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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 Department
Product Support Division
Komatsu
August 23, 2010

Contents

1. Outline

2. Applicable Capacitors

3. Precautions

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

-1-

1. Outline
This 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 Capacitors
This tool is applicable for capacitors of under DC400V. If this
tool is connected to the ones that exceed 400V, breakage and fire
may be caused. Do not connect to the ones that exceed 400V.

-2-

3. Precautions
3.1 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 upon
operation.

[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 start
switch 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)

-3-

[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 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. 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,

-4-

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.)

-5-

3.2 Shown below are safety labels attached to this tool.


(1) Labels on panel surface

(Emergency Stop
Button)

Refer to 7. and 10.

24.5 kg
(Weight)
Refer to 7.

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

(2) High temperature caution label of resistance inside chassis

Refer to 9. 1 (1) Note

(Do not touch)


(3) Ground terminal label

(High Temperature)
Refer to 6. (1) 2)
-6-

3.3 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.

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
in this manual.

is used to mark precautions

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

-7-

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.
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

Good arrangement

Correct work clothes

Following work standard

Making and checking signs

Prohibition of operation and handling by


unlicensed workers

Safety check before starting work

Wearing protective goggles


(for cleaning or grinding work)

Wearing shielding goggles and protectors


(for welding work)

Good physical condition and preparation

10

Precautions against work which you are


not 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

-8-

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 on
or 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 long
time, 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

-9-

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 or
dirt 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

- 10 -

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

- 11 -

4. Main Specification and Operation


4.1 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)
V)

Shift in capacitor voltage (V)


350
300
250
Voltage (V)

200
V)
150
100
50
0
0

100Time of electric
200 discharge
300(sec)
sec

- 12 -

400

500

5. Environmental Conditions
(1) In use

Items
Operating temperature
range
Operating humidity
range
Waterproof

Conditions
-10 to 40 deg C
30 to 85% RH (No dew condensation)
*Do not use in places where may get water or water
drop.
*Do not use in places where may receive vibration or

Vibration/Impact

impact larger than the time of transport on the paved


road.
*Do not use in places where powder dust, dust or oil

Dust etc.

mist especially conductive ones are in the air or


deposited.
*Do not use in places where fan ventilation is
blocked.
*Do not use in places where salt is contained in the
air.

Surrounding

*Do not use in atmospheres of corrosive gas or

environment

flammable gas.
*Do not drop this tool. Do not put or use in unstable
high places with risks of dropping.
*Do not let this tool tip over. Do not put or use on
inclined or unlevel place with risks of tipping over.

Other

*Do not let human or other things ride on this tool.

Note) High-pressure electric charge is applied inside capacitor when removing power
wire of capacitor and connecting power line of Capacitor Discharger. It is
necessary to pay close attention to safety such as wearing gloves to prevent
electric shock.

- 13 -

(2) In storage

Items
Storage temperature
range
Storage humidity
range
Waterproof

Conditions
5 to 35 deg C
45 to 75% RH (No dew condensation)
*Do not store in places where may get water or water
drop.
*Do not store in places where may receive vibration

Vibration/Impact

or impact larger than the time of transport on the


paved road. (Pack with shock-absorbent material
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

Dust etc.

flammable gas. (Sealing package in


anti-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.

Note) This tool must be stored indoor.

- 14 -

6. Set
This 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 the
ground 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.

- 15 -

7. Composition and Part Names

Voltmeter
EMG STOP SW

POWER SW/LED

START SW/LED

ERROR LED
Acrylic cover

Ground terminal

Ground wire

Signal cable

Ring terminal cable for

Power cable

battery connection

Note 1) Please place this tool longitudinally. (The surface of voltmeter


facing up)
Note 2) Keep the acrylic cover open when this tool is connected so that the
emergency stop switch can be operated promptly.

- 16 -

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

There is a connector on the


back of this side.
(Refer to the picture in 8.2.)
Capacitor
Status display
LED

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).

- 17 -

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.

Remove signal cable.

Remove 2 power
cables.

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.)

<Ring terminals are exposed.>

<Ring terminals are covered with tube.>

- 18 -

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 connector

Signal cable

After connection
8.4 & 8.5

Electric
discharger

- 19 -

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. (Product
equivalent 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 is
necessary to cover relay portion including ring terminal/bolt/nut with insulating tape.
Please take other necessary measures according to usage environments.

- 20 -

Battery relay cable 1


(To be prepared by local
service staff)

Battery SW
(To be prepared by
local service staff)
Battery relay cable 2
(To be prepared by local
service staff)

Fuse [4A]
(To be prepared by local

If the machine is in the condition that battery

service staff)

relay is connected by key ON and is able to


supply DC24V to auxiliaries, it is not necessary

DC24V battery

to connect ring terminal cable.

(To be prepared by local


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.

- 21 -

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.

- 22 -

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.

- 23 -

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 line

If 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.

Remove these
screws.

Side cover

Note: When side cover is removed, do not touch the inner resistance. The resistance
temperature may be high which may cause burns.
Attached decal says High temperature!!
Do not touch resistance

(Do not touch)

- 24 -

(High Temperature)

(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 they
come off together.
Remove fuse cover

Main fuse (F1)

Spare fuse

Remove these screws.


(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.

- 25 -

9. 2. Fuse replacement of battery power line


*In power line of signal cable and ring terminal cable, spare fuses are built-in in case of
damaged cable or battery due to short-circuiting inside the tool or cable fire. If the
fuses blowout due to short-circuiting etc., replace them with inner spare fuses.
Replacement procedure is as follows.
(1) Remove mounting screws on tool body side cover with driver.
Same as 9. 1 (1).
(2) There are 3 fuses on the lower left side. The top line has fuses for signal cable (F2),
the middle line has fuses for round terminal cable (F3) and the lower line has spare
fuses. Remove the cover of the blowout fuse and pull out the fuse, replace with the
spare fuse, and then put the cover on again.

Fuse for signal cable (F2)

Fuse for terminal cable (F3)

Spare fuse

(3) Close the side cover of the 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. Please use fuses made by
the manufacturer/type specified in the footnote. There will be no guarantee for
operation if other fuses are used. Please dispose of the blowout fuses.

*Manufacturer

and type of fuse are as follows.


Manufacturer: Littelfuse / Type: 02193.15MXAP

*Main component materials of fuse are as below.


Body: Glass / Cap: Brass nickel plating (Rohs-conforming product)
Please follow the regulations of your company and your area upon disposing.
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10. Measures for Abnormalities


-POWER LED does not light up although POWER SW is ON
a. 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 electric
discharge, 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 discharge


inside 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 disposal


When 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

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