SAFETY INSTRUCTIONS FOR EXCAVATORS WITH ELECTRIC MOTOR

Maintenance and inspection work on electrical systems may only be performed by qualified electricians or by workshops employing such personnel.

A qualified electrician for the purpose of this regulation is a person who has the corresponding technical training, know-how and experience as well as knowledge of the pertinent prescriptions and who is therefore in a position to judge the work entrusted to him and the potential dangers in connection therewith.

Before carrying out any maintenance and inspection work on the electrical system, the following precautions must be taken:

In the transformer station

 Cut out the supply voltage.

 Secure against switching on; apply a warning sign.

 Check that the electrical system is off circuit.

 Connect to earth and short-circuit.

 Protect adjacent and live parts against accidental contact.

On the excavator

 Cut out the circuit breaker (see the " Switching off the circuit breaker " chapter in part 2 of the present Operation and Maintenance Manual)

 Secure circuit breaker against switching on, apply a warning sign.

 Switch off the earthing switch (see manufacturers Operating Instructions).

After finishing repair work:

In the transformer station

 Disconnect the earthing and short-circuiting line.

 Unlock the safety device preventing switch-on; remove the warning sign.

 Remove the partitions.

 Switch on the supply voltage.

On the hydraulic excavator

 Unlock the safety device preventing switch-on; remove the warning sign.

 Switch on the circuit breaker, (see the " Switching on the circuit breaker " chapter in part 2 of the present Operation and Maintenance Manual).

REPAIR WORK - SAFETY INSTRUCTIONS

Operation and Maintenance Manual

Never carry out repair work without having read and understood the Operation and Maintenance Manual.

Pay special attention to: "Fundamental Safety Instructions", "Inspection and servicing - safety instructions" and all warnings and safety instructions attached to the machine.

The descriptions of job sequences provide only experienced personnel with the necessary instructions.

The operating manual must be kept with the machine at all times.

Repair personnel

Repair personnel must have know-how and experience relevant to repairing this or comparable machines.

In the absence of such know-how, meticulous training must be given by experienced repair personnel, e.g. from CGM HMS GmbH .

Working in greater heights

Always wear safety harnesses when working at greater heights.

Wear an approved safety harness; it must be equipped with fall arresters and safety cables.

Prestressed units

Never open defective prestressed units but replace them as an entirety.

In exceptional cases, open only when the system and the operating sequence are precisely known and any special tools required are available.

The operating manual contains no information on this point.

Dismantling components

Never do dismantling while the machine is at operating temperature.

Oils, greases, or coolants may have a high temperature and result in burning or scalding. Leave time for the machine to cool down.

Before starting work, depressurize piping and hoses, cylinders, radiator, hydraulic tank and other systems or units.

Replace defective components in good time to prevent major damage.

Clean the defective component carefully before dismantling it.

Mark the dismantled parts in the correct sequence to faciliate re-assembly.

When dismantling the component, close off exposed hose and piping connections, exposed drill holes and housings carefully to prevent any dirt from penetrating.

Never remove lead seals.

Never change rated pressure of pressure relief valves without the explicit authorization of CGM HMS GmbH .

Never remove lead seals from pressure relief valves and accumulators.

After the repair work

To prevent corrosion, coat all bright metal machine parts with a grease film.

On completing the work, re-assemble all protective devices, covers and noise- and vibrationinsulation material.

Never start up the electric motor while work is being done on the machine.

Check the repaired components and all machine functions in a trial run.

Never release the machine for recommissioning until it is fully functioning.

FIRE AND EXPLOSION HAZARD Safety Instructions

Prior to commencing work, inform on the national and corporate rules for prevention of accidents. Pay particular attention to hazards caused by combustible and easily flammable substances.

on the safe handling of the fire extinguishers to be used.

Avoid smoking and open fire on, next to and below the excavator.

Combustible and easily flammable substances or liquids increase the fire and explosion hazard. Do not store or handle any flammable substances during operation.

Clean the excavator thoroughly, if possible, with a steam jet (rubber parts and electric components with compressed air - refer to information label), when, for example, oil, grease, fuel or cleaner was spilled.

Such substances may spontaneously ignite if they get into the vicinity of hot units. Even battery gases can ignite in open flames or fire.

Avoid parking the excavator in places where

 combustible substances such as coal dust or tar are present.

 open or smouldering fire may occur.

Remove the excavator from such an area where combustible or easily flammable liquids have spilled from the excavator onto the ground.

Flying sparks (caused by welding, flame cutting, grinding, electrical short-circuit) may cause fire on the ground that can spread to the excavator.

Place suitable fire guardings (fire barriers) if open fire or flying sparks cannot be avoided during repair work. Apply special protection to cables, cable ducts as well as to hose and pipe lines.

If necessary, also cover the ground with fireprotective blankets.

Ensure sufficient ventilation.

Clean the excavator before starting a job.

Do not keep any fire extinguishers that are not suitable or have not been tested.

Do not extinguish flammable liquids with water. Use:

 dry-powder,

 carbon-dioxide or

 foam extinguishing compounds.

When getting into contact with burning substances, the fire-fighting water would abruptly evaporate and distribute the substance such as oil over a wide area. Water causes short-circuits in the electrical system thus possibly entailing new hazards.

Call the fire brigade. Have all your welding, flame cutting and grinding work approved.

HYDRAULIC SYSTEM Repair

Always depressurize the hydraulic system before disconnecting any hydraulic hoses or pipes.

Read and observe also the chapters "Inspection and servicing - Safety instructions" and "Repair - Safety instructions".

Replace damaged and leaking hydraulic hoses and pipes as soon as possible by new ones.

Use original spare parts from CGM HMS GmbH. They are adapted to the respective function. Do not re-use old hoses.

Never repair damaged hoses.

Discard escaped oil and oily wastes without polluting the environment. These substances must not be allowed to penetrate into the soil.

Hydraulic hoses – Instructions

Even hoses that have been properly stored or used are subject to natural ageing. Their useful life is therefore limited.

Hydraulic hoses must replaced after a service life of six years (including a storage time of 2 years). Check the date of manufacture on the hose or on the hose fitting regularly.

The recommended interval after which hydraulic hoses - and especially those used in harsh conditions - must be replaced depends on the number of operating hours and on pressure loading.

The use of hoses close to their recommended load limit shortens the replacement interval (e.g. high temperatures, frequent working cycles, extremely high pulse frequencies as well as multi-shift operation and round-the-clock work).

Hydraulic hoses must be replaced, if one of the following defects is detected during a visual inspection:

 Damage to the outer fibre reinforcement layer reaching down to the inner layer (cuts, chafe marks, cracks).

 Embrittlement of the outer fibre reinforcement layer (cracks in the hose material).

 Changes in the ususal shape of the hose under pressure or in pressureless condition in bends or curves such as detachment of fibre layers, formation of bubbles or bulges.

 Leaks.

 Non-observance of fitting requirements.

 Damage to or deformation of hose fittings that may result in a reduction of the strength of the screwed union.

 Detachment of the hose from the fitting.

 Corrosion in fittings reducing the strength of the function of the fitting.

Pressure Accumulatorssafety Instructions

The hydraulic system is equipped with pressure accumulators containing nitrogen under high initial pressure.

Even when the hydraulic pressure in the system is reduced, the nitrogen in the accumulator will remain under pressure.

The accumulators are completely safe in operation. If incorrectly handled, however, there is a risk of explosion.

So:

 Never handle accumulators mechanically, never weld or solder.

 Testing and servicing work must be carried out by experts only.

 Prior to any testing and servicing work, depressurize the hydraulic part of the system.

 To dismantle the accumulator, always wear goggles and working gloves.

 Fill accumulator with nitrogen only, never with compressed air or oxygen.

 Report any defects or damage to the machine owner without delay.

 Prior to recommissioning, an inspection by a specialist or expert is essential if the accumulator was damaged or if the admissible operating temperature or operating pressure was exceeded.

Never remove or paint over warning and information plates, rating plates or type identification markings. Replace illegible or damaged plates immediately

WELDING AND FLAME CUTTING WORKS - SAFETY INSTRUCTIONS

The present safety instructions are valid for both types of work. For easier reading, the text only uses the terms "welding work", "welding" or simply "work". These terms do however always refer to both types of work, i.e. "welding and flame-cutting work".

Read these safety instructions before starting any welding or flame-cutting operations.

Welding work by qualified personnel only

Carry out welding work only if you have received special training and if you have been ordered to perform such work.

Always bear in mind that you are performing welding work on heavily loaded components. The quality of your welding work can be decisive for the operational capability of the machine and also for the health and life of persons.

Observe the health protection and accident prevention laws and regulations as well as the fire protection regulations in force in your country.

Observe all warning and instruction signs attached to the machine.

Wear the prescribed personal protective equipment such as:

 protective clothing,

 protective gloves,

 protective mask and,

 a fall-arrest system for persons working at height.

Increased risk of fire during welding work

Always bear in mind that the heat, the sparks or dripping red-hot metal or slag produced in the process constitute a considerable risk of fire. The present safety instructions provide information on how to minimize the risk of fire.

Remove all combustible materials close to the welding location or cover them up with noncombustible materials.

If works in the vicinity of combustible materials cannot be avoided, further persons with firefighting equipment must be present on site as fireguards.

Observe the instructions of the machine owner and of the mine.

Health hazards

Welding operations produce harmful gases. Do not inhale the fumes and gases and make sure the surroundings of the welding location are well ventilated or equipped with an exhaust system. Remove all kinds of paint and all coatings as well as all residues of oils and greases from the weld area.

Do not wind the welding cables round your body or parts of your body. The electromagnetic fields produced may damage your health.

Tanks, pressure vessels and pressure accumulators

Any work on vessels containing or having contained

 combustible or combustion-accelerating substances,

 potentially explosive substances or

 substances susceptible to develop harmful gases, fumes, mists or dusts during welding may only be carried out under expert supervision and only by experienced personnel especially assigned to such work.

This prescription applies, for instance, to all tanks and reservoirs for hydraulic fluid, engine oil, diesel fuel or lubricating grease.

Welding work on pressure vessels and pressure accumulators is forbidden.

Pressure vessels containing cold-starting fluid (ether) may be installed in or near the engine compartment.

Ether is toxic and highly flammable; the vessels are under pressure. These pressure vessels can explode if exposed to high temperatures (above 49°C / 120°F) or in the event of damage.

Protect the vessels against damage and high temperatures.

Do not perform welding work in the vicinity of these pressure vessels before they have been covered up safely against accidental contact or flying sparks. Have the pressure vessels removed from the machine, if safe protection cannot be ensured. Inform yourself about the locations in the machine where the pressure accumulators of the hydraulic system are installed. Do not perform welding work in the vicinity of these pressure accumulators before they have been covered up safely against accidental contact or flying sparks. Have the pressure accumulators removed from the machine, if safe protection cannot be ensured.

Slewing rings and articulated joints

The welding current must not flow through ballbearing or roller-bearing slewings rings, through bolted connections or articulated joints or through hydraulic cylinders.

An electric current flowing through an air gap (e.g. in the bearing or in the articulation) produces a spark which damages the metallic surface.

The welding clamps must therefore always be connected very close to the weld area (max. 2 - 3 m away (6.6-9.8 ft)).

Information relating to the electrical system and to electronic modules

Electric arc welding produces electromagnetic fields, electrostatic charges and voltage spikes which can cause damage to electronic modules. Although the electronic modules of the machine are carefully protected against these influences, it is nevertheless necessary to take additional precautions in order to prevent such damage to the greatest possible extent.

Switch off the electrical system ("ignition OFF").

Open the battery main switch (or disconnect the starter batteries from the machine).

Lay the welding cables as far away from electric lines as possible.

If it is not possible to implement all of the abovementioned precautions, all connectors must be removed from the electronic modules before beginning any welding work.

Protect withdrawn terminals and connectors from short circuits and soiling. Cover up terminals and connectors with foils or adhesive tape.

Never touch the enclosures of electrical and electronic modules with the welding electrode.

Protect electric lines against the heat emanating from the weld area.

Restore all electrical connections when the welding operations are terminated.

Never connect the ground clamp of the welding cable to the enclosures of electric or electronic modules.

Welding on the counterweight

Counterweights may contain a build-up of flammable gases. Before starting to work, counterweights must be flushed for at least 20 minutes with compressed air in order to remove these build-ups of gas. To permit flushing, the counterweight has two bores in its upper part: a threaded bore M18x1.5 for the compressed-air line and another unthreaded bore to let the air out.

Detailed information / instructions on this subject can be found in Service Information 2006-33 which is available on the CGM HMS GmbH website under Maintenance & Service.

Welding on components of the working equipment and on other fully or partly closed steel structures

Components may be equipped with pipelines routed inside. These lines can contain combustible substances such as hydraulic oil or lubricating grease which may be set on fire by welding operations.

Check whether pipes or hosepipes are connected to the steel component.

Depressurize these lines.

Open the screwed connections and empty the lines routed inside the component.

Start welding only after these operations have been carried out.

Electric lines may also be be laid inside partly open steel structures in order to protect them against damage. They are not always visible from each viewing direction. Electric lines may catch fire as a result of the heat produced during welding. Therefore check carefully whether electric lines are laid in the vicinity of the weld area.

Protect electric lines against the heat produced at the weld area or have them removed before starting the welding operations.

Welding on the cab

The operator's cab is designed in such a way that it meets the FOPS (Falling Objects Protective Structure) requirements in accordance with DIN EN ISO 3449.

Welding and other mechanical work is forbidden as there is a risk of reducing the structural stability of the cab.

Further information

More detailed information concerning the state-ofthe-art execution of welding operations can be found in the Service Manual "Welding for maintenance and repair".

For problems or queries please contact the competent service personnel.

If parts of the machine have to be removed or dismantled, please read and observe the chapters: "Assembly of working equipment, safety instructions", "Inspection and servicing, safety instructions", "Repair, safety instructions".

Disposal At The End Of The Service Life

Dismantling and removal instructions

Before beginning work, think about the risks involved, e.g.:

 Most of the machine components have considerable mass. Therefore use only lifting gear and slings of sufficient bearing capacity.

 Risk of residual pressures still in the hydraulic system. Be very careful when opening hydraulic lines.

Read the following text attentively and observe the instructions given. Respecting the instructions will help you to protect yourself against health hazards and injuries and to prevent avoidable environment pollution.

Risk of deflagrations

In the course of time, flammable gases may have formed or accumulated in the hollow spaces of welded constructions, e.g. the counterweight. To remove these flammable gases, the hollow spaces must be purged carefully with compressed air before work with hand grinders, flame cutters or other sparking tools is being undertaken.

Risk of fire

Remainders of fuel or oils may lead to the formation of flammable gases in tanks or other hollow spaces. When these tanks or hollow bodies are cut into pieces, the gases may ignite or even explode. For this reason, remove all fuel or oil remainders from these components and purge them carefully with compressed air in order to eliminate flammable gases (other efficient methods of removing flammable gases can also be applied) before work with hand grinders, flame cutters or other sparking tools is being undertaken.

Disposing of the machine without polluting the environment

Before stripping down the machine at the end of its service life observe the following instructions: The assemblies of the machine contain various operating fluids or lubricants. These substances may pollute the environment (so-called hazardous substances) and must therefore be disposed of properly.

Observe the national laws and regulations governing the non-polluting disposal of these substances. Remove all operating fluids from the systems, remove all lubricants and dispose of these substances properly.

 Fuel system: fuel tanks, fuel filters, fuel lines, filling station. Auxiliary attachment and units, such as an onboard crane or an auxiliary heater have their own fuel tanks with the corresponding line systems.

 Hydraulic oil: hydraulic oil reservoir, hydraulic cylinders, hydraulic motors, hosepipes, piping, hydraulic pumps, hydraulic valves, hydraulic oil filter, filling station.

 Engine coolant: engine, radiator, expansion reservoir, piping and hosepipes, filling station.

 Gearbox oil in slewing, travelling and drive gearbox systems, expansion tanks, piping and hospipes, filling station; idlers, support and track rollers.

 Have the refrigerant (R134A) sucked out of the air conditioner system.

 Grease from the central lubricating system, grease drum, piping and hosepipes, distributors, filling station; grease accumulations in bearings of the working equipment, grease filling in the slewing ring, grease filling in track and support rollers as well as in idlers.

Further hazardous substances

 Batteries contain lead and acid.

 Electronic modules are located in switch cabinets of the cab module, the engine module, the control column.

 Pressure accumulators contain nitrogen under high pressure and possibly remainders of hydraulic oil.

 Lamps of Xenon working lights contain mercury.

The required electronic control circuits are integrated in the housings of the working lights.

 The fluorescent lamps of the maintenance lighting (discharge types) contain mercury.

 Insulating material of cables can contain PVC.

 The fire extinguishing system (if installed) contains trigger charges (ATTENTION, explosion risk) on the extinguishing agent containers. Pressure accumulators, extinguishing gas and extinguishing powder.

For more detailed information please refer to the manufacturer's safety datasheets.

Appropriate disposal of batteries

The machine is equipped with batteries containing lead and other harmful and polluting substances. Damaged or used batteries must therefore not be disposed of in the environment. They must be disposed of properly and separately from other waste. The batteries are marked with the corresponding symbols (Fig. 4-1:).

Since batteries contain also reusable materials, they are taken back free of charge by the manufacturer, dealer or by other specialized companies.

In the European Community, the final consumer is obliged by law to to dispose of used batteries in designated waste collections centers.

Observe the current regulations and laws of your country with regard to the handling of damaged or used batteries.

The symbols in Fig. 4-1: have the following meaning:

 Crossed-out waste bin= Do not dispose of batteries with normal household waste.

 Pb……= Chemical symbol for lead.

 Circle of bent arrows= Recycling symbol, ingredients of the battery can be reused.

The operating personnel must have knowhow relevant to the operation and the application of this or comparable machines.

The inspection and servicing personnel must have know-how relevant to the inspection and servicing of this or comparable machines.

The repair personnel must have know-how and experience relevant to the repair of this or comparable machines. Part 5

Inspection and servicing personnel

Inspection and servicing personnel

Troubleshooting

Instructions on troubleshooting

Faults are often due to the machine not being correctly operated or serviced.

For this reason, it is vital to read through the relevant section of the Operation and Maintenance Manual once again before rectifying any faults. If you are unable to detect the cause of the fault or to rectify it, apply to the CGM HMS GmbH aftersales service.

Describe the fault and all accompanying circumstances as precisely as possible when calling on the CGM HMS GmbH after-sales service. Exact data allow for fast troubleshooting.

Never do any jobs for which you are not qualified. The fault table lists all faults which have been reported to date and outlines their possible causes and rectifying measures. In exceptional cases, a described fault may also have a different cause.

Layout of the fault table Fault

The fault is described here as the outcome of an observation or a previous activity. Therefore make careful observations.

Study the problem carefully. First think, then act. Ask yourself the following questions:

 Which warning signals preceded the fault?

 What repair and servicing work was carried out previously?

 Has this defect already occurred?

 Is it one or several simultaneously occurring faults?

Possible causes

The possible causes of the observed fault are outlined in this group. They are arranged in order of probability, i.e. the possible cause occurring in most cases heads the list.

Measures

This describes the troubleshooting procedure.

Section

This specifies where information on troubleshooting is given in the Operation and Maintenance Manual. If there is no entry, the CGM HMS GmbH after-sales service should be consulted

Fault Tables

Working hydraulics – Fault table

too high (warning lamp lit, PMS fault indicator

Track drive – Fault table

No forward travel and no reversing travel