ACCIDENT PREVENTION REGULATIONS FOR ELECTRICALLY POWERED HYDRAULIC SHOVELS

The safety and accident-prevention regulations valid in the respective country must be observed.

The following requirements are based on extracts from the German accident prevention regulations "Electrical Systems (BGV A3)".

The installation, modification and repair of the electromechanical component of electrical systems and components must be delegated only to qualified electricians or firms employing such experts.

A "qualified electrician" in the context of this regulation is a person who, on the basis of specialized training, know-how and experience as well as knowledge of the relevant regulations, is in a position to judge the extent of the work assigned to him and to recognize any potential hazards.

The machine owner/contractor must inform all persons working on electrical installations and components or in the vicinity of components conducting electricity during operation, or who are responsible for the operation of electrical systems, of the potential danger of electricity and must instruct them on the accident prevention regulations relevant to their work. Instruction in safety measures is to be repeated at intervals appropriate to the operating conditions. If necessary, special working regulations must be displayed.

The hydraulic shovel and its electrical systems must be adequately protected against other potential hazards of electricity, e.g. fire and explosion. Electrical systems and components must be protected against electric shock in the case of a fault, e.g. short circuit to exposed conductive part.

Any parts of the electrical system conducting current when in operation must be housed in lock-up switchgear cabinets. Hazard warning signs are displayed on these lock-up cabinets.

Voltage Hazard

The switchgear cabinets must be secured against unauthorized opening. The key must be kept by the electrician in charge.

Electrical systems and components must not be used unless they comply with the operational and local safety requirements. They must be in an orderly state and must be kept in such a state.

Any defects or malfunctions occurring in electrical systems or components must be reported to the electrician in charge.

Before switching on any systems, the hydraulic shovel operator must check that no one is working on the machine or its electrical systems.

The heavy-duty power cable must never be driven over, buried or ripped away. The hydraulic shovel equipment must never be set down on the power cable. When the hydraulic shovel is being moved, the cable must never be pulled or dragged over the ground.

Whenever work is being carried out on electrically powered hydraulic shovels, the general rules of engineering - especially those concerning low and medium voltage - must be observed. Regulations such as those issued by the German VDE, e.g. specification VDE 0100, should be observed. Observe all the related laws and rules in your state or country.

Before commencing any work on electrical systems and components, the electrician in charge (or an electrician appointed by him) must switch the power off all circuits and lock them in the OFF state as follows:

 Switch voltage OFF all systems.

 Check with voltage detectors that all systems are voltage-free.

 Lock switches/systems to prevent them from being switched ON.

The above procedures must be carried out in the given sequence.

The machine contractor must provide all the necessary protective equipment and adopt the necessary safety procedures. He must ensure that the safety equipment is used and the safety procedures observed.

The hydraulic shovel operator and all personnel working on the hydraulic shovel must use the protective equipment and carry out the specified safety procedures.

It is absolutely forbidden to work on any systems or components while they are conducting current. Fatal injury can occur.

If work has to be done in special cases on systems or components conducting current, appropriate safety measures must be taken. Work must not be done on "live" systems and components except by the electrician in charge. The machine contractor must also be notified.

The hydraulic shovel and its electrical systems must not be switched on again until the above safety procedures have been cancelled and all working areas are prepared for the resumption of operations. Start-up can be ordered only by the person in charge (qualified electrician). Time-based switch-on agreements are absolutely forbidden.

Safety instructions for hydraulic shovels with electric motor

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

In the transformer station

 Switch off the supply voltage

 Lock the safety device preventing switch-on; apply a warning sign

 Check that the electrical system is off circuit and dead

 Connect to earth and short-circuit

 Protect adjacent and live parts against accidental contact

On the hydraulic shovel

 Switch off the switch-disconnector

 Lock the safety device preventing switch-on; apply a warning sign

 Remove the cover

 Check that the electrical system is off circuit and dead

 Connect to earth and short-circuit

 Slide the partition into the disconnector housing

Fire And Explosion Hazard

Prior to commencing work, obtain informationon the national and corporate rules for the 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 hydraulic shovel.

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 hydraulic shovel 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 or objects such as turbo superchargers.

Even battery gases can ignite in open flames or fire. Avoid parking the hydraulic shovel in places where

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

 open or smouldering fire may occur.

Remove the hydraulic shovel from such an area where combustible or easily flammable liquids have spilled from the hydraulic shovel 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 hydraulic shovel.

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 hydraulic shovel 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.

Danger To Life

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

Part 2 OPERATION

Operating personnel

Inspection and servicing personnel

Repair personnel

Operating personnel

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

Part

Part

Part 5

Inspection and servicing personnel

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

Repair personnel

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

Inspection and servicing personnel

Repair personnel

Part 6 INDEX Operating personnel

Inspection and servicing personnel

Repair personnel

OPERATION - SAFETY INSTRUCTIONS

Operation and Maintenance Manual

Never operate the machine before having read and understood the Operation and Maintenance Manual.

Pay special attention to the "Fundamental Safety Instructions" and to all warning and instruction signs attached to the machine.

Familiarize yourself with the layout, the functioning and the sense of actuation of the control elements prior to starting up the machine.

Activate the control elements from the operator's seat only.

Keep the Operation and Maintenance Manual with the machine at all times.

Operating personnel

The operating personnel must be fully informed of the operation and application of this or comparable machines.

The necessary know-how can be acquired in several days' instruction, e.g. by an CGM-HMS GmbH mechanic or by attending an CGM-HMS GmbH operator's training course.

Personal protective gear and working clothing

Wear a safety helmet and working footwear with non-slip soles. Smooth soles may slip from steps and pedals resulting in injury or incorrect operation. Wear closely fitting working clothing when operating the machine. Loose, wide garments may result in control levers being inadvertently activated.

Safety belts

For machines with safety belts for operating personnel:

Check the safety belts attached to the operator's seat as well as at the trainer’s seat. In the event of damage or after an accident, have them replaced immediately.

Apply the safety belts before starting work.

State of the machine

Operate the machine only in a safe state and only in accordance with its designated use. Always observe the safety instructions.

Always have inspection and maintenance work carried out on schedule.

Operate the machine only with the equipment and component combinations approved by CGM-HMS GmbH .Clear-cut data are given in the technical specification.

Never install and commission other equipment and component combinations without CGM-HMS GmbH having first inspected and approved the project.

Before starting work or travelling with the machine, check that the braking, signalling and lighting systems are fully functional.

Poor visibility may result in accidents. Always clean the windows and the glass covers of all lamps before starting the machine.

Check that all warning and instruction signs attached to the machine are present and legible.

Entering and leaving the machine

Always face the machine when entering or leaving it.

Use only the ladders, steps, platforms and grab handles provided when entering and leaving the machine.

Always maintain a three point contact with the steps and grab handles.

Always keep ladders, steps and platforms in a nonslip, safe state and remove any oil, grease, soil, snow, ice and other foreign matter immediately.

Hazard range

The hazard range is that zone around the machine in which persons are within reach of loads or attachments falling as a result of operational movements by the machine, of its equipment and attachments or of swinging loads.

Persons within the hazard zone

Always use the horn to warn persons in the immediate vicinity of the machine before starting up the machine.

Ensure that no one sets foot in the hazard zone of the machine. Interrupt work until such persons have left the hazard zone.

Marshallers

The marshaller must keep outside the hazard zone.

Have a marshaller to assist you:

 when you have no clear overview over the hazard zone of the machine,

 when reversing,

 when shunting.

Use only those communication signals which you and the marshaller understand, or use aids for communication (e.g. walkie-talkie/camera). Calls cannot be understood by the marshaller because of the noise made by the machine during operation.

Keep in constant contact with the marshaller. Stop the machine immediately if you lose contact with the marshaller.

Securing the machine

Secure the machine as described under "Securing the machine" before:

 mounting or dismantling the attachment,

 parking the machine after daily operation,

 carrying out any servicing or repair work.

Visibility aids

Your machine may be equipped with visual aids. Some examples of visual aids are cameras and mirrors. Before operating the machine, ensure that the visual aids are in proper working condition and that the visual aids are clean.

For the best visibility of the area that is close to the machine adjust the visual aids using the procedures that are located in this Operation and Maintenance Manual.

Shut the machine down until damaged or nonfunctioning visibility aid is repaired (if applicable) or until appropriate job site organization is used to minimize hazards that are caused by any resulting restricted visibility.

Shut the machine down until damaged or nonfunctioning visibility aid(s) is repaired (if applicable) or until appropriate job site organization is used to minimize hazards that are caused by any resulting restricted visibility.

Operation and Maintenance Manual, where to store it in the operator’s cab

One copy of the Operation and Maintenance Manual for the machine must be available in the operator’s cab during operation.

Replace Operation and Maintenance Manual if lost, damaged or unreadeable.

The binder with the Operation and Maintenance Manual can be stored in the tray (Fig. 2-2:).

Fire And Explosion Hazard

Safety instructions

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

Combustible and easily flammable substances or liquids increase the fire and explosion hazard. Do not store such substances on the hydraulic shovel.

Clean the hydraulic shovel 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 hydraulic shovel in places where – combustible substances such as coal dust or tar are present,

– open or smouldering fire may occur.

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

Flying sparks may cause fire on the ground that can spread to the hydraulic shovel.

Hydraulic shovel layout

Fig. 2-3:

Undercarriage

1 - Track drive

2 - Idler

3 - Track roller

4 – Upper roller

5 - Crawler track

6 - Track tensioner

7 - Swing ring

8 - Escape ladder

9 - Slip ring assembly

10 - Cable guide for drag cable

Upperstructure

11 - Electric motor

12 - Switchgear cabinet medium voltage (7.2kV), circuit breaker

13 - Switchgear cabinet

14 - Switchgear cabinet

15 - Switchgear cabinet 400V, motor protection relay, mains power supply

16 - Switchgear cabinet power factor correction

17 - Hydraulic oil reservoir

18 - Hydraulic oil cooler

20 - Pump drive gearbox

21 - Working pump

22 - Cooling oil pump

23 - Gearbox circulating pump 24 - Servo system pump

27 - Swing pump

29 - Swing gear

30 - Travel block and rotor

31 - Operator's cab

32 - Control stand with BCS

33 – Additional heater (optional)

34 - Air conditioner

35 – Fire extinguisher (if equipped)

36 – Batteries

37 - Control-cabinet with CMS

38 - Control-cabinet (24V) with battery main switch

39 - On-board-crane (optional)

40 - Drive unit for on-bord-crane (optional)

41 - Service station

44 - Grease container of central lubricating system

46 – Hydraulic ladder

47 - Ladder

50 - Counterweight

Face shovel attachment

51 - Boom

52 - TriPower linkage

53 - Stick

54 - Bottom-dump bucket

55 - Boom cylinder

56 - Stick cylinder

57 - Tipping cylinder

58 - Bottom-dump cylinder

64 - Control valves on attachment

65 - Quick-action valve

Undercarriage

The undercarriage of the hydraulic hydraulic shovel serves as a stable base and for travelling. The crawler tracks are driven hydraulically with oil motors and travel gearboxes. Undercarriage and superstructure are connected by means of a swing ring.

Upper structure

The superstructure accommodates the drive and part of the hydraulic and electrical equipment.

Drive unit

The drive unit comprises electric motor, pump drive gearboxes, hydraulic pumps, hydraulic cylinders and hydraulic motors.

Hydraulic system

All working and travelling movements are performed hydraulically. The movements are controlled by servovalves. The working commands are initiated by hand and transmitted to the valves via control circuits. The oil supply from the superstructure to the undercarriage is ensured by the rotor. The hydraulic system is overload-protected by pressurerelief valves. The hydraulic pumps are supplied with oil from a hydraulic reservoir.

Control and Monitoring Platform (CAMP)

The electronic CAMP system ensures the control and monitoring of all electrical and hydraulical functions of the hydraulic shovel.

Four interconnected electronic units ensure optimal use of the installed engine power. Microprocessors are used to adapt the power output of the hydraulic pumps optimally to actual operating conditions. The machine is thus prevented from demanding more hydraulic power than the diesel engines can provide.

The desired working movements are detected by microcontrollers which permanently sense the position of hand levers and pedals.

As soon as movement is detected, the corresponding signals are transmitted to the electronic units. These units activate the drive control in order to provide the hydraulic energy needed for working. Only then do they activate the electro-hydraulic valves which control the execution of the working movements.

Demand control / Zero-flow regulation

In the fine-control range, swivelling of the hydraulic pumps, and thus the variation of oil flow, are proportional to control lever and pedal valve travel. This means that during the work, the pumps supply only as much hydraulic oil as required to perform the working movement. In the neutral position of the control levers, the pumps are automatically swivelled to zeroflow.

These special features offer the following advantages:

 minimum power losses,

 reduced temperature of the hydraulic oil,

 greater service life of hydraulic pumps and electric motor.

Automatic reset to idling

If no servovalves are actuated by the control pedals or levers for more than 8 seconds (factory-set value, adjustable), the engine is automatically set back to idling speed (factory setting ca. 1000 rpm, adjustable). This feature, too, contributes to reducing the fuel consumption.

Board-Control-System (BCS)

The BCS is a micro-processor-controlled system for the acquisition and processing of measuring data. It's function consists in collecting data of the hydraulic shovel operating conditions and to evaluate, store and display these data to the hydraulic shovel operator. For this purpose, the BCS is connected via a bus system to the Control and Monitoring Platform (CAMP). An interface with the outside world ensures the drive of stored data and software updating.

The measured values (actual values) from the sensors and transducers installed in the hydraulic shovel are compared to the predefined reference values. Inadmissible deviations are indicated as fault messages on a display screen. Sensor or transducer defects or defective connecting cables are detected and indicated by plain-text messages.

The data from the engine electronics are acquired, processed and displayed in the same way.

Critical states of operation are brought to the operator's attention by means of optical and acoustic warning signals.

The display screen of the BCS is a touch-screen with a surface sensitive to the touch. This feature supports the hydraulic shovel operator or the service technician in navigating through the menus of the BCS sorftware.

For further information in this respect, please refer to section 5 in this Operation and Maintenance Manual or to the brochure "Board-Control-System –Operation and Maintenance Manual"

Power supply

The electric power is supplied to the hydraulic shovel through the drag cable (1, Fig. 2-4:) and connection box (3).

The drag cable is guided by a cable guide (2). The power is then transmitted via the slip ring assembly (4) to the circuit breaker in the switchgear cabinet (Fig. 2-5:).

The drag cable can be wound on a cable reel (optional).

Operation with cable reel (if equipped)

(Fig. 2-6:)

1 Button Cable reel – wind up manual

2 Button Cable reel – wind off manual

3 Rotary switch Cable reel – manual resp. automatic operation

Automatic operation

During travelling the cable reel automatically winds up or winds off the power cable.

 Turn rotary switch - cable reel (3, Fig. 2-6:) to automatic operation (Auto).

Manual operation

 Turn rotary switch - cable reel (3, Fig. 2-6:) to manual operation (Man).

 Press in button (1) to wind up the cable reel or

 Press in button (2) to wind off the cable reel

The BCS (Fig. 2-7:) gives a warning when

 the cable is winded off completely from the cable reel,

 the resistance during winding up and off the cable is too high.

Safety films and warning messages – Overview and Description

Warning and additional messages

Observe the safety films and warning and additional messages attached to the machine.

There are several specific safety messages on this machine. The exact location of the hazards and the description of the hazards are reviewed in this section. Become familiarized with all safety messages. Make sure that all of the safety messages are legible.

Keep all the safety films and warning messages legible and clean.

Clean the safety messages if you cannot read the words.

When you clean the safety messages, use a cloth, water, and soap. Do not use solvent, gasoline, or other harsh chemicals to clean the safety messages.

Solvents, gasoline, or harsh chemicals could loosen the adhesive that secures the safety message. Loose adhesive will allow the safety message to fall.

Replace warning messages and films immediately if they have become illegible or have been lost. New warning messages and films can be ordered from the CGM-HMS Spare Parts Service. The ordering part numbers are set out in the spare-parts list of the machine.

Fig. 2-8: - Fig. 2-14: show the location of warning and instruction signs on the machine. The numbers in brackets, for example (23), tell the item number in the resp. spare parts group.

Safety messages (ANSI) – Description

In this section you can find a description of all safety messages and additional messages fitted to the machine (ANSI compliant messages set). The number in brackets, f.ex. (27), corresponds with the number of the film shown in the safety messages overview graphics.

The number corresponds also with the films item number in the spare parts manual.

Do Not Operate (18)

This safety message is located in the cab on the left side window.

WARNING

Do not operate or work on this machine unless you have read and understand the instructions and warnings in the Operation and Maintenance Manual. Failure to follow the instructions or heed the warnings could result in injury or death. Contact any Caterpillar dealer for replacement manuals. Proper care is your responsibility.

Hot Fluid Under Pressure (16)

This safety message is located on the cooling system expansion reservoir pressure cap.

WARNING

Pressurized system! Hot coolant can cause serious burns, injury or death. To open the cooling system filler cap, stop the engine and wait until the cooling system components are cool. Loosen the cooling system pressure cap slowly in order to relieve the pressure. Read and understand the Operation and Maintenance Manual before performing any cooling system maintenance.

Refer to Operation and Maintenance Manual, “Cooling System Coolant Level - Check” for further information.

Batteries, Flammable Gas (10)

This safety message is positioned on the battery cabinet.

CAUTION

Explosion hazard. Battery gases can cause explosions. Could cause serious injury or death. Do not smoke. No open flames.

Crushing Hazard (2)

This safety message is located on all four corners of the machine.

DANGER

Machine swings. Crushing hazard could cause serious injury or death. Stay back.

Falling Hazard (23)

This safety message is located on the upper structure of the machine at the handrail gates.

CAUTION

Falling hazard. Could cause serious injury or death when falling down from great height. Use caution when performing service work on the attachment. Always wear your fall protection equipment.

Refer to Operation and Maintenance Manual, “Working on the attachment- Safety Instructions” for further information.

Fire Hazard (9)

This safety message is located on the upper structure of the machine at the entrance to the pump bay and at the door of the cab module.

CAUTION

Fire hazard. Oil or fuel escaping in the event of damage can produce flammable vapours. Could cause serious injury. No open flames. Do not smoke.

Refer to Operation and Maintenance Manual, “Fire and Explosion Hazard – Safety Instructions” for further information.

Head Bump Hazard (8)

This safety message is located on the upper structure of the machine at the entrance to the pump bay, at the door of the oil cooler module and at the doors to the engine compartments.

CAUTION

Head bump hazard because of low clearance. Could cause serious injury. Stay back and wear a hard hat.

Trip Hazard (7)

This safety message is located on the upper structure of the machine at the entrance to the pump bay, at the door of the oil cooler module and at the doors to the engine compartments.

CAUTION

Trip hazard because of obstacles on the floor. Could cause serious injury. Be careful and pay extra attention on your steps.

Refer to Operation and Maintenance Manual, “Fundamental Safety Instructions” for further information.

Hot Surface (6)

This safety message is located in two locations. This safety message is located on the upper structure of the machine at the entrance to the pump bay and at the door of the oil cooler module.

CAUTION

Components and assemblies of the hydraulic system and components in the engine compartments can be hot while engines are running or immediately after engine shutdown. Hot parts or hot components can cause burns or serious injury. Do not allow these parts to contact your skin, when engines are running or immediately after engine shutdown. Use protective clothing or protective equipment to protect your skin. Wait until hot components have cooled down.

Cutting Hazard (14)

This message is located outside the oil cooler module.

WARNING

Self-starting, rotating fan blades. Can cause serious injury or cut. Keep hands away from fan. Turn off and lock-out electrical system before servicing.

Refer to Operation and Maintenance Manual, “Other Maintenance Work” for further information.

Cutting Hazard (15)

This message is located outside the counterweight near the cooling fan wheels.

WARNING

Rotating fan blades. Can cause serious injury or cut. Keep hands clear. Lock-out / tag out engine before servicing.

Refer to Operation and Maintenance Manual, “Other Maintenance Work” for further information.

Belt Entanglement Hazard (28)

This safety message is located in two locations. This safety message is located on the belt cover assembly on each engine.

WARNING

Entanglement hazard. Could cause serious injury or death. Do not touch while engine is running. Keep hands away. Do not operate engine with guard removed. Shut off engines before starting maintenance work.

Head Bump Hazard (17)

This safety message is located under the upper structure near to the fast fill arm / servicestation.

CAUTION

Head bump hazard when the servicestation is moving downwards. Could cause serious injury. Stay back and wear a hard hat.

Injury hazard, Personal Protection Equipment (PPE) Required (3)

This message is located on the upper structure of the machine at the entrance to the pump bay. Eye, ear, head, hand and foot protection are mandatory beyond this place.

WARNING

Serious injury can result from failure to use personal protective equipment. Wear appropriate personal protective equipment required for tasks being performed.

Hazardous noise level (5)

This message is located on the upper structure of the machine at the entrance to the pump bay. Ear protection is mandatory beyond this place.

CAUTION

Hazardous noise level when engine running. May cause loss or degration of hearing over a period of time. Wear proper personal protective equipment / ear protection beyond this point.

Always Use Seat Belt (22)

This message is located in the cab on the right side of the operator’s seat.

CAUTION

A seat belt should be worn at all times during machine operation to prevent serious injury or death in the event of an accident or machine overturn. Failure to wear a seat belt during machine operation may result in serious injury.