Capacitor Discharger Manual

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Document #: E796-426-1800-00

Operation Manual of

Capacitor Discharger Tool

P/N: 796-426-1800

Type: DISCAP400V-2

Applicable S/N: #1003003 and up

Service DepartmentProduct Support Division

Komatsu

August 23, 2010


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Contents

1. Outline 2

2. Applicable Capacitors 2

3. Precautions 3

4. Main Specification and Operation 12

5. Environmental Conditions 14

6. Set 16

7. Composition and Part Names 17

8. Operation Procedure 18

9. Parts Replacement 25

10. Measures for Abnormalities 27

11. Cautions for Transportation 29

12. Caution for disposal 29

13. Related matters 29

14. List of Parts to Purchase 30


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1. OutlineThis tool is used for electric discharge of capacitor which is used for hybrid

construction machines. Capacitor contains high-voltage electric charge. Normally,

electric discharge is carried out by using electric discharge function which is built into the

machine, but if that function is not working due to failure, there is a risk of electric shock

to human and damage or fire on equipments due to short-circuiting. This tool (capacitor

discharger) can be used to prevent those accidents.

This capacitor discharger tool applies the electric charge contained in capacitor to

the resistance contained inside, converts it into heat and consumes it. The heat

generated inside is released to outside by cooling fan. It is controlled automatically from

the start until finishing electric discharge, and stops when START LED goes out.

2. Applicable CapacitorsThis tool is applicable for capacitors of under DC400V. If this

tool is connected to the ones that exceed 400V, breakage and firemay be caused. Do not connect to the ones that exceed 400V.


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3. Precautions3.1 Below are precautions for safety of this tool. Details are described in the specified

sections in this manual, so please make sure to read it carefully to maintain safety uponoperation.

[1] Environmental condition in use ( 5. (1))

[2] Environmental condition in storage ( 5. (2))

[3] Grounding ( 6. (1)-2)

Before use, connect the ground terminal of this tool to the ground. This tool deals

with direct high voltage (under DC400V), grounding which is regulated in local areas is

necessary. This work must be carried out by qualified persons or the persons who have the

equivalent knowledge.

[4] Setting on service car ( 6. (2))

If setting this tool on service cars, please carry out below.

1. Fix the tool so that it does not fall when traveling.

2. When using, park the service car as close as possible to the

construction machine. However, it must be within the area that this

tool and capacitor can be connected with a 5 meter cable.

[5] Place this tool longitudinally when use. (The side of voltmeter facing up) ( 7. Note 1)

[6] Keep the acrylic cover open when this tool is connected so that the emergency stop

switch can be operated promptly. ( 7. Note 2)

[7] Before starting operation, turn off the machine body key, power switch key and the startswitch of this tool. ( 8. 1)

[8] Before starting operation, remove 3 cables (2 power cables and 1 signal cable) that are

connected to the capacitor. ( 8.2)

[9] Be sure to stop the engine of the construction machine before removing the cables. (

8.2 Note1)


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[10] Do not put fingers or tools inside the power connector (orange portion) of capacitor side

while power cables are removed. Capacitor voltage is output only when control power to

capacitor is provided (by connection of signal cable). However, it is very dangerous if highvoltage is output from the connector of the capacitor (MAX DC400V) because there is a risk

of burns or deaths. It is necessary to consider safety by wearing electric shock preventive

gloves etc. ( 8. 2 Note 2)

[11] Confirm that 2 ring terminals of the ring terminal cable of this tool are both covered with

tube. If ring terminal is exposed even though ring terminal is not used, cover the applicable

portion with tube. (This is to prevent short-circuiting due to terminal contact.) ( 8.3)

[12] Be sure to stop the engine of the construction machine before connecting cables. ( 8.

4 Note)

[13] Connection with battery body must be carried out under the responsibility of local

Service. Be sure not to cause battery short-circuiting while this operation. Also, be sure not

to cause electric shock although it is rare that it leads to serious conditions on DC24V.

Especially, be sure that your hands are not wet. ( 8. 6 Note)

[14] Electric discharge of capacitor proceeds automatically, but a person must attend to

monitor this operation. ( 8. 9 Note)

[15] After use, protect the connector by covering with plastic bags to prevent dust. ( 8. 11*)

[16] Parts replacement for this tool is applicable to the ones described in this section only.

Do not replace other parts. ( 9. Note 1)

[17] Never modify this tool since it is dangerous. ( 9. Note 3)

[18] When replacing fuse, be sure that this tool is separate from battery and capacitor. ( 9.

Note 3)

[19] When side cover is removed, do not touch the inner resistance. The resistance

temperature may be high which may cause burns. ( 9.1 (1) Note)

[20] In cases of apparent abnormalities such as smoke or spark discharge inside the box,


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push “EMG STOP” button immediately. And then, turn “POWER SW” off and stop “START

SW”. If repairing this tool, be sure to return it to the manufacturer. ( 10. ☆ )

[21] When transporting this tool by car etc., prevent crack or breakage due to vibration or

impact by putting shock-absorbent material inside, outside and around the acrylic cover.

If severe vibration or impact is expected, wrap up this tool in air-gap and put it in the box with

shock-absorbent material for transport. ( 11. (1))

[22] When transporting this tool, be sure to wear safety tools such as protective shoes even

for a short-distance and be careful for the following points. ( 11. (2))

1) Wrap the 4 cables all together around the cable fixing bars which are at 2 places on top

and bottom of cable exit surface. Tie the wrapped cables together tightly with cable ties etc.

In addition to that, be careful not to cause accidents such as tipping over or falling by having

cables caught by nearby projections during transportation.

2) If lifting this tool between high places such as loading platform, please handle this tool as

a heavy load since it weights 24.5kg, and it requires 2 workers. If available, use cranes.

[23] When disposing this tool, follow the local rules for industrial waste. ( 12.)

[24] When exporting this tool, please follow the regular procedures that are regulated by the

local law. Please note that this tool conforms to Rohs standard, but it is not certified. Some

uncertified parts are used also. ( 13.)


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3.2 Shown below are safety labels attached to this tool.

(1) Labels on panel surface

(2) High temperature caution label of resistance inside chassis

(3) Ground terminal label

(Emergency StopButton)

(Dangerous voltage)

Refer to 6. (1) 2)

Refer to 9. 1 (1) Note

Refer to 7.

Refer to 7. and 10. ☆

Refer to 5. (1) Note, 8. 2 Note 2, and 9. Note 3

24 5 kg

(Weight)

(Do not touch)

(High Temperature)


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3.3 Before using this tool, please secure the safety of construction machines that areapplicable

to capacitor discharging as below.1. Stop the engine of the machine.

2. Keep the safe, stopped condition that all movable portions of work equipment,

swing body and undercarriage are locked.

3. Set the key switch of the machine OFF.

4. Maintain the safety by reading all items concerning safety in Shop Manual carefully.

Extracts from Shop Manual are shown in the following pages.

3.4 Safety precautions on Shop Manual

Important safety notice

Proper service and repair are extremely important for safe machine operation. The service

and repair techniques recommended by Komatsu and described in this manual are both

effective and safe.

Some of these techniques require the use of tools specially designed by Komatsu for the

specific purpose.

To prevent injury to workers, the symbol is used to mark safety precautions in this

manual. The cautions accompanying these symbols should always be followed carefully.

If any dangerous situation arises or may possibly arise, first consider safety, and take the

necessary actions to deal with the situation. The symbol is used to mark precautions

in this manual. Special technical precautions or other precautions for preserving

standards are necessary when performing work.

1. General precautions

Mistakes in operation are extremely dangerous. Read the Operation and

Maintenance Manual carefully before operating the machine. In addition, read this

manual and understand its contents before starting the work.

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


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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 loosework clothes, or clothes with buttons missing.

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) Before starting work, warm up your body thoroughly to start work under good condition.

Safety points

1 Good arrangement

2 Correct work clothes

3 Following work standard

4 Making and checking signs

5 Prohibition of operation and handling byunlicensed workers

6 Safety check before starting work

7 Wearing protective goggles(for cleaning or grinding work)

8 Wearing shielding goggles and protectors(for welding work)

9 Good physical condition and preparation

10 Precautions against work which you arenot used to or you are used to too much

2. Preparations for work

1) Before adding oil or making any repairs, park the machine on a hard and level ground, and

apply the parking brake and block the wheels or tracks to prevent the machine from moving.

2) Before starting work, lower the work equipment (blade, ripper, bucket, etc.) to the ground. If

this is not possible, insert the lock pin or use blocks to prevent the work equipment from falling.

In addition, be sure to lock all the control levers and hang warning signs on them.

3) When disassembling or assembling, support the machine with blocks, jacks, or stands before


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starting work.

4) Remove all mud and oil from the steps or other places used to get on and off the machine.

Always use the handrails, ladders or steps when getting on or off the machine. Never jump onor off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to

provide safe footing.

3. Precautions during work

1) Before starting work, stop the engine. When working on or around a rotating part, in particular,

stop the engine. When checking the machine without stopping the engine (measuring oil

pressure, revolving speed, temperature, etc.), take extreme care not to get rolled or caught in

rotating parts or moving parts.

2) Before starting work, remove the leads from the battery. Always remove the lead from the

negative (–) terminal first.

3) When raising a heavy component (heavier than 25 kg), use a hoist or crane. Before starting

work, check that the slings (wire ropes, chains, and hooks) are free from damage. Always use

slings which have ample capacity and install them to proper places. Operate the hoist or crane

slowly to prevent the component from hitting any other part. Do not work with any part still

raised by the hoist or crane.

4) When removing a cover which is under internal pressure or under pressure from a spring,

always leave 2 bolts in diagonal positions. Loosen those bolts gradually and alternately to

release the pressure, and then remove the cover.

5) When removing components, be careful not to break or damage the electrical wiring.

Damaged wiring may cause electrical fires.

6) Precautions when carrying out removal work

Action to take after removing connectors After

removing any connector, cover it with a vinyl

bag to prevent any dust, dirt, oil, or water from

getting in the connector portion.

( If the machine is left disassembled for a longtime, it is particularly easy for improper

contact to occur, so always cover the

connector.)

Confirm the match marks showing the installation position, and make match marks in the

necessary places before removal to prevent any mistake when assembling.

To prevent any excessive force from being applied to the wiring, always hold the connectors

when disconnecting the connectors. Do not pull the wires.

Fit wires and hoses with tags to show their installation position to prevent any mistake when


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installing.

Check the number and thickness of the shims, and keep in a safe place.

Before removing any unit, clean the surrounding area and fit a cover to prevent any dust ordirt from entering after removal.

7) If any fuel or oil drips onto the floor, wipe it up immediately. Fuel or oil on the floor can cause

you to slip and can even start fires.

8) As a general rule, do not use gasoline to wash parts. Do not use it to clean electrical parts, in

particular.

9) Be sure to assemble all parts again in their original places. Replace any damaged parts and

parts which must not be reused with new parts.

10) When installing hoses and wires, be sure that they will not be damaged by contact with other

parts when the machine is operated.

11) When assembling or installing parts, always tighten them to the specified torques. When

installing protective parts such as guards, or parts which vibrate violently or rotate at high

speed, be particularly careful to check that they are installed correctly.

12) Precautions when carrying out installation work

Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.

Install the hoses without twisting or interference and fix them with intermediate clamps, if

there are any.

When coating with adhesive, clean the part and remove all oil and grease, then coat the

threaded portion with 2 – 3 drops of adhesive.

Clean all parts, and correct any damage, dents, burrs, or rust.

When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then

connect securely.

When using eyebolts, check that there is no deformation or deterioration, screw them in fully,

and align the direction of the hook.

When using the machine for the first time after repair or long storage, follow the same

procedure.

13) Precautions for sling work

Read the Shop Manual of the crane carefully in advance and operate the crane safely.

14) Precautions for using mobile crane

Read the Operation and Maintenance Manual of the crane carefully in advance and operate

the crane safely.

15) Precautions for using hoist crane


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Read the Shop Manual of the crane carefully in advance and operate the crane safely.

Precautions when completing the operation 1) Be sure to assemble all covers and equipments again in their original places. 2) Check the connector visually.

Check that there is no oil, dirt, or water stuck to the connector pins (mating portion).

Check that there is no deformation, defective contact, corrosion, or damage to the

connector pins.

Check that there is no damage or breakage to the outside of the connector.

If there is any oil, water, or dirt stuck to the connector, wipe it off with a dry cloth. If any

water has got inside the connector, warm the inside of the wiring with a dryer, but be

careful not to make it too hot as this will cause short circuits.

If there is any damage or breakage, replace the connector.

3) Fix the connector securely.

Align the position of the connector correctly, and then insert it securely. For connectors with the

lock stopper, push in the connector until the stopper clicks into position.

4) Be sure to assemble all bolt s and nuts again in their original places, and check them for

looseness. If any part is loosed, retighten it. For the tightening torque, see “Disassembly and

assembly”.


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V)

0

50

100

150

200

250

300

350

0 100 200 300 400 500

sec

V)

4. Main Specification and Operation4.1 Main Specification

-Operating voltage (Ring terminal voltage) DC24V±

4V-Maximum load voltage Max DC400V

-Residual charge after electric discharge Under DC20V

-Time required for electric discharge Less than 30 minutes*

*Varies depending on condition of

capacitor (temperature, ages etc.)

-External dimensions (Width x Length x Height) [Unit: mm]

556 x 229 x 519

(Incl. projections/Exc. cables)

-Weight Approx. 24.5kg (Incl. cables)

Note: Electric discharge is not carried out if electric charge of capacitor is

under 30V.

4.2 Operation

This capacitor discharger tool operates automatically, lowering electric chart

under 20V safely and surely while switching 4 resistances inside according to

electric charge of capacitor.

Below is an example of shift in decreasing electric charge while discharging

measured on the actual machine. (See figure 1.)

Figure 1: Example of shifting electric charge by electric discharge tool

(PC200-8E0 #300037)

Shift in capacitor voltage (V)

Time of electric discharge (sec)

Voltage (V)


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(2) In storage

Note) This tool must be stored indoor.

Items Conditions

Storage temperaturerange

5 to 35 deg C

Storage humidity

range45 to 75% RH (No dew condensation)

Waterproof*Do not store in places where may get water or water

drop.

Vibration/Impact

*Do not store in places where may receive vibration

or impact larger than the time of transport on the

paved road. (Pack with shock-absorbent materialetc.)

Dust etc.

*Do not store in places where powder dust, dust or oil

mist are in the air exposed. (Sealing package etc.)

*Do not store in places where salt is contained in the

air exposed. (Sealing package in anti-corrosion box

etc.)

*Do not store in atmospheres of corrosive gas or

flammable gas. (Sealing package inanti-corrosion/fire-resistant box etc.)

*Store this tool on the flat, stable place to prevent

falling or dropping in earthquakes. (Use earthquake

resistant belt etc.)

*Do not store in places where are exposed to direct

sunlight.


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6. SetThis tool must be set on the level ground beside construction machines or on the

loading platform of the service car for use. Precautions are as below.(1) General precautions

1) Safety of construction machines

Before using this tool, please secure the safety of construction machines that are

applicable to capacitor discharging as below.

1. Stop the engine of the machine.

2. Keep the safe, stopped condition that all movable portions of work equipment,

swing body and undercarriage are locked.

3. Set the key switch of the machine OFF.

4. Maintain the safety by reading all items concerning safety in Shop Manual carefully.

Extracts from Shop Manual are shown in the following pages.

2) Grounding (Type-C grounding)

Before use, connect the ground terminal of this tool to the ground. This tool deals

with direct high voltage (under DC400V), type-C grounding which is regulated in Japan is

necessary. This work must be carried out by qualified persons or the persons who have the

equivalent knowledge.

(2) Setting on service car

If setting this tool on service cars, please carry out below.

1. Fix the tool so that it does not fall when traveling.

2. When using, park the service car as close as possible to the

construction machine. However, it must be within the area that this

tool and capacitor can be connected with a 5 meter cable. (If not

reachable in this range, follow (3) next.)

(3) Setting on field

If service car is not available or cables are unreachable, place a sheet on theground beside the construction machine and put this tool on it. In cases of rain or strong

wind, secure the environmental conditions mentioned in the section 5. (1) by setting up a

tent etc.


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7. Composition and Part Names

Note 1) Please place this tool longitudinally. (The surface of voltmeterfacing up)Note 2) Keep the acrylic cover open when this tool is connected so that the

emergency stop switch can be operated promptly.

Acrylic cover

Voltmeter

ERROR LED

START SW/LED

POWER SW/LED

Signal cable

Power cable Ring terminal cable forbattery connection

Ground wire

Ground terminal

EMG STOP SW


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8. Operation Procedure

This tool can be used only when capacitor is charged. Charging condition can bechecked on status display LED of capacitor. (See picture below.)

Explanation below is on the assumption that capacitor is charged.

8.1. Turn the key SW of machine body OFF.

Confirm two switches of Capacitor Discharger are in the conditions below.

(If not, set them in the conditions below.)

(1) “POWER SW” is OFF (downward).

(2) “START SW” is in STOP (downward).

There is a connector on the

back of this side.

(Refer to the picture in 8.2.)

Capacitor

Status display

LED


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8. 2. Remove all cables connected to capacitor (Power cable and signal cable).

Note 1) Be sure to stop the engine of the machine before removing cables.Note 2) Do not put fingers or tools inside the power connector (orange portion) of capacitor

side while power cables are removed. Capacitor voltage is output only when control power

to capacitor is provided (by connection of signal cable). However, it is very dangerous if high

voltage is output from the connector of the capacitor (MAX DC400V) because there is a risk

of burns or deaths. It is necessary to consider safety by wearing electric shock preventive

gloves etc.

8. 3. Confirm that 2 ring terminals of ring terminal cable are covered with tube. If ring

terminals are exposed without using ring terminal cable, cover them with root tube. (This is

to prevent short-circuiting due to terminal contact.)

Remove signal cable.

Remove 2 power

cables.


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8. 4. Connect power connector of electric discharger tool to capacitor.

Note) Be sure to stop the engine of the machine before connecting cables.

8. 5. Connect signal connector of Capacitor Discharger between signal connector of

capacitor and signal cable of machine body side.

Note) Be sure to stop the engine of the machine before connecting cables.

Capacitor Machine side

Signal cableSignal connector

Electric

discharger

After connection

8.4 & 8.5


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8.6. Connect ring terminal cable to DC24V battery which will be prepared locally only

when battery of machine body is removed. The size of ring terminal is M10. (Productequivalent to R5.5-10 [Product of JST Mfg. Co., Ltd.])

Note: Connection of this tool with battery body must be carried out under the

responsibility of local Service staff. Be sure not to cause battery short-circuiting

while this operation. Also, be sure not to cause electric shock although it is rare

that it leads to serious conditions on DC24V. Especially, be sure that your hands

are not wet. Connection example is shown in the picture next page.

This example shows the case of tightening ring terminal cable of this tool

to battery relay cable [M10 with ring terminal] which will be prepared by local

service staff with bolt and nut which will also be prepared by local service staff.

When connecting, be sure not to mix up the plus and minus. The red line of ring

terminal cable of this tool is “+”, and the black line is “-“. Marking tubes are inserted

such as BAT (+) on plus side and BAT (-) on the minus side.

In the picture, battery junction cable 2 which is prepared by service staff is

connected to battery through battery SW which is prepared by local service staff. In

this case, turn off the battery SW first and complete the connection, and then turn

on the battery switch finally. This can prevent the short-circuiting. To prevent

damage on battery or cable or cable fire in cases of short-circuiting, put the fuse

which is prepared by local service staff (The built-in fuse is 3.15A, so it is better to

use 4A to prevent the situation that the location of short-circuiting cannot be

identified due to simultaneous blowout.) or the apparatus which has the equivalent

functions such as breaker etc. in the line near battery outlet as shown in the

picture.

Also, please make sure to take short-circuiting protection measures when

connecting battery to ring cable of this tool. In the example next page, it isnecessary to cover relay portion including ring terminal/bolt/nut with insulating tape.

Please take other necessary measures according to usage environments.


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Battery relay cable 1

(To be prepared by local

service staff)

Battery SW

(To be prepared by

local service staff)Battery relay cable 2


service staff)

If the machine is in the condition that battery

relay is connected by key ON and is able to

supply DC24V to auxiliaries, it is not necessaryto connect ring terminal cable.

Fuse [4A]


service staff)

This is not the chassis battery which is built in the machine.

This is the DC24V output battery which will be prepared by local

service staff.

Never connect to the chassis battery which is built in the

machine.

DC24V battery


service staff)


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8.7. Turn battery relay ON by turning key SW of machine body ON.

This tool is electrified by this.(This operation is not necessary if ring terminal cable is used.)

8.8. Turn “POWER SW” on the panel ON (upward).

Confirm that “POWER LED” lights up. At this time, voltmeter shows voltage of

electric charge remaining in capacitor.

8.9. Turn “START SW” on the panel ON (upward).

Confirm that “START LED” lights up. After this, discharging will start, so capacitor

voltage shown on voltmeter will decrease gradually.

Note: Electric discharge of capacitor proceeds automatically, but a person must

attend to monitor this operation.


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However, if capacitor has safe electric potential (under 30V), discharging will not

start and “ERROR LED” lights up. (“START LED” is not lit up.)

8.10. It finishes in approximately 10 to 30 minutes, depending on initial electric voltage.When finished, “START LED” goes out. After confirming it went out, turn “START

SW” to STOP (downward).

Note: Do not turn “START SW” to STOP even if voltage in voltmeter becomes 0V in

the middle.

8.11. Finishing procedure(1) Turn “POWER SW” on the panel OFF (downward).

(2) Turn key SW of machine body OFF.

(If ring terminal cable is used, remove it. Cover the removed ring cable terminal

with root tube.)

(3) Remove power connector of capacitor side.

(4) Remove signal connector of machine cable side.

*After use, protect from dust by covering plastic bag on connector. Connect male and female

connectors of signal cable.


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9. Parts Replacement

Note 1: Parts replacement for this tool is applicable to the ones described in this section only.Do not replace other parts.

Note 2: Never modify this tool since it is dangerous.

Note 3: When replacing fuse, be sure that this tool is separate from battery and capacitor.

9. 1. Fuse replacement of capacitor power lineIf fuse of capacitor power line blows out due to short-circuiting etc., replace with spare

fuse inside.

Replacement procedure is as below.

(1) Remove side cover of tool with driver.

Note: When side cover is removed, do not touch the inner resistance. The resistance

temperature may be high which may cause burns.

Side cover

Remove these

screws.

Attached decal says “High temperature!!

Do not touch resistance”

(Do not touch) (High Temperature)


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(2) There are 2 fuses on the left side. The one in the back is main fuse, and the one in the

front is the spare fuse. Remove the fuse and the spare fuse from the fuse terminal block by

loosening screws with driver. Main fuse is tightened together with wiring terminal, so theycome off together.

(3) Install removed spare fuse on machine body side. Tighten removed wiring terminals

together with driver.

(4) Close side cover of tool body and tighten with driver.

Note: After replacing fuse, please purchase a new fuse and install it in the place where

the spare fuse used to be to be prepared for next blowout. (Do not use fuses made

by manufacturers/types other than the ones specified in the footnote. There will be

no guarantee for operation if fuses that are not made by specified manufactures or

types are used.)

Please dispose the blown out fuses*.

-----------------------------------------------------------------------------------------------*Main component materials of fuse are as below.

Tube: Ceramic (Aluminum)

Terminal: Brass

Arc extinguishing sand: Silica

Element: Silver

Label: Paper

Please follow your local regulations upon disposing.

Main fuse (F1)

Spare fuse

Remove these screws.

Remove fuse cover


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10. Measures for Abnormalities

-“POWER LED” does not light up although “POWER SW” is ONa. All of 4 cooling fans do not operate

1. EMG STOP button may be kept pushed in. In such cases, understand the fact and

confirm that there is no problem, turn EMG STOP button to the right to reset it (button

facing upward).

2. There is a possibility that power is not connected. Confirm that battery relay is ON and

connection of connector and ring terminal cable.

b. One/some of cooling fans operate

There may be abnormalities due to damaged LED or non-operating cooling fans or

short-circuiting of internal wiring. When inspecting/repairing this tool, please return it to us.

(Same for below)

-“START LED” does not light up although “START SW” is in START (*Note)

There is a possibility of wiring or circuit abnormality inside the tool. Please return the tool

body to us.

-Electric voltage does not decrease although “START SW” is in START

There is a possibility that the fuse built in the tool body is blown out. In this case, please

replace the fuse according to the procedure 4.1.

-“ERROR LED” lights up (*Note)

There is a possibility that temperature of the tool body has risen above 80 deg C. Please

use it again after cooling it down for a while. If “ERROR LED” is still lit up after that, there

may be an abnormality of inner circuit, so please return the tool body to us.

Note: If “ERROR LED” lights up while “START LED” is not lit up when starting electricdischarge, please check the voltmeter since there is a possibility that capacitor voltage is

under 30V as mentioned earlier in 3.8. In this case, there is no abnormality. It is not

necessary to carry out electric discharge.

*In cases of apparent abnormalities such as smoke or spark dischargeinside the box, push “EMG STOP” button immediately. And then, turn“POWER SW” off and stop “START SW”. If repairing this tool, be sure to

return it to the manufacturer.


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11. Cautions for Transportation(1) During transportation, please prevent crack and breakage due to vibration or impact

by putting shock-absorbing material in and out of acrylic cover.If excessive vibration or impact is expected, wrap this tool with air-gap and put it in the

box with shock-absorbing material etc. for transportation.

(2) When transporting this tool, be sure to wear safety tools such as protective shoes

even for a short-distance and be careful for the following points.

1. Wrap the 4 cables all together around the cable fixing bars which are at 2 places

on top and bottom of cable exit surface. Tie the wrapped cables together tightly

with cable ties etc. In addition to that, be careful not to cause accidents such as

tipping over or falling by having cables caught by nearby projections during

transportation.

2. If lifting this tool between high places such as loading platform, please handle

this tool as a heavy load since it weights 24.5kg, and it requires 2 workers. If

available, use cranes.

12. Caution for disposalWhen disposing this tool, follow the local rules for industrial waste.

13. Related matters*When exporting this tool, please follow the regular procedures that are regulated by the

local law.

*Please note that this tool conforms to Rohs standard, but it is not certified. Some

uncertified parts are used also.


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14. List of Parts to Purchase

Distributor: Service Dept., Product Support Div., Komatsu Ltd.Manufacturer: Komatsu Engineering Ltd.TEL: 0463-22-9200 FAX: 0463-22-8776

Address: 3-25-1 Shinomiya, Hiratsuka-shi, Kanagawa-ken 254-8555 Japan

Capacitor Discharger Manual

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Transcript of Capacitor Discharger Manual