KOMATSU GD825A-2 SHOP MANUAL SEBM002322 – PDF DOWNLOAD

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KOMATSU GD825A-2 SHOP MANUAL SEBM002322 – PDF DOWNLOAD

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KOMATSU GD825A-2 SHOP MANUAL SEBM002322 – PDF DOWNLOAD

Language : English
Pages : 1022
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

KOMATSU GD825A-2 SHOP MANUAL SEBM002322 – PDF DOWNLOAD

Cover......................................................................................................................................................   1
	10 STRUCTURE AND FUNCTION..............................................................................................................................  55
		General............................................................................................................................................  56
		Power train diagram................................................................................................................................  57
		Joint..............................................................................................................................................  58
		HYDROSHIFT transmission and transfer piping........................................................................................................  59
		Hydraulic circuit for power train..................................................................................................................  60
		Hydraulic circuit diagram for power train..........................................................................................................  61
		PTO (Power Take Off)...............................................................................................................................  64
		HYDROSHIFT transmission and transfer...............................................................................................................  66
		Transmission control valve.........................................................................................................................  76
		Transmission control............................................................................................................................... 104
		Inching control.................................................................................................................................... 112
		Drive shaft........................................................................................................................................ 113
		Final drive, differential lock and unlock piping................................................................................................... 114
		Final drive........................................................................................................................................ 116
		Tandem drive....................................................................................................................................... 119
		Steering piping.................................................................................................................................... 121
		Steering circuit system............................................................................................................................ 122
		Steering circuit diagram........................................................................................................................... 123
		Steering valve..................................................................................................................................... 124
		Double relief valve................................................................................................................................ 128
		Check valve........................................................................................................................................ 129
		Emergency steering system.......................................................................................................................... 130
		Front axle......................................................................................................................................... 131
		Wheel.............................................................................................................................................. 136
		Disc brake......................................................................................................................................... 139
		Parking brake...................................................................................................................................... 141
		Brake air piping................................................................................................................................... 143
		Brake air circuit system........................................................................................................................... 144
		Brake air circuit diagram.......................................................................................................................... 145
		Air drier.......................................................................................................................................... 146
		Air governor....................................................................................................................................... 148
		Air tank........................................................................................................................................... 150
		Safety valve....................................................................................................................................... 150
		Automatic drain valve.............................................................................................................................. 151
		Check valve........................................................................................................................................ 153
		Brake valve........................................................................................................................................ 154
		Parking brake system............................................................................................................................... 158
		Parking brake solenoid valve....................................................................................................................... 159
		Exhaust valve...................................................................................................................................... 160
		Spring cylinder.................................................................................................................................... 161
		Hydraulic control piping........................................................................................................................... 162
		Hydraulic circuit system........................................................................................................................... 170
		Hydraulic circuit diagram.......................................................................................................................... 172
		Closed center load sensing system (CLSS)........................................................................................................... 184
		Hydraulic pump..................................................................................................................................... 188
		Priority flow divider valve........................................................................................................................ 193
		Surge pressure absorbing valve..................................................................................................................... 199
		Hydraulic control valve............................................................................................................................ 202
		Pressure compensating mechanism of hydraulic control valve......................................................................................... 206
		Blade lift speed adjustment mechanism.............................................................................................................. 212
		Pilot check valve.................................................................................................................................. 214
		Pilot check valve (with safety valve).............................................................................................................. 216
		Circle rotation motor.............................................................................................................................. 218
		Blade accumulator system........................................................................................................................... 221
		Blade float system................................................................................................................................. 223
		Drawbar and lifter................................................................................................................................. 224
		Blade.............................................................................................................................................. 228
		Lifter bracket control piping...................................................................................................................... 230
		Circle rotation gear............................................................................................................................... 231
		Rear mount ripper.................................................................................................................................. 233
		Hydraulic control linkage.......................................................................................................................... 234
		Main Frame......................................................................................................................................... 236
		Air conditioner.................................................................................................................................... 238
		Electrical wiring diagram.......................................................................................................................... 241
		Monitor panel, cluster gauge and pilot lamp........................................................................................................ 247
		Electrical circuit diagram......................................................................................................................... 251
		Electrical vehicle monitoring system (EVMS)........................................................................................................ 297
		Transmission control system........................................................................................................................ 307
		Sensors............................................................................................................................................ 314
		Engine starting circuit............................................................................................................................ 322
		Engine stopping circuit............................................................................................................................ 330
	20 TESTING AND ADJUSTING............................................................................................................................... 337
		Standard value table for engine.................................................................................................................... 339
		Standard value table for testing and adjusting, failure judgment of chassis........................................................................ 342
		Precautions before work............................................................................................................................ 348
		Tool list for testing and adjusting................................................................................................................ 350
		Testing and adjusting valve clearance.............................................................................................................. 352
		Measuring compression pressure..................................................................................................................... 353
		Testing and adjusting fuel injection timing........................................................................................................ 354
		Measuring blow-by pressure......................................................................................................................... 358
		Measuring engine oil pressure...................................................................................................................... 359
		Measuring exhaust gas color........................................................................................................................ 360
		Measuring exhaust gas temperature.................................................................................................................. 361
		Measuring intake air pressure (boost pressure)..................................................................................................... 362
		Testing and adjusting fan belt tension............................................................................................................. 364
		Testing and adjusting alternator belt tension...................................................................................................... 366
		Procedure for adjusting the engine stop motor cable................................................................................................ 368
		Adjusting accelerator control...................................................................................................................... 369
		Inching pedal travel and operating force........................................................................................................... 370
		Measuring transmission oil pressure................................................................................................................ 371
		Checking differential locking device oil pressure.................................................................................................. 374
		Steering system.................................................................................................................................... 375
		Checking tire runout............................................................................................................................... 376
		Checking air pressure of tire...................................................................................................................... 376
		Checking toe-in.................................................................................................................................... 377
		Installation of articulate center pins............................................................................................................. 378
		Checking wear of brake disc........................................................................................................................ 379
		Checking parking brake............................................................................................................................. 379
		Checking work equipment control lever travel and operating force................................................................................... 380
		Checking hydraulic oil temperature................................................................................................................. 380
		Checking work equipment hydraulic pressure......................................................................................................... 381
		Adjusting work equipment hydraulic pressure........................................................................................................ 381
		Measuring hydraulic drift.......................................................................................................................... 382
		Charging blade accumulator with gas................................................................................................................ 383
		Adjusting blade lift speed......................................................................................................................... 384
		Bleeding air from hydraulic pump................................................................................................................... 385
		Adjusting slip load of circle rotation clutch...................................................................................................... 386
		Adjusting speedometer module of machine monitor.................................................................................................... 393
		Pm-CLINIC.......................................................................................................................................... 394
	TROUBLESHOOTING........................................................................................................................................ 401
		Precautions before work............................................................................................................................ 402
		Points to remember when troubleshooting............................................................................................................ 404
		Sequence of events in troubleshooting.............................................................................................................. 405
		Handling of electric equipment and hydraulic component............................................................................................. 406
		Checks before troubleshooting...................................................................................................................... 416
		Electrical circuit system diagram.................................................................................................................. 417
		Connector types and mounting locations............................................................................................................. 433
		Electrical wiring diagram.......................................................................................................................... 443
		Connection table for connector pin numbers......................................................................................................... 447
		T-branch box and T-branch adapter table............................................................................................................ 483
		Method of using troubleshooting charts............................................................................................................. 486
		Details of troubleshooting and troubleshooting procedure........................................................................................... 488
		TROUBLESHOOTING OF ENGINE (S MODE)................................................................................................................. 493
			S-1  Starting performance is poor (Starting always takes time)................................................................................. 494
			S-2  Engine does not start..................................................................................................................... 495
				(1) Engine does not turn................................................................................................................... 495
				(2) Engine turns but no exhaust gas comes out (Fuel is not being injected)................................................................. 496
				(3) Exhaust gas comes out but engine does not start (Fuel is being injected)............................................................... 497
			S-3  Engine does not pick up smoothly (Follow-up is poor)...................................................................................... 498
			S-4  Engine stops during operations............................................................................................................ 499
			S-5  Engine does not rotate smoothly (hunting)................................................................................................. 500
			S-6  Engine lacks output (no power)............................................................................................................ 501
			S-7  Exhaust gas is black (incomplete combustion).............................................................................................. 502
			S-8  Oil consumption is excessive (or exhaust gas is blue)..................................................................................... 503
			S-9  Oil becomes contaminated quickly.......................................................................................................... 504
			S-10  Fuel consumption is excessive............................................................................................................ 505
			S-11  Oil is in cooling water, or water spurts back, or water level goes down.................................................................. 506
			S-12  Oil pressure lamp lights up (drop in oil pressure)....................................................................................... 507
			S-13  Oil level rises.......................................................................................................................... 508
			S-14  Water temperature becomes too high (overheating)......................................................................................... 509
			S-15  Abnormal noise is made................................................................................................................... 510
			S-16  Vibration is excessive................................................................................................................... 511
		TROUBLESHOOTING CHART FOR ELECTRONIC VEHICLE MONITORING SYSTEM (M MODE)............................................................................ 513
			M-1.  When starting switch is turned ON, monitor panel display does not appear................................................................. 514
			M-2.  When starting switch is turned ON, monitor panel display does not go out................................................................. 514
			M-3.  When starting switch is turned ON (engine stopped), check items flash.................................................................... 515
			M-4.  Preheating operation is not being used but preheating display lights up.................................................................. 517
			M-5.  When starting switch is turned ON and engine is started, caution items flash (but there is no abnormality with engine or CHECK items).... 520
			M-6.  Buzzer does not sound for 1 minute when starting switch is turned ON (engine stopped).................................................... 527
			M-7.  There is no abnormality displayed on monitor, but buzzer sounds.......................................................................... 527
			M-8.  Monitor panel lighting does not light up................................................................................................. 528
			M-9.  Service meter does not move after engine is started / Service meter continues to move when engine is stopped............................. 531
			M-10.  Coolant temperature gauge displays abnormally low temperature........................................................................... 532
			M-11.  Coolant temperature gauge does not give a display....................................................................................... 533
			M-12.  Fuel level gauge always displays FULL................................................................................................... 534
			M-13.  Fuel gauge does not give any display.................................................................................................... 534
			M-14.  Speedometer display does not work normally.............................................................................................. 535
			M-15.  Turn signal indicator pilot lamp does not light up...................................................................................... 536
			M-16.  High beam pilot lamp does not light up.................................................................................................. 537
		TROUBLESHOOTING CHART FOR ELECTRONIC (ENGINE, PARKING BRAKE, TRANSMISSION CONTROL) (E MODE)........................................................ 539
			E-1  Engine does not start (starting motor works).............................................................................................. 540
			E-2  Starting motor does not turn.............................................................................................................. 540
			E-3  Parking brake does not work............................................................................................................... 546
			E-4  Parking brake cannot be released.......................................................................................................... 546
			E-5  Transmission does not shift when transmission lever is moved to a position between F1 and F8, or R1 and R8................................ 548
			E-6  Transmission does not shift to 1st (F and R).............................................................................................. 558
			E-7  Transmission does not shift to 2nd (F and R).............................................................................................. 558
			E-8  Transmission does not shift to 3rd (F and R).............................................................................................. 558
			E-9  Transmission does not shift to 4th (F and R).............................................................................................. 559
			E-10  Transmission does not shift to 5th (F and R)............................................................................................. 559
			E-11  Transmission does not shift to 6th (F and R)............................................................................................. 559
			E-12  Transmission does not shift to 7th (F and R)............................................................................................. 560
			E-13  Transmission does not shift to 8th (F and R)............................................................................................. 560
		TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (ET MODE)........................................................................................ 561
			LED display for transmission controller........................................................................................................ 562
			ET-1  [A1] (Short circuit in 1st solenoid) is displayed........................................................................................ 568
			ET-2  [A2] (Short circuit in 2nd solenoid) is displayed........................................................................................ 569
			ET-3  [A3] (Short circuit in 3rd solenoid) is displayed........................................................................................ 570
			ET-4  [A4] (short circuit in 4th solenoid) is displayed........................................................................................ 571
			ET-5  [A5] (Short circuit in High/Low solenoid) is displayed................................................................................... 572
			ET-6  [A7] (Short circuit in FORWARD/REVERSE solenoid) is displayed............................................................................ 574
			ET-7  [b1] (Disconnection in 1st solenoid) is displayed........................................................................................ 576
			ET-8  [b2] (Disconnection in 2nd solenoid) is displayed........................................................................................ 577
			ET-9  [b3] (Disconnection in 3rd solenoid) is displayed........................................................................................ 578
			ET-10  [b4] (Disconnection in 4th solenoid) is displayed....................................................................................... 579
			ET-11  [b5] (Disconnection in Low solenoid) is displayed....................................................................................... 580
			ET-12  [b6] (Disconnection in High solenoid) is displayed...................................................................................... 581
			ET-13  [b7] (Disconnection in FORWARD solenoid) is displayed................................................................................... 582
			ET-14  [b8] (Disconnection in REVERSE solenoid) is displayed................................................................................... 583
			ET-15  [c1] (Disconnection in inching potentiometer) is displayed.............................................................................. 584
			ET-16  [c2] (Failure in shift potentiometer 1) is displayed.................................................................................... 585
			ET-17  [c3] (Failure in shift potentiometer 2) is displayed.................................................................................... 586
			ET-18  [d1] (Failure in F and R switches) is displayed......................................................................................... 587
			ET-19  [d4] (Disconnection in engine speed sensor) is displayed................................................................................ 590
			ET-20  [d5] (Disconnection in speed sensor) is displayed....................................................................................... 591
			ET-21  [d6] (Failure in transmission oil temperature sensor) is displayed...................................................................... 592
			ET-22  [E0] (Drop in power source voltage) is displayed........................................................................................ 593
			ET-23  [E1] (Short circuit in parking brake) is displayed...................................................................................... 595
			ET-24  [E2] or [F2] (Short circuit, disconnection in parking brake lamp) is displayed.......................................................... 596
			ET-25  [E3] or [F3] (Short circuit, disconnection in differential lock relay) is displayed..................................................... 597
			ET-26  [E4] or [F4] (Short circuit, disconnection in backup buzzer relay) is displayed......................................................... 599
			ET-27  [E5] or [F5] (Short circuit, disconnection in caution lamp) is displayed................................................................ 601
			ET-28  [E6] or [F6] (Short circuit, disconnection in alarm buzzer relay) is displayed.......................................................... 602
			ET-29  [E7] or [F7] (Short circuit, disconnection in starting motor relay) is displayed........................................................ 604
			ET-30  [F1] (Disconnection in parking brake) is displayed...................................................................................... 606
			ET-31  [C4] (Disconnection in rotary switch photo-interrupter) is displayed.................................................................... 608
			ET-32  [C5] (Abnormality in rotary switch photo-interrupter) is displayed...................................................................... 609
		TROUBLESHOOTING CHART FOR HYDRAULIC SYSTEM (H MODE)................................................................................................ 613
			STANDARDS FOR MEASURING HYDRAULIC PRESSURE, AND JUDGEMENT VALUES............................................................................... 614
			TABLE OF FAILURE MODES AND CAUSES.............................................................................................................. 616
			HYDRAULIC PRESSURE MEASUREMENT AND FILTER MOUNTING POSITIONS................................................................................... 618
			H-1  Abnormal noise is made (from around pump)................................................................................................. 620
			H-2  Relief sound is heard (when not operating)................................................................................................ 620
			H-3  Hydraulic oil overheats (when not operating).............................................................................................. 620
			H-4  Work equipment does not move when control lever is operated (steering at neutral)......................................................... 621
			H-5  Work equipment is slow, lacks power....................................................................................................... 622
			H-6  There is excessive hydraulic drift of work equipment...................................................................................... 623
			H-7  Steering wheel does not turn (work equipment at neutral).................................................................................. 623
			H-8  Turning speed is slow, lacks power (work equipment at neutral)............................................................................ 624
			H-9  Feeling when operating steering wheel is strange.......................................................................................... 624
	30 DISASSEMBLY AND ASSEMBLY............................................................................................................................ 625
		PRECAUTIONS BEFORE WORK............................................................................................................................ 627
		HOW TO READ THIS MANUAL............................................................................................................................ 629
		COATING MATERIAL LIST.............................................................................................................................. 631
		SPECIAL TOOL LIST.................................................................................................................................. 634
		STARTING MOTOR..................................................................................................................................... 636
			Removal and Installation....................................................................................................................... 636
		ALTERNATOR......................................................................................................................................... 636
			Removal and Installation....................................................................................................................... 636
		NOZZLE HOLDER...................................................................................................................................... 638
			Removal and Installation....................................................................................................................... 638
		FUEL INJECTION PUMP................................................................................................................................ 639
			Removal and Installation....................................................................................................................... 639
		WATER PUMP......................................................................................................................................... 640
			Removal and Installation....................................................................................................................... 640
		ENGINE OIL COOLER CORE............................................................................................................................. 642
			Removal and Installation....................................................................................................................... 642
		TURBOCHARGER....................................................................................................................................... 643
			Removal and Installation....................................................................................................................... 643
		AIR COMPRESSOR..................................................................................................................................... 644
			Removal and Installation....................................................................................................................... 644
		CYLINDER HEAD...................................................................................................................................... 645
			Removal........................................................................................................................................ 645
			Installation................................................................................................................................... 649
		ENGINE (INCL. TRANSMISSION)........................................................................................................................ 652
			Removal........................................................................................................................................ 652
			Installation................................................................................................................................... 659
		RADIATOR........................................................................................................................................... 667
			Removal........................................................................................................................................ 667
			Installation................................................................................................................................... 669
		FUEL TANK.......................................................................................................................................... 671
			Removal........................................................................................................................................ 671
			Installation................................................................................................................................... 672
		PTO................................................................................................................................................ 674
			Disassembly.................................................................................................................................... 674
			Assembly....................................................................................................................................... 679
		TRANSMISSION....................................................................................................................................... 684
			Removal........................................................................................................................................ 684
			Installation................................................................................................................................... 688
			Disassembly.................................................................................................................................... 692
			Assembly....................................................................................................................................... 700
		TRANSFER........................................................................................................................................... 715
			Disassembly.................................................................................................................................... 715
			Assembly....................................................................................................................................... 718
		TRANSMISSION CONTROL VALVE......................................................................................................................... 722
			Disassembly.................................................................................................................................... 722
			Assembly....................................................................................................................................... 724
		HYDROSHIFT TRANSMISSION PUMP....................................................................................................................... 726
			Removal and Installation....................................................................................................................... 726
		TANDEM AND FINAL DRIVE............................................................................................................................. 727
			Removal........................................................................................................................................ 727
			Installation................................................................................................................................... 729
		FINAL DRIVE........................................................................................................................................ 731
			Disassembly.................................................................................................................................... 731
			Assembly....................................................................................................................................... 742
		BEVEL GEAR......................................................................................................................................... 758
			Disassembly.................................................................................................................................... 758
			Assembly....................................................................................................................................... 761
		BEVEL PINION....................................................................................................................................... 766
			Disassembly.................................................................................................................................... 766
			Assembly....................................................................................................................................... 767
		FRONT AXLE......................................................................................................................................... 768
			Removal........................................................................................................................................ 768
			Installation................................................................................................................................... 770
			Disassembly.................................................................................................................................... 772
			Assembly....................................................................................................................................... 775
		STEERING VALVE..................................................................................................................................... 781
			Disassembly.................................................................................................................................... 781
			Assembly....................................................................................................................................... 784
		WHEEL BRAKE........................................................................................................................................ 788
			Removal........................................................................................................................................ 788
			Installation................................................................................................................................... 792
			Disassembly.................................................................................................................................... 796
			Assembly....................................................................................................................................... 799
		PARKING BRAKE CALIPER PADS......................................................................................................................... 803
			Removal........................................................................................................................................ 803
			Installation................................................................................................................................... 805
		AIR TANK........................................................................................................................................... 809
			Removal and Installation....................................................................................................................... 809
		HYDRAULIC TANK..................................................................................................................................... 810
			Removal and Installation....................................................................................................................... 810
		HYDRAULIC PUMP..................................................................................................................................... 811
			Removal........................................................................................................................................ 811
			Installation................................................................................................................................... 812
			Disassembly.................................................................................................................................... 814
			Assembly....................................................................................................................................... 828
		HYDRAULIC CONTROL VALVE............................................................................................................................ 851
			Removal........................................................................................................................................ 851
			Installation................................................................................................................................... 852
		MAIN CONTROL VALVE................................................................................................................................. 854
			Disassembly.................................................................................................................................... 854
			Assembly....................................................................................................................................... 856
		CIRCLE ROTATION MOTOR.............................................................................................................................. 858
			Disassembly.................................................................................................................................... 858
			Assembly....................................................................................................................................... 861
		DRAWBAR SHIFT CYLINDER, BLADE LIFT CYLINDER, LIFTER GUIDE.......................................................................................... 877
			Removal........................................................................................................................................ 877
			Installation................................................................................................................................... 879
		ARTICULATE CYLINDER................................................................................................................................ 881
			Removal and Installation....................................................................................................................... 881
		REAR MOUNT RIPPER CYLINDER......................................................................................................................... 882
			Removal and Installation....................................................................................................................... 882
		HYDRAULIC CYLINDER................................................................................................................................. 883
			Serial No. 11001 - 12502....................................................................................................................... 883
				Disassembly................................................................................................................................ 883
				Assembly................................................................................................................................... 885
			Serial No. 12503 and up........................................................................................................................ 888
				Disassembly................................................................................................................................ 888
				Assembly...................................................................................................................................   0
		CIRCLE ROTATION GEAR AND HYDRAULIC OIL MOTOR....................................................................................................... 898
			Removal........................................................................................................................................ 898
			Installation................................................................................................................................... 899
			Disassembly.................................................................................................................................... 902
			Assembly....................................................................................................................................... 905
		BLADE.............................................................................................................................................. 917
			Removal and installation....................................................................................................................... 917
		CIRCLE AND DRAWBAR................................................................................................................................. 920
			Removal and Installation....................................................................................................................... 920
			Disassembly.................................................................................................................................... 921
			Assembly....................................................................................................................................... 923
		REAR MOUNT RIPPER.................................................................................................................................. 934
			Removal........................................................................................................................................ 934
			Installation................................................................................................................................... 935
		METHOD FOR LIFTING UP ROPS CAB..................................................................................................................... 936
		INSTALLATION OF ROPS............................................................................................................................... 938
		ROPS cab........................................................................................................................................... 939
			Removal........................................................................................................................................ 939
			Installation................................................................................................................................... 945
		DISCONNECTION AND CONNECTION OF ARTICULATE SECTION................................................................................................. 952
			Serial No. 11001 - 12502....................................................................................................................... 952
				Disconnection.............................................................................................................................. 952
				Connection................................................................................................................................. 955
			Serial No. 12503 and up........................................................................................................................ 957
				Disconnection.............................................................................................................................. 957
				Connection................................................................................................................................. 960
		FLOOR FRAME........................................................................................................................................ 962
			Removal........................................................................................................................................ 962
			Installation................................................................................................................................... 970
	40 MAINTENANCE STANDARD................................................................................................................................ 973
		01 GENERAL.........................................................................................................................................  45
			Specification dimension drawings...............................................................................................................  46
			Specifications.................................................................................................................................  48
			Weight table...................................................................................................................................  51
			Fuel, coolant and lubricants...................................................................................................................  52
		HYDROSHIFT transmission and transfer............................................................................................................... 974
		Transmission pump.................................................................................................................................. 980
		Transmission control valve......................................................................................................................... 982
		Transmission solenoid valve........................................................................................................................ 988
		Final drive........................................................................................................................................ 991
		Differential lock-up pump.......................................................................................................................... 992
		Tandem drive....................................................................................................................................... 993
		Front axle......................................................................................................................................... 994
		Steering cylinder.................................................................................................................................. 998
		Disc brake......................................................................................................................................... 999
		Parking brake......................................................................................................................................1000
		Spring cylinder....................................................................................................................................1001
		Hydraulic control valve............................................................................................................................1002
		Hydraulic cylinder.................................................................................................................................1006
		Hydraulic pump.....................................................................................................................................1010
		Drawbar and lifter.................................................................................................................................1012
		Blade..............................................................................................................................................1016
		Circle rotation gear...............................................................................................................................1018
		Ripper.............................................................................................................................................1020
		Frame..............................................................................................................................................1021

DESCRIPTION:

KOMATSU GD825A-2 SHOP MANUAL SEBM002322 – PDF DOWNLOAD

1. General precautions
1) Before carrying out any greasing or repairs, read all the safety labels stuck to the machine. For the locations of the safety labels and detailed explanation of precautions, see the Operation and Maintenance Manual.
2) Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt, water, or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.
3) When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing.
A. Always wear safety glasses when hitting parts with a hammer.
B. Always wear safety glasses when grinding parts with a grinder, etc.
4) When carrying out any operation with 2 or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR warning signs in the operator’s compartment.
5) Only the approved personnel can do the work in a closed environment or in a prohibited area.
6) Only qualified workers must carry out work and operation which require license or qualification.
7) Keep all tools in good condition, learn the correct way to use them, and use the proper ones of them. Before starting work, thoroughly check the tools, machine, forklift, service car, etc.
8) If welding repairs are needed, always have a trained and experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, shielding goggles, cap and other clothes suited for welding work.
9) Before starting work, warm up your body thoroughly to start work under good condition.
10) Avoid continuing work for long hours and take rests at proper intervals to keep your body in good condition. Take rests in specified safe places.
11) When you work in high places, use a platform.
12) Before you start the work, use the personal fall-arrest equipment to prevent falling. There is a danger of personal accident that you fall by slipping.
13) Always do the work correctly. If you find the unsafe behavior of co-worker, give him/her a notice and stop it.
14) Because there is a danger that you are caught, be very careful when the work is done in dangerous areas such as: when you go in the range where the lifted load possibly falls, or when you stand directly in front of tire, or when you are near the sliding parts.
15) When you handle chemical materials (such as nitrogen gas), see the MSDS (safety data sheet) and local guidelines, and get the important information (such as a safe handling method). Also, put on applicable protective equipment (such as protective goggles, gloves, and masks).

S.S 29/12/24