Kato SR-300L Instruction Manual Download Page 11

Page: 11 / 233

[9]

Table of Contents

(611A-0001-0E)

Introduction

…………………………………………………………………………………………

[5]

How to use this manual

……………………………………………………………………………

[6]

Inspection and servicing

……………………………………………………………………………

[7]

Serial number nameplate

…………………………………………………………………………

[7]

Operation qualifications

……………………………………………………………………………

[7]

General devices

(for driving and crane)

214521

1. Part names and terms

…………………………………………………………………………

2. For safe operation

……………………………………………………………………………

3. General operation devices

……………………………………………………………………

4. Safety signs

……………………………………………………………………………………

5. Precautions on getting on and off the machine

……………………………………………

6. Precautions when filling with fuel

……………………………………………………………

7. Starting and stopping the engine

……………………………………………………………

8. Handling the machine in winter and summer

………………………………………………

Driving operation

214521

9. Driving safely

……………………………………………………………………………………

10. What to do when the machine breaks down

………………………………………………

11. Drive operation devices

………………………………………………………………………

12. Driving the machine

……………………………………………………………………………

Crane operation

214521

13. For safe operation

…………………………………………………………………………

105

14. How to read the capacity charts

……………………………………………………………

129

15. Crane operation devices

……………………………………………………………………

137

16. Crane operation when the outriggers are used

…………………………………………

147

17. Crane operation without outriggers

………………………………………………………

168

18. Crane operation

……………………………………………………………………………

175

19. Changing the wire rope number of parts

…………………………………………………

192

Summary of Contents for SR-300L

Page 1: ...h 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 anyb...

Page 2: ...SR 300L 214521 11 5 mm...

Page 3: ...ure to check the following before starting work Has the strength of the ground where the outriggers will be set been suffciently discussed with the work supervisor Is the crane set horizontal Are the...

Page 4: ...utriggers and then operate according to the rated lifting capacity chart Operation very close to or slightly in excess of the limits could result in an accident Everyone including the crane operator a...

Page 5: ...ore 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 breaki...

Page 6: ...4 MEMO...

Page 7: ...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...

Page 8: ...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 circumstanc...

Page 9: ...r to the separate Service Manual for servicing procedures for breakdowns and disassembly Serial number nameplate 0099 0221 0E When you order parts or repairs from your authorised KATO dealer please he...

Page 10: ...8 MEMO...

Page 11: ...recautions when filling with fuel 47 7 Starting and stopping the engine 49 8 Handling the machine in winter and summer 52 Driving operation 214521 9 Driving safely 55 10 What to do when the machine br...

Page 12: ...perational checks Pre drive checks 214521 20 Preoperational checks Pre drive checks 195 Index 214521 Index 211 Manual Jib Section Separate manual 214531 Inspection and Servicing Section Separate manua...

Page 13: ...17 3 2 Front panel 24 3 3 Side panel 26 3 4 Radio optional 27 3 5 Cabin air conditioner 31 3 6 Outside the cab 33 4 Safety signs 37 5 Precautions on getting on and off the machine 46 6 Precautions whe...

Page 14: ...1 1 Part names and terms 541A 0019 0E 1 1 Part names 541A 0020 0E 1 1 1 Exterior 541A 0268 0E...

Page 15: ...2 MEMO...

Page 16: ...ade 8 Flare optional 9 Fuse box 10 Holders for the rated lifting capacity chart and instruction manual 11 Keys 12 Fire extinguisher optional 13 Emergency kit 14 Rear window 3 2 Front panel 1 Lighter 2...

Page 17: ...4 For details of this page Refer to pages 33 36 2 Outside the cab...

Page 18: ...tion 1 Multiplex communication error warning lamp 2 PTO indicator lamp 3 Working lamp indicator lamp 4 Outrigger operation OK indicator lamp 5 Hydraulic oil warning lamp 6 Suspension locked indicator...

Page 19: ...6 For details of this page Refer to pages 92 and 93 2 Outside the cab...

Page 20: ...ch 8 Boom extension retraction switch 15 2 Side panel 1 Overhoisting emergency switch self reset type 2 Boom extension retraction emergency switch self reset type 3 Jib side lifting switch self reset...

Page 21: ...8 For details of this page Refer to page 146 2 Outside the cab...

Page 22: ...rrier 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 m...

Page 23: ...y 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 ri...

Page 24: ...ns and laws of the country where the crane is used 2 1 General precautions 0099 0008 0E 2 1 1 General precautions 0099 0226 0E 1 Wear protective clothing and equipment When operating the crane do not...

Page 25: ...e near fuel oil Long Life Coolant or battery there is the risk that it could ignite Extinguish all fires and potential sources of ignition when handling these flammable materials and do not allow them...

Page 26: ...tarting the engine so that you can reach all control levers and pedal comfortably with your back resting on the seat back and fasten the seatbelt 10 Only the operator may be in the cab Before and duri...

Page 27: ...ck that paper scraps or other flammable materials are not scattered about or piled up near the engine 14 Start the engine from the operator s seat Always start the engine while seated in the operator...

Page 28: ...ne 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 ped...

Page 29: ...16 MEMO...

Page 30: ...ut 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...

Page 31: ...e 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 r...

Page 32: ...ge 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...

Page 33: ...e buckle to remove the tang from the buckle Sit in the seat and insert the tang into the buckle and push until it clicks Pull the seatbelt as far as your hip and adjust the fastening pulling the belt...

Page 34: ...dow The only left hand side of the door window can slide 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 I...

Page 35: ...e 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 ch...

Page 36: ...Keys 12 Fire extinguisher optional Refer to the label on the fire extinguisher to check its instructions and limit of use 13 Emergency kit 14 Rear window Grip and pull out the lock to slide open the...

Page 37: ...en lighting a cigarette 541A 0032 1E 2 Ashtray When cleaning it pull it toward you with pressing down the stopper and remove 3 Starter switch OFF In this position the key may be inserted and withdrawn...

Page 38: ...uplex 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...

Page 39: ...pressed to use the sprayed fluid to clean the roof window 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 coul...

Page 40: ...CLOCK Press this button to switch to the clock display Press it again to switch back to the frequency display 5 Auto store preset scan button AST Pressing this button plays each preset station for 5...

Page 41: ...radio is equipped with an internal fuse which cannot be replaced If a fuse failure is suspected contact your authorised KATO dealer for service Do not attempt to replace the fuse by disassembling the...

Page 42: ...he other buttons in the same way as described in steps 1 and 2 above Pressing a preset button already set to a particular station for more than 2 seconds will change the preset setting If preset setti...

Page 43: ...uce undesired noise If the signal becomes stronger again the radio will automatically switch back to the stereo broadcast 9 Setting the clock If the display is showing the frequency press the CLOCK bu...

Page 44: ...2 Fan controller Controls the air flow rate and functions as the main air conditioner switch Air flow can be adjusted to three levels Low Medium or High Move the slider to OFF to switch the air condit...

Page 45: ...rate the air conditioner Once the interior air begins cooling down close the windows and adjust the air conditioner to the desired temperature 2 Scratchy eyes Smoking in the cab with the windows close...

Page 46: ...washer tank If you press the washer switch while the tank is empty or continue to hold the switch down for a long period you could cause the pump to break down so refill the tank before it becomes emp...

Page 47: ...indicator lamp Engine control warning lamp Buzzer Malfunction that prevents driving or dangerous to driving Red lamp lights Lights Rapid intervals every 0 5 seconds Malfunction that permits driving on...

Page 48: ...ely after operating the engine Therefore make sure the engine has cooled down sufficiently before opening the engine cover to inspect the engine Leaving the engine cover open can be dangerous as it ma...

Page 49: ...fore make sure the engine has cooled down sufficiently before opening the engine cover to inspect the engine Leaving the engine cover open can be dangerous as it may close unexpectedly from wind gusts...

Page 50: ...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 repla...

Page 51: ...38 WARNING 5 Content Notes for the rated lifting capacity chart Location Inside the cab Part No 611 75105001 6 1 Content Notes for crane operation Location Inside the cab Part No 611 75106000...

Page 52: ...taching the safety rope for stowing jib Location Right side of the boom base Part No 899 81405772 8 Content Precautions when driving and handling the brake lock Location Inside the cab Part No 611 751...

Page 53: ...ide of the jib top Part No 899 81600782 13 Content Exhaust gas hazard Location Inside the cab Part No 611 75113000 16 Content Check list for outrigger setting Location Inside the cab Part No 611 75116...

Page 54: ...any other parts of the body in the sheave Location Top surface of the table Part No 161 74814001 39 Content Warning of suspension lock release with the outriggers extended Location Inside the cab Par...

Page 55: ...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 th...

Page 56: ...the fan while the engine is running or immediately after it has stopped Location Inside the engine cover Part No 001 81332019 11 Meaning Never bring any flame or source of ignition near the fuel tank...

Page 57: ...gh temperature If touched carelessly you will get burned or serious injury Location Near the exhaust pipe Part No 001 81332003 16 Content Prohibition of high pressure cleaning Location Front side of t...

Page 58: ...07 75122001 41 Meaning Do not use the outriggers to climb onto or off the machine or climb onto or off the outriggers themselves Location Side of each outrigger beam Part No 161 74806001 42 Meaning Be...

Page 59: ...nd 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 s...

Page 60: ...mpaired 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 b...

Page 61: ...sfy the following criteria Does not contain even fine dust Has adequate viscosity Has a high cetane number Has good low temperature flowability Has low sulfur content Has low carbon residue Use standa...

Page 62: ...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 4 Starting the engine 1 In no...

Page 63: ...fter 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 v...

Page 64: ...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...

Page 65: ...y point at least 5 C below the minimum outside air temperature For example if the outside air temperature falls to 15 C use an oil which remains fluid at 20 C Use of a non recommended fuel will reduce...

Page 66: ...0069 2E 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...

Page 67: ...54 MEMO...

Page 68: ...unction in the automatic transmission system 64 10 5 Dealing with breakdowns 66 11 Drive operation devices 69 11 1 Cluster meter panel 69 11 2 Switch panel 75 11 3 Front and side panel switches 82 11...

Page 69: ...position and equipment 2 Set the PTO switch to the OFF position and return the machine to the driving position before driving on the roads Never operate the crane in any way when driving on the roads...

Page 70: ...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...

Page 71: ...place with poor visibility This guidance will help to avoid scrapes or impacts with obstacles people or machines etc 11 Take care around train power cables and bridge spans When driving pay close atte...

Page 72: ...sound to warn of inadequate air pressure In this case it will not be possible to release the parking brake 2 Make a habit of depressing the foot brake before releasing the parking brake If you try to...

Page 73: ...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 downh...

Page 74: ...60 MEMO...

Page 75: ...he breakdown 1 Breakdown warning methods Emergency signal equipment emergency signal lights Red flag or red lamp Stop sign Tie a handkerchief etc in a prominent place on the back of the machine 3 You...

Page 76: ...t 5 minutes Be sure to read the instructions indicated on the label affixed to the flare case before using a flare The flare should be used within 4 years Be sure to replace the flare with a new flare...

Page 77: ...ower 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 s...

Page 78: ...t 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...

Page 79: ...ng 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...

Page 80: ...d 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 co...

Page 81: ...r towing then proceed cautiously with towing according to the applicable laws Exercise extreme caution when towing keeping your speed low and constant Sudden change of speed could break the tow bar or...

Page 82: ...without causing problems If you do not provide the broken down machine with compressed air the parking brake cannot be released and the foot brake will not work during towing Supply compressed air unt...

Page 83: ...trip meter 1 Odometer Displays the cumulative distance driven by the machine Displays up to 6 digits in 1 km increments 2 Trip meter Displays the distance driven since the last time it was reset Disp...

Page 84: ...imbs back to the 5 9 range when the engine is running If the air pressure climbs above 9 stop the engine immediately and contact your authorised KATO dealer 9 Engine oil pressure gauge Indicates the p...

Page 85: ...e water temperature gauge Engine oil filter blockage If there is any problem with the engine oil pressure sensor or its wiring the lamp will flash 541A 0088 0E 6 Radiator coolant level warning lamp Th...

Page 86: ...ounds 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 ope...

Page 87: ...n 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...

Page 88: ...authorised KATO dealer 17 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 w...

Page 89: ...O switch is ON 3 Working lamp indicator lamp This lamp lights when the working lamps are turned on 4 Outrigger operation OK indicator lamp This lamp lights when the PTO switch is ON and the machine is...

Page 90: ...spension operation OK indicator lamp is lit 9 Rear steering lock release confirmation indicator lamp This lamp lights when the rear steering lock release switch is set to the release position to relea...

Page 91: ...splayed 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 switch...

Page 92: ...rent angle as a proportion of the maximum angle expressed on a scale of 1 9 NOTE When the maximum steering angle 9 is displayed it will flash at 1 second intervals 11 2 2 Switch section 611A 0019 0E E...

Page 93: ...heel drive mode 2 To shift to two wheel drive press the switch while the four wheel drive indicator lamp is lit The confirmation tone pip will sound and the four wheel drive indicator lamp will flash...

Page 94: ...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...

Page 95: ...arking 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 bra...

Page 96: ...is performing Do not operate the suspension while the outriggers are extended When the suspension lock is released there is some risk that the axles could drop off 541A 0106 0E Stop the machine before...

Page 97: ...will return to the driving position and the suspension locked indicator lamp will go out If you set the PTO switch to the ON position while the suspension lock is released for the driving position th...

Page 98: ...itch to the original position Then try again to lock or release the rear steering A pressure of at least 500kPa 5kgf cm2 in the compressed air tank is required If you attempt this operation while the...

Page 99: ...starter switch is OFF 11 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 ne...

Page 100: ...ition 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...

Page 101: ...e for use while the machine is in motion The disk brakes on the front and rear wheels act when the pedal is pressed in proportion to the amount of pedal depression If the air pressure in the foot brak...

Page 102: ...sition NOTE The ranges of adjustment are as follows Height adjustment 40mm Angle 10 Only adjust the steering wheel position while the machine is at rest Always fasten the lock lever securely after adj...

Page 103: ...ing position Wiper action OFF Stop INT Intermittent LO Slow HI Fast 541A 0121 1E 2 Windscreen washer switch The windscreen washer switch is located on the end of the knob Press it to spray cleaning li...

Page 104: ...re NOTE When the exhaust brake acts the exhaust brake indicator lamp on the cluster meter panel will light 2 Turn signal and dimmer switch This switch incorporates the following switching functions Tu...

Page 105: ...ch 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...

Page 106: ...ly 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 instru...

Page 107: ...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...

Page 108: ...e 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 superstructure 6 Engage the winch drum lock...

Page 109: ...position required for driving The machine should be on the firm level ground for suspension operation 541A 0130 0E 12 Check that no warning lamps are lit 13 Check that the turn signal lamps flash corr...

Page 110: ...r to a lower position before decelerating to the shift down speed the transmission will not shift until the speed has reduced sufficiently 2 Driving on slopes 1 When climbing a slope move the shift le...

Page 111: ...ong 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 by a phenomenon called soaking If you do not notice thi...

Page 112: ...r wheel drive switch are not lit 611A 0027 0E 12 3 1 Low range drive 121A 0073 0E 1 Use high range for normal drive and switch to low range for driving on particularly steep roads or even or soft grou...

Page 113: ...ngine 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 b...

Page 114: ...ing the rear steering lock release confirmation indicator lamp will flash and the misoperation warning buzzer will sound Reduce the driving speed to 7km h or less and return the rear steering lock rel...

Page 115: ...er 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...

Page 116: ...l flash and the misoperation warning buzzer will sound Reduce the driving speed to 7km h or less and return the rear steering lock release switch to the original position Then try again to lock or rel...

Page 117: ...h 12 3 3 Two four wheel drive selection 121A 0074 0E 1 Use two wheel drive for normal drive and switch to four wheel drive for driving on particularly steep roads or even or soft ground or for pick an...

Page 118: ...ing 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 dri...

Page 119: ...hen the outriggers are used 147 16 1 Suspension operation 149 16 2 PTO switch operation 152 16 3 Precautions on setting the outriggers 154 16 4 Outrigger control panel 157 16 5 Outrigger setting and s...

Page 120: ...19 Changing the wire rope number of parts 192 19 1 Wire rope standard number of parts 192 19 2 Changing the wire rope number of parts 193...

Page 121: ...site Observe the safety regulations and laws of the country where the crane is used 13 1 General precautions 0099 0008 0E 13 1 1 Precautions on working environment 0099 0228 0E 1 Always discuss the w...

Page 122: ...u 2 Always keep the cab windows mirrors wipers and working lamps clean 3 When working in dark places switch on the working lamps mounted on the crane and place further illumination where necessary 4 W...

Page 123: ...ys 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 7 Precautions when working near power cables If you a...

Page 124: ...oach retract the boom and get out of the crane 10 Work according to signals Choose one person to be the signaler If the signaler does not signal appropriately with the sling handler and other workers...

Page 125: ...cautions before you start work 0099 0166 1E 1 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 unexpecte...

Page 126: ...t on or off the crane When you get on or off the crane face toward it and use the hand grips and steps Getting on and off the crane while it is in motion is dangerous Always wait until it is at rest 6...

Page 127: ...t leave tools rags etc lying around in the engine compartment Clear everything away as soon as you finish inspection or servicing Cleanly wipe away any spilled oil or fuel Check that paper scraps or o...

Page 128: ...to note when choosing outrigger setting positions 1 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...

Page 129: ...ater and gas mains and high voltage cable ducts 2 Improving the ground surface for outrigger setting Improve the ground surface as far as possible if it is soft crumbly uneven or sloping Use wooden bl...

Page 130: ...ility 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 6 Check the state of outrigger setting If the out...

Page 131: ...lifting capacity If you lift loads in excess of the rated 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 ca...

Page 132: ...able 5 Proceed cautiously with compound operations Compound operations combining winch hoisting and lowering slewing and boom derricking and lowering will be slower than the individual operations When...

Page 133: ...ntion 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 outri...

Page 134: ...ecurely 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...

Page 135: ...load by derricking or extending the boom until it is a few centimeters off the ground 16 Apply the drum lock when you hold the load suspended If the load is held aloft for a long period by the brake a...

Page 136: ...hoisting Put the load back on the ground and check that the wire rope wasn t damaged before hoisting the load any further 20 When an overload occurs during an operation If you suddenly derrick or lowe...

Page 137: ...nd deformation or falling objects as follows Lower the load to a safe place Slew to an orientation away from the danger of falling or toppling objects while retracting the boom and then lower the boom...

Page 138: ...n 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 13 2 5 Winch operation 0099 0169 0E 1 Choose a hook and wire...

Page 139: ...wer the hook sufficiently before you extend the boom Extending the boom can put the hook into an overhoisted condition which causes an automatic stop 2 Be careful when extending and retracting the boo...

Page 140: ...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...

Page 141: ...t long boom lengths 6 Never slew carelessly If you carelessly slew from a direction with long outrigger extension to one with short outrigger extension with a load suspended the crane could tip over E...

Page 142: ...e operation 4 As a rule control the cranes by single lever operations and avoid compound lever operations 5 Avoid slewing operations 2 Crane operation on sites with underground areas 1 Choose the numb...

Page 143: ...e in which to park 3 If there is no alternative to parking on an incline place chocks against the tires so that the crane cannot move 4 If there is no alternative to parking on a road take appropriate...

Page 144: ...hed operating the crane check all its parts and add lubricants and fuel as required If you find any defective parts repair them immediately 6 Check the crane for safety before you leave it When you le...

Page 145: ...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 defle...

Page 146: ...us on the rated lifting capacity chart 2 Look at the column for the boom length with which you will be working 3 Find the rated lifting capacity load mass hook mass mass of slings for the distance to...

Page 147: ...operations are complete and the machine is about to leave the site and drive on the road Always keep the suspension locked for moving between different working positions on site Never release the susp...

Page 148: ...sted load swings sideways in the wind it could not only damage the crane but is extremely dangerous for workers as well Be sure to stay aware of conditions and stop operations early The higher the hei...

Page 149: ...load to just above the ground and keep your speed strictly below 2km h Avoid any sudden actions such as starting steering accelerating and decelerating 12 Never operate the crane during pick and carr...

Page 150: ...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 i...

Page 151: ...op 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 sa...

Page 152: ...136 14 3 4 Crane performance tracks when using outriggers 541A 0293 0E...

Page 153: ...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 need...

Page 154: ...auge to confirm that the crane is level when supported on the outriggers 4 Crane operation switch When operating the crane set this switch to the ON position Slewing boom derricking lowering extension...

Page 155: ...uxiliary winch is not in use set this switch to the OFF position to prevent misoperation etc 8 Boom extension retraction switch When operating the boom using the boom extension retraction pedal this s...

Page 156: ...ial extension retraction circuit or when greasing the boom sections 3 and 4 3 Jib side lifting switch self reset type To swing out the jib set this switch to the extension side This will move the jib...

Page 157: ...e same for hoisting and lowering NOTE The buzzer sound becomes faster the faster the drum rotates When the drum speeds up further the buzzer sounds continuously and then dies away 6 Working lamp switc...

Page 158: ...left to slew the crane left 2 Auxiliary winch operation Set the auxiliary winch switch to the ON position before operating the auxiliary winch Set the crane operation switch to the ON position and pul...

Page 159: ...ne operation switch to the ON position and pull the right control lever backward to wind up the winch Set the crane operation switch to the ON position and push the right control lever forward to lowe...

Page 160: ...edle 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 lubricati...

Page 161: ...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...

Page 162: ...ions indicated on the ACS display then press the ACS setting switch to rest the outrigger extension widths If it is not reset on the ACS the crane cannot be operated 491A 0043 1E 2 Outrigger emergency...

Page 163: ...cedure below to change the machine s position from driving condition to a position suitable for crane operation Always follow the specified procedure and precautions strictly to set the machine in its...

Page 164: ...sition 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...

Page 165: ...a major accident Do not release the suspension lock until all crane operations are complete and you are about to move the machine on the road Push the suspension retraction switch to the suspension re...

Page 166: ...TO 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 suspensio...

Page 167: ...ck the suspension when the machine is on firm level ground with the outriggers stowed 541A 0176 2E 1 Set the crane to the following conditions Fully retract the boom and lower it to a boom angle of at...

Page 168: ...ll 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 op...

Page 169: ...153 ON OFF...

Page 170: ...the rated lifting capacity chart are based on the assumption that the crane is supported on the level by the outriggers Therefore the strength of the ground where the outriggers are set is one of the...

Page 171: ...s 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 n...

Page 172: ...s 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 p...

Page 173: ...tal or vertical cylinder When you select the individual switch and use the extension retraction switch the engine speed will not increase 1 Left rear horizontal vertical selection switch 2 Right rear...

Page 174: ...press the same switch again The indicator lamp will go out to indicate that the selection has been canceled Press the switch firmly until the confirmation tone sounds If the extension retraction swit...

Page 175: ...f reset type When you press either the extension switch or the retraction switch to operate the outriggers while the position selection and horizontal vertical selection switches have been set a pip c...

Page 176: ...igger beams 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...

Page 177: ...ger beams Check that four tires are not touching the ground 491A 0048 1E 5 Leveling the body Watch the level gauge to level the body with as few operations as possible The data for each outrigger exte...

Page 178: ...onditions for lighting If the crane position is in a boom length and boom angle as indicated on the capacity chart for pick and carry operation If the ACS boom operation status is set to jib setting 2...

Page 179: ...ertical cylinder is extended 541A 0183 1E 4 Outrigger beam retraction 1 Check that the vertical cylinders are fully retracted then move the selection switch to the horizontal side 2 Move the extension...

Page 180: ...e 2 If you stop the machine suddenly the boom could be extended by inertia 16 6 1 Hook releasing procedure 611A 0038 0E 1 Fully extend the four outriggers and confirm that the ACS outrigger status dis...

Page 181: ...be released from the hook fixing ring When lowering the main winch take care not to lower the wire rope further than necessary The wire rope could get tangled on the drum When derricking the boom take...

Page 182: ...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...

Page 183: ...d on the drum At this time take care that the wire rope does not get too tightened If excessive tension is applied to the wire rope the automatic function will work 541A 0192 1E 7 Before driving on th...

Page 184: ...cted 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 f...

Page 185: ...gers are not used the working area or the lifting capacity differs greatly from those when the outriggers are used Check the relevant rated lifting capacity chart before you start work The crane s lif...

Page 186: ...stationary crane on rubber operation 5 Apply the parking brake and the brake lock at the same time When the pressure in the compressed air tank falls while the brake lock is in use and the foot brake...

Page 187: ...he relevant rated 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 scree...

Page 188: ...ditions for the operation Take adequate precautions trying to foresee dangers keeping all other personnel away from the crane and posting guides to supervise the operation Choose a path for pick and c...

Page 189: ...Set the pick and carry operation on the working status setting screen Any mistake in setting the ACS working status can be extremely dangerous 6 Apply the slewing brake to immobilize the superstructu...

Page 190: ...linders fully retracted and secured in locked position 3 PTO switch ON position 4 Slewing table Slewing brake engaged and slewing lock in use 5 Driving peed Low speed Moving within a site to change wo...

Page 191: ...d all outriggers as far as possible when leveling the crane and inset the stopper pins in each outrigger to check the extension width 2 Check that all tires are lifted off the ground 4 ACS setting 1 S...

Page 192: ...re 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...

Page 193: ...operations Slewing is not stopped automatically 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 lowerin...

Page 194: ...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...

Page 195: ...omatically applies the brake 5 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...

Page 196: ...10 3250 0E Where it is absolutely necessary to use joint hoisting between the main hook and the auxiliary hook with the jib mounted set the boom operation status to jib operation on the ACS working st...

Page 197: ...1 Extending the boom section 2 1 Set the crane operation switch to the ON position 2 Set the boom extension retraction switch to the boom section 2 side 3 Check that the main and auxiliary hooks are...

Page 198: ...switch to the ON position 2 Fully extend the boom section 2 3 Set the boom extension retraction switch to the boom sections 3 and 4 side 4 Check that the main and auxiliary hooks are lowered sufficie...

Page 199: ...ke 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 i...

Page 200: ...s Check the safety before slewing and pay attention to people and obstacles nearby while slewing When operating the crane with the outriggers at anything other than full extension refer to the rated l...

Page 201: ...ane 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 18 6 1 Slewing operations and sy...

Page 202: ...Danger maximum lifting capacity will be emitted one time Just before stopping a warning chime DING DONG DANG DONG is emitted continuously to notify the operator that the system is functioning If the...

Page 203: ...lerates 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...

Page 204: ...ay stop automatically under the conditions indicated below such as an unlevel machine or strong winds 1 Situations where slewing may automatically stop when operating within rated load limits and slew...

Page 205: ...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 co...

Page 206: ...d 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 depe...

Page 207: ...Point D and beyond DING DONG DING DONG Restart slewing in same direction Region E Slewing limit reached each time lever operated DING DONG DING DONG Region E and beyond Point D 20 or more Reverse sle...

Page 208: ...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 o...

Page 209: ...tract and lower the boom fully and slew it to the side or front 2 Remove the rope retaining pins from the boom top 3 Detach the rope socket 4 Remove the rope socket from the rope 5 Refer to the table...

Page 210: ...he 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 tangl...

Page 211: ...611A 0056 0E Preoperational checks Pre drive checks 214521 20 Preoperational checks Pre drive checks 195 20 1 Pre drive checks 196 20 2 Preoperational checks 202...

Page 212: ...g 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 whichev...

Page 213: ...haust Drive system Tires Air pressure Check the tire pressure with a tire gauge while the tires are still cool before driving anywhere Adjust the pressure as necessary to the rated pressure Check that...

Page 214: ...d more coolant through the cap on the top of the reserve tank Total coolant volume about 30L Engine 13L Radiator 9L Sub tank 1 5L When FULL Piping 4L Lamps and turn indicators Lighting and flashing st...

Page 215: ...198 20 1 2 Points for pre drive checks 511A 0076 0E...

Page 216: ...199...

Page 217: ...200...

Page 218: ...201...

Page 219: ...ct Excessive slack in the fan belt can cause overheating and inadequate generation by the alternator Excessive tension can damage the engine bearings and snap the fan belt Check the tension of the fan...

Page 220: ...ine With reference to the ambient air temperature check that the oil level is within the scale and add more oil if the level is too low Reservoir capacity 400L Cylinder Oil leakage Inspect Responsivit...

Page 221: ...dicate when the limit of wear has been reached Air pressure 900kPa 9kgf cm2 Tire size 385 95 R25 170E ROAD Crack damage abnormal wear Inspect Lodged metal fragments stones etc Inspect Wheel nut Inspec...

Page 222: ...tion switch to check that all the turn signal lamps on the machine light normally and at the same time confirm that all indicator lamps are flashing Keep the pressure reading on the pressure gauge abo...

Page 223: ...unication error warning lamp flushes and an intermittent buzzer sounds do not start the engine and contact your authorised KATO dealer Action of the door and cover locks Inspect Crane safety devices A...

Page 224: ...207 20 2 2 Points for preoperational checks 511A 0079 0E...

Page 225: ...208...

Page 226: ...209...

Page 227: ...210...

Page 228: ...witch 139 B Battery charge indicator lamp 74 Boom extension retraction emergency switch self reset type 140 Boom extension retraction pedal 143 Boom extension retraction switch 139 Brake lock switch 8...

Page 229: ...evel warning lamp 72 Fuse box 22 33 H Hazard warning switch 85 Heater switch optional 26 Height and angle adjustment lock lever 88 High beam indicator lamp 70 High low speed switch 80 Holders for the...

Page 230: ...warning lamp 74 Power steering pressure warning lamp 75 Preheat indicator lamp 72 PTO indicator lamp 75 PTO switch 137 R Radiator coolant level warning lamp 71 Radio optional 27 Radio aerial optional...

Page 231: ...on locked indicator lamp 75 Suspension operation OK indicator lamp 76 Suspension retraction switch 83 T Tachometer 69 Turn signal and dimmer switch 90 Turn signal switch 90 Dimmer switch 91 Lighting s...

Page 232: ...27 5051 221 0844 1 2 2 045 311 7992 422 8042 1 1 46 054 286 3141 461 0004 3 23 3 14 052 934 0588 930 0046 1 3 6 076 493 1833 532 0011 2 3 20 06 6303 1131 520 0801 2 1 48 077 524 8001 733 0035 7 16 15...

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Kato SR-300L, Instruction Manual

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