Crane operation without outriggers (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.
(541A-0172-0E)
- 188 -
19-1 Precautions on crane operation without outriggers (T217671-053-0E)
In addition to normal crane operation with the outriggers set, this machine can perform some lifting tasks (stationary
crane-on-rubber operation and pick and carry operation) without using the outriggers.
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 [505/95 R25: 800kPa (8.00kgf/cm2), 23.5-25: 475kPa (4.75kgf/cm2) <optional>], 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 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 retracted fully.
・ 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.
(T217671-068-0E)
- 189 -
19-2 Stationary crane-on-rubber operation (T217671-054-0E)
・ 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)
- 190 -
(2) Procedure for stationary crane-on-rubber operation
1) Recheck the working area.
Check again that the ground in the area where you are going to perform stationary crane-on-rubber operation is
firm and level.
If the ground is crumbly or muddy, stationary crane-on-rubber operation will not be possible there.
2) Recheck the lifting capacity chart.
Recheck the rated load, boom length and other conditions for the stationary crane-on-rubber operation and
perform according to the values in the relevant lifting capacity chart.
3) Recheck the tire pressure.
4) Lock the suspension.
5) Set the ACS working status.
Set the "stationary crane-on-rubber operation" on the "working
status setting screen".
Any mistake in setting the ACS working status can be extremely
dangerous.
6) When you have finished setting the ACS working status, proceed
with crane operation.
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)
- 191 -
19-3 Pick and carry operation (511A-0029-1E)
・ 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)
- 192 -
1) Recheck the working area.
Check again that the ground in the area where you are going to perform pick and carry operation is firm and
level.
If the ground is crumbly or muddy, pick and carry operation will not be possible there.
2) Recheck the lifting capacity chart.
Recheck the rated load, boom length and other conditions for the pick and carry operation and perform
according to the values in the relevant lifting capacity chart.
3) Recheck the tire pressure.
4) Lock the suspension.
Lock the suspension with the cylinders fully retracted.
5) Set the ACS working status.
Set the "pick and carry operation" on the "working status setting
screen".
Any mistake in setting the ACS working status can be extremely
dangerous.
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)
- 193 -
20. Crane operation (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.
- 194 -
(6) Confirming that the keys of the ACS emergency switch and bridging device key switch have been extracted
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)
(7) Lever position
Sit in the operator's seat and lock the console lock lever to set it to the working position.
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)
- 195 -
20-1-2 Precautions when operating the crane (T217671-082-0E)
(1) While operating the crane, pay attention to the ACS display status, the illumination status of the safety level bar
graph, the sound alarms, and voice alarms. In particular, it is necessary to be especially cautious during slewing
operations.
(2) If the ACS automatically stops the crane motion, immediately take measures to avoid the danger, such as by raising
the boom, retracting the boom, lowering the load, or reversing the slewing direction.
(3) If an error code is shown on the ACS auxiliary display, perform an inspection of the problem and contact your
authorised KATO dealer if the error cannot be resolved.
(4) Strictly observe the ACS operating precautions noted in the section 16-3-3.
(5) Outrigger floats lifting off the ground during crane operations
When a load is hoisted in an orientation diagonal with respect to
the carrier, the diagonally opposite outrigger float sometimes lifts
off the ground. However, this does not mean it lifts off the ground
because the crane is near its stability limit. Rather, it occurs due to
flexure of the carrier frame. Since the distance from the center of
slewing to the outrigger intersection point is farther in the diagonal
directions than in the fore-aft or lateral directions, the diagonal
direction is more stable. Consequently, if the total load is within
the lifting capacity and the crane is positioned level on level firm
ground, then there should be no problem with stability, even if an
outrigger float lifts off the ground.
- 196 -
20-2 Boom derricking and lowering (4210-3247-0E)
: Set the crane operation switch to the "ON" position and push the right control lever left to derrick the boom.
: Set the crane operation switch to the "ON" position and push the right control lever right to lower the boom.
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)
Depending to the slewing position when lowering the boom to a low angle, a voice alarm
("Danger") is emitted and a warning is displayed on the ACS screen to notify the operator that
the boom or jib has entered a region where it is at risk of colliding with the engine cover, mirror,
or other parts. If that occurs, stop slewing (toward the danger) or lowering the boom.
(T217671-083-0E)
- 197 -
Precautions on derricking and lowering the boom
・ Work the lever gently.
Sudden lever operation causes strong shocks in the structure of the crane, particularly when a
load is suspended, so work with care.
・ The working radius increases as the boom lowers, possibly causing an overload which could
tip the crane, so proceed with caution.
・ Never try to drag a load sideway or toward the crane by derricking the boom.
・ Rapid, careless derricking and lowering of the
boom causes the hook to swing and strike the
underside of the boom, making dents and
deformation which harm the boom. Be
particularly careful when the boom angle is
large and when the hook is close to the boom
top.
(4210-0040-0E)
- 198 -
20-3 Hoisting and lowering (T217671-084-0E)
: Set the crane operation switch and main or auxiliary winch switch to the "ON" positions and pull the right or left
control lever backward to wind up the winch.
: Set the crane operation switch and main or auxiliary winch switch to the "ON" positions and push the right or left
control lever forward to lower the winch.
NOTE
The buzzer sound becomes faster the faster the drum rotates.
When the drum speeds up f urther, the buzzer sounds
continuously and then dies away.
(6) Main winch high speed switch
(7) Auxiliary winch high speed switch
If the winch is not lifting a load, setting the winch high speed
switch to the "ON" position and operating the winch lever operates
the winch at high speed.
- 199 -
・ Do not operate the winch at high speed when lifting a load. Doing so is dangerous.
・ Do not operate the winch lever suddenly. Doing so is dangerous.
(T217671-075-0E)
・ 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)
(611A-0042-1E)
NOTE
Using the flow control system, you can hoist or lower the load at a constant speed regardless of the weight of the
load.
- 200 -
20-4 Boom extension and retraction (T217671-056-0E)
Extend : Set the crane operation switch to the "ON" position and depress the boom extension/retraction pedal forward
to extend the boom.
Retract: Set the crane operation switch to the "ON" position and depress the boom extension/retraction pedal
backward to retract the boom.
- 201 -
・ 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 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.
(T217671-058-1E)
- 202 -
20-5 Slewing (T217671-085-0E)
: Set the crane operation switch to the "ON" position and push the left control lever left to slew the crane left.
: Set the crane operation switch to the "ON" position and push the left control lever right to slew the crane right.
- 203 -
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 slewing upper structure stops
suddenly, causing the load to swing and affecting the structure of the crane adversely, so work carefully in this
case.
If the machine is equipped with an optional slewing alarm, an external warning alarm will sound when the
slewing control lever is operated.
・ If slewing the boom with the boom lowered, be careful not to damage the engine cover or
other parts.
・ Depending on the boom angle when slewing the boom with the boom at a low angle, a
warning sound ("pip") is emitted and a warning is displayed on the ACS screen to notify the
operator that the boom or jib has entered a region where it is at risk of colliding with the
engine cover or other parts. If that occurs, stop slewing (toward the danger) or lowering the
boom.
(T217671-086-0E)
- 204 -
20-6 Function of the "slewing stop system" (511A-0057-0E)
When the outriggers are not fully extended, the "slewing stop system" functions by using the ACS to predict how much
the crane load will increase as it slews and when the crane is about to enter a region specified in the ACS as restricted
from slewing, then gently slowing the slewing movement and automatically stopping slewing before it causes a
dangerous situation, such as the crane becoming overloaded or entering a restricted region. However, this system will
not function properly unless it is level.
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)
- 205 -
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-0047-1E)
Slewing position
Voice warning Warning sound Slewing status Display
(slewing angle)
A ――――― ――――― Start ―――
"Caution when slewing" Operator
B ――――― ―――
(emitted 1 time) determined speed
Automatic
B-C ――――― ――――― ―――
deceleration
*: 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)
- 206 -
20-6-2 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 slew-
restricted 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)
- 207 -
Slewing position
Voice warning Warning sound Slewing status Display
(slewing angle)
A ――――― ――――― Start ―――
"Caution when slewing" Operator
B ――――― ―――
(emitted 1 time) determined speed
Automatic
B-C ――――― ――――― ―――
deceleration
*: 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)
- 208 -
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.
(611A-0052-0E)
- 209 -
(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.
- 210 -
2) Voice warning, warning chime or emergency sound emitted
depending on extent of entry into restricted region
If slewing does not stop automatically immediately before the
restricted region, but overruns into the region 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 far it slewed into the restricted region, to
notify the operator of the danger.
In addition, even if slewing is reversed to escape the restricted
region, the warning sound will continue until the crane is no
longer in the restricted region.
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" malfunctioning, always report the situation to the safety manager and
obtain their permission.
(611A-0055-1E)
- 211 -
21. Changing the wire rope number of parts (541A-0245-0E)
The standard hook and number of parts of line for each boom length are as shown in the table below. If you use a non-
standard number of parts of line, observe a limit of 45.1kN (4.6tf) on each part of wire rope.
・ 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)
- 212 -
21-2 Changing the wire rope number of parts (T217671-088-0E)
(1) Set the outriggers. Then retract and lower the boom fully and slew
it to the side or front.
(2) Remove the rope retaining pins from the boom top.
(4) Refer to the table for the wire rope standard number of parts to
change the wire rope number of parts of line.
- 213 -
・ 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)
- 214 -
(T217671-097-0E)
Preoperational checks/
217671
Pre-drive checks
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)
- 215 -
22-1 Pre-drive checks (511A-0073-0E)
Before After
Inspection procedure Notes
Inspection location Inspection item start start
Excluding machines
Pedal stroke length ○ equipped with air
brakes
Brake pedal
Braking system
Hydraulic suspension
sion
○
functionality
The battery electrolyte level should be between the
"UPPER" and "LOWER" levels.
Electrical
system
Battery Battery fluid level ○ If the level is at "LOWER" or below, top it up to the
"UPPER" level with battery electrolyte or distilled
water.
- 216 -
Daily
Inspection/servicing item inspection
Before After
Inspection procedure Notes
Inspection location Inspection item start start
level. Use the level gauge to check the level of the 15L
Lubrication system Oil level ○
engine oil and add more oil if the level is low. Change
the engine oil if it is extremely dirty.
Inspect water separator Look at the level gauge on the water separator to check Remove water
Fuel system ○
and remove water how much moisture there is in the fuel. properly.
Excessive slack in the fan belt can cause overheating
and inadequate generation by the alternator. Excessive
Loosening, tension status,
○ tension can damage the engine bearings and snap the
or damage of the fan belt
fan belt. Check the tension of the fan belt and adjust it
if necessary.
The engine should be cool when you check the coolant Total coolant volume:
Cooling system level. Make sure that the body of the machine is level about 30L
and use the level gauge on the side of the reserve tank Engine: 13L
Water level in radiator
to check the coolant level. Radiator: 9L
and other parts of the ○
The coolant level should lie between the "FULL" and Sub-tank: 1.5L
cooling system
"LOW" levels. If the level is "LOW" or below, add (When FULL)
more coolant through the cap on the top of the reserve Piping: 4L
tank.
・ Work the combination switch to check that the
headlamps, clearance lamps, tail lamps, meter lights
etc. light normally.
・ Turn the headlamps on and use the lever on the left
side of the combination switch to switch between
high beam and low beam.
At the same time, check that the high beam indicator
lamp lights at the right time.
・ Use the lever on the left side of the combination
Lighting and flashing switch to check that all the turn signal lamps on the
Lamps and turn indicators ○
status, dirt, or damage machine light normally, and at the same time confirm
that all indicator lamps are flashing.
・ Keep the pressure reading on the pressure gauge
above 500kPa (5kgf/cm2) and depress the brake pedal
to check that the brake lamps light.
・ Engage the parking brake and then move the shift
lever to "R" to check that the reverse lamp lights and
the reverse buzzer sounds.
If the parking brake is not engaged, the machine
could start reversing which is hazardous.
Work the wiper switch to check that the wiper works
Windscreen washer fluid
Warning sound emitter, ○ and that it switches normally between high and low
level and spraying status
windscreen wipers, windscreen speed. Also check that the wiper blade is not damaged.
washer, defroster, and lock Press the button on the wiper switch to check that water
Windscreen wiper wiping
system ○ sprays well out of the spray nozzle, the nozzle is not
status blocked and the reservoir is not empty.
Condensation in the air
Air compressor ○
tank
When sitting in the cab, always adjust the mirror
Rear view mirrors and reflectors Image status ○ positions and clean them if necessary to get an adequate
field of view.
Location of anything unusual Check for any problems
○
noticed during driving at corresponding location
Oil leakage from any part
Others ○
of the chassis
(T217671-064-0E)
- 217 -
22-1-2 Points for pre-drive checks (511A-0076-0E)
- 218 -
- 219 -
- 220 -
- 221 -
22-2 Preoperational checks (511A-0077-0E)
defective
Inspection location
When
Part Task Inspection procedure Notes
and service task Before After
start start
Check the engine oil when the machine is parked Engine oil volume:
on the level. Use the level gauge to check the 15L
Check oil
Oil pan Engine oil ○ level of the engine oil and add more oil if the Oil pan: 11L
level
level is low. Change the engine oil if it is Oil filter: 2.3L
extremely dirty. Others: 1.7L
Radiator core, fin The engine should be cool when you check the Total coolant volume:
Inspect ○
and tank coolant level. Make sure that the body of the about 30L
Check machine is level and use the level gauge on the Engine: 13L
Coolant ○
water level side of the reserve tank to check the coolant Radiator: 9L
Radiator level. Sub-tank: 1.5L
Cracks and damage The coolant level should lie between the "FULL" (When FULL)
to hoses of the Inspect ○ and "LOW" levels. If the level is "LOW" or Piping: 4L
cooling system below, add more coolant through the cap on the
top of the reserve tank.
Look at the air cleaner blockage warning
Air cleaner element Inspect ○ indicator lamp on the cluster meter panel to
check how dirty the air cleaner element is.
Check oil Look at the fuel gauge in the cab to check how Fuel tank volume:
Fuel tank ○
level much fuel is left. 300L
Check for Look at the level gauge on the water separator to Remove water
Fuel system
- 222 -
Engine
defective
Inspection location
When
Part Task Inspection procedure Notes
and service task Before After
start start
・ Af ter starting the engine, depress the
accelerator pedal and check the following. If
you notice anything abnormal, stop the engine
Pedal slack and play Inspect ○ immediately and investigate the cause.
・ Does the engine rise smoothly to high
Engine-related
Accelerator
Abnormal noise on
Slewing-related
gear
Bearing Inspect ○
slewing
Move the slewing brake switch to the "brake"
Slewing brake action Inspect ○ side then check that the superstructure does not
slew even when you work the slewing control.
Attachment bolt Inspect ○ Check the hook for play, abnormal wear, screw
deformation, damage to the wire rope retainer,
Bearing play Inspect ○
opening of the key etc.
Sheave wear Inspect
Winch-related
○
Hook Wire rope retainer Inspect ○
Hook Inspect ○
34 ton hook
Protector attachment bolt Inspect ○
(51 ton hook)
Wire rope Inspect ○
Boom extension/retraction wire rope Inspect ○
Boom-related
- 223 -
Engine
defective
Inspection location
When
Part Task Inspection procedure Notes
and service task Before After
start start
Defroster Inspect ○
Refrigerant gas Inspect ○
Air conditioner Belt tension Inspect ○
Condenser Clean ○
Clean and
○
Filter inspect
Replace ○
・ Check the tire pressure with a tire gauge while Air pressure: 800kPa
the tires are still cool before driving anywhere. (8.00kgf/cm2)
Adjust the pressure as necessary to the rated Tire size:
pressure. 505/95 R25 183E
・ Check that there is no damage to the sidewalls
and no cracks or abnormal wear to the treads.
Replace any tires which have exposed canvas,
Air pressure Inspect ○ regardless of their age.
・ Check whether the treads are worn to the limit Air pressure 475kpa
of use. Also check for metal fragments, nails, (4.75kgf/cm2)
Tires stones and other foreign bodies stuck into the Tire size
Drive-related
- 224 -
Engine
defective
Inspection location
When
Part Task Inspection procedure Notes
and service task Before After
start start
The battery electrolyte level should be between
Check the "UPPER" and "LOWER" levels.
Battery electrolyte ○ If the level is at "LOWER" or below, top it up to
volume the "UPPER" level with battery electrolyte or
distilled water.
Press the horn switch when the pressure in the
Check
Warning horn ○ air tank is high enough and check that it sounds
action
normally.
Work the wiper switch to check that the wiper
works and that it switches normally between
high and low speed. Also check that the wiper
Check
Wiper ○ blade is not damaged. Press the button on the
action
wiper switch to check that water sprays well out
of the spray nozzle, the nozzle is not blocked
and the reservoir is not empty.
・ Work the combination switch to check that
the headlamps, clearance lamps, tail lamps,
Electrical system
- 225 -
Engine
defective
Inspection location
When
Part Task Inspection procedure Notes
and service task Before After
start start
Check that the indicator lamps do not indicate
Cluster meter panel Inspect ○ ○ any problem. If there is any problem, you must
stop the engine and investigate the cause.
Cab-control and steering systems
- 226 -
22-2-2 Points for preoperational checks (511A-0079-0E)
- 227 -
- 228 -
- 229 -
- 230 -
(T217671-063-0E)
Index 217671
A
Accelerator pedal …………………………………………………………………………………………… 98, 162
Accessory socket …………………………………………………………………………………………………… 25
ACS emergency switch (self-reset type) ………………………………………………………………………… 156
Air cleaner blockage warning indicator lamp ……………………………………………………………………… 81
Air pressure gauge ………………………………………………………………………………………………… 78
Armrest ………………………………………………………………………………………………………… 163
AT/M (automatic transmission) malfunction warning lamp ……………………………………………………… 79
AT/M emergency switch ………………………………………………………………………………………… 103
Auxiliary winch high speed switch ……………………………………………………………………………… 158
Auxiliary winch switch ………………………………………………………………………………………… 157
B
Battery charge indicator lamp ……………………………………………………………………………………… 82
Boom extension/retraction pedal ………………………………………………………………………………… 161
Brake lock switch ………………………………………………………………………………………………… 91
Brake pedal ………………………………………………………………………………………………………… 98
Bridging device key switch (self-reset type) …………………………………………………………………… 164
C
Cabin air conditioner ……………………………………………………………………………………………… 31
Combination switch …………………………………………………………………………………………… 100
Console lock lever ……………………………………………………………………………………………… 163
Crane operation switch ………………………………………………………………………………………… 156
D
Defroster switch …………………………………………………………………………………………………… 26
Diagnostic indicator lamps ………………………………………………………………………………………… 34
Differential lock indicator lamp …………………………………………………………………………………… 83
Differential lock switch …………………………………………………………………………………………… 88
Digital display ……………………………………………………………………………………………………… 86
Dimmer switch ………………………………………………………………………………………………… 102
Door ……………………………………………………………………………………………………………… 17
Drum rotation detector switch …………………………………………………………………………………… 159
- 231 -
E
Emergency kit ……………………………………………………………………………………………………… 23
Engine control warning lamp ……………………………………………………………………………………… 81
Engine cover ……………………………………………………………………………………………………… 35
Engine inspection cover …………………………………………………………………………………………… 35
Engine oil pressure gauge ………………………………………………………………………………………… 78
Engine stop emergency switch ………………………………………………………………………………… 157
Engine trouble warning lamp ……………………………………………………………………………………… 79
Engine water temperature gauge …………………………………………………………………………………… 78
Exhaust brake indicator lamp ……………………………………………………………………………………… 80
Exhaust brake lever ……………………………………………………………………………………………… 101
F
Fire extinguisher (optional) ………………………………………………………………………………………… 23
Fuel gauge ………………………………………………………………………………………………………… 78
Fuel level warning lamp …………………………………………………………………………………………… 80
Fuse box ……………………………………………………………………………………………………… 22, 33
H
Hazard warning switch …………………………………………………………………………………………… 95
Heater switch (optional) …………………………………………………………………………………………… 26
Height and angle adjustment lock lever …………………………………………………………………………… 99
High beam indicator lamp ………………………………………………………………………………………… 78
High/low speed switch …………………………………………………………………………………………… 90
Holders for the lifting capacity chart and instruction manual ……………………………………………………… 22
Horn switch ………………………………………………………………………………………………………… 99
Hour meter ………………………………………………………………………………………………………… 77
Hydraulic oil warning lamp ……………………………………………………………………………………… 84
I
Idle speed knob …………………………………………………………………………………………………… 25
Interior lamp ……………………………………………………………………………………………………… 21
K
K-COR ………………………………………………………………………………………………………… 164
Keys ……………………………………………………………………………………………………………… 23
L
Left control lever………………………………………………………………………………………………… 160
Left window ……………………………………………………………………………………………………… 21
Level gauge ……………………………………………………………………………………………………… 156
Lighting switch ………………………………………………………………………………………………… 102
Low air pressure warning lamp …………………………………………………………………………………… 82
- 232 -
M
Main winch high speed switch ………………………………………………………………………………… 158
Main winch switch ……………………………………………………………………………………………… 157
Multiplex communication error warning lamp …………………………………………………………………… 84
O
Odometer/trip meter switch………………………………………………………………………………………… 77
Outrigger control panel ………………………………………………………………………………………… 165
Outrigger emergency switch (self-rest type) …………………………………………………………………… 165
Outrigger operation OK indicator lamp …………………………………………………………………………… 84
Overhoisting emergency switch (self-reset type)………………………………………………………………… 158
Overrun warning lamp …………………………………………………………………………………………… 82
P
Parking brake switch ……………………………………………………………………………………………… 95
Parking brake/brake fluid level warning lamp …………………………………………………………………… 83
Power steering pressure warning lamp …………………………………………………………………………… 84
Preheat indicator lamp …………………………………………………………………………………………… 81
PTO (Power Take Off) switch …………………………………………………………………………………… 155
PTO indicator lamp ………………………………………………………………………………………………… 84
R
Radiator coolant level warning lamp ……………………………………………………………………………… 79
Radio (optional) …………………………………………………………………………………………………… 27
Radio aerial ………………………………………………………………………………………………………… 36
Rear steering emergency switch (for lower structure) …………………………………………………………… 104
Rear steering lock release confirmation indicator lamp …………………………………………………………… 85
Rear steering lock release indicator lamp ………………………………………………………………………… 83
Rear steering lock/release switch ………………………………………………………………………………… 94
Rear steering switch (self-reset type) ……………………………………………………………………………… 97
Rear window ……………………………………………………………………………………………………… 23
Revolving warning lamp switch (optional) ………………………………………………………………………… 95
Right control lever ……………………………………………………………………………………………… 161
Roof window wiper/washer switch ………………………………………………………………………………… 26
S
Seat ………………………………………………………………………………………………………………… 18
Seatbelt …………………………………………………………………………………………………………… 20
Service switches …………………………………………………………………………………………………… 34
Shift lever ………………………………………………………………………………………………………… 96
Shift position indicator lamp ……………………………………………………………………………………… 79
Slewing alarm button …………………………………………………………………………………………… 160
Slewing brake switch …………………………………………………………………………………………… 156
Slewing free/lock switch ………………………………………………………………………………………… 158
Slewing warning lamp switch …………………………………………………………………………………… 158
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Specialized driving indicator lamp ………………………………………………………………………………… 80
Speedometer ……………………………………………………………………………………………………… 77
Starter switch ……………………………………………………………………………………………………… 24
Step lamp switch ……………………………………………………………………………………………… 25, 95
Sun visor …………………………………………………………………………………………………………… 21
Sunshade …………………………………………………………………………………………………………… 21
Suspension lock/release switch …………………………………………………………………………………… 92
Suspension locked indicator lamp ………………………………………………………………………………… 84
Suspension operation OK indicator lamp ………………………………………………………………………… 85
Suspension retraction switch ……………………………………………………………………………………… 93
T
Tachometer ………………………………………………………………………………………………………… 77
Torque converter oil temperature display switch…………………………………………………………………… 87
Torque converter trouble warning lamp …………………………………………………………………………… 80
Turn signal and dimmer switch ………………………………………………………………………………… 101
Turn signal indicator lamp (left) …………………………………………………………………………………… 78
Turn signal indicator lamp (right) ………………………………………………………………………………… 78
Turn signal switch ……………………………………………………………………………………………… 101
Two/four wheel drive switch ……………………………………………………………………………………… 89
W
Washer tank………………………………………………………………………………………………………… 33
Winch lighting switch (optional) ………………………………………………………………………………… 159
Windscreen washer switch ……………………………………………………………………………………… 100
Windscreen wiper switch ……………………………………………………………………………………… 100
Working lamp indicator lamp ……………………………………………………………………………………… 84
Working lamp switch …………………………………………………………………………………………… 159
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9-37, Higashi-ohi 1-chome, Shinagawa-ku, Tokyo 140-0011 Japan.
Tel. : Head Office Tokyo (03) 3458-1111
Overseas Marketing Department Tokyo (03) 3458-1115
Fax. : Tokyo (03) 3458-1163
URL http://www.kato-works.co.jp
150206TI 6.2016-50(TI)1
899-92176710