Malfunctions

Fuses and relays

Before exchanging a fuse or relay, set the battery main switch to position 0 (OFF).

4.4.1Fuse box E50

The fuse box E50 is located behind the door to the engine compartment. Remove the lid of the fuse box and close it after the fuse has been replaced.

K16 Starter relay

K43 Engine stop relay

K66 Cylinder shut-down relay

K93 Cold start system relay

K103

K141

K280

K288

Diesel engine ON (12 V for operating hours counter) relay

Relay E5

Relay E150

Main relay terminal 15

K360 Headlight relay copyright by

4.4.2A1010 printed circuit board

The A1010 board is located in the left control console and is accessible when the operator's cab door is open.

Remove the cover of the control console and replace it after the problem has been rectified.

F1 15 AReserve

F2 15 AReserve

F3 15 AReserve

F4 15APre-heating, control of windscreen wiper/washer system, beacon*, rotating grapple*

F5 7.5 AWindscreen wiper

F6 7.5 AEmergency speed adjustment

F7 7.5 AKeyboard and display

F8 15 ASafety lever, solenoid valves of pilot pressure system, slewing gear brake, fast travel, additional pressure stage

F9 15 ASpeed-adjustment motor, excavator control

F10 25 AAttachment headlight, revolving deck headlight, auxiliary headlight*

F11 15 AReserve

F12 15 AReserve

F13 7.5 AIgnition, starter, voltage converter, radio*, engine stop*

F14 15 ACab lighting, cigarette lighter, horn

F15 15 AReserve

K5 Emergency control, engine stop* relay

K6 Horn relay

K7 Cab roof headlight relay

K8 Float position relay

K9 Emergency mode flow reduction relay

* optional equipment copyright by

4.5Emergency operation

In certain situations, it might be necessary to restore a function that failed before the machine is properly repaired. Depending on the type and extent of the malfunction, this might be achieved by setting the machine to emergency mode.

In emergency mode, certain control electronics and control elements are bypassed so that certain functions can be controlled directly. This mode allows for the temporary limited operation of the machine.

Emergency mode is designed for use in emergency situations only.

Due to the reduced functionality of the machine in emergency mode and the associated risks, this mode may only be used in exceptional situations (see Tab. 41).

Emergency operationApplication

ControlShort-term continuation of operation until repair can be performed (it is always recommended to carry out repairs without delay)

Hydraulic pumpMove the machine away from the construction site or a dangerous position (immediate repair is required)

Tab. 4-1 Emergency mode, purpose

Danger!

In emergency mode, certain safety functions of the control system are disabled. This can lead to accidents or damage to the machine. Use the emergency mode only for the intended purpose. Inform all persons involved in the operation and maintenance of the machine that it is in emergency mode.

Immediately switch off the emergency mode when it is no longer required. Have the machine repaired as quickly as possible.

4.5.1Emergency control

In the event of a failure of the control electronics, certain machine components might not work properly.

Depending on the type and extent of the malfunction, it might be possible to reestablish proper operating conditions for the machine components.

The emergency control feature includes three functions:

These functions may be combined with each other.

The control panel for emergency control operation is located in the rear section of the right control console.

S71 Emergency control switch / speed adjustment R6 Speed controller

S73 Emergency control switch / machine control

4.5.1.1Emergency speed adjustment

S84-2 Emergency control switch / central lubrication system

The emergency speed adjustment caters for the following failures: S86

S228 and S229

If the diesel engine is in emergency mode, the engine speed can be adjusted with the regulator R6

Set the switch S71 to position 1.

Start the diesel engine with the ignition key. The indicator light H11 is on.

The symbol n-min/MANU is shown at the display. The speed adjustment is in emergency mode.

Adjust the speed with the regulator R6

Turn the regulator clockwise to increase speed. Turn the regulator counter-clockwise to reduce the speed.

4.5.1.2Emergency machine control

The emergency machine control caters for the following situations:

Danger!

In emergency machine control mode, the servo control system and the slewing gear brake cannot be operated with the normal switches, but only with the safety lever. In emergency mode, the machine might make unexpected movements when the safety lever is pushed down (instant release of slewing gear brake). There is thus an increased risk of accidents!

Therefore, use the emergency machine control mode if this is absolutely necessary.

Use the emergency machine control option only to remove the machine from the danger zone.

Fig. 4-7 Emergency control screen

Move the safety lever up.

Set the switch S71 to position 1 Emergency control mode is now on. The emergency mode symbols are shown in the screen (see Fig. 4-7). The servo control and the slewing gear brake can now be operated with the safety lever.

Move safety lever down. The slewing gear brake is released. The servo control is activated.

4.5.1.3Emergency mode for central lubrication system

The emergency mode for the central lubrication system is used in the event of a failure of the central lubrication system due to a control fault.

Move the switch S84-2 briefly to the left or right to initiate a complete lubricating cycle.

If the central lubrication system is in working order, the actuation of the switch initiates an additional lubricating cycle.

Set the switch S84-2 to position 1 A lubricating cycle is completed.

4.5.2Emergency operation of the hydraulic pump

In the event of a failure in the pump control, the performance of the hydraulic pumps is automatically reduced to a minimum.

For such a situation, the excavator is equipped with an emergency operation function for the hydraulic pump. This function is activated/deactivated at the control oil unit. It bypasses the control electronics so that the hydraulic pump can be operated at an only slightly reduced output rate.

Switch off the diesel engine.

Disconnect the plug connector 1 (Y50)

Remove the cotter pin 2

Move the lever 3 into a horizontal position (emergency position). The hydraulic pump is switched to emergency operation. Start the diesel engine.