S.1Section S.1S.1Safe Work

NOVEMBER, 2013 Ver. 1.00

S.1 Safe Work .......................................................................... S.1-2

S.1.1 Rules for Installation Work................................................. S.1-2

[ 1 ] Before Installation.................................................... S.1-2

[ 2 ] During Installation.................................................... S.1-3

S.1.2 Before Trial Running.......................................................... S.1-6

[ 1 ] Area Around the Machine........................................ S.1-6

[ 2 ] Electrical Components............................................. S.1-6

S.1.3 Rules for Safe Operation ................................................... S.1-7

[ 1 ] General Rules ......................................................... S.1-7

[ 2 ] Precautions for Weaving ......................................... S.1-8

S.1.4 Rules for Maintenance....................................................... S.1-10

[ 1 ] Before Maintenance Work ....................................... S.1-10

[ 2 ] Precautions for Maintenance Personnel.................. S.1-10

[ 3 ] During Maintenance Work ....................................... S.1-11

[ 4 ] Lubrication............................................................... S.1-12

S.1.5 Rules for Operating or Checking the Electrical Devices .... S.1-13

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S. SAFETY

S.1 Safe WorkIntroductionThere is no such thing as a perfectly safe machinewhen improper handling or ignoring precautionsstands in the way. Any incorrect usage could possi-bly result in a serious bodily injury, in the worst caseit could cause death, and/or substantial propertydamage.

TOYOTA has made every effort to assure as safework as possible, which cannot be completed how-ever, without your understanding and cooperation.

It is impossible for the manufacturer to take intoaccount individual operating conditions of themachinery at the user site and prepare an instruc-tion manual covering all information relating to themachine operation. We, therefore, ask you toestablish your own individual safety standards foreach safe job of installation, operation, adjustment,and maintenance.

S.1.1 Rules for Installation Work[ 1 ] Before Installation(1) Check the safety rules and the workmanship standards for the plant.(2) Make sure that all personnel involved know the nature of the job and the installation procedure, and

agree as to the best way to get them done.(3) For jobs requiring a group effort, choose a supervisor whose instructions should be followed thoroughly

by all.(4) For jobs requiring a group effort, agree beforehand on words or gestures for giving and confirming sig-

nals.(5) Wear safety shoes.(6) Check the work places and their surroundings. If any unsafe point is found, take the necessary action to

make it safe.For example

i) When foundation bolts, power cable conduitsand air inlet piping are spread out beforeinstallation, mark them clearly with brightly col-ored cloth or a flag so that workers can avoidtripping or hitting the machine and carriersagainst them during installation.

ii) If there is any unstable footing due to any pits(for exhaust, piping, wiring, or other purposes)which are dangerously uncovered, put on atemporary cover to prevent falling accidents.

iii) Use specified tools matched to the job to bedone.

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S.1 Safe Work

[ 2 ] During Installation[ 2.1 ] General points for installation work(1) Always wear a helmet whenever installation is

being carried out at the same time as otherjobs, such as construction and piping.

(2) Always wear gloves whenever there is thepossibility of injuring hands or fingers.

(3) Never use gloves if there is the possibility oftheir becoming caught in a rotating section ofthe machine.

(4) Never get oil or grease on the floor, sincethese can cause slipping accidents.

(5) Always provide a stable platform or scaffold forthose jobs in places too high to reach from thefloor.

(6) Never climb onto a heavy hoisted object norget under it.

(7) Keep your tools, parts, devices and instru-ments neatly arranged, and observe the fol-lowing rules:

i) Put them where they are not likely to fall down.ii) Whenever standing or leaning them against

something else, do what is necessary to pre-vent them from falling over.

iii) Whenever piling round bars or pipes, do whatis necessary to prevent them from fallingdown.

(8) Observe the following rules when conducting agroup effort:

i) Choose a supervisor whose instructionsshould be followed thoroughly by all.

ii) Agree beforehand on words or gestures forgiving and confirming signals.

iii) Be especially careful when handling heavyobjects. If the weight exceeds 20 kg, two ormore workers should handle them.

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S. SAFETY

[ 2.2 ] Transport(1) Before bringing in machinery, always prepare

well-maintained carriers.

(2) Never lift the machine or load any higher than200 mm above the floor during transport.

(3) Never stand in small spaces between themachine/load and the wall during transporta-tion.

(4) Always assign a guide and transport accordingto his or her instructions.The guide should pay sufficient attention toany protruding parts on the transport route.

(5) Whenever inserting wooden blocks under themachine/load, never let fingers get betweenthe machine/load and floor.

(6) Always push hand carts when carrying loads.Never pull them.

(7) Fix the load with a rope or other means if nec-essary, to prevent the load from falling downduring transport.

(8) When putting a lift beneath the machine, makesure that its hook catches the place betweenthe back and front cross rails and balances itright and left securely.

Carriers Q’ty Specifications

Forklift (or wrecker) 1 3.5 t (Reed space:150-190 cm)

Hand lift 2 3.0 t or moreSmall jack 2 1.5 t or moreWooden block 4 Approx. 90 x 150 x 60 mm

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S.1 Safe Work

[ 2.3 ] Unpacking and cleaning

(1) Parts are coated with rust-preventive oil. Takenecessary action so they will not slip whencarrying them.

(2) When washing parts, use waterproof paper toprevent the floor from becoming stained.

(3) Use New-sol Deluxe (Nippon Oil Corporation)or equivalent cleaning fluid. Never use trichlo-roethyl-ene-base cleaning fluid; otherwise thepainting will peel off or discolor.

(4) Never put anything on the parts storage area,passages, or footing area.

[ 2.4 ] Levelling work(1) When using a small jack, apply it to two points

underneath the front and back cross rails andmake sure that it catches them securely.

(2) When conducting a group effort, agree before-hand on words or gestures for giving and con-firming signals.

(3) Whenever inserting fiber packings under thebottom of the machine's feet or removing themduring the levelling work, never let fingers getbetween the packings and the floor.

[ 2.5 ] Wiring work(1) Never allow non-qualified workers to carry out

connection or disconnection of the primarypower lines.

(2) Before starting wiring work, be sure to checkthat the main circuit breaker is open and thewarning notice (tag) is put up for all to see.

(3) Before starting wiring work, make sure that thelines are not alive or no voltage is applied tothe lines.

Never apply gasoline or other volatile cleaning agents for cleaning.

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S. SAFETY

S.1.2 Before Trial Running[ 1 ] Area Around the Machine(1) Clear away bolts, nuts, tools and other unnec-

essary things around, on and under themachine.

(2) Check that all sections of the machine aresecurely tightened and that the safety coversare on.

[ 2 ] Electrical Components(1) See that the grounding wires of the factory

power supply are correctly connected to ter-minals PE in the control boxes.

(2) Check the wiring, routing and connection tothe machine.

(3) Check the rotating direction for: the mainmotor, drum motor, and electrical let-off motor.Also check the rotating direction of forward/reverse inching.

(4) Check the functions of each of the stopmotions and limit switches.

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S.1 Safe Work

S.1.3 Rules for Safe Operation[ 1 ] General Rules[ 1.1 ] Absolute precautions(1) Never allow non-qualified workers to carry out

connection or disconnection of the primarypower lines.

(2) Never try live-wire operation when changingthe wiring on the machine.

(3) Never start the machine without communicat-ing your intention to co-workers or without con-firming their answer to your signal.

(4) Never touch rotating or operating parts untilthe machine comes to a complete stop.

(5) Never operate the machine in clothes whichcould become entangled in the rotating parts.

(6) Never remove any of the warning notice, cau-tion plates or instruction plates from themachine, no matter what.

[ 1.2 ] Handling abnormal situations(1) Always turn the power off before making any

adjustments or repairs to correct abnormalitiesoccurring during operation.

(2) If you turn off the power, be sure to put up thewarning notice on the power switch.

(3) The temporary warning notice (tag) should beremoved only by the person who put it up,once it has become unnecessary.

[ 1.3 ] Other precautions(1) The supervisor should make sure that each

worker sufficiently observes all safety rules.(2) Observe the safety codes and regulations

enforced in individual countries.

"DON’T TURN THE SWITCH ON"

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S. SAFETY

[ 2 ] Precautions for Weaving[ 2.1 ] Starting(1) When two or more workers are to handle oper-

ation, they must always commutate throughwords or gestures before starting up themachine.

(2) Before pressing any switches on the machine,be sure to identify them to prevent mistakes.

(3) The standard procedure is two-handed opera-tion: holding down the INTERLOCK switchwith your left hand and pressing any of thedr ive sw i tches (START, FORWARD orREVERSE) with your right hand.

[ 2.2 ] During weaving(1) No one other than the person in charge must

take recovery action if any of the electricalparts in the control box operates so as tocause the machine in operation to either stopor become non-workable.

(2) While the machine is in operation:i) Never touch the running portion.ii) Never open or remove any of the safety cov-

ers.iii) Never try to remove yarn or fly.

(3) Do not operate the machine wearing thesetypes of clothes, shoes, or hairstyles:

i) Loose fitting jacketii) Long sleeves with buttonsiii) Work cloths with buttons sticking out in frontiv) Sandal-type shoesv) Necktie hanging in frontvi) Long hair worn loose or hanging in front

(4) Never put scissors or tools in a non-flap breastpocket.

(5) Never restart the machine without permissionif it is stopped by:

i) A person in charge of maintenanceii) A patrol inspectoriii) A person in charge of lubricationiv) Other responsible people

(6) Never touch the main motor. Its surface will beHOT depending upon the working conditions.If any motor error occurs, the temperature willgo up. Touching an overheated motor couldcause a serious hand burn. (Reference: If thetemperature inside the motor exceeds thespecified level, the internal thermal sensorworks to stop the weaving machine.)

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S.1 Safe Work

(7) Be sure to clean the weaving machine to pre-vent fire as follows:• Periodically wipe off fly or fleece accumu-

lating around the main motor and mainbrake.Even though the main motor has a thermalsensor (which works if the motor tempera-ture exceeds the specified level), this is noexcuse to neglect any cleaning.

• Periodically blow air to the magnet switchand its surroundings in the main control boxto remove fly or fleece accumulatingaround them.When activated normally, the magnetswitch will spark which could result in fire iffly or fleece accumulates around the mag-net switch.

• If the rotating sections of the machinebecome entangled with any fly, fleece oryarn dust, immediately remove those for-eign materials. Otherwise, they will buildup coming into contact with other parts,which could result in abnormal heat or fire.

(8) If the machine stops, check• the signal indicator 1,• the warning lamp 2 on each of the opera-

tion panels, and• the function panel to see whether warning

icon 3 appears.1) If only warning lamp 2 lights:

It means that the pick finder is in operation.The machine is temporarily on halt and willrestart running, so never reach out towards themovable parts or the working area while warn-ing lamp 2 lights.

2) If the signal indicator 1 flashes (in case ofstandard setting), warning lamp 2 lights andwarning iron 3 is displayed:It means that the Toyota Automatic Pick Oper-ator (TAPO) is in operation. The machine istemporarily on halt and will restart running, sonever reach out towards the movable parts orthe working area while these indications areon.

1

DON'T TOUCH

2

3

Confirm

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S. SAFETY

(9) Put on a gauze mask in the weaving roomwhen the machine is in operation. There willbe a lot of invisible fly, fleece or yarn particlesfloating around.

(10) Put on a pair of ear plugs to protect your earsfrom noise when working around operatingmachines for a long time.

S.1.4 Rules for Maintenance[ 1 ] Before Maintenance Work[ 1.1 ] Checking the work procedure

Check the work procedure with co-workers in advance. Be sure to inform the operators that themachine is to be stopped, and always put up the maintenance notice (specified by the plant) on thepower switches.

[ 1.2 ] Checking the jigs and toolsSelect and inspect the jigs and tools for the job purpose. Use spanners and wrenches suitable forthe sizes and locations of bolts and nuts.

[ 1.3 ] Keeping things neat and tidyDetermine the storage location for disassembled parts, making sure that passages are clear foroperators.

[ 2 ] Precautions for Maintenance Person-nel

(1) If you stop the machine for maintenance, besure to put up the warning notice saying"DON'T TURN THE SWITCH ON."

(2) Never put tools or any items on top of themachine whether it is in operation or on halt.Otherwise, they may fall into the machine,causing parts damage or even bodily injury.

(3) Never use compressed air for cleaning yourskin. It may cause infection if your skin hasany open wounds.

"DON’T TURN THE SWITCH ON"

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S.1 Safe Work

(4) When using lubricant, paint, adhesive, sealant,or detergent, put on the protectors, safetygloves, and safety goggles to protect your skinand eyes from those materials.Such materials may cause bodily damage. Ifyour skin or eyes become contaminated, washthe affected part at once and get appropriatemedical care.When using any detergent, always ventilatethe workshop sufficiently.Follow the instructions provided by the mate-rial manufacturer or supplier.

(5) For any work which could damage the eyes,always wear safety goggles.

[ 3 ] During Maintenance Work

[ 3.1 ] Basic maintenance procedure(1) Stop the machine by pressing the STOP switch.(2) Inch the machine so that the heald frames become aligned or leveled.(3) Press the BRAKE RELEASE switch to make sure that the reed will not move. (In the case of the elec-

tronic dobby, turning off the machine may turn the crank, resulting in collapsed patterns.(4) Turn off the machine.(5) Check that the machine is stopped and then start maintenance work.

[ 3.2 ] Basic rules for maintenance jobs with the power being ON

(1) If you need to run the machine, inch it (in slow speed).(2) When conducting a group effort to run the machine, agree beforehand on words or gestures for giving

and confirming signals. Always put up the maintenance notice (specified by the plant) on the switches toprevent other persons from turning on or off the machine unexpectedly.

(3) For the dobby being used, be sure to observe the instructions given in [3.1], steps (2) and (3) above inorder to remove load from the machine before starting maintenance jobs.If the dobby is used, an unbalanced load may be applied to the machine depending upon weaving struc-ture. Under such a condition, if the power to the machine is accidentally cut off due to lightning or anyother power failure, then the machine may idle. It is DANGEROUS.

For safety, be sure to turn off the machine before starting maintenance work. At the same time, be sure to put up the maintenance notice (specified by the plant) on the switches.

Jobs using the main motor brake or electrical signals should be carried out while the machine is powered ON. For those jobs, observe the following:

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S. SAFETY

[ 4 ] Lubrication(1) Make sure that the machine has stopped before greasing of the bearings or gears.(2) Always wipe up oil spilled on the floor after supplying oil to the oil bath.(3) Waste oil drained from the oil bath should be disposed of in containers specified by the plant.

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S.1 Safe Work

S.1.5 Rules for Operating or Checking the Electrical Devices

(1) All operating and checking jobs must be carried out by persons with appropriate special qualifications(e.g., duly trained persons or electrical experts).

(2) Always turn off the main switch before opening the control box.

For Chinese GB specification1) A hole to set a padlock that can be locked in the Off (disconnection) position is located on the breaker

cover. Set a padlock in the hole to lock it to the Off position.2) Use our recommended padlock (76321-00141-00) or those whose diameter of the U-shaped latch is ø4

to 4.5 mm.3) Never set a padlock in the On status. The breaker needs to trip if excess current runs. If you set a pad-

lock, the breaker cannot trip and poses a danger.(3) After turning off the main switch, be sure to put up the warning tag "DON'T TURN THE SWITCH ON" on

the main switch.(4) Handle an electrical component or part only when no power is supplied to it. Note that the primary side

terminals of the main switch are applied with a voltage even when it is turned off.(5) Voltage application may be needed for checking control system functions. Be especially careful when

conducting such a job.(6) Use the measuring devices and tools, all kept in proper condition.(7) When connecting the power supply to the loom, always connect the protective wire (green or yellow/

green spiral) first to the PE terminal. For disconnection, be sure to disconnect the protective wire last ofall.

(8) During electrical installation work, the observer responsible for security of the workers must absolutely,without fail, attend at the field. The observer should be limited to someone with know-how concerningelectrical troubles.

(9) Never try to modify an electrical unit or device because it may cause a malfunction or accident. If it isinevitable, please consult with us.

Even after the main switch (main circuit breaker CB1) on the control box is turned off, the group-control inverter power is fed to the terminal board (TB3) and the primary side of the magnet switch (MSI). Take extra care.

Optional SC inverter power will be cut off if you turn off the main switch (CB1).

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S. SAFETY

(10) Precautions for disposal of componentsWhen disposing electrical components or wires, they should be separated from general garbage for dis-posal.Due caution is needed especially for disposal of items below.

1) LCD panels and backlightThe backlight, a component of the function panel, contains mercury.Upon disposal, comply with applicable ordinances or regulations.

2) BatteriesBatteries (including accumulators) contain substances harmful to the environment and human body.The machine being handled uses batteries (including accumulators), and therefore upon disposal, com-ply with applicable ordinances or regulations.The symbol illustrated indicates the need for handling batteries (including accumla-tors) separately from general garbage for disposal (EU Directives: 2006/66/EC).In case chemical symbols are displayed below the illustrated symbol, the battery (oraccumulator) contains heavy metals above the standard concentration level.The following is the standard:

Hg: Mercury (0.0005%), Cd: Cadmium (0.002%), Pb: lead (0.004%)

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S.2Section S.2Optical Safety Sensor (Option)

NOVEMBER, 2013 Ver. 1.00

S.2 Optical Safety Sensor (Option).......................................... S.2-2

S.2.1 Positioning the Light Emitter and Receiver........................ S.2-3

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S. SAFETY

S.2 Optical Safety Sensor (Option)The optical safety sensor consists of a photoelectric tube which is placed at the front side of the weavingmachine. If an operator’s hand or other body part breaks the light beam between the light emitter 1 and lightreceiver 2 at the start of machine operation or when the machine is in operation, the safety sensor detects theinterruption and stops the machine operation for safety.

The following two types of optical safety sensors are available:

• Standard type: Works when the machine is in operation (during the pick finder operation also).• Pick finder type: Works only when the pick finder is in operation.

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S.2 Optical Safety Sensor (Option)

S.2.1 Positioning the Light Emitter and Receiver

Adjustment Procedure(1) Mount each of the light emitter 1 and receiver

2 into the corresponding safety bracket 3 withtwo nuts 4 facing each other with safetybracket 3 sandwiched in-between. Then, fixeach of 1 and 2 so that the end of each inter-nal nut becomes flush with end A of the corre-sponding light emitter 1 or receiver 2.

(2) Turn on power and check that left-hand lightemitter 1 emits light and red LED 5 comes on.Also check that right-hand light receiver 2receives the light and red LED 6 comes on.(These LED states indicate that the machine isready to run.)

(3) If LED 6 in light receiver 2 does not come on,the centerlines of the light emitter and receiverare not aligned with each other. Correct theposition of safety bracket 3 holding lightreceiver 2.

Check(1) Shield the emitting side of emitter 1 and press

the START switch.

(2) Make sure that the machine cannot be startedand that the message “LIGHT BARRIER(SAFETY DEVICE) ON” appears on the func-tion panel.

1, 2

3

Never use your hand or a part of yourbody to shield it. Doing so may cause yourhand or body to come into contact withmovable machine sections, resulting inbodily injury. Be sure to set any shieldmaterial to the emitting side.

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