Can I keep operating the lever by hand while the retrofit kit is installed?
Do not force the lever by hand while the servo is powered. Press Emergency Stop or cut the supply first, then unbolt the clamp; it is no quick release.
Because the kit grips the manual lever mechanically, forcing the lever by hand while the servo is powered is not correct use. If you need to go back to operating by hand, first press Emergency Stop or cut the kit supply, then remove the mounting clamp to detach the motor from the lever. This is not a quick-release mechanism but a removal operation that needs tools.
Why the servo pushes back
The servo motor tries to stay at the angle it is commanded to. If you pull the lever by hand while it is powered, the motor draws current to close the position error and pushes back; and you end up working against that force. Over the long term this shortens the life of the gears and the connection elements. In the short term it can drive the driver into overcurrent protection: the movement stops, you take this for a fault, whereas the cause is the force you applied from outside.
Read this behaviour not as a fault but as a requirement of the design. If the servo did not hold its position, the lever would drift on its own with spring force and vibration and the hydraulic movement would be unsteady. The force that holds the position and the force that pushes back against your hand are the same force; you cannot want one and avoid the other.
A temporary stop or permanent manual use
| Aim | The right way | Scope |
|---|---|---|
| Cutting the movement instantly | Press Emergency Stop | Momentary |
| Leaving the system unpowered | Cut the kit supply | For the shift |
| Returning to permanent manual use | Cut the supply, undo the mounting clamp with a tool, detach the motor from the lever | Permanent |
Emergency Stop stops the movement by cutting the control signal; why it stops instantly is explained separately. Get confirmation from us before going over to permanent removal; not every installation geometry is the same.
Knowing the difference between these three rows prevents unnecessary removal work in the field. In most cases what is needed is not permanent removal but an unpowered break of a few minutes. Opening and closing the clamp every time it is needed spoils the seating of the connection and shifts the lever range over time.
Why removal is easy
The design philosophy of the kit is already built around making reversal easy. The hydraulic circuit is not touched, no hose is cut, the valve block is not changed; the work is carried out over the control lever. Thanks to this reversible installation approach, when the clamp is removed the machine returns exactly to its factory manual state and no permanent change remains. The kit can be taken off and taken away when you sell the machine or move to another one.
Rules to follow in the field
- Do not intervene mechanically on a powered system. The order is this: first Emergency Stop, then the supply, and the tool last.
- Do not try to beat the servo by forcing the lever by hand; it tires the connection elements and upsets the setting.
- Do not carry out removal while a load is suspended. Lower the load or support it mechanically.
- Do not overtighten the clamp bolts; a connection that restricts the lever's own movement will slip at the first heavy load.
- After removal, try the lever by hand over its full stroke; if any friction is left from the clamp, clean it off.
- On refitting, verify the directions of movement unloaded; if the clamp has seated differently the working range of the lever may have shifted.
In summary
In an emergency the priority is always the Emergency Stop button, not forcing the lever by hand. If you are planning to return to permanent manual use, treat it as a planned removal: stop the machine, cut the power, undo the clamp with a tool and confirm that the lever moves freely. If your work means you often need to use it by hand, say so at the outset; the mounting position and the choice of clamp can be planned accordingly.
The full topic: What is a hydraulic lever retrofit kit?