Welcome to the SYIL 5 Series Safety Manual
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This manual provides important instructions and procedures for the safe operation and upkeep of SYIL 5 Series machines. As well as helping ensure the safety of machine operators and other personnel, these instructions can help prevent costly damage to machine equipment and worksite facilities.
Before reading further, ensure you are familiar with the information introduced in the following sections of the Overview.
The Safety Labels section introduces the various types of safety labels that appear throughout this manual and their meanings.
The Safety Decals section introduces the decals that are posted on SYIL 5 Series machine equipment to indicate potential hazards.
The General Precautions section provides information that operators and other personnel should be aware of before beginning to work on or around machine equipment in any capacity.
The primary purpose of the safety messages displayed on SYIL 5 Series machines is to alert operators to hazards that can lead to preventable accidents due to misuse. “Danger”, “Warning”, and “Caution” indicate three different levels of safety criteria, ranked from most serious to least serious. The severity of these message types reflects both the level of the associated danger and the likelihood of mishap resulting from failure to observe them.
Be sure you have fully read and understood the meanings of the following safety messages before operating the machine:
|Safety Level||Message Text||Meaning|
|Indicates that failure to observe the message will result in serious injury or death.|
|Indicates that failure to observe the message may result in serious injury or death.|
|Indicates that failure to observe the message may result in minor to moderate injuries.|
|Indicates a suggestion or recommendation that operators should observe and be aware of.|
Safety decals are reminders of risk factors and safety considerations that are displayed on the machine for operators’ reference. These decals help to identify the origins of potential dangers and provide preventive measures for ensuring worksite safety.
Operators should make sure they are familiar with the contents of this section to prevent accidents and injuries caused by negligence of the risks of operating machine equipment.
To prevent accidents, operating personnel should carefully read and observe the following general requirements and precautions before operating any SYIL 5 Seriesequipment:
Operators of the machine must have received standard training on correct methods for operating CNC machinery.
Operators should be proficient in the assembly, operation, maintenance, inspection, and adjustment of CNC machines.
- Operators should follow the correct sequence specified in the Worksite Safety Precautions section when applying lubricant oil or cleaning the machine, and must only perform this type of maintenance following complete shutdown of the power supply and air pressure supply.
SYIL will not assume liability for any accidents resulting from operators’ failure to observe the instructions in this manual or from any unauthorized modification or disassembly of the machine.
Operators should carefully read and observe all rules and procedures specified in the user manual and should heed all safety warnings displayed on the machine.
Never attempt to move, remove, or otherwise damage the warning signs displayed on the machine's body.
Safety Mechanisms And Procedures
The SYIL 5 Series is equipped with several important safety mechanisms designed to prevent and resolve emergency situations that may arise from unsafe operating conditions.
To ensure worksite safety, operators and service personnel should fully understand the mechanisms and procedures introduced in this section before beginning work on the machine.
Emergency Stop Button
The SYIL 5 Seriesmachine comes equipped with an Emergency Stop button to enable operators to easily shut down the system in the event of an emergency.
If at any time the machine's structural integrity becomes compromised or if it begins to move abnormally, operators should immediately press the Emergency Stop button to halt all operations.
Operators must be aware of the location of the Emergency Stop button at all times and able to reach it quickly in the event of an emergency.
During an emergency stop, the machine will enter a non-operational status as follows:
The machine will be unable to run;
All motors will be held in STOP status;
Power to the motors of the main spindle and stroke spindle will be disconnected.
During an emergency stop, the machine will continue to conduct power to maintain a standby status as follows:
Working lamps that have been switched on will remain lit;
The power supply to the control panel and to the AC socket will remain normal;
Power to the hydraulic or pneumatic solenoid valve will remain uninterrupted in order to maintain essential machine functions.
Following an emergency stop, the machine will remain in the above standby status until the operator releases the Emergency Stop button.
Lockout Procedures and Indicators
To prevent the possibility of accidental startup and the sudden release of accumulated energy, the machine should always be put into lockout before beginning inspection and maintenance work.
During lockout, signs should be posted to indicate the machine’s service status and prevent unauthorized personnel from accessing its main energy isolation facilities. In addition, labels should be pasted over the closure of the electrical cabinet in such a way that opening it requires breaking or tearing them, thus indicating whether any attempt has been made to activate the equipment during lockout.
Locking and Marking the Breaker
- Personnel responsible for maintaining the machine must be familiar with the lockout procedures in this chapter and their significance before performing any maintenance on the system.
Initial lockout procedures are as follows:
After ending operations according to the procedures specified in the operation manual, turn off the power supply to the machine.
Adjust the switch of the main breaker to the OFF position.
Extend the lock brackets and lock the cabinet using a padlock.
Paste the lockout labels onto the lock bracket to indicate that any personnel who attempt to open the lock will assume liability in the event of an accidental startup.
- The designated personnel in charge of the maintenance of this system should realize the importance of the lockout. Meanwhile, they must have fully understood all lockout procedures described in this chapter before commencement of any maintenance work.
- Lockout is a crucial precaution required before starting maintenance work. Personnel who fail to observe these precautions risk their own and others’ injury or death.
- If the system has been running prior to lockdown, follow the shutdown procedures specified in the operation manual and confirm that the machine has completely stopped before entering lockout.
- In cases where maintenance work will be performed by several workers simultaneously, one should be designated as supervisor to oversee maintenance procedures.
- The designated maintenance supervisor is responsible for ensuring the safety of all procedures and should continuously monitor progress while ensuring lockdown is maintained throughout.
Locking Safety Door
As a protection for operators, SYIL 5 Series machines feature a locking safety door, which is controlled by the corresponding switch in the image below:
When closed with the interlocking switch engaged, the safety door should be impossible to open, protecting operators from any potential contact with moving parts or debris. If the door does open during operation due to a fault in the locking mechanism, operators should immediately activate the Emergency Stop button and address the fault.
Possible faults scenarios include:
Safety switch fault, preventing the door from locking when closed
Damage to the lock or key
To resolve a fault scenario, operators should take the following steps:
Shut down the main power supply.
Replace any faulty components with new components.
Reconnect the power supply and verify the locking function is working properly.
The machine’s warning lamp has three indicators of different colors. Each color indicates a specific operating status, as shown in the following table:
|Red||The red warning lamp will be lit or flashing in the event of an emergency or when the machine is operating dangerously.|
|Yellow||The yellow lamp will be lit or flashing when the system is stopped.|
|Green||The green lamp will be lit or flashing when the system is running and operating normally.|
Worksite Safety Precautions
Taking precautionary measures to prevent and eliminate potential hazards is essential to ensuring the safe operation of SYIL 5 Seriesmachine equipment.
To ensure worksite safety, operators and service personnel should fully understand the precautions introduced in this section before beginning work on the machine.
Follow these basic precautions to ensure safe operation of the machine.
- Areas of the machine where electric shock warnings appear, such as the electrical control panel, current converter, motor, terminal box interior, and control panel, present an elevated risk of electrical hazards such as electrocution. Ensure these areas are safe to work in before beginning operation of the machine.
- To prevent electrocution, never use wet hands to touch the machine at any time.
Operators must be able to locate and activate the Emergency Stop button at all times, and should observe the following rules to ensure they can activate it without hesitation in the event of an emergency:
Never operate the machine without first confirming the location of Emergency Stop button.
Always follow the specified methods and procedures when operating the machine.
Never operate the machine unless familiar with its technical specifications and functions.
- Never perform an unauthorized dismount or alteration of the system or its safety enclosure.
Keep hands and other bodily appendages at a safe distance from rotating materials or equipment while the machine is running.
Clear any water or oil from the floor around the machine to prevent operators from slipping or falling.
Never enter the inside of the machine or its safety enclosure except to perform repairs or maintenance work according to the procedures specified in the Maintenance and Service Manual.
Where multiple operators are present, tasks should be assigned to designated specialists qualified for the work involved. When two or more operators are working simultaneously, they should establish clear signals to communicate that all are ready to proceed before beginning a new procedure.
Never place any tools, equipment, or other foreign objects on top of or inside the machine.
Pay special attention when working with flammable materials (such as wood), magnetic materials, plastics, or other materials with properties that can interfere with normal running procedures.
Never perform any modification to the machine except as explicitly authorized by a qualified representative of SYIL.
Always disconnect the power supply before replacing safety fuses.
Maintain sufficient working space around the machine to avoid contact with dislodged debris.
Always keep the safety door in the closed position and locked when the machine is running .
Check the machine for faults or errors at least once every 15 minutes.
In the event of any fault in the power supply system, immediately shut down the main power source.
Always wear standard protective equipment when operating the machine, including safety boots, protective glasses, standard work attire, and earplugs.
Never wear gloves or ill-fitting attire while operating the machine.
Ensure that the floor or working platform surrounding the machine is firm and solid and free of slippery surfaces.
Ensure that the area surrounding the machine is kept dry, neat, and well-lit.
Remove any dust and debris from the control panel and surrounding equipment before installation.
Never knock or strike the machine’s control panel.
Avoid changing parameters and settings on the machine. In cases where it becomes necessary to do so, save and record all initial parameters and settings before modifying them.
Ensure the machine’s fuse wiring is rated for your worksite’s electrical system to prevent any disruptions that could impact the performance of components such as NC instruments.
Never operate the machine while under the influence of alcohol or drugs.
Never operate the machine in a state of mental fatigue or physical exhaustion.
Always wear standard ear protection when exposed to noise for prolonged periods of operation.
Never point the air gun toward yourself or another person, and be aware of any cutting chips or oil it may cause to become airborne.
Always use safe lifting techniques during the transportation and installation process to avoid injuries or damage.
Electrical Precautions Prior to Connection of the Power Supply
To avoid equipment faults and personal injury, ensure you have read and fully understood the following instructions before connecting the power supply to the machine.
- Damaged cables and conductive wires can cause short circuits and electrical shocks. Be sure to carefully inspect cables and conductive wires for damage before connecting the machine to a power source.
Do not begin to operate the machine until you have read the applicable procedures and understood the specifications for each of its instruments.
Ensure the safety door is closed tightly during operation to prevent water, dust, or cutting chips from entering the NC instruments or control panel.
Never ever connect the machine to external equipment after grounding, as doing so can create an electrical overload resulting in fire.
- Always measure the worksite voltage rating before running the machine.
The machine’s power supply must be connected in the following sequence:
Connect the worksite distribution board.
Connect the machine's main power supply.
Turn on the machine using the main power switch.
Release the Emergency Stop button.
Reset the system.
Conductive wiring used in the power cord for the main power supply’s breaker must match the system specifications.
The cable connecting the worksite power switch to the machine must meet the necessary power safety standards.
Ensure that the power cable is installed in a position where it is not vulnerable to damage from cutting chips to prevent damage that could result in a short circuit.
Ensure that each oil tank is filled to the level specified in the system’s operating requirements.
Ensure that all switches and handles are working normally.
For grounding, ensure you have installed a grounding bar with a diameter of no less than 15 millimeters and length of no less than 1 meter. If it is not possible to use a preexisting grounding apparatus, ensure the grounding end extends no less than 1 meter into the earth.
Grounding should be performed by an authorized third-party engineer. The grounding resistance should be less than 100 Ohms.
Never install the grounding line near water pipes or other buried conductive objects.
Check and confirm that all wiring is well connected, as weak connections can result in equipment faults.
Check and confirm the integrity of pipeline connections for the oil and air pipes, as leakage from poor pipe connections can result in equipment faults.
Ensure that the machine's main power switch remains in the OFF position while the worksite power switch is turned off. Sudden connection to the worksite power supply can damage the machine's main power switch.
Ensure cutting oil is replenished regularly and to the specified level.
Electrical Precautions Following Connection of the Power Supply
Follow these precautions to ensure safe operation of the machine after it has been connected to the power supply.
- Once the power supply is connected, confirm that the power indicator on the control panel is connected and functioning properly.
After connecting the power supply, avoid all contact with the keys in the control panel until the monitor clearly displays system information. Unintentionally activating operational keys can cause faults resulting in personal injury.
Check the system for any oil or air leakage and confirm the accuracy of all measurement instruments.
After connecting the power supply, check that the fan is running correctly. Faults or failures in the fan can cause internal heat accumulation and damage the machine tool.
After connecting to the power supply, check that the lubrication pump is working correctly. In cases where machine components are allowed to move without sufficient lubrication, sliding surfaces and ball screws will experience wear that can result in further damage and equipment faults.
Check that the readings displayed on the system’s pressure gauges are accurate.
Check that the cutting head and other moving parts are sufficiently lubricated.
Confirm that all safety devices are functioning correctly.
Suddenly running a machine that has not been used for an extended period of time can cause faults and damage to the equipment due to the thermal expansion and contraction of its components while inactive. Always take thermal preheating measures to prepare the machine to resume running following a long period of inactivity.
To preheat the main spindle and the feeding spindle, set the machine to automatically run for 10 to 20 minutes at 1/2 to 1/4 of its maximum rotation speed.
During automatic running, observe and note the operating conditions at all positions on the machine tool.
Never increase the rotation speed of the machine if it is not thoroughly lubricated. Due to adhesion within its bearings, the machine’s rotation can only be increased gradually without causing damage to the equipment.
Use the above preheating criteria to run all functions of the machine.
- Never allow the machine to reach maximum rotation speed before completing preheating procedures.
Equipment and Worksite Precautions
Follow these precautions for maintaining the worksite and machine equipment in safe working condition.
- Flammable materials must be kept away from all switching devices, control panels, and distribution boxes at all times.
Ensure the machine is maintained in accordance with the technical and dimensional specifications defined for its model.
Using heavily worn or damaged cutters can result in personal injury. Replace worn cutters tools with new ones.
To facilitate safety checks, always ensure that the working area is sufficiently illuminated.
Ensure that cutters and other objects that may be placed around the machine are properly stored to prevent any blocking of passageways.
Never place cutters or other objects inside the main spindle box, knife tower, protection shield, or other machine partition.
Heat and direct sunlight can cause deformation of the machine, which will negatively impact its precision.
Check the level of lubrication in the motor and ensure all sliding components are properly lubricated.
Ensure that the length of the cutting tool meets the specified dimensions and eliminate any potential causes of interference between different cutting tools.
Always run a trial production after installing a new cutting tool.
Confirm that the bolts used to secure machine components are firmly installed.
Precautions Before Operating the Machine
Follow these precautions to ensure you are fully prepared and the equipment is safe to use before beginning to operate the machine.
Do not operate the machine until you have fully understood its components’ uses and functions.
Workpiece material should be firmly fixed in the intended position, and machining work should begin with shallow cutting and minimal overload.
Never adjust the cooling liquid spray nozzle while standing in front of it. The position of the cutting oil nozzle should only be adjusted following complete shutdown of the machine tool.
Never touch the machine with wet hands.
Never wear gloves while operating the machine tool’s control panel, as this raises the likelihood of error and equipment fault.
Operating the machine for extended periods of time can generate high operating temperatures that may result in fire. Be sure to clear accumulated chip debris from the machine at regular intervals.
When the machine is running, regularly monitor the motor and other components for any abnormal noises.
When machining workpieces with special materials or technical requirements, ensure you have prepared the necessary treatment measures prior to starting work.
- Perform regular visual checks of the control panel to ensure the controls are operating correctly.
Perform regular accuracy checks of the pressure gauge.
- Always maintain safe practices and observe worksite protocol when handling large or cumbersome workpieces.
Ensure that mooring ropes and lifting equipment are stable enough to support the loaded materials and fully comply with standard regulations.
- Ensure that all clamps and fixing tools are securely fastened and working correctly.
Ensure that any long hair or loose sleeves are tied back and cannot become tangled in the machine or its moving parts.
- Never use your hands or other external tools to touch a rotating workpiece or cutting tool.
Always use a brush when removing cutting chips from the cutting tool.
- Never attempt to clean or rearrange cutting tools or other machine accessories until the machine has been fully shut down.
Be sure to wear standard protective equipment whenever handling hazardous materials.
Precautions Required When Running the Machine
Operators must ensure that no parts of their body or any other articles come into contact with the machine while it is running.
- If the machine is performing abnormally, press the Emergency Stop button, shut down the power supply, and assess the situation before attempting to solve the problem.
No person other than the designated operator should enter the operating area while the machine is running.
When dismounting a workpiece, sufficient space should be maintained between the work piece and cutting tool, and all rotating components or cutting tools must be fully stopped.
- As cutting chips that have become attached to the cutting tool or that have fallen onto the working bench must be cleared by hand, operators must ensure the machine is fully stopped and should use gloves and a brush while working to clear them.
Precautions for Running in Auto Mode
Follow these precautions to ensure safe operation of the machine when it is running in auto mode.
Never lean against any part of the machine while it is running in auto mode.
- Ensure all doors are closed and fastened shut before operating the machine in auto mode.
Never attempt to touch or otherwise contact machine components while they are running or until operation has fully stopped.
- Never attempt to open any doors or protective covers when the machine is running in auto mode.
Always maintain an awareness of all system controls and switches, and perform a visual check of the control panel to confirm its settings before attempting to operate the controls.
- Always confirm the safety of operations such as rotating the main spindle, changing cutting tools, or setting axial movements before performing these operations.
Before running a new program, be sure to arrange a thorough check of it. After confirming that the program does not have any defects, use a single-program section to machine the workpiece. Start auto mode only if no problems are found in the confirmation process.
- Do not touch or activate any switches while the machine is running in auto mode.
Never open the machine tool’s door at any time while it is running in auto mode.
Precautionary Shutdown Measures
Following shutdown, the machine may suddenly start up without warning if the power supply has not been properly disconnected according to specified procedures.
Before leaving the machine, operators must ensure that the power switch on the control panel is turned off and the breaker is disconnected.
The power supply should be turned off in the following sequence:
Check the equipment for any warning signs or abnormal conditions.
- Press the Emergency Stop button.
Turn off the Power switch on the control panel.
Turn off the main Power switch.
Precautions Following the Completion of Work
Follow these precautions after finishing work with the machine to ensure worksite safety.
Always maintain the machine and surrounding equipment in a clean, orderly state.
- Cleaning work such as clearing cutting chips should only begin after the machine and related equipment have been shut down completely.
Machine tool components should be set to return to their initial states and positions when not in use.
- Check the cooling liquid, hydraulic oil, and lubricant agent for any debris or pollutants and replace them completely if contaminated.
When leaving the machine at the end of a work shift, power off the machine in the following sequence:
Press the Emergency Stop button.
- Switch off the machine tool’s main breaker.
Switch off the power supply to the worksite.
Upon completing work, turn off the power supply in the specified sequence, clear the machine of any debris, apply lubricant oil to all sliding surfaces, and apply rust-prevention oil as needed. Operators should exercise maximum care when applying machining oils to the machine tool.
After completing work and shutting down the machine tool, clear the interior of the machine and arrange the surrounding area surrounding in an orderly fashion. After properly lubricating the equipment as needed, adjust the worktable so that it is aligned with the center of the machine tool.
For worksites in geographic regions with heavy rainfall or elevated humidity levels, be sure to apply a layer of rust-prevention oil as needed following completion of work.
Precautions for Maintenance and Inspection
Follow these precautions during maintenance procedures to avoid potential hazards and ensure effective maintenance of the machine.
Ensure that the main power supply is switched off before performing any maintenance work.
After the main power supply has been disconnected. Be sure to check that the machine's electrical components are not carrying a charge before beginning any maintenance work.
Keep all doors and cabinet covers closed at all times except as needed to conduct repair and maintenance procedures.
- To prevent any unauthorized personnel from activating switches in the power control panel, place a warning sign in front of the electrical control cabinet to indicate that maintenance is underway and that contact with the equipment is forbidden.
Never attempt to dismount or modify devices or circuits with safety functions, such as baffle blocks for restricting the stroke of the transmission indicator, limit switches, or interlock limit switches.
Ensure that operators and maintenance personnel can and do carefully read and observe all warning signs attached to the machine. Damaging or removing these signs is strictly prohibited.
- Only personnel who have successfully completed standard professional training should engage in the maintenance, inspection, modification, oiling, or cleaning of the machine. Personnel performing these jobs should follow the correct procedures and ensure that the power supply is disconnected before beginning any such work.
Never attempt to operate the machine when its cover is open for repairs or maintenance.
Never use compressed air during maintenance or cleaning of the machine, as doing so may cause dust and particulate foreign matter to enter its bearings or sliding components.
Keep the floor of the worksite clear and free of water, oil, and other fluids at all times when repairs, maintenance, or cleaning work are being performed on the machine.
Whenever maintaining a machine installed in an elevated position, be sure to use the appropriate brackets and ladders and wear a safety helmet at all times.
Be sure to use only fuses and conductive wires of the correct specification when performing repairs and maintenance work.
- Before performing repairs, arrange all necessary components in an orderly fashion and ensure that the work environment is in the best possible condition for repair work.
Dispose of any discarded components or wasted oil according to the specified procedures and regulations for your facility.
Be sure to keep up-to-date records of all repair, maintenance, and inspection work for future reference.
- Use only specified lubricating oils and greases to conduct maintenance and repair work on the machine.
Periodically replenish and replace the supply of lubricant oil to each component of the machine.
Upon completing repairs and maintenance work, be sure to apply a layer of rust prevention oil to each component of the machine.
- Use only specified tools such as non-adjustable wrenches and open-ended wrenches to perform repairs and maintenance work.
Personnel overseeing inspections, repairs, and maintenance work are responsible for ensuring all procedures are carried out as required by the equipment’s specifications.
- Upon completing work each day, ensure the machine is left in a clean, orderly state to enable easy recognition of potential faults.
Check the accuracy of the readings on all components and instruments in the machine.
- Always wear gloves when clearing cutting chips from the machine.
Following removal of any dangerous objects from the worksite, perform a final check to confirm the safety of the work environment.
Precautions for Handling Electrical Components
Follow these precautions whenever handling the machine's electrical components to reduce the risk of electrocution and other serious electrical hazards.
Never knock or strike the machine tool’s control panel.
- Use only specified electrical cables to perform initial wiring of the machine tool. Avoid using excessively long cables if the initial wiring needs to be arranged over a length of floor space in the working area, and take all necessary measures to prevent cutting chips or other debris from damaging the cable.
The control panel should be tightly sealed to prevent exposure to outside air. Direct sunshine may damage the components on the power control board, and the door of the control panel should not be left open for extended periods of time while the power supply is connected.
Only designated products should be used in control panel devices and components.
- Before repairing or maintaining the machine tool’s electrical equipment, turn off the power switch in the control panel, disconnect the electrical control cabinet, and disconnect the power supply to the worksite. Never move or remove any warning signs in the worksite indicating that the power supply should remain disconnected. No person other than the designated operator should operate the machine at any time.
Take particular care when handling the machine tool’s electrical components and devices.
- Clean the electrical control panel’s fan and filtering device on a regular basis.
Perform regular checks of the program code as displayed on the control panel screen.
Precautions for Lubrication
Lubricant oil plays significant role in sustaining the machine's durability and precision. It is thus essential to perform regular, comprehensive maintenance on the machine's entire lubricant oil supply mechanism.
Ensure that the bottom of the oil supply tank is clean, dry, and free of cutting chips. Take care to protect all parts and components from potential damage or contamination while working on the oil supply tank.
- Periodically inspect the bottom of the oil supply tank for any debris or foreign matter and replace the oil if contaminated. To avoid damping and precipitation, never replace the full volume of oil in the system on a one-time basis.
Only use specified oil products and ensure the oil tank is filled to the designated level.
- To maintain the cleanliness of the oil supply line, take precautions to prevent dust, moisture, and cutting chips from entering the oil tank.
If the oil level suddenly decreases, check for faults around the oil outlet.
Replace the hydraulic pump filter and oil supply line filter at least once per year.
Precautions For Handling Machine Coolant
Coolant solutions used in the machine have the potential to harm to operators and the machine itself. Always observe the following precautions when using coolants:
- Water-soluble coolants are chemically basic and can dissolve fats and oils, including those of the human body. Never allow water-soluble coolants to come in direct contact with the surface of your skin.
Water-soluble coolants are prone to contamination by microorganisms, which can reduce the effectiveness of their rust-prevention ingredients and impact the machine tool’s performance. Replace the coolant immediately if it begins to emit a rotten odor.
- Upon completing work, clear any cutting chips that have accumulated in or around the machine tool, then wipe away any water-soluble coolant that has accumulated on its backing surfaces, rotating devices, supporting plates, or vertical column. Apply a layer of lubricating oil to each affected area after cleaning.
Water-soluble coolant contains rust prevention ingredients that help guard against problems caused by the exposure of the machine equipment to moisture. However, the machine may also develop rust if it becomes exceedingly dry. To ensure performance, apply rust prevention oil as needed following the completion of each operating session.
- Different coolant solutions require different dilution methods and thinners. Always be aware of any specific requirements for the thinner you have selected to use.
Industrial water contains a high volume of microorganisms. Check for the presence of microorganisms before using a water source to supplement coolant thinners or other solutions, and use tap water if possible.
- Operators should remove the machine tool’s cover to clean components such as the ball screw, limit switches, transmission motors at all connection points, and X-, Y-, and Z-spindles at a minimum of once every six months.
Never use additional chemicals to process soluble machining oil, as this may corrode the paint layer or resin components of the sealing box.
- Operators should ensure that maintenance practices are well-suited to the specific types of oils and solutions used in each of the machine tool’s inlets.
Precautions For Setting The Machine
Setting the machine involves a number of operational procedures that must be completed before starting production, including program input, work piece arrangement, cutting tool compensation measurement, program checking, and an initial machining test. Always observe the following precautions when setting the machine:
The machine should only be set by designated personnel who have completed the required training.
- If two or more operators are working on the machine together, they should maintain communication and remain aware of each other’s activities. Never press or activate the machine's controls or otherwise cause the machine to begin moving while another operator is working with clamping devices or other machining equipment.
Ensure that the main spindle’s maximum rotation speed setting falls within the maximum rating of the clamping devices and that the workpiece and machining equipment are aligned with their intended positions. Failure to do so may result in the workpiece or other equipment being ejected from the machine, resulting in injury or damage to the machine.
- Confirm that all machining equipment and clamping devices are firmly fixed and securing the workpiece. Failure to do so may result in the workpiece or other equipment being ejected from the machine, resulting in injury to the operators or damage to the machine.
Before running the main spindle, ensure it is fixed to the intended position with the correct rotation speed setting. Failure to do so may result in the workpiece or other equipment being ejected from the machine, resulting in injury to the operators or damage to the machine.
Selecting the correct machining equipment, clamping devices, and methods for each workpiece is essential to ensuring the quality and outer appearance of the finished product and preventing potential injuries or damage to the machine.
Always use appropriate moving equipment such as a crane or hoisting machine to move large workpieces or to dismount machine equipment.
Never touch the machine's lamp, as it may remain at a high temperature even after disconnecting the machine's power supply.
Keep the machine's lamp turned on at all times during the setting process. Poor lighting can hinder the effectiveness of interior inspections and trial operations, resulting in injury or damage to the machine.
Follow these additional safety precautions to ensure safe operation of the machine.
Never place any part of your body into the space where the machine operates unless the power supply is completely disconnected and all components have stopped moving.
- In the event of an earthquake, windstorm, flood, or fire, immediately activate the Emergency Stop button and turn off the machine’s power supply.
Interruptions due to the use of unauthorized power sources, storms, and electrical grid failures can cause the machine to run abnormally. Immediately shut down the main power switch after detecting abnormal voltage levels or other electrical abnormalities to prevent injuries or damage to the machine.
- Following a power interruption, confirm that the machine’s power supply is working and that the machine’s programs, parameters, and compensation data have not been altered or damaged.
Always use ropes and lifting devices with the correct specifications to lift or move machine equipment or workpieces.
- Always check that any forklifts, hoisting machines, ropes, or other lifting devices used to transport equipment are free of defects before using them, and repair or replace them as needed.
The use of keys for accessing the machine’s switches is strictly limited to qualified, designated personnel.
Address any problems in the machine’s systems immediately after discovery.
- Ensure that noise protection equipment used at the worksite is performing properly and will not interfere with the operation of the machine.
Do not attempt to touch the machine lamp immediately following shutdown, as it may remain at a high temperature for some time.
Ensure that routine checks are performed at regular intervals to ensure proper maintenance of all specifications for the operation of the machine.
Fire prevention measures are essential to ensuring a safe environment for operating SYIL 5 Series machines.
The following sections provides instructions for reducing the risk of fire before, during, and after operation of the machine.
Fire Prevention Before Operation
To minimize the risk of fire, always observe the following safety precautions before beginning to operate the machine:
Ensure there are no flammable materials or devices in the area surrounding the machine.
- Ensure that a sufficient supply of machining oil is available and that the machining oil is free of pollutants or other contamination.
Ensure that there is a fire extinguisher available in the machining area or nearby in the surrounding worksite.
Fire Prevention During Operation
The minimize the risk of fire, always observe the following safety precautions while operating the machine:
Never smoke around the machine while it is running.
- Carefully monitor for any signs of fire while the machine is processing flammable materials such as wood, plastic, or magnesium metal.
As the meeting point of the cutting tool and the workpiece material is likely to generate sparks, continuously monitor for any hazardous conditions when using non-soluble machining fluid.
- Never use machining fluids containing water when machining magnesium metal, as the cutting chips that result can react with water to generate hydrogen, elevating the risk of fire. Soluble machining fluids should be used only if treated to suppress the generation of hydrogen.
Never apply any liquid to the workpiece except for the specified machining oil.
- Always check to confirm that the machining oil in use is safe to apply to the workpiece.
Never perform welding or other work with an open flame around the machine while it is running.
Fire Prevention After Operation
The minimize the risk of fire after completing work with the machine, always observe the following safety precautions:
Power off the machine and ensure that its power supply is completely disconnected.
Check for the presence of any fire risk in the machine’s surroundings.
Machine Maintenance and Operator Proficiency Criteria
The following sections provides detailed specifications for the correct maintenance of SYIL 5 Series machines and proficiency criteria for machine operators.
To prevent hazardous conditions that can result injury or equipment damage, ensure that the equipment and personnel at your worksite fully satisfy these requirements.
The following table provides the proficiency criteria for different SYIL 5 Series machine functions and operators.
|Operating of absolute coordinates and incremental coordinates||Full proficiency|
|Operation of machine functions in auto mode||Full proficiency|
|Setting the offset parameters for the clamping device and cutting tool||Full proficiency|
|Selecting and set the requisite cutting tools||Full proficiency|
|Writing programs and applying standard G code and M code||Full proficiency|
|Operating in MDI mode||Full proficiency|
|Modifying/editing programs||Full proficiency|
|Testing and running programs||Full proficiency|
|Adjusting and monitoring the cutting tool’s abrasion offset parameters||Full proficiency|
Machine Maintenance Guidelines
The following table provides safety guidelines for the correct maintenance of the machine.
|Review inspection plans||At least once per day|
|Select appropriate measurement equipment||At least once per day|
|Perform inspections and make corresponding records to ensure components meet requirements.||At least once per day|
|At least once per day|
|Confirm whether needed at least once per day|
Equipment, Tool, and Machinery Safety
Operating SYIL 5 Series machines requires operators to work closely with potentially hazardous equipment, making professional grade work wear and safe tool use essential to preventing injuries and equipment damage.
Operators must be familiar with the guidelines and procedures established in this section before working on or around the machine.
Safety Equipment and Work Wear
To ensure personal protection, follow the rules for safety equipment and attire in this section whenever working on or around machine equipment.
Always wear comfortable, properly sized work clothes. If necessary, tie the lower ends of upper-body garments and trousers to prevent them from becoming tangled in the machine's moving components.
- Immediately sew shut any rips or tears in work clothes.
Always wear a safety helmet while working around machine equipment.
- If necessary, secure any long or protruding hair inside your safety helmet using a headband or hair tie.
Always wear professional grade work boots while working around machine equipment.
Other Safety Equipment
Always wear appropriate safety equipment for your worksite and ensure you are familiar with its proper use.
- Never use safety equipment that is damaged (such as damaged safety goggles or a damaged safety helmet).
Hand Tool Safety
To avoid injury, follow the rules in this section whenever using hand tools to work on or around machine equipment.
Remove any dirt or fluids from your hands before using tools to perform work manually.
- Keep the working site clean and clear of clutter at all times.
Never use a hand-held tool for any application other than its intended purpose.
- Use only reliable, high-quality tools that are in good working repair.
Never use socket wrenches or open spanners to support a hammer.
- Use wrenches only which comply with the machinery's specifications and in combination with anchoring nuts.
Always exercise caution when operating tools manually.
- Be aware of any surrounding personnel who could be injured by falling tools or components.
Never use large-sized open spanners to work on small bolts.
Never attempt to use a hammer or the sleeve of your clothing for added torque when operating a wrench.
- Be aware of the force you exert while using a tool, and never apply force in a way that could cause you to lose control of your body or the equipment you are operating.
Never attempt to increase the contact area between a wrench and a nut using a steel plate or any other object.
- Use screwdrivers only with matching specifications for their screws.
Never use a screwdriver with a burr or other deformity.
- Take precautions to prevent slippage while using a screwdriver to rotate a screw.
Always use an insulated screwdriver when working in the vicinity of electrical components. A standard electrical inspection screwdriver should be used during the electrical testing process.
Machine Equipment Safety
To avoid injury, follow the safety rules in this section whenever working with core machine equipment or performing cutting and drilling work.
Safety Requirements for Operating Core Machinery
Never place tools or other objects in or on the machine.
- Do not stop the machine while feeding work is underway.
Never attempt to use your hands or another tool to stop the machine while it is running.
- Ensure that both the workpiece and the machine’s cutting tool are correctly installed and secured.
If the cutting tool is unable to meet performance specifications, immediately replace it with a new one.
- Wear safety goggles at all times to prevent injuries from scattered cutting chips and other projectiles.
Always use a brush or other cleaning tool to clear cutting chips from the machine. Never attempt to clear cutting chips with your bare hands.
Never allow your hands or other areas of your body to come in contact with the cutting edge of the cutting tool.
- Never attempt to measure a workpiece while cutting or rotation is in progress.
Safety Requirements for Drilling and Cutting
Always maintain your hands, head, and feet at a safe distance from the rotating spindle or drill bit.
- Always use drill bits of reliable quality, and never attempt to use drill bits with cracks or other material defects.
If the drill bit is not sharp enough to endure the drilling and cutting process, be sure to sharpen it before beginning work.
- Installation and dismounting of drill bits should be performed only when the main spindle has been shut down and all components have stopped moving.
Always use a bench clamp or wedge to fix smaller workpieces in place. Never attempt to use your hands to stabilize a workpiece.
- When drilling or cutting into a workpiece with thin dimensions, place the workpiece on a hard surface such as a wooden board.
When the top of the drill bit penetrates the exterior of the workpiece, reduce the machine’s feeding speed to avoid causing the workpiece to rotate.
- If the drill bit becomes stuck inside the workpiece, shut down power to the machine, then remove the drill bit manually.
When removing an embedded drill bit, pliers can be used in place of a hammer.
- Removing an embedded drill bit requires reducing the gap between the main spindle and the workbench. When doing so, place a wooden board or other protective article on top of the workbench.
SYIL 5 Series machines contain a range of electrical components that must be properly configured and monitored to ensure a safe working environment.
This section provides important electrical safety considerations and instructions for preventing potential electrical hazards.
Electrical Hazards and Prevention Measures
The human body is highly prone to harm from electricity, and the risk of injury or death increases with voltage levels. While people have suffered fatal accidents from as little as 35 volts, many mistakenly believe they can withstand contact with 100 volts or more.
Though the human body has strong capacity for resisting electrical currents, even low current levels can have a significant impact. The following chart compares different current levels and their impact on the human body:
|Current||Impact on the Human Body||Current||Impact on the Human Body|
|Less than 1mA||Feeling of weakness and tingling||Higher than 50mA||Pain and physical injury|
|Less than 5mA||Painful shock||Higher than 100mA||Fatal injury|
|10~20mA||Pain accompanied by uncontrollable muscular spasms|
When the voltage in an electrical circuit exceeds its rated value, overcurrent relays can limit the current and protect the circuit, making their installation in the machine’s electrical system essential.
Overcurrent relays can be categorized as electric relays, thermal inductance relays, and magnetic inductance relays. Among these types, thermal inductance relays are used most widely.
Thermal inductance overcurrent relays are manufactured with dual-layer metal plates. When the current exceeds the circuit’s rated value, the dual-layer metal board will receive an electrical signal to shut down the current due to overheating.
Thermal inductance overcurrent relays come in several varieties, as shown in the following comparison chart:
|Direct heating||Directly conducts the current to the dual-layer metal board, with a high sensitivity to movements; however, its resistance level results in some loss of current.|
|Semi-indirect||Features a dual-layer metal board with asbestos insulation and thermal component coils; one side of the thermal component connects to the dual-layer metal board, enabling it to conduct the current.|
|Thermal release||Thermal release Does not transmit current signals to the dual-layer metal board; instead transmits signals to thermal components to generate activation gradually.|
Switch Control Faults and Possible Diagnosis
This section identifies commonly occurring switch control problems and their causes.
Inactive Controls and Switch Functions
Possible causes of inactive controls or switch functions include:
Electrodeposition resulting from short circuit
- Low switching volume
Excess motor worktime
Negative phase damping
- Increased remanence induction
Vibration of electric contacts due to low voltage (resulting in electro-deposition)
- Part of the magnetic core is too long, or the part entering the oscillator is too short
Sticky oil on the magnetic core
Abnormal current attenuation on electric contacts
Possible causes of for current abnormalities on electric contacts include:
Electric arcs generated by short circuits, low switching volume, excess motor worktime, negative phase damping, or increased remanence induction.
- Excessive operation
Electric arcs generated by worn or dirty contacts
To resolve these problems, separate the affected electric contacts and take the following measures:
Adjust the electric contacts so their surfaces are parallel when connected.
- Remove any foreign matter adhering to the contact points.
Thermal Induction Overvoltage Relay Faults
Possible causes of faults in thermal induction overvoltage relays include:
- Operation performance fault
Phase Position Short Circuit
Possible causes of phase position short circuits include:
Dust or humidity in the phase position
- Overheating of the phase position
Electrical Coil Fires
Possible causes of fire on the electrical coils include:
- Voltage levels exceeding 110% of the rated voltage
Voltage levels below 85% of the rated voltage
Deterioration due to exposure to cutting liquid
- Faults due to contact separation
Overuse of switches
Possible causes of electromagnetic vibration include:
Low voltage levels
- Foreign matter adhering to electric contacts
- Absent shielding coil
Precautions for Working with Electrical Equipment
Please these precautions to minimize the risk of harm or damage.
Due to the presence of explosive hazards including gas, dust, and other flammable materials, operators should avoid creating sparks while operating the machine. To counter the risk of explosions, switches and other devices should be installed in explosion-proof housing structures with the appropriate pressure, liquid chemical, or other explosion-type resistance ratings.
Electrical Equipment Inspections
Regular safety inspections are needed for all insulated wires and covers, conductive wiring and cables, and protective switch casings. Ensure that electrical equipment safety inspections are arranged in accordance with worksite electrical specifications.
- Inspect the equipment to ensure it is properly grounded and check for breaks in the conductive wiring.
Inspections of the fuse box and related electrical safety systems must be conducted at regular intervals, regardless of their performance.
Preventing Hazardous Static Electricity
In areas where gas, dust, and other flammable or explosive materials are present, the sudden discharge of static electricity can result in explosions.
- Conveying gasoline and other liquids, cutting solid materials, and performing printing operations can present an elevated risk of static discharge.
In order to limit the generation of static electricity, measures should be taken to reduce friction, maintain a steady flow rate, and ensure the proper grounding of all equipment.
- If necessary, use an inhibitor or air ionization mechanism to reduce static electricity at the worksite.
Industrial Accidents, Safety Measures, and Precautions
This section introduces the most common causes for industrial accidents, safety measures, and precautions to avoid or limit these hazards while working with SYIL 5 Series machines.
Strictly adhering to the measures and precautions introduced in this section will reduce the risk of harm due to an unsafe environment or improper machine handling.
Common Causes of Industrial Accidents
This section introduces some of the most common causes of industrial accidents that can arise from unsafe conditions or conduct at the worksite.
To minimize the risk of industrial accidents, take precautions to prevent the risk factors introduced in this section.
Psychological factors contributing to human error include:
- Excessive fatigue
- Violent behavior or loss of temper
- Willful misconduct
Bodily factors contributing to human error include:
- Physical weakness
- Physical handicap
- Drinking and other forms of intoxication
- Inadequate sleep
- Physical fatigue
Other factors contributing to human error include:
- Ill-fitting clothing
- Poor training
- Lack of orientation to the worksite
External factors in the building environment that can increase the risk of industrial accidents include:
- Inadequate ventilation
- Poor lighting
- Inadequate working space
- Narrow passageways
External factors in the worksite's facilities that can increase the risk of industrial accidents include:
- Poor safety protection systems
- Poorly maintained equipment
- Damaged tools
- Improperly installed support equipment
Work Environment Safety
Please apply the following criteria to your workplace to ensure optimal safety.
Ideal Illumination Levels by Working Area (Measured in Lux)
|High-precision machining work or service||700~1500||Intensive deskwork||700~1500|
|Precision machining work or service||300~700||General deskwork||300~700|
|General machining work or service||70~155||Reception room service||150~300|
Lamps and Lighting
Whenever possible, use daylight-level lighting (> 4500 lux).
The most ideal temperature, relative humidity and air flow conditions are shown as below:
|Summer||25~27℃ / 77-80°F|
|Winter||15~23℃ / 59-73°F|
For machining purposes, noise is defined as sound that is harmful to people’s hearing or ability to operate the machinery. Different models present different noise range criteria, with requirements generally falling between 85 and 95 db.
Preventing Fires and Explosions
The following instructions can help machine operators avoid potential accidents involving fires and explosions:
- Ensure any sources of open flame in the surrounding area are strictly controlled to avoid potential risks.
- Take measures to limit the occurrence of electrical faults, which should include allocating a reliable backup power supply. Electrical faults that occur while the machine is running can generate complications resulting in fires.
- Comprehensive inspections should be arranged for the machine’s pipeline equipment to prevent the leakage of flammable gas or compressed air.
- To avoid faults in the machine and its mechanical components, ensure the automatic control system is properly equipped, and re-arrange its valves as needed to avoid confusion. The status of each control mechanism should be clearly indicated at all times.
- Keep any source of open flame at a sufficient distance to prevent fires in the working area.
- Place fire protection devices at positions where they can be easily accessed in the event of an emergency.
- The following table compares the performance specifications for several types of fire extinguishers in different scenarios:
|Type||General Fires||Oil Fires||Electrical Fires|
|Foam fire extinguisher||Effective||Effective||Not effective|
|Powder fire extinguisher device||Relatively effective||Relatively effective||Relatively effective|
|CO2 fire extinguisher||Relatively effective||Relatively effective||Effective|
It is essential to adhere to the following machinery and worksite safety regulations to reduce the risk of injury or equipment damage.
Machinery Safety Regulations
Mandatory safety devices:
- Never purchase, rent, or install a machine that has not been equipped with standard safety protection devices.
Installing dangerous machine equipment:
- Dangerous machine equipment such as grinding equipment, pressure systems, cutting tools and machinery, sawblades, planers, and welders should only be installed with safety device matching the corresponding specifications.
Classifications of safety devices:
- Safety devices controlled with both hands
- Magnetic safety devices
- Scanning protection and safety devices
- Protective doors
- Disconnection devices
- Pull-out safety devices
- Electrical lighting devices
- Safety relief devices
Hazard Prevention Measures:
- As well as safety devices provided to prevent equipment-related hazards, ensure machine operators observe specified safety regulations at all times.
Avoiding Hazardous Work Scenarios:
- Never manufacture, install, or attempt to reconstruct any machine or related equipment where risks are present without first obtaining the prior consent of the responsible departments.
- Never attempt to operate a machine or equipment that has not undergone formal performance testing by a qualified department.
Working Restrictions for Dangerous Worksites:
- Dangerous work should only be performed by skilled, qualified workers.
Power Interruption Prevention:
- Each machine in the worksite must be equipped with its own power interruption devices of the specified ratings.
- Devices for emergency power stops such as running pulleys must be installed and easily accessible at the worksite.
Worksite Safety Management Regulations
Worksite Passageway Regulations:
- Never place or allow a barrier to be placed within a 2 meter radius of any worksite passageway.
- Maintain a passageway between adjacent machines of no less than 80 cm.
- Ensure that a minimum of two unblocked emergency exits are available at any worksite where explosive or flammable materials are present or where more than 50 workers are present.
- For staircases higher than 5 meters, stairwells should be no less than 5 meters wide.
- At least one side of the staircase should have handrail.
- Worksites with underground staircases used by more than 20 persons and worksites located on or above the second floor must have at least two outdoor emergency staircases.
Temporary Passageway Regulations:
- The gradient of any sloping passageways should not exceed 35°. Unless otherwise installed with handrail at a height of less than two meters, slopes at a gradient of more than 15° should be equipped with anti-slip surfaces.
- Solid protective fencing with a height no less than 75 centimeters must be installed in front of ledges where there is a risk of falling.
- If the axial length of a temporary passageway exceeds 15 meters, one protective fence segment should be arranged for every 10 meters.
- For temporary lifting platforms with a height above 8 meters, one backup lifting platform should be arranged for every 7 meters.
Emergency Response Procedures
Working with SYIL 5 Series machines involves inherent risks and hazards that can lead to injuries even when proper precautions are observed. The information in this section is provided to help you quickly assess and respond to common worksite injuries and medical emergencies using the correct first aid and CPR procedures.
Please note that this section is not intended as a replacement for formal first aid training and does not cover all possible emergency scenarios that may arise while operating the machine. Be sure to coordinate regular first aid trainings for all operators and personnel and establish clear emergency response procedures for your worksite.
Initial Emergency Response
If you or anyone around you is involved in an accident at work:
Observe the injury and scene of the incident and immediately report it to a supervisor.
- For serious emergencies requiring emergency medical services, pass all available information to emergency responders and follow their advice. Keep emergency responders updated with any developments.
Administer first aid only within the scope of your training to avoid the risk of injuring a person further.
First Aid Kit
A first aid kit should be kept in an accessible location near the machine facilities and should include the following items:
- Cotton gauze
- Gypsum bandages
- Cotton balls
- Rubbing alcohol
- Antiseptic ointment
Boric acid solution
After discovering that a person is unconscious and their breathing and heartbeat have stopped, immediately contact emergency services and proceed to administer CPR. If possible, two staff members should work together to perform CPR.
Performing CPR With Two Staff Members:
Lay the victim flat on their back.
- Clear any obstructions from the victim’s airways.
Deliver mouth-to-mouth resuscitation and chest compressions at a 1:5 breath-to-compression ratio. The first staff member should deliver 1 breath while checking that the victim’s chest rises and falls, after which the second staff member should deliver 5 chest compressions.
Repeat step 3 for 60-90 minutes until an emergency responder can take over. Stop CPR if the victim regains consciousness.
Performing CPR With One Staff Member:
Lay the victim down flat on their back.
Clear any obstructions from the victim’s airways.
- Deliver mouth-to-mouth resuscitation and chest compressions at a 2:15 breath-to-compression ratio, delivering 2 breaths while checking that the person’s chest rises and falls, then delivering 15 chest compressions.
Repeat step 3 for 60-90 minutes until an emergency responder can take over. Stop CPR if the victim regains consciousness.
If you believe someone has been electrocuted at the worksite:
Turn off the electricity supply to the worksite at the source.
If it is not possible to turn off the electricity, separate the victim from the source of electricity without endangering yourself. Wear rubber gloves and rubber-soled footwear if available. Examples of safe methods include:
Using a dry wooden or bamboo stick to move the cable or other electrical source away from the victim.
- Wrapping a dry rope around the victim and using it to pull the victim away from the source of electrical current while avoiding any other contact with the victim.
- Never touch a victim while they are being electrocuted or remain in contact with a live current.
If it is safe to do so, move the victim to a safe location and gently lay them flat on their back. Never allow the victim to stand upright.
- If the victim is unconscious, check their breathing and pulse. If necessary, perform CPR using the methods specified in the CPR section of this guide.
Burns can generally be categorized as minor burns and major burns. Minor burns are first degree or small-sale second degree burns smaller than the area of your outstretched hand where there is reddish and painful or blistered skin. Major burns are large-scale second degree or third degree burns larger than the area of your outstretched hand where there is subcutaneous tissue damage or necrosis.
Major and minor burns require different approaches to treatment. However, you should never give a burn victim hot water to drink, regardless of the category or severity of the burn.
To treat minor burns:
Run or submerge the afflicted area under cold water for at least 10-30 minutes. Alternatively, apply either a cold compress or boric acid to the wound.
- After the pain has subsided, remove any clothing from the area surrounding the wound.
Dress the wound using sterile gauze pads without applying oils or salves.
Never attempt to pierce blisters.
To treat major burns:
Remove the burn victim from the source of burning if it is safe to do so.
- Remove any burning material from the burn victim’s body.
Contact emergency services.
- Wrap the injured body part with a sterile cloth if it possible to do so without causing further injury.
Do not expose the burn or any part of the victim’s body to cold water as this may lower their body temperature and cause hypothermia.
When treating cuts and other wounds, avoid direct contact with the injured person's blood. If you do make contact, wash the blood off with warm, soapy water as soon as possible.
Basic First Aid Measures
Wash your hands with warm soapy water and wear rubber gloves if available.
- Using a piece of sterile gauze or a clean cloth, apply firm but gentle pressure against the cut for approximately 20 minutes (if possible, lay the injured person down and keep their injuries elevated).
After bleeding stops, clean the wound with water and remove any debris using tweezers. Keep the area around the wound clean and clear of dirt and debris.
- If the bleeding does not stop, follow the instructions in “First Aid for Severe Bleeding” below.
Apply a band aid or wound dressing according to the size of the wound.
First Aid for Severe Bleeding
If the victim falls unconscious at any time, check their breathing and pulse. If necessary, perform
CPR using the methods specified in the CPR section of this guide.
Contact emergency services.
Use a sterile surgical bandaging and apply firm manual pressure to the wound. Elevate the wound and continue to apply pressure.
When the bleeding slows or stops, tie the gauze or cloth in place using bandages. (If the bleeding does not slow or stop, follow the instructions in the “First Aid for Uncontrollable Bleeding” section below).
Continue to monitor the victim until emergency services arrive. If necessary, perform CPR using the methods specified in the CPR section of this guide.
- Never attempt to remove large objects that are embedded in the wound.
First Aid for Uncontrollable Bleeding
If bleeding cannot be slowed or stopped by applying pressure:
Call emergency services if you have not done so already, or contact them again to update responders and request further advice.
Apply a sterile bandage and tourniquet to the wound. Tighten and fasten the tourniquet until the bleeding stops and you can no longer detect a pulse near the wound.
Write down the time of bandage application on the victim's skin.
After 30 minutes, remove the bandage and check the wound.
- If the bleeding has stopped, remove the bandage and apply a sterile wound dressing and new bandage.
- If the bleeding has not stopped, repeat steps 2-4.
Continue to monitor the victim until emergency services arrive. If necessary, perform CPR using the methods specified in the CPR section of this guide.
Breaks, Fractures, and Dislocations
Never attempt to move a person who has suffered an injury caused by impact unless they are in immediate danger. It is extremely important to avoid aggravating possible injuries to the spine or neck, which can cause paralysis or permanent disability. To minimize these risks, proceed with the following steps:
Assess the severity of the injury by observing and asking the victim questions. If necessary, gently run your fingers along the afflicted area to feel for fractures. Ask the victim if they are able to move their limbs and to describe how they are feeling to determine if they have any of the following:
- Concussion or other head injuries
Bone fractures or joint dislocations
- Bleeding (external or internal)
Contact emergency services and provide as much information about the situation as possible. Be sure to follow their instructions.
Do not attempt to move the victim if there is any reason to suspect a head or spinal injury, as this could potentially cause further injury. Remind the victim to remain still until emergency services arrive.
If the victim is unconscious, check their breathing and pulse. If applicable, perform CPR using the methods specified in the CPR section of this guide. Seek additional advice from medical services if a spinal injury might also be present.
If the victim is bleeding, try to stop the bleeding and treat the wound using the methods specified in the Cuts section of this guide.
If the victim has suffered a non-spinal break, fracture, or dislocation:
Immobilize the injured body part with a splint, bandages, and padding.
- Apply a cold compress to reduce swelling and pain.
Never attempt to straighten or set a break, fracture, or dislocation.
- Never give food or drink to break or fracture victims.