8.2 REMOVING/INSTALLING THE BATTERY CAUTION

Ensure that the battery does not move after securing the battery. If it moves, secure it again.

[1] REMOVAL

1. See “Operation 1.6 Machinery Cover” to remove machinery cover.

2. Remove the wing nut (4) and the remove rod (5) and battery holder (3).

3. Pull out the battery (6) toward you.

4. Disconnect the (-) terminal (7) on the ground side first and then the (+) terminal (8) to disconnect the battery cable.

5. Remove the battery (6).

[2] INSTALLATION

• Reverse the removal procedure to install the battery.

Notes

Connect the (-) terminal (7) on the ground side last when connecting the battery.

8.3 CAUTIONS WHEN CHARGING THE BATTERY

When charging the battery mounted to the machine

• Abnormal voltage may be applied to the alternator, resulting in the breakage. Disconnect the battery terminal wires before charging the battery.

• Remove all the fluid plugs to release the gas generated.

• Stop charging if the battery becomes overheated (fluid temperature exceeded 45 °C).

• Stop charging promptly once the charging is completed. Charging even after the charging is completed will;

(1) overheat the battery

(2) reduce the electrolyte level

(3) cause failures in the battery

• Never inverse the connection of [(+) terminal and (-) terminal]. Doing so can cause damage to the alternator.

• Remove the battery cable when handling the battery other than for a battery electrolyte level check and specific gravity measurements

8.4 STARTING THE ENGINE WITH BOOSTER CABLE

Start the engine with booster cable as described below.

[1] CAUTIONS IN CONNECTING/DISCONNECTING BOOSTER CABLE

• Never let the (+) terminal and (-) terminal come into contact with the other when connecting the cable.

• Wear goggles and rubber gloves when starting the engine with the booster cable.

• Do not let the normal machine and machine in failure come into contact with each other. Because the battery produces hydrogen gas, sparks around the battery can cause explosion.

• Do not make mistakes when connecting the booster cable. Note that there will be some sparks when making the last connection. Make this connection at the location as far as possible from the battery.

• Do not let the booster cable clips contact one another or the machine when disconnecting the booster cable.

Caution

• Use booster cable and clips of appropriate size for the battery size.

• The battery in the normal machine and machine in failure should be of the same capacity.

• Check that the cable and clips have no breakage and corrosion.

• Connect the clips securely.

• Verify that the operation levers are at the NEUTRAL position.

[2] CONNECTING BOOSTER CABLE

Connect the booster cable in the numerical order shown in the diagram on the right.

1. Turn the starter switch of both of the normal machine and machine in failure to the OFF position.

2. Connect a clip of the booster cable (A) to the (+) terminal of the machine in failure.

3. Connect the other clip of the booster cable (A) to the (+) terminal of the normal machine.

4. Connect a clip of the booster cable (B) to the (-) terminal of the normal machine.

5. Connect the other clip of the booster cable (B) to the engine block of the machine in failure.

[3] STARTING THE ENGINE

Ensure that the operation levers are at the NEUTRAL position. If the safety lock lever is equipped, also verify that the safety lock lever is at the lock position.

1. Ensure that the clips are securely connected to the battery terminals.

2. Start the engine of the normal machine and increase the engine speed to full speed (highest speed).

3. Turn the starter switch of the machine in failure to the “START” position to start the engine. If the engine does not start, wait at least 2 minutes before re-starting.

Notes

See “Operation 2.2 Starting the Engine” for how to start the engine.

[4] DISCONNECTING BOOSTER CABLE

When the engine starts, disconnect the booster cable in the reverse order of connecting the booster cable.

1. Disconnect the clip of the booster cable (B) connected to the engine block of the machine in failure.

2. Disconnect the clip of the booster cable (B) connected to the (-) terminal of the normal machine.

3. Disconnect the clip of the booster cable (A) connected to the (+) terminal of the normal machine.

4. Disconnect the clip of the booster cable (A) connected to the (+) terminal of the machine in failure.

9. TROUBLESHOOTING

9.1 ELECTRICAL COMPONENTS

• Make sure that you contact us or our sales service agency for the actions indicated in parentheses in the Actions field.

• Ask our sales service agency for repair if you suspect other abnormality or causes than those given below.

Abnormal Phenomenon Major Cause(s) Actions

Dim light even at highest engine speed

Light blinks during engine operation

Battery charge lamp does not goes off even after the engine starts

Starter not rotating even after the starter switch is turned

Starter pinion going out and in repeatedly (struggling)

Starter motor turning slowly

Starter disengaged before the engine starts

9.2 MACHINE BODY

• Defective wiring (• Check and repair slackened terminals and open circuits)

• Defective alternator

• Defective wiring

(• Replace) (• Check and repair)

• Defective wiring (• Replace) (• Check and repair)

• Defective alternator

• Defective wiring

• Insufficient battery charge

• Defective fuse

• Insufficient battery charge

• Insufficient battery charge

• Defective starter

(• Check and repair)

• Charge the battery

• Replace the fuse

• Charge the battery

• Charge the battery (• Replace)

• Defective wiring

• Charge the battery

• Insufficient battery charge (• Check and repair)

• Make sure that you contact us or our sales service agency for the actions indicated in parentheses in the Actions field.

• Ask our sales service agency for repair if you suspect other abnormality or causes than those given below.

Abnormal Phenomenon Major Cause(s) Actions

Crane cannot operate but can travel

• Travelling speed, boom and hook block operation speed too slow

• Abnormal noise from pump

• Defective travelling lever stand position detector

• Insufficient hydraulic oil

• Hydraulic oil tank strainer and element clogged

• Insufficient hydraulic oil

(• Check and repair)

• Refill with hydraulic oil to the specified oil level, referring to the section “Check before operation”

• Clean and replace the filter by referring to the “Periodical Checks”.

Hydraulic oil temperature too high

• Rubber tracks coming off

• Abnormal wear on the sprockets

• Clogged cooling fins

• Rubber tracks too loose

• Refill with hydraulic oil to the specified oil level, referring to the section “Check before operation”

• Clean

• See “Check before operation” and adjust the tension

9.3 ENGINE

• Make sure that you contact us or our sales service agency for the actions indicated in parentheses in the Actions field.

• Ask our sales service agency for repair if you suspect other abnormality or causes than those given below.

Abnormal Phenomenon Major Cause(s) Actions

• Insufficient fuel

• Insufficient battery charge

• Fuel not available at carburetor

Engine does not start even after the starter key is turned

• Defective spark plug

• Firing of spark plug deficient

• Insufficient compression

• Engine emergency stop switch is ON position

• See “Check before operation” and refuel

• Charge the battery (• Check and repair)

• Clean, check and replace

(• Check and repair)

(• Check and replace)

• Operate the switch to OFF position

Engine starts but stops right away

• Insufficient oil in oil pan

• Air cleaner element clogged

• See “Check before operation” and adjust oil level to appropriate one

• See causes and actions for “Engine does not start”

• See “Periodical Maintenance” for cleaning or replacement of the parts

Engine power is low, the power gradually drops

• Recoil starter screen clogged

• Defective spark plug

• Firing of spark plug deficient

• Insufficient compression

• See “Check before operation” for cleaning

• Clean, check and replace

(• Check and repair)

(• Check and replace)