Komatsu 830E-AC, Shop Manual

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A03030 3/06 General Safety and Operating Instructions A3-17
WHEN REPAIRS ARE NECESSARY
1. Only qualified maintenance personnel who
understand the systems being repaired should
attempt repairs.
2. Many components on the Komatsu truck are
large and heavy. Ensure that lifting equipment -
hoists, slings, chains, lifting eyes - are of ade-
quate capacity to handle the lift.
3. DO NOT stand under a suspended load. DO
NOT work under raised body unless body
safety cables, props, or pins are in place to hold
the body in up position.
4. DO NOT repair or service the truck while the
engine is running, except when adjustments
can only be made under such conditions. Keep
a safe distance from moving parts.
5. When servicing any air conditioning system with
refrigerant, wear a face shield and cold resistant
gloves for protection against freezing. Be cer-
tain to follow all current regulations for handling
and recycling refrigerants.
6. Follow package directions carefully when using
cleaning solvents.
7. If an auxiliary battery assist is needed, first use
one cable to connect the 24V positive (+) post
of the disabled truck batteries to the 24V posi-
tive (+) post of the auxiliary assist. Use second
cable to connect the 24V negative (-) post of the
auxiliary assist battery to a frame ground (-) on
the disabled truck away from the battery.
8. Always disconnect the positive and negative
battery cables of the vehicle before doing any
welding on the unit. Failure to do so may seri-
ously damage the battery and electrical equip-
ment. Disconnect the battery charging
alternator lead wire and isolate electronic con-
trol components before making welding repairs.
(It is not necessary to disconnect or remove any
control circuit cards on electric drive dump
trucks or any of the Alarm Indicating Device
(AID) circuit control cards.)
Always fasten the welding machine ground (-)
lead to the piece being welded; the grounding
clamp must be attached as near as possible to
the weld area. Never allow welding current to
pass through ball bearings, roller bearings, sus-
pensions, or hydraulic cylinders. Always avoid
laying welding cables over or near the vehicle
electrical harnesses. Welding voltage could be
induced into the electrical harness and cause
damage to components.
9. If a truck is to be towed for any reason, use a
rigid tow bar. Check the truck cab for decals for
special towing precautions. (Also refer to the
Operation and Maintenance Manual, Operating
Instructions - Towing.)
10. Drain, clean and ventilate fuel tanks and/or
hydraulic tanks before making any welding
repairs.
Any operating fluid, such as hydraulic oil or
brake fluid escaping under pressure, can have
sufficient force to enter a person's body by pene-
trating the skin. Serious injury and possibly
death may result if proper medical treatment by a
physician familiar with this injury is not received
immediately.
11. Relieve pressure in lines or hoses before mak-
ing any disconnects.
12. After adjustments or repairs, replace all shields,
screens and clamps.
13. Working near tires can be dangerous. Use
extreme caution when working around tires.
DO NOT stand in front of a rim and locking ring
when inflating a tire mounted on the machine.
Observers must not be permitted in the area.
DO NOT weld or apply heat to the rim assembly
with the tire mounted on the rim. Resulting gases
inside the tire may ignite, causing explosion of
the tire and rim.
14. Only a qualified operator or experienced main-
tenance personnel who are also qualified in
operation can move the truck under its own
power in the repair facility or during road testing
after repairs are complete.