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KOMATSU PC160LC-8 HYDRAULIC EXCAVATOR SHOP MANUAL SEN04566-14TH – PDF DOWNLOAD
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Description
KOMATSU PC160LC-8 HYDRAULIC EXCAVATOR SHOP MANUAL SEN04566-14TH – PDF DOWNLOAD
FILE DETAILS:
KOMATSU PC160LC-8 HYDRAULIC EXCAVATOR SHOP MANUAL SEN04566-14TH – PDF DOWNLOAD
Language : English
Pages : 1054
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
KOMATSU PC160LC-8 HYDRAULIC EXCAVATOR SHOP MANUAL SEN04566-14TH – PDF DOWNLOAD
COVER ..................................................................................................................... 1 00 Index and foreword...................................................................................................... 3 100 Index.............................................................................................................. 3 Composition of shop manual......................................................................................... 4 Table of contents.................................................................................................. 6 200 Foreword and general information................................................................................... 15 Safety notice...................................................................................................... 16 How to read the shop manual........................................................................................ 21 Explanation of terms for maintenance standard...................................................................... 23 Handling of electric equipment and hydraulic component............................................................. 25 Handling of connectors newly used for engines...................................................................... 34 How to read electric wire code..................................................................................... 37 Precautions when carrying out operation............................................................................ 40 Method of disassembling and connecting push-pull type coupler...................................................... 43 Standard tightening torque table................................................................................... 46 Conversion table................................................................................................... 50 01 Specification........................................................................................................... 57 100 Specification and technical data................................................................................... 57 Specification dimension drawings................................................................................... 58 Specifications..................................................................................................... 60 Weight table....................................................................................................... 62 Table of fuel, coolant and lubricants.............................................................................. 64 10 Structure, function and maintenance standard............................................................................ 67 100 Engine and cooling system.......................................................................................... 67 Engine related parts............................................................................................... 68 Radiator, oil cooler, aftercooler and fuel cooler.................................................................. 69 200 Power train system................................................................................................. 71 Power train........................................................................................................ 72 Swing circle....................................................................................................... 73 Swing machinery.................................................................................................... 74 Final drive........................................................................................................ 76 Sprocket........................................................................................................... 78 300 Undercarriage and frame............................................................................................ 81 Track frame, recoil spring......................................................................................... 82 Idler.............................................................................................................. 84 Carrier roller..................................................................................................... 86 Track roller....................................................................................................... 87 Track shoe......................................................................................................... 88 401 Hydraulic system, Part 1........................................................................................... 93 Hydraulic equipment layout drawing................................................................................. 94 Hydraulic tank..................................................................................................... 96 Hydraulic pump..................................................................................................... 98 402 Hydraulic system, Part 2........................................................................................... 125 Control valve...................................................................................................... 126 CLSS............................................................................................................... 140 Functions and operation by valve................................................................................... 144 403 Hydraulic system, Part 3........................................................................................... 181 Valve control...................................................................................................... 182 PPC valve.......................................................................................................... 183 Solenoid valve..................................................................................................... 204 Accumulator........................................................................................................ 206 Anti-drop valve for boom........................................................................................... 208 Anti-drop valve for arm............................................................................................ 214 Return oil filter.................................................................................................. 221 Center swivel joint................................................................................................ 222 Travel motor....................................................................................................... 223 Swing motor........................................................................................................ 233 Attachment circuit selector valve.................................................................................. 234 Hydraulic cylinder................................................................................................. 238 500 Work equipment..................................................................................................... 241 Work equipment..................................................................................................... 242 Dimensions of components........................................................................................... 244 600 Cab and its attachments............................................................................................ 249 Air conditioner piping............................................................................................. 250 700 Electrical system.................................................................................................. 253 Engine control system.............................................................................................. 254 Electronic control system.......................................................................................... 264 Monitor system..................................................................................................... 292 Sensor............................................................................................................. 318 KOMTRAX system..................................................................................................... 322 20 Standard value table.................................................................................................... 325 100 Standard service value table....................................................................................... 325 Standard value table for engine.................................................................................... 326 Standard value table for chassis related parts..................................................................... 327 30 Testing and adjusting................................................................................................... 339 101 Testing and adjusting, Part 1...................................................................................... 339 Tools for testing, adjusting and troubleshooting................................................................... 341 Testing engine speed............................................................................................... 344 Testing intake air pressure (boost pressure)....................................................................... 345 Testing exhaust gas color.......................................................................................... 346 Adjusting valve clearance.......................................................................................... 347 Testing compression pressure....................................................................................... 349 Testing blow-by pressure........................................................................................... 351 Testing engine oil pressure........................................................................................ 352 Handling fuel system parts......................................................................................... 353 Releasing residual pressure from fuel system....................................................................... 353 Testing fuel pressure.............................................................................................. 354 Measuring fuel discharge, return and leakage....................................................................... 356 Bleeding air from fuel circuit..................................................................................... 360 Checking fuel circuit for leakage.................................................................................. 362 Checking and adjusting air conditioner compressor belt tension..................................................... 363 Replacing fan belt................................................................................................. 364 Testing clearance in swing circle bearings......................................................................... 365 Testing and adjusting track shoe tension........................................................................... 366 Inspection and adjustment oil pressure in work equipment, swing, and travel circuits............................... 367 Testing control circuit basic pressure............................................................................. 370 Testing and adjusting pump PC control circuit oil pressure......................................................... 371 Testing and adjusting pump LS control circuit oil pressure......................................................... 374 Testing solenoid valve output pressure............................................................................. 378 Testing PPC valve output pressure.................................................................................. 381 Adjusting play of work equipment and swing PPC valves.............................................................. 382 Inspecting locations of hydraulic drift of work equipment.......................................................... 383 Testing and adjusting travel deviation............................................................................. 385 Releasing remaining pressure in hydraulic circuit.................................................................. 387 Measurement of oil leakage......................................................................................... 388 Bleeding air from various parts.................................................................................... 390 Testing and charging accumulator (manufactured by NOK) nitrogen gas pressure for attachment (low pressure side).... 392 Testing and charging accumulator nitrogen gas pressure for attachment (high pressure side)......................... 394 Replacing accumulator bladder on high pressure side for accumulator piping......................................... 396 Inspection procedures for diode.................................................................................... 401 Checking cab tipping stopper....................................................................................... 402 Installation and adjustment of mirrors and camera.................................................................. 403 Inspection of air conditioner Recirc/Fresh air filter.............................................................. 407 102 Testing and adjusting, Part 2...................................................................................... 409 Special functions of machine monitor............................................................................... 410 103 Testing and adjusting, Part 3...................................................................................... 463 Handling voltage circuit of engine controller...................................................................... 464 Preparation work for troubleshooting of electrical system.......................................................... 465 Procedure for testing diodes....................................................................................... 470 Pm-clinic service.................................................................................................. 471 40 Troubleshooting......................................................................................................... 477 100 Failure code table and fuse locations.............................................................................. 477 Failure code table................................................................................................. 478 Fuse locations..................................................................................................... 481 200 General information on troubleshooting............................................................................. 485 Points to remember when troubleshooting............................................................................ 486 Sequence of events in troubleshooting.............................................................................. 487 Checks before troubleshooting...................................................................................... 488 Classification and troubleshooting steps........................................................................... 489 Information in troubleshooting table............................................................................... 490 Phenomena looking like troubles and troubleshooting Nos............................................................ 492 Connection table for connector pin numbers......................................................................... 495 T- branch box and T- branch adapter table.......................................................................... 531 301 Troubleshooting by failure code, Part 1............................................................................ 535 Failure code [989L00] Engine controller lock caution 1............................................................. 537 Failure code [989M00] Engine controller lock caution 2............................................................. 537 Failure code [989N00] Engine controller lock caution 3............................................................. 538 Failure code [AA10NX] Air cleaner clogging......................................................................... 539 Failure code [AB00KE] Charge voltage low........................................................................... 540 Failure code [B@BAZG] Eng oil press. low........................................................................... 542 Failure code [B@BAZK] Eng oil level low............................................................................ 543 Failure code [B@BCNS] Eng coolant overheat......................................................................... 544 Failure code [B@BCZK] Eng water level low.......................................................................... 546 Failure code [B@HANS] Hydr oil overheat............................................................................ 548 Failure code [CA111] ECM critical internal failure................................................................. 550 Failure code [CA115] Eng Ne and bkup speed sens error.............................................................. 551 Failure code [CA122] Chg air press sensor high error............................................................... 552 Failure code [CA123] Chg air press sensor low error................................................................ 554 Failure code [CA131] Throttle sensor high error.................................................................... 556 Failure code [CA132] Throttle sensor low error..................................................................... 558 Failure code [CA144] Coolant temp sens high error.................................................................. 560 Failure code [CA145] Coolant temp sens low error................................................................... 562 Failure code [CA153] Chg air temp sensor high error................................................................ 564 Failure code [CA154] Chg air temp sensor low error................................................................. 566 Failure code [CA155] Chg air temp high speed derate................................................................ 568 Failure code [CA187] Sens supply 2 volt low error.................................................................. 570 Failure code [CA221] Ambient press sens high error................................................................. 572 Failure code [CA222] Ambient press sens low error.................................................................. 574 Failure code [CA227] Sens supply 2 volt high error................................................................. 576 Failure code [CA234] Eng. overspeed................................................................................ 577 Failure code [CA238] Ne speed sens supply volt error............................................................... 578 Failure code [CA271] IMV/PCV1 short error.......................................................................... 579 Failure code [CA272] IMV/PCV1 open error........................................................................... 580 Failure code [CA322] Inj #1 open/short error....................................................................... 582 Failure code [CA324] Inj #3 open/short error....................................................................... 584 Failure code [CA331] Inj #2 open/short error....................................................................... 586 Failure code [CA332] Inj #4 open/short error....................................................................... 588 302 Troubleshooting by failure code, Part 2............................................................................ 591 Failure code [CA342] Calibration code incompatibility.............................................................. 593 Failure code [CA351] Injectors Drive Circuit Error................................................................. 594 Failure code [CA352] Sens supply 1 volt low error.................................................................. 596 Failure code [CA386] Sens supply 1 volt high error................................................................. 598 Failure code [CA428] Water in fuel sensor high error............................................................... 600 Failure code [CA429] Water in fuel sensor low error................................................................ 602 Failure code [CA435] Eng oil press sw error........................................................................ 604 Failure code [CA441] Battery voltage low error..................................................................... 606 Failure code [CA442] Battery voltage high error.................................................................... 608 Failure code [CA449] Rail press very high error.................................................................... 610 Failure code [CA451] Rail press sensor high error.................................................................. 612 Failure code [CA452] Rail press sensor low error................................................................... 614 Failure code [CA488] Chg air temp high torque derate............................................................... 616 Failure code [CA553] Rail press high error......................................................................... 616 Failure code [CA559] Rail press low error.......................................................................... 617 Failure code [CA689] Eng Ne speed sensor error..................................................................... 618 Failure code [CA731] Eng Bkup speed sens phase error............................................................... 620 Failure code [CA757] All persistent data lost error............................................................... 622 Failure code [CA778] Eng Bkup speed sensor error................................................................... 624 Failure code [CA1633] KOMNET datalink timeout error................................................................ 626 Failure code [CA2185] Throttle sens. sup. volt. high error......................................................... 628 Failure code [CA2186] Throttle sens. sup. volt. low error.......................................................... 629 Failure code [CA2249] Rail press very low error.................................................................... 630 Failure code [CA2311] IMV solenoid error........................................................................... 632 Failure code [CA2555] Grid htr relay volt high error............................................................... 634 Failure code [CA2556] Grid htr relay volt low error................................................................ 636 Failure code [D110KB] Battery relay drive short.................................................................... 638 Failure code [D19JKZ] Personal code relay abnormality.............................................................. 640 Failure code [D862KA] GPS antenna discon........................................................................... 642 Failure code [DA22KK] Pump solenoid power low error................................................................ 644 Failure code [DA25KP] 5V sensor 1 power abnormality................................................................ 646 Failure code [DA26KP] 5V sensor 2 power abnormality................................................................ 649 Failure code [DA29KQ] Model selection abnormality.................................................................. 650 303 Troubleshooting by failure code, Part 3............................................................................ 653 Failure code [DA2RMC] CAN discon (Pump controller detected)........................................................ 656 Failure code [DAF8KB] Short circuit in camera power supply......................................................... 658 Failure code [DAFGMC] GPS module error............................................................................. 660 Failure code [DAFRMC] CAN discon (Monitor detected)................................................................ 662 Failure code [DGH2KB] Hydr oil sensor short........................................................................ 664 Failure code [DHPAMA] F Pump press sensor abnormality.............................................................. 666 Failure code [DHPBMA] R Pump press sensor abnormality.............................................................. 668 Failure code [DHS5KX] Travel PPC press sensor abnormality.......................................................... 670 Failure code [DHSAMA] Sw RH PPC press sen. abnormality............................................................. 672 Failure code [DHSBMA] Sw LH PPC press sen. abnormality............................................................. 674 Failure code [DHX1MA] Overload sensor abnormality (Analog)......................................................... 676 Failure code [DW43KA] Travel speed sol discon...................................................................... 677 Failure code [DW43KB] Travel speed sol short....................................................................... 678 Failure code [DW45KA] Swing brake sol discon....................................................................... 680 Failure code [DW45KB] Swing brake sol short........................................................................ 682 Failure code [DW91KA] Travel junction sol discon................................................................... 684 Failure code [DW91KB] Travel junction sol short.................................................................... 686 Failure code [DWA2KA] Service sol discon........................................................................... 688 Failure code [DWA2KB] Service sol short............................................................................ 689 Failure code [DWJ0KA] Merge-divider sol discon..................................................................... 690 Failure code [DWJ0KB] Merge-divider sol short...................................................................... 692 Failure code [DWK0KA] 2-stage relief sol discon.................................................................... 694 Failure code [DWK0KB] 2-stage relief sol short..................................................................... 696 304 Troubleshooting by failure code, Part 4............................................................................ 699 Failure code [DXA8KA] PC-EPC sol discon............................................................................ 700 Failure code [DXA8KB] PC-EPC sol short............................................................................. 702 Failure code [DXE4KA] Service current EPC discon................................................................... 704 Failure code [DXE4KB] Service current EPC short.................................................................... 706 Failure code [DY20KA] Wiper working abnormality.................................................................... 708 Failure code [DY20MA] Wiper parking abnormality.................................................................... 710 Failure code [DY2CKA] Washer drive discon.......................................................................... 712 Failure code [DY2CKB] Washer drive short........................................................................... 714 Failure code [DY2DKB] Wiper drive (for) short...................................................................... 716 Failure code [DY2EKB] Wiper drive (rev) short...................................................................... 718 400 Troubleshooting of electrical system (E-mode)...................................................................... 721 Before carrying out troubleshooting of electrical system........................................................... 723 Information in troubleshooting table............................................................................... 725 E-1 When starting switch turned ON, machine monitor displays nothing............................................... 726 E-2 When starting switch is turned to ON position (before starting engine), basic check item lights up............. 728 E-3 Engine does not start (Engine does not crank).................................................................. 731 E-4 Preheater does not operate..................................................................................... 734 E-5 Automatic warm-up system does not operate (in cold season)..................................................... 736 E-6 All work equipment, swing, and travel mechanism do not move or cannot be locked................................ 738 E-7 Precaution lights up while engine is running................................................................... 740 E-8 Emergency stop item lights up while engine is running.......................................................... 744 E-9 Engine coolant temperature gauge does not indicate normally.................................................... 745 E-10 Hydraulic oil temperature gauge does not indicate normally.................................................... 746 E-11 Fuel level gauge does not indicate normally................................................................... 748 E-12 Contents of display by machine monitor are different from applicable machine.................................. 750 E-13 Machine monitor does not display some items................................................................... 750 E-14 Function switch does not work................................................................................. 750 E-15 Auto-decelerator does not operate normally.................................................................... 751 E-16 Working mode does not change.................................................................................. 752 E-17 Travel speed does not change.................................................................................. 753 E-18 Alarm buzzer cannot be stopped................................................................................ 754 E-19 Windshield wiper and window washer do not operate............................................................. 755 E-20 Power maximizing function does not operate normally........................................................... 757 E-21 Swing holding brake does not operate normally................................................................. 759 E-22 Travel alarm does not sound or does not stop sounding......................................................... 761 E-23 Air conditioner does not operate normally (including air conditioner abnormality record)...................... 763 E-24 While starting switch is in OFF position, service meter is not displayed...................................... 774 E-25 Machine monitor cannot be set in service mode................................................................. 774 E-26 Monitoring function does not display lever control signal normally............................................ 776 E-27 KOMTRAX system does not operate normally...................................................................... 786 500 Troubleshooting of hydraulic and mechanical system (H-mode)........................................................ 789 Information contained in troubleshooting table..................................................................... 791 System chart for hydraulic and mechanical systems.................................................................. 792 H-1 Speed or power of all work equipment, swing, and travel are low................................................ 794 H-2 Engine speed sharply drops or engine stalls.................................................................... 795 H-3 No work equipment, travel and swing move....................................................................... 796 H-4 Abnormal noise is heard from around hydraulic pump............................................................. 796 H-5 Auto-decelerator does not work................................................................................. 797 H-6 Fine control mode does not function............................................................................ 797 H-7 Speed or power of boom is low.................................................................................. 798 H-8 Speed or power of arm is low................................................................................... 799 H-9 Speed or power of bucket is low................................................................................ 800 H-10 Work equipment does not move in its single operation.......................................................... 801 H-11 Hydraulic drift of work equipment is large.................................................................... 802 H-12 Time lag of work equipment is large........................................................................... 803 H-13 One-touch power max system does not operate................................................................... 803 H-14 Work equipment loaded more is slower during compound operation................................................ 804 H-15 Boom RAISE speed is low in compound operation of swing + boom RAISE........................................... 804 H-16 Travel speed lowers largely during compound operation of work equipment/swing + travel........................ 805 H-17 Machine deviates during travel................................................................................ 806 H-18 Travel speed is low........................................................................................... 807 H-19 Machine cannot be steered easily or steering power is low..................................................... 808 H-20 Travel speed does not change or it is kept low or high........................................................ 809 H-21 Track does not move (Only either side)........................................................................ 809 H-22 Machine does not swing........................................................................................ 810 H-23 Swing acceleration or swing speed is low...................................................................... 811 H-24 Excessive overrun when stopping swing......................................................................... 812 H-25 When upper structure stops swinging, it makes large shock..................................................... 813 H-26 When upper structure stops swinging, it makes large sound..................................................... 813 H-27 Hydraulic drift of swing is large............................................................................. 814 H-28 Attachment circuit does not change............................................................................ 815 H-29 Flow rate in attachment circuit cannot be adjusted............................................................ 815 600 Troubleshooting of engine (S-mode)................................................................................. 817 Method of using troubleshooting chart.............................................................................. 820 S-1 Starting performance is poor.................................................................................. 824 S-2 Engine does not start......................................................................................... 825 S-3 Engine does not pick up smoothly.............................................................................. 828 S-4 Engine stops during operations................................................................................ 829 S-5 Engine does not rotate smoothly............................................................................... 830 S-6 Engine lack output (or lacks power)........................................................................... 831 S-7 Exhaust smoke is black (incomplete combustion)................................................................ 832 S-8 Oil consumption is excessive (or exhaust smoke is blue)....................................................... 833 S-9 Oil becomes contaminated quickly.............................................................................. 834 S-10 Fuel consumption is excessive................................................................................ 835 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)........................................ 836 S-12 Oil pressure drops........................................................................................... 837 S-13 Oil level rises (Entry of coolant/fuel)...................................................................... 838 S-14 Coolant temperature becomes too high (overheating)........................................................... 839 S-15 Abnormal noise is made....................................................................................... 840 S-16 Vibration is excessive....................................................................................... 841 50 Disassembly and assembly................................................................................................ 843 100 General information on disassembly and assembly.................................................................... 843 How to read this manual............................................................................................ 844 Coating materials list............................................................................................. 846 Special tool list.................................................................................................. 849 Sketches of special tools.......................................................................................... 852 200 Engine and cooling system.......................................................................................... 855 Removal and installation of fuel supply pump assembly.............................................................. 856 Removal and installation of fuel injector assembly................................................................. 860 Removal and installation of cylinder head assembly................................................................. 867 Removal and installation of front oil seal......................................................................... 880 Removal and installation of rear oil seal.......................................................................... 882 Removal and installation of radiator assembly...................................................................... 885 Removal and installation of aftercooler assembly................................................................... 887 Removal and installation of hydraulic oil cooler assembly.......................................................... 889 Removal and installation of engine and hydraulic pump assembly..................................................... 891 Removal and installation of engine hood assembly................................................................... 899 Removal and installation of fuel tank assembly..................................................................... 901 300 Power train........................................................................................................ 905 Removal and installation of travel motor and final drive assembly.................................................. 906 Disassembly and assembly of final drive assembly................................................................... 908 Removal and installation of swing motor and swing machinery assembly............................................... 915 Disassembly and assembly of swing motor and swing machinery assembly............................................... 917 Removal and installation of swing circle assembly.................................................................. 924 400 Undercarriage and frame............................................................................................ 927 Disassembly and assembly of carrier roller......................................................................... 928 Disassembly and assembly of track roller assembly.................................................................. 931 Disassembly and assembly of idler assembly......................................................................... 933 Disassembly and assembly of recoil spring.......................................................................... 936 Expansion and installation of track shoe assembly.................................................................. 938 Removal and installation of sprocket............................................................................... 940 Removal and installation of revolving frame assembly............................................................... 941 Removal and installation of counterweight assembly................................................................. 943 500 Hydraulic system................................................................................................... 947 Removal and installation of center swivel joint assembly........................................................... 948 Disassembly and assembly of center swivel joint assembly........................................................... 950 Removal and installation of hydraulic tank assembly................................................................ 952 Removal and installation of hydraulic pump assembly................................................................ 955 Removal and installation of hydraulic pump input shaft oil seal.................................................... 958 Removal and installation of control valve assembly................................................................. 959 Disassembly and assembly of control valve assembly................................................................. 963 Disassembly and assembly of work equipment PPC valve assembly...................................................... 965 Disassembly and assembly of travel PPC valve assembly.............................................................. 966 Disassembly and assembly of hydraulic cylinder assembly............................................................ 969 600 Work equipment..................................................................................................... 977 Removal and installation of work equipment assembly................................................................ 978 Remove and installation anti-drop valve assembly for boom.......................................................... 981 Removal and installation of anti- drop valve assembly for arm...................................................... 984 Disassembly and assembly anti- drop valve assembly................................................................. 986 700 Cab and its attachments............................................................................................ 989 Removal and installation of operator’s cab assembly................................................................ 990 Removal and installation of operator cab glass (stuck glass)....................................................... 994 Removal and installation of front window assembly..................................................................1004 Removal and installation of floor frame assembly...................................................................1011 Removal and installation of air conditioner unit assembly..........................................................1015 800 Electrical system..................................................................................................1019 Removal and installation of monitor assembly.......................................................................1020 Removal and installation of pump controller assembly...............................................................1022 Removal and installation of engine controller assembly.............................................................1025 Removal and installation of KOMTRAX terminal.......................................................................1027 90 Diagrams and drawings...................................................................................................1029 100 Hydraulic circuit diagram..........................................................................................1029 Hydraulic circuit diagram..........................................................................................1031 200 Electrical diagrams and drawings...................................................................................1037 Electrical circuit diagram (1/6)...................................................................................1039 Electrical circuit diagram (2/6)...................................................................................1041 Electrical circuit diagram (3/6)...................................................................................1043 Electrical circuit diagram (4/6)...................................................................................1045 Electrical circuit diagram (5/6)...................................................................................1047 Electrical circuit diagram (6/6)...................................................................................1049 Connectors table and arrangement drawing...........................................................................1051
DESCRIPTION:
KOMATSU PC160LC-8 HYDRAULIC EXCAVATOR SHOP MANUAL SEN04566-14TH – 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 qualified workers must carry out work and operation which require license or qualification.
6) 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.
7) 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.
8) Before starting work, warm up your body thoroughly to start work under good condition.
9) 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.
S.S 27/12/24
