Control and operation

Working with the machine

–Familiarise yourself with the emergency exit through the front window.

–The windshield is used as an emergency exit and may not become blocked by placing any items against it, e.g. a front guard! If a front guard is necessary, it should be arranged so that an emergency exit through the front window is still possible .

–Put on the safety belt immediately on entering the cab and close the cab door before starting the engine.

–The cab elevation is designated for a maximum 160 kg .

–It is forbidden to carry passengers on the outside of the cab.

–Weekly check the emergency lowering function via the both shut-off valves inside the cab.

–Weekly check that the cut off for swing movements and for cab lowering movements are functioning and that they react promptly.

–Familiarise yourself with the cab's movements using the control lever before operating the cab elevation .

–Only adjust the cab when the machine is stationary.

–Presence of a third person in the danger zone of the excavator is not to be tolerated during the adjustment procedure of the cab.

–Never drive the cab underneath a load in the clamshell or the lifting hook. It can be hazardous if the load drops from the clamshell or the lifting hook.

–Please be fully aware of the danger that could occur during operation of the cab elevation and the lift frame, e.g. collision with parts of the undercarriage or with the load in the clamshell or the lifting hook.

–Always maintain visual contact with the undercarriage when lowering the cab.

–Be aware of the location of electrical lines around the working area and maintain sufficient distance at all times between the cab, elevation or other machine parts and electrical overhead cables.

–Familiarise yourself with the safety distances which must be maintained and do not undertake any jobs where the necessary distance from electrical overhead cables can not be maintained at any time.

–Never use the cab elevation as a crane.

–The cab elevation should never be used during thunderstorms.

–Adhere to all safety guidelines listed under heading "Safe use of machines with tower elevation" before in this manual.

–With travel movements, please ensure that:

•the working attachment is load-free and retracted as far as possible ,

•the travel surface is even, stable and free of any obstacles.

–Travel in the machine should fundamentally only be carried out with the cab retracted and in the upper position, thus. with the uppercarriage side element of the elevation fully raised and the cab side element fully lowered.

–Travelling the machine with the cab in raised up position is not permitted if the travel routes are not even and free of any obstacles or with inclines or bankings which could affect the stability of the machine.

–Hold the cab as near as possible to the excavator's swing centre in order to reduce vibrations and swings in the cab as much as possible. Raise the uppercarriage side element completely, and adjust the height with the cab side element.

–In the event of an unbalanced position - via a main block valve that has jammed, or a burst hydraulic hose, release the control lever immediately. Then shut off the diesel engine to cut off the oil supply. The cab will remain in position via the linebreak protection valve.

–The cab can then be lowered using two emergency lowering shut-off valves located in the cab.

–In addition, two emergency lowering shut-off valves are also arranged on the basic machine, allowing a third person, standing outside the driver’s cab, to lower the hoist frame in an emergency case.

–Never continue operating a machine with a malfunction until the malfunction has been remedied

Adjustment of the cab position

The adjustment of the cab elevation is possible when the machine is ready to operate, with the safety lever pushed down and the engine running.

Caution!

Only adjust the cab when the machine is not travelling. Ensure that no persons are within the machine’s danger area during the cab height adjustment.

The movements of the cab elevation with double parallelogram are controlled via the joystick U45 on the right side control desk.

The joystick U45 is operative only as long as the touch S370 on the left control console is kept depressed.

Movements of the cab side element I

Press the touch S370 and at the same time tilt the joystick U45 to the right (n). the cab side element I raises, as long as the joystick is actuated. Press the touch S370 and at the same time tilt the joystick U45 to the left (m). the cab side element I is lowered, as long as the joystick is actuated.

Movements of the uppercarriage side element II

Press the touch S370 and at the same time tilt the joystick U45 backwards (p). the uppercarriage side element II raises, as long as the joystick is actuated. Press the touch S370 and at the same time tilt the joystick S45 forewards (o). the uppercarriage side element II is lowered, as long as the joystick is actuated.

Safety cut off of cab lowering movements

The cab lowering movements are automatically stopped when the cab arrives as low as about 2 meters above ground level. This safety cut off function prevents collision of the cab or cab support with the un- dercarriage.

Unlatching the safety cut off I

To let the cab down below the level where safety cut off occurs, the safety function must be unlatched while pressing the touch S477.

To lower the cab fully to the ground, press the touches S370 and S477 simultaneously, while actuating the joystick U45.

Caution!

If the safety cut off is unlatched, there is a risk the cab frame collides with the undercarriage of the excavator, Pay attention that the hoist frame or the cab does not touch any part of the undercarriage while being lowered.

Swing movements shut-off

Simultaneously with the cab lowering movements, the swing movements of the uppercarriage are also automatically stopped when the cab arrives at the level where a risk of collision occurs between the bottom of the driver’s cab and the undercarriage.

The warning light H83 lights up at the same time.

The actuation of swing movements will become possible again as soon as the cab has been raised to a high enough position.

Weekly check that the cut off of the cab lowering and swing movements and the warning light H83 are functioning and respond quickly.

Notice!

Check this function while lowering the cab and without swing movement actuated, to avoid fast abrasion of the swing brake discs. Verify that no swing movement can be actuated once the warning light H83 has lit up.

Emergency lowering of the height adjustable cab

The machine is fitted with two different sets of valves for emergency lowering, allowing to bring the cab into its lowest position in case of a trouble in the cab elevation system, due for example to a failure of the Diesel engine, of the hydraulic circuit or in the electrical control circuits.

One of these sets is situated inside the cab, the other one, on the rear of the elevation structure allows emergency lowering by a third person outside the cab.

Caution!

Depending on obstacles that could be present around the cab area, and on the possible laying down positions on the ground, it should be considered, before emergency lowering, in which order the two elements of the elevation are to be lowered.

Emergency lowering from inside the cab:

Turn the handle of the valve 1 situated in the cab to the open position A the cab side element I of the elevation lowers due to its own weight, as long as the valve 1 is maintained in position A

Turn the handle of the valve 2 situated in the cab to the open position A the uppercarriage side element II of the elevation lowers due to its own weight, as long as the valve 2 is maintained in position A.

Immediately after an emergency lowering return the both valves 1 und 2 into the closed position B

Emergency lowering from outside:

The cab elevation can likewise be lowered from outside the cab by a third person situated on the catwalk near the cab elevation structure and actuating the both valves 11 and 12

Turn the handle of the valve 11 on the hoist frame to the open position A. the cab side element I of the elevation lowers due to its own weight, as long as the valve 11 is maintained in position A

Turn the handle of the valve 12 on the hoist frame to the open position A the uppercarriage side element II of the elevation lowers due to its own weight, as long as the valve 12 is maintained in position A

Danger!

There is a risk of crushing by the mobile parts of the cab elevation. Ensure that no one is standing in the vicinity of the lifting frame during an emergency lowering from the outside of the cab. Take care to keep yourself away from the cab and from the mobile parts of the the lifting device when emergency lowering the cab.

Immediately after an emergency lowering return the both valves 11 and 12 into the closed position B

Notice!

The cab elevation cannot be raised as long as one of the four above mentionned valve remains in the open position A

Instruction for repair works and maintenance

Danger!

Repair and maintenance works on the cab, the lifting frame or on the related hydraulic and electrical installations should, when ever possible, be carried out only with the cab lowered.

For repair and maintenance works which can only be carried out with the cab in raised up position, the cab must be supported in a safe manner with a suitable supporting device, so that any unattempted movement of the cab is hindered.

3.5Emergency operation

3.5.1Emergency control circuit board E52 for electric motor & servo control

The printed circuit board E52 is located at the very rear of the right control console. The emergency control function enables the operator to manoeuvre and operate the hydraulic excavator to a limited extent in the event of failure of the electronic main control circuit.

E52 Emergency control circuit board

H_b Indicator light / control system 24V in emergency mode

H73_bIndicator light / emergency operation of servo pressure circuits

S_b Switch / emergency start of control system 24V

S73 Switch / emergency operation of servo pressure circuits

Emergency switching of control system 24V

Set the battery main switch S9 to position 1 (ON).

In normal operating mode, the control electronics of the machine release the control system 24V. In the event of a fault in the electronics, the control system can be released manually by tilting the switch S_b to its emergency position.

Move the safety lever down.

Actuate the rocker switch S_b to set the machine to emergency mode. The indicator light H_b is on. The control system is powered on.

Emergency switching of servo pressure circuits

In normal operating mode, the control electronics of the machine release the servo pressure to the pilot control units and the slewing gear brake.

In the event of a fault in the electronics, the servo pressure can be released manually by tilting the switch S73 to its emergency position.

Move the safety lever down.

Actuate the rocker switch S73 to set the machine to emergency mode. The three symbols S73a, S73b and S73c are displayed on the screen. The indicator light H73_b is on. The pilot control units are pressurised with servo pressure. The slewing gear brake is released.

Danger!

The emergency mode must only be used for short times and if it is not possible to release the slewing gear brake and/or if the servo pressure supply to the pilot control units is not reliably ensured through the normal control circuit. In emergency mode, the slewing gear brake is released as soon as the key is in contact position and the normal control of the brake system is disabled. Inform all persons involved in the operation and maintenance of the machine of the fact that the machine is in emergency mode and that its control is thus altered.

Have the damage or fault that required you to switch to emergency mode rectified as soon as possible.

Note!

The servo pressure supply to the pilot control units is shut off as the safety lever 1 is tilted up and remains shut off even when the switch S73 in set to its emergency position.

3.5.2Emergency operation of the working pumps

In normal operating mode, the volumetric flow of the hydraulic pumps is continuously adjusted by the electronic performance regulator based on the current pressure level in the working circuits.

In the event of a fault or malfunction at the performance regulator or its auxiliary circuits, the pumps are automatically set to minimum flow. In this case, the machine can still be operated at reduced pump performance.

2 Cotter pins H Horizontal position (emergency position)

3 Lever V Vertical position

Y50-1Regulating valve

Y50-2Regulating valve

Switch the lever 3 at the control oil unit at the rear of the hydraulic tank. To do this: –Disconnect the plugs from the regulating valves Y50-1 and Y50-2

–Remove the cotter pins 2

–Move the lever 3 into a horizontal position (emergency position). The system is now in emergency mode.

3.5.3Emergency operation of boom cylinders (option)

Thanks to this optional device mounted at customer’s wish and depending on machine application, the boom cylinders can be fed with the oil from an external pressure source.

With this device, the working attachment can be moved upwards or down also in emergency cases (defective engine, trouble in the hydraulic circuit of the machine, ....).

Caution!

The oil, the external pressure source feeds into the hydraulic circuit of the machine must in any case:

•comply with the requirements for hydraulic oil specifications given in the chapter "Maintenance" of this manual,

•be mixable with the oil contained in the hydraulic circuit of the machine,

•correspond to a purity class that is better or the same as the one of the hydraulic circuit of the machine (10 – 20 µm filtering).

Fig. 3-93 Shut off valves for the emergency operation of the boom cylinders

To connect the external pressure source:

The connection fittings and the shut off valves of the device for emergency operation are mounted to the bottom of the basic boom, right side. Remove the union nut and the taper collet at the top of the T- fitting 8U or 8D and connect the pressure source with the T- fitting.

Notice !

Wenn the pressure increases in the external source, it will also build up automatically in the servo control circuit of the machine, even if the shut off valves 5U and 5D remain in closed position.

To lift the working attachment: slowly and progressively actuate the joystick for boom cylinders until the working attachment has been lifted into the desired position.

The external pressure source must be connected to the T- fitting 8U. push the safety lever in lower position and turn the ignition key to contact position. open the shut off valve 5U (align the actuation lever of the valve with the hydraulic lines).

To lower the working attachment: eventually open the the shut off valve 5D (align the actuation lever of the valve with the hydraulic lines).

The external pressure source must be connected to the T- fitting 8D. push the safety lever in lower position and turn the ignition key to contact position. slowly and progressively actuate the joystick for boom cylinders in direction lowering the working attachment until the attachment has reached the desired position.

After the attachment has been moved with the external source:

Close the shut off valves 5U and 5D immediately (return the actuation levers in crosswise position to the hydraulic lines), in any case before disconnecting the external pressure source. check the level in the hydraulic tank, if necessary adjust to correct level.

3.6Recovering, towing the machine

3.6.1Towing with the machine, emergency towing of the machine

As well the towing of another machine with the excavator as the emergency towing of the excavator are difficult and problematic operations which are always realized under is the responsibility of the owner of the machine.

Damages or accidents, that could occur when towing another machine with the excavator or when emergency towing the excavator cannot be covered by the manufacturer's guarantee under any circumstances.

Towing and lashing hooks and eyes on the undercarriage

The hooks and eyes mounted to the undercarriage central piece are destined for the anchoring of the excavator during transportation, resp. for towing smaller machines or vehicles.

Always notice the indication for the maximum authorized pulling force on the hooks 3 or on the eyes 4.

Always expect a maximum pulling force of 10 tons for hooks which are welded to the undercarriage central piece and which show no indication.