)

No. Element Function Symbol

32 Key-switch

33 Buzzer (inside the control column)

34 Socket connectors

35 Switch Emergency shut-off

Switches the electrical system on and off.

Gives three acoustic warning signals if a fault is reported. The signals appear every 30 seconds.

Connection of electronic devices for fault diagnosis purposes.

De-energizes the outputs of the electronic control units:

The electric motor is shut off, all valves are de-energized, working movements are no longer possible.

(See chapter: "Emergency shut-off function").

EM028480-01

OMM 6060AC, 6060ACFS(3 847 036.00)-EN

Operation

(Fig.

2-71:)

All switches and pushbuttons have an illuminated symbol face. The opposite side is equipped with an LED. The LED lights up when the switch / pushbutton is actuated.

No. Element Function Symbol

41 Push-button Electric motor ON Switches on the electric motor.

42 Push-button Electric motor OFF Switches off the electric motor.

49 Indicator lamp Medium voltage Lamp is lit up when the circuit breaker is switched on. Medium voltage 7.2kV applied.

50 Indicator lamp Rotary field monitoring Lamp is lit up when the rotary field (phasing) is correct.

(Fig. 2-72:)

All switches and pushbuttons have an illuminated symbol face. The opposite side is equipped with an LED. The LED lights up when the switch / pushbutton is actuated. No. Element Function Symbol

61 Push-button Superstructure holding brake Blocks the superstructure.

Press this button when the superstructure is stationary. Do not use this button while the superstructure is still in motion. Risk of damage to the brake and the swing gearboxes.

63 Push-button Hydraulic shovel parking brake, for Service and Maintenance purposes only

Press the switch face with the symbol: The parking brake is applied permanently. The hydraulic shovel cannot be moved. For more information refer to chapter “Track parking brake”. Actuate this switch only when the hydraulic shovel is stationary. Do not use this switch while the hydraulic shovel is still in motion. Risk of damage to the brakes and the travel gearboxes.

64 Push-button Central greasing system reset

Reset function of the central greasing system control (Press for at least 3 sec.). Press switch face without symbol: Resets the control of the superstructure. Press the switch face with the symbol: Resets the control of the undercarriage.

65 Push-button Emergency lowering Lowering of the working equipment in an emergency situation. For instance, if the electric motor has failed. For more information refer to chapter “Emergency lowering of the working equipment”.

(Fig. 2-73:)

All switches and pushbuttons have an illuminated symbol face. The opposite side is equipped with an LED. The LED lights up when the switch / pushbutton is actuated.

No. Element Function Symbol

71 Switch Servo-control

72 Switch Travelling speed

Press the switch face with the symbol: The electro-hydraulic servo-control is enabled.

Not actuated: 1st travelling stage travelling forwards / backwards is possible. Press the switch face with the symbol: 2nd travelling stage, travelling forwards / backwards is possible.

76 Push-button When the machine has to be manoeuvered out of dangerous situations

Press the switch face with the symbol: The machine can be driven and the superstructure be swung although these functions are automatically deactivated. Use this function only in dangerous situations to manouever yourself or the machine out of hazard zones. Risk of damaging parts of the machine, e.g. the hydraulic ladder or the service station.

81 Switch Floodlamps

82 Switch Lighting

83 Switch Lighting

84 Switch Rotary beacon (if equipped)

Switches all floodlamps on and off.

Press the switch face with the symbol: Switches on the lights in the operator's cab.

Press the switch face with the symbol: Switches on the maintenance lights in the modules.

Press the switch face with the symbol: Rotary beacon ON.

Op

(Fig. 2-74:)

All switches and pushbuttons have an illuminated symbol face. The opposite side is equipped with an LED. The LED lights up when the switch / pushbutton is actuated.

No. Element Function Symbol

91 Push-button Dumper count

Press the switch face with the symbol: Resets the loaded dumper count.

92 Switch Windscreen wiper Press the switch face with the symbol: Windscreen wiper in intermittent operation mode.

Press the switch face without symbol: Windscreen wiper in permanent operation mode.

93 Pushbutton Windscreen washer Press the switch face with the symbol: Windscreen wiper in wipe/wash operation.

94 Switch Preheating (optional)

96 Switch Cable reel (optional)

Switches the preheating system on and off.

Switches the cable reel system on and off.

(Fig. 2-75:)

No. Element Function Symbol

101 Push-button (Free for options) Can be used as a push-to-speak button on a radio, or to switch over from one camera to another one.

102 Push-button Stick floating position (shovel equipment only)

Button is pressed: The stick cylinders are pressurized on retracting.

Press button (102) only in position "0" of control lever (115).

103

Push-button Boom floating position Button is pressed: The boom cylinders are pressurized on retracting.

Press button (103) only in position "0" of control lever (116).

104 Push-button Warning signal Button is pressed: Acoustic warning signal / horn is activated. 105 Push-button inside the seat Electronic hydraulic shovel control (servo-control)

The electronic hydraulic shovel control (servo-control) is activated when the operator sits down on the seat.

The electronic hydraulic shovel control (servo-control) is deactivated when he leaves the seat. 111 Pedal Shovel clam (shovel equipment only)

Forwards – shovel clam is opened; Backwards – shovel clam is closed. 112

Forwards – raising the stick

Backwards – lowering the stick.

To the left / right –swinging and braking of the superstructure. 116 Control lever Forwards – lowering the boom; Backwards – raising the boom.

To the left – backwards tipping of shovel / bucket;

To the right – dumping of shovel / bucket. 117 Push-button Not used on this machine. 118 Thumb wheel Shovel clam (shovel equipment only)

Turn Forwards – shovel clam is opened; Turn Backwards – shovel clam is closed. Function can be overridden by Pedal 111. (Thumb wheel is spring centered). 119

Push-button By-pass for the automatically switch off for stick- and /or backhoe cylinders (Option)

Lower half pushed – automatically stopped stick- and/or backhoe cylinders can be driven slowly to the limit stopps.

Upper half pushed – Each press on the button increments the loaded dumper count for by "1". (Count reset with button (91)). 120 Thumb wheel

Not used on this machine.

Operation

(Fig. 2-76:)

Optional equipment: Air conditioning

(Depending on the options ordered with the machine, the described elements can be found on different positions on the control column).

No. Element Function Symbol

150 Rotary switch Fan (Air conditioner)

151 Knob Thermostat (Air conditioner)

152 Rotary switch Mode (Air conditioner)

Selects the intensity level of the blower (3 levels).

Sets the desired temperature inside the cab.

Selects the desired control function (heating, cooling, ventilation, defrosting).

Putting The Machine Into Operation

Before daily start-up, carry out works in accordance with servicing plan T (see Part 3 "Inspection and servicing")

Prior to your dailiy start-up, make sure the machine has been cleaned of combustible and easily flammable substances.

Otherwise, increased fire and explosion hazard will exist.

Electrical Storm Injury Prevention

When lightning is striking in the vicinity of the machine, the operator should never attempt the following procedures:

 Mount the machine.

 Dismount the machine.

If you are in the operator's station during an electrical storm, stay in the operator's station. If you are on the ground during an electrical storm, stay away from the vicinity of the machine.

Reducing the operator's exposure to noise

All noise protection devices of the machine must be in place and fully functional when the machine is in operation.

e.g.

 doors, flaps and cover of the engine compartments must be closed,

 access doors to the compartments of the radiator fans must not be left open,

 the cab door must be closed,

 the exhaust silencer must be checked for holes,

 the screwed conections of all components fastend with bolts must be checked for tightness. Loose components tend to vibrate and to rattle, thus increasing the noise level. Wear ear protectors when leaving the operator's cab with the engines on and running.

Service station

The hydraulic shovel is equipped with a central service station (Fig. 2-77:). The service station is attached to the frame and accessible from the ground below the uppercarriage. Express couplings are provided for refilling the following consumables (fluids).

Fig. 2-77:

Pos. Fig. 2-77:

Fluid Express coupling for

5 Gearbox oil for pump drive gearbox Filling and / or draining

10 Hydraulic oil Filling and / or draining

11 Grease for the central greasing system Filling

A service vehicle is needed for filling and/or draining of the fluids.

Lowering the service station

Draw out control knob (21, Fig. 2-77:) of valve (22) with rope (25). The service station is brought down to the lower position. Turn knob (21) by 90° and engage.

Raising the service station

Disengage control knob (21) of valve (22), turn by 90° and press in. The service station is raised to the top position.

Refilling and draining

For filling in or for draining fluids, unscrew the cap of the corresponding express coupling (Fig. 2-77:). Attach express coupling of filling hose from the service vehicle to the corresponding express coupling at the service station. Fill in or drain off fluid. Take off filling hose and refit cap on the express coupling.

Assemblies resp. reservoirs Measuring device

Remarks

Pump drive gearbox Dipstick (1, Fig. 2-78:) Stop filling when the oil reaches the "max" mark on the dipstick (see Part 3, chapter "Pump drive gearboxChecking the gearbox oil level/Filling in oil").

Hydraulic oil tank BCS monitor (Fig. 2-81:), Inspection glass (1, Fig. 2-79:), sign (2. Fig. 2-79: and Fig. 2-80:)

Checking the oil level:

Extend the piston rods of stick and bucket cylinders halfway and stand working equipment on the ground (as shown on sign 2, Fig. 2-80:).

Check oil level at an oil temperature of ca. 50 °C (122°F), with the electric motor shut off.

Fill in oil when the oil level in the inspection glass hasdropped below the "min" mark. Stop filling if the oil reaches the "max" mark on the inspection glass or the acoustic warning signal "Travel alarm" sounds (see chapter "Hydraulic system - Checking the hydraulic oil level / Refilling hydraulic oil").

Operation

Assemblies resp. reservoirs Measuring device Remarks

Grease container –cental lubricating system

BCS display (Fig. 2-81:) BCS display indicates a warning when the grease container is empty.

Fill in grease using express coupling (11, Fig. 2-82:). Switch on the display system with the toggle switch (23, Fig. 2-82:). Monitoring lamp (22) lits up.

Stop filling when BCS indicates "Grease container filled". The indicator lamp (24) lights up.

On completion of filling, switch the display system off again with the toggle switch (23).

Monitoring lamp (22) is then off.

Battery main switch - Switch on and off

When the hydraulic shovel is disconnected from the medium voltage (7.2kV) the electrical system (24V) is supplied with voltage by two batteries. With the battery main switch, the electrical system (24V) is disconnected from the batteries.

The battery main switch is located at the left side wall of the control cabinet (24V). The control cabinet (24V) is mounted in the operator's cab module beneath the operator's cab.

Switching the battery main switch on

 Turn switching handle of main switch (1, Fig. 2-83:) to position "ON".

Switching the battery main switch off

 Turn switching handle of main switch (1. Fig. 2-83:) from position "ON" to position "OFF". The handle can be locked in the "OFF" position by means of a padlock.

Electrical system (24V) - Switch on and off

The electrical system is switched on or off with key-switch (32, Fig. 2-84:).

Switching the electrical system (24V) on

 Insert key into key-switch (32) and turn to the right.

Now all electronical assemblies of the hydraulic shovel are supplied with voltage, computer systems are started. A selftest is carried out.

The Board Control System (BCS) displays current operating data as well as detected faults.

If there are no critical faults detected BCS enables starting the electric motor.

If there are critical faults or failings detected BCS disables starting the electric motor and displays corresponding explanatory text.

For more information see " Operation and Maintenance Manual, Board-Control-System".

Switching the electrical system (24V) off

 Turn key in key-switch (32) to the left and withdraw

Electric motor – Switch on and off Before switching on the electric motor

Before switching on the electric motor, check that nobody is working on the electrical system or on the hydraulic shovel itself.

Switch on the electric motor only when all these work on the hydraulic shovel is finished and all persons leave the danger area.

 Switch on battery main switch (see: "Battery main switch, switching on and off").

 Switch on electrical system (24V) (see: "Electrical system (24V), switching on and off").

 Check telltales (49 and 50, Fig. 2-85:), they must lit up in green colour

If so, electric motor can be switched on (see: "Switching the electric motor on").

If telltales didn`t lit up in green colour, BCS has detected critical operating conditions or faults which prohibit starting the electric motor. BCS indicates this case with telltales as well as by displaying corresponding text.

Switching the electric motor on

 Actuate switch-key (41, Fig. 2-86:), the electric motor is switched on.

During starting period the electric motor heavily warm up. Therefore it is not allowed to switch it on and off at will. By means of an electronical time-out circuit (PLC) the electric motor can be switched on only three times a hour (time-out period is 30 minutes).

Switching the electric motor off

During breaks in operation and at the end of each shift, the working equipment must be lowered onto the ground.

The electric motor must NOT be switched off until the equipment is resting on the ground.

To avoid straining the vacuum contactor, the electric motor should be shut down only when load-free, i.e. without any of the hydraulic units being activated at the same time via the control valve.

 Actuate switch-key (42, Fig. 2-87:). The electric motor starts running down.

 Turn key in key-switch (32) counter-clockwise and withdraw

The control voltage is switched off.

The electric motor only can be switched on again, after the time-out period (30 minutes after last switching on) is over (see: "Time-out before restart", "Before switching on the electric motor" and "Switching on the electric motor").

Time-out before restart

During starting period the electric motor heavily warms up. Therefore it is not allowed to switch it on and off at will. By means of an electronical time-out circuit (PLC) the electric motor can be switched on only three times a hour (time-out period is 30 minutes).

The 30 minutes period means the time from switching on the electric motor up to the next switching on, e. g.

Electric motor is switched on, runs 20 minutes and then is switched off. Now the time-out period is 10 minutes before restart.

After running more than 30 minutes without interruption the electric motor can be switched on without any time-out period.

The eCAMP system prohibits switching on the electric motor until it is cooled down.

The BCS monitor (Fig. 2-88:) displayes the remaining time until the time-out period is over.

Electric motor can not be switched on

If BCS prohibits switching on the electric motor the operator should check the following:

 Time-out before restart period still running?

 EMERGENCY STOP switch in control column unlocked?

 EMERGENCY STOP switch in control cabinet (400V) unlocked?

 EMERGENCY STOP pullswitch near the service station unlocked?

 Servicing switch unlocked?

 Monitoring lamps "7.2kV OK" and "PHASE SEQUENCE OK" on the control cabinet (400V) and on the control column lighting? If not, the circuit breaker is switched off or the 7.2kV voltage supply is missing.

 Shut-off flaps at the hydraulik oil reservoir closed?

 Check BCS display: Faults or explanatory text displayed? If so, give information to the electric maintenance personnel.

If after all of these checks the electric motor cannot be switched on the operator has to inform the specialist personnel for maintenance and service on electric hydraulic shovels. Only these have the skills to work in a safe way, for trouble shooting and removing the fault.

In case of failure

If failures in the electrical systems occur, BCS displayes warnings and corresponding explanatory text

Failures in electrical systems may exclusively be removed by specialist personnel for maintenance and service on electrical systems. The following faults may be responsible:

 fault in high-voltage transformer

 7.2kV/ 400V/ 230V transformer overloaded.

 earth fault.

If BCS display shows "Overcurrent", the operator does not know if an "Earth fault" happens. In worst case the hydraulic shovel may be energized.

The operator must notify the electrician in charge from the hydraulic shovel superstructure.

The electrician must then cut off the voltage supply from the transformer station and locate and rectify the fault.

Circuit breaker - Switch on and off

By means of the circuit breaker the supplied medium voltage 7.2kV can be connected to the hydraulic shovels electrical system or can be disconnected from it. The circuit breaker is installed in the control cabinet 7.2kV (outer view, Fig. 2-89:, inside view Fig. 2-90:).

Switching the circuit breaker on is possible only when the eCAMP system and the motor protection relay enable this function. In this case, all four monitoring lamps (1, Fig. 2-90:) light up in green colour.

The circuit breaker is operated with an actuating lever which is stored in a fixture inside the control cabinet 7.2kV.

Switching the circuit breaker

 The circuit breaker is switched on and off by means of a actuating lever (Fig. 2-91:).

The actuating lever is slipped over the actuating shaft of the circuit breaker.

 Detailed information is given in the brochure of the manufacturer “Medium-voltage switching devices”. See volume “Components” of the printed machine documentation.

Motor protection relay - Function

The electric motor is equipped with a motor protection relay. The relay is located in the 400 V switch cabinet (Fig. 2-92:).

The relay monitors the operating conditions of the electric motor and protects the motor against faults in the electrical system of the motor

Depending on the nature of the fault, the motor protection relay switches off

 the power supply of the motor via the vacuum contactor or

 the power supply of the machine via the switch-disconnector.

At the factory, the motor protection relay is programmed for the following functions:

 protection against overcurrents,

 protection against overloading,

 detection of ground faults,

 temperature monitoring,

 restart inhibit,

 protection against undervoltage,

 protection against load unbalance (failure of a phase)

 phase sequence monitoring,

 change of frequency,

 run-up period monitoring

In case a severe fault of the motor system is detected in operation, the motor protection relay is activated and the electric motor shut off automatically. If the motor protection relay detects a severe fault before or during the starting sequence of the electric motor, it prevents the motor from being started. Depending on the type of fault detected, one or more LEDs on the front panel light up (9, Fig. 2-93:).

After rectification of the fault press button (7). The LED is extinguished. The motor protection relay is again operational.

For more information please refer to the the manufacturer's description.

Front panel control and monitoring elements

(Fig. 2-93:):

Fig. 2-93:

1 RUN indicator (LED)

2 Display screen (provides information on states of operation)

3 Display screen navigation keys

4 Function key freely programmable (not used for this machine)

5 Control of other equipment (not used for this machine)

6 USB interface for communication with external devices (only for CGM-HMS GmbH Service)

7 Reset for LEDs of item 9.

8 Cover for keypad of item 4.Functional description of the LEDs of item 9.

9 LEDs G1 – G8, on after detection of a fault: G1 – Overcurrent

G2 – Undervoltage/overvoltage

G3 – Load unbalance

G4 – Frequency change

G5 – Overload

G6 – Phase sequence fault, ground fault

G7 – Run-up monitoring, restart inhibit G8 – Emergency STOP activated

For more information please refer to the the manufacturer's description.