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
12
5. Environmental Conditions
14
6. Set
16
17
8. Operation Procedure
18
9. Parts Replacement
25
27
29
29
29
30
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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.
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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.
[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)
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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 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)
[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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(Emergency Stop
Button)
24.5 kg
(Weight)
Refer to 7.
(Dangerous voltage)
Refer to 5. (1) Note, 8. 2 Note 2, and 9. Note 3
(High Temperature)
Refer to 6. (1) 2)
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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.
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.
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 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
10
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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 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
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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 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
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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.
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DC24V 4V
Max DC400V
Under DC20V
-External dimensions
-Weight
Note:
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.
200
V)
150
100
50
0
0
100Time of electric
200 discharge
300(sec)
sec
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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
Dust etc.
Surrounding
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
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.
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(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
Dust etc.
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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.
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Voltmeter
EMG STOP SW
POWER SW/LED
START SW/LED
ERROR LED
Acrylic cover
Ground terminal
Ground wire
Signal cable
Power cable
battery connection
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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.)
8.1.
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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.
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.)
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8. 4.
8. 5.
Capacitor
Machine side
Signal connector
Signal cable
After connection
8.4 & 8.5
Electric
discharger
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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. (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
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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
service staff)
DC24V battery
- 21 -
8.7.
8.8.
8.9.
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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.)
8.11.
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.
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
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(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
Spare fuse
(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*.
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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
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.
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