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Importantsafetynotice
Properserviceandrepairareextremelyimportantforsafemachineoperation.Theserviceandrepair techniquesrecommendedbyKomatsuanddescribedinthismanualarebotheffectiveandsafe. SomeofthesetechniquesrequiretheuseoftoolsspeciallydesignedbyKomatsuforthespecific purpose.
Topreventinjurytoworkers,thesymbolkisusedtomarksafetyprecautionsinthismanual.The cautionsaccompanyingthesesymbolsshouldalwaysbefollowedcarefully.Ifanydangeroussituationarisesormaypossiblyarise,firstconsidersafety,andtakethenecessaryactionstodealwith thesituation.
1.Generalprecautions
kMistakesinoperationareextremely dangerous.ReadtheOperationand MaintenanceManualcarefullybefore operatingthemachine.Inaddition, readthismanualandunderstandits contentsbeforestartingthework.
1)Beforecarryingoutanygreasingor repairs,readallthesafetylabelsstuckto themachine.Forthelocationsofthe safetylabelsanddetailedexplanationof precautions,seetheOperationandMaintenanceManual.
2)Decideaplaceintherepairworkshopto keeptoolsandremovedparts.Always keepthetoolsandpartsintheircorrect places.Alwayskeeptheworkareaclean andmakesurethatthereisnodirt,water, oroilonthefloor.Smokeonlyintheareas providedforsmoking.Neversmokewhile working.
3)Whencarryingoutanyoperation,always wearsafetyshoesandhelmet.Donot wearlooseworkclothes,orclotheswith buttonsmissing.
qAlwayswearsafetyglasseswhenhittingpartswithahammer.
qAlwayswearsafetyglasseswhen grindingpartswithagrinder,etc.
4)Whencarryingoutanyoperationwith2or moreworkers,alwaysagreeontheoperatingprocedurebeforestarting.Always informyourfellowworkersbeforestarting anystepoftheoperation.Beforestarting work,hangUNDERREPAIRwarning signsintheoperator'scompartment.
5)Onlyqualifiedworkersmustcarryoutwork andoperationwhichrequirelicenseor qualification.
6)Keepalltoolsingoodcondition,learnthe correctwaytousethem,andusethe properonesofthem.Beforestartingwork, thoroughlycheckthetools,machine,forklift,servicecar,etc.
7)Ifweldingrepairsareneeded,always haveatrainedandexperiencedwelder carryoutthework.Whencarryingout weldingwork,alwayswearwelding gloves,apron,shieldinggoggles,capand otherclothessuitedforweldingwork.
8)Beforestartingwork,warmupyourbody thoroughlytostartworkundergoodcondition.
9)Avoidcontinuingworkforlonghoursand takerestsatproperintervalstokeepyour bodyingoodcondition.Takerestsin specifiedsafeplaces.
Safetypoints
1Goodarrangement
2Correctworkclothes
3Followingworkstandard
4Makingandcheckingsigns
5Prohibitionofoperationandhandlingby unlicensedworkers
6Safetycheckbeforestartingwork
7Wearingprotectivegoggles (forcleaningorgrindingwork)
8Wearingshieldinggogglesandprotectors (forweldingwork)
9Goodphysicalconditionandpreparation
10Precautionsagainstworkwhichyouare notusedtooryouareusedtotoomuch
2.Preparationsforwork
1)Beforeaddingoilormakinganyrepairs, parkthemachineonahardandlevel ground,andapplytheparkingbrakeand blockthewheelsortrackstopreventthe machinefrommoving.
2)Beforestartingwork,lowerthework equipment(blade,ripper,bucket,etc.)to theground.Ifthisisnotpossible,insert thelockpinoruseblockstopreventthe workequipmentfromfalling.Inaddition, besuretolockallthecontrolleversand hangwarningsignsonthem.
3)Whendisassemblingorassembling,supportthemachinewithblocks,jacks,or standsbeforestartingwork.
4)Removeallmudandoilfromthestepsor otherplacesusedtogetonandoffthe machine.Alwaysusethehandrails,laddersorstepswhengettingonoroffthe machine.Neverjumponoroffthe machine.Ifitisimpossibletousethe handrails,laddersorsteps,useastandto providesafefooting.
3.Precautionsduringwork
1)Beforedisconnectingorremovingcomponentsoftheoil,water,oraircircuits,first releasethepressurecompletelyfromthe circuit.Whenremovingtheoilfillercap,a drainplug,oranoilpressurepickupplug, loosenitslowlytopreventtheoilfrom spurtingout.
2)Thecoolantandoilinthecircuitsarehot whentheengineisstopped,sobecareful nottogetscalded.Waitfortheoiland coolanttocoolbeforecarryingoutany workontheoilorwatercircuits.
3)Beforestartingwork,stoptheengine. Whenworkingonoraroundarotating part,inparticular,stoptheengine.When checkingthemachinewithoutstopping theengine(measuringoilpressure, revolvingspeed,temperature,etc.),take extremecarenottogetrolledorcaughtin rotatingpartsormovingparts.
4)Beforestartingwork,removetheleads fromthebattery.Alwaysremovethelead fromthenegative(–)terminalfirst.
5)Whenraisingaheavycomponent(heavier than25kg),useahoistorcrane.Before startingwork,checkthattheslings(wire ropes,chains,andhooks)arefreefrom damage.Alwaysuseslingswhichhave amplecapacityandinstallthemtoproper places.Operatethehoistorcraneslowly topreventthecomponentfromhittingany otherpart.Donotworkwithanypartstill raisedbythehoistorcrane.
6)Whenremovingacoverwhichisunder internalpressureorunderpressurefroma spring,alwaysleave2boltsindiagonal positions.Loosenthoseboltsgradually andalternatelytoreleasethepressure, andthenremovethecover.
7)Whenremovingcomponents,becareful nottobreakordamagetheelectricalwiring.Damagedwiringmaycauseelectrical fires.
8)Whenremovingpiping,stopthefueloroil fromspillingout.Ifanyfueloroildrips ontothefloor,wipeitupimmediately.Fuel oroilonthefloorcancauseyoutoslip andcanevenstartfires.
9)Asageneralrule,donotusegasolineto washparts.Donotuseittocleanelectricalparts,inparticular.
10)Besuretoassembleallpartsagainintheir originalplaces.Replaceanydamaged partsandpartswhichmustnotbereused withnewparts.Wheninstallinghosesand wires,besurethattheywillnotbedamagedbycontactwithotherpartswhenthe machineisoperated.
11)Wheninstallinghighpressurehoses, makesurethattheyarenottwisted.Damagedtubesaredangerous,sobe extremelycarefulwheninstallingtubesfor highpressurecircuits.Inaddition,check thatconnectingpartsarecorrectly installed.
12)Whenassemblingorinstallingparts, alwaystightenthemtothespecified torques.Wheninstallingprotectiveparts suchasguards,orpartswhichvibrateviolentlyorrotateathighspeed,beparticularlycarefultocheckthattheyare installedcorrectly.
13)Whenaligning2holes,neverinsertyour fingersorhand.Becarefulnottogetyour fingerscaughtinahole.
14)Whenmeasuringhydraulicpressure, checkthatthemeasuringtoolsarecorrectlyassembled.
15)Takecarewhenremovingorinstallingthe tracksoftrack-typemachines.When removingthetrack,thetrackseparates suddenly,soneverletanyonestandat eitherendofthetrack.
16)Iftheengineisoperatedforalongtimein aplacewhichisnotventilatedwell,you maysufferfromgaspoisoning.Accordingly,openthewindowsanddoorstoventilatewell.
4.Precautionsforslingworkandmaking signs
1)Onlyoneappointedworkermustmake signsandco-workersmustcommunicate witheachotherfrequently.Theappointed signmakermustmakespecifiedsigns clearlyataplacewhereheiswellseen fromtheoperator'sseatandwherehecan seetheworkingconditioneasily.Thesign makermustalwaysstandinfrontofthe loadandguidetheoperatorsafely.
qDonotstandundertheload.
qDonotstepontheload.
2)Checktheslingsbeforestartingsling work.
3)Keepputtingonglovesduringslingwork. (Putonleathergloves,ifavailable.)
4)Measuretheweightoftheloadbytheeye andcheckitscenterofgravity.
5)Useproperslingaccordingtotheweight oftheloadandmethodofslinging.Iftoo thickwireropesareusedtoslingalight load,theloadmayslipandfall.
6)Donotslingaloadwith1wireropealone. Ifitisslungso,itmayrotateandmayslip outoftherope.Install2ormorewire ropessymmetrically.
kSlingingwith1ropemaycause turningoftheloadduringhoisting, untwistingoftherope,orslipping oftheropefromitsoriginalwindingpositionontheload,whichcan resultinadangerousaccident.
7)Limitthehangingangleto60°,asarule. Donotslingaheavyloadwithropesformingawidehanginganglefromthehook. Whenhoistingaloadwith2ormore ropes,theforcesubjectedtoeachrope willincreasewiththehangingangle.The tablebelowshowsthevariationofallowableloadinkN{kg}whenhoistingismade with2ropes,eachofwhichisallowedto slingupto9.8kN{1,000kg}vertically,at varioushangingangles.Whenthe2ropes slingaloadvertically,upto19.6kN{2,000 kg}oftotalweightcanbesuspended. Thisweightisreducedto9.8kN{1,000 kg}whenthe2ropesmakeahanging angleof120°.Ifthe2ropesslinga19.6 kN{2,000kg}loadataliftingangleof 150°,eachofthemissubjectedtoaforce aslargeas39.2kN{4,000kg}.
8)Wheninstallingwireropestoanangular load,applypadstoprotectthewireropes. Iftheloadisslippery,applypropermaterialtopreventthewireropefromslipping.
9)Usethespecifiedeyeboltsandfixwire ropes,chains,etc.tothemwithshackles, etc.
10)Applywireropestothemiddleportionof thehook.
qSlingingnearthetipofthehookmay causetheropetoslipoffthehook duringhoisting.Thehookhasthe maximumstrengthatthemiddleportion.
11)Donotusetwistedorkinkedwireropes. 12)Whenliftingupaload,observethefollowing.
qWindinthecraneslowlyuntilwire ropesarestretched.Whensettling thewireropeswiththehand,donot graspthembutpressthemfrom above.Ifyougraspthem,yourfingers maybecaught.
qAfterthewireropesarestretched, stopthecraneandchecktheconditionoftheslungload,wireropes,and pads.
qIftheloadisunstableorthewirerope orchainsaretwisted,lowertheload andliftitupagain.
qDonotliftuptheloadslantingly.
13)Whenliftingdownaload,observethefollowing.
qWhenliftingdownaload,stopittemporarilyat30cmabovethefloor,and thenloweritslowly.
qCheckthattheloadisstable,and thenremovethesling.
qRemovekinksanddirtfromthewire ropesandchainsusedforthesling work,andputtheminthespecified place.
5.Precautionsforusingmobilecrane aReadtheOperationandMaintenance Manualofthecranecarefullyinadvance andoperatethecranesafely.
6.Precautionsforusingoverheadhoistcrane kWhenraisingaheavypart(heavier than25kg),useahoist,etc.InDisassemblyandassembly,theweightofa partheavierthan25kgisindicated afterthemarkof4.
1)Beforestartingwork,inspectthewire ropes,brake,clutch,controller,rails,over windstopdevice,electricshockpreventionearthleakagebreaker,cranecollision preventiondevice,andpowerapplication warninglamp,andchecksafety.
2)Observethesignsforslingwork.
3)Operatethehoistatasafeplace.
4)Checkthedirectionindicatorplates(east, west,south,andnorth)andthedirections ofthecontrolbuttonswithoutfail.
5)Donotslingaloadslantingly.Donotmove thecranewhiletheslungloadisswinging.
6)Donotraiseorloweraloadwhilethe craneismovinglongitudinallyorlaterally.
7)Donotdragasling.
8)Whenliftingupaload,stopitjustafterit leavesthegroundandchecksafety,and thenliftitup.
9)Considerthetravelrouteinadvanceand liftupaloadtoasafeheight.
10)Placethecontrolswitchonaposition whereitwillnotbeanobstacletowork andpassage.
11)Afteroperatingthehoist,donotswingthe controlswitch.
12)Rememberthepositionofthemainswitch sothatyoucanturnoffthepowerimmediatelyinanemergency.
13)Ifthehoiststopsbecauseofapowerfailure,turnthepowerswitchOFF.When turningonaswitchwhichwasturnedOFF bytheelectricshockpreventionearth leakagebreaker,checkthatthedevices relatedtothatswitcharenotinoperation state.
14)Ifyoufindanobstaclearoundthehoist, stoptheoperation.
15)Afterfinishingthework,stopthehoistat thespecifiedpositionandraisethehook toatleast2mabovethefloor.Donot leavetheslinginstalledtothehook.
7.Selectingwireropes
1)Selectadequateropesdependingonthe weightofpartstobehoisted,referringto thetablebelow.
Wireropes (Standard“Z”twistropeswithoutgalvanizing) (JISG3525,No.6,Type6X37-A)
Nominal diameterofropeAllowableload mmkNton 108.80.9 1212.71.3 1417.31.7 1622.62.3 1828.62.9 2035.33.6 2555.35.6 3079.68.1 40141.614.4 50221.622.6 60318.332.4
aTheallowableloadisone-sixthofthe breakingstrengthoftheropeused (Safetycoefficient:6).
8.Precautionsfordisconnectingandconnectinghosesandtubesinairconditioner circuit
1)Disconnection
kFortheenvironment,theairconditionerofthismachineusesthe refrigerant(airconditionergas: R134a)whichhasfewerfactorsof thedepletionoftheozonelayer. However,itdoesnotmeanthatyou maydischargetherefrigerantinto theatmosphereasitis.Besureto recovertherefrigerantwhendisconnectingtherefrigerantgascircuitandthenreuseit.
aAskprofessionaltradersforcollecting andfillingoperationofrefrigerant (R134a).
aNeverreleasetherefrigerant(R134a) totheatmosphere.
kIftherefrigerantgasgetsinyour eyesorcontactsyourskin,you mayloseyoursightandyourskin maybefrozen.Accordingly,put onsafetyglasses,safetygloves andsafetyclotheswhenrecoveringoraddingtherefrigerant. Refrigerantgasmustberecovered andaddedbyaqualifiedperson.
2)Connection
1]Wheninstallingtheairconditionercircuithosesandtubes,takecarethat dirt,dust,water,etc.willnotenter them.
2]Whenconnectingtheairconditioner hosesandtubes,checkthatO-rings (1)arefittedtotheirjoints.
3]CheckthateachO-ringisnotdamagedordeteriorated.
4]Whenconnectingtherefrigerantpiping,applycompressoroilforrefrigerant(R134a)(DENSO:ND-OIL8, VALEOTHERMALSYSTEMS: ZXL100PG(equivalenttoPAG46)) toitsO-rings.
aExampleofO-ring(Fittedtoeveryjointof hosesandtubes)
aFortighteningtorque,seetheprecautionsfor installationineachsectionof"Disassembly andassembly".