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Cat 6030, 6030FS Hydraulic Shovel Operating Instructions Manual BI017763 – PDF DOWNLOAD
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Description
Cat 6030, 6030FS Hydraulic Shovel Operating Instructions Manual BI017763 – PDF DOWNLOAD
FILE DETAILS:
Cat 6030, 6030FS Hydraulic Shovel Operating Instructions Manual BI017763 – PDF DOWNLOAD
Language : English
Pages : 330
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Cat 6030, 6030FS Hydraulic Shovel Operating Instructions Manual BI017763 – PDF DOWNLOAD
PREFACE
About this Operating Instructions
- These operating instructions are designed to familiarize the operator with the machine and its designated use. The operating instructions contain important information on how to operate the machine safely, properly and with maximum efficiency.
- Observing these instructions helps to prevent hazardous situations, to reduce repair costs and downtimes and to increase the reliability and service life of the machine. The operating instructions must be supplemented by the respective national rules and regulations for accident prevention and environmental protection.
- The operating instructions must always be available in the driver’s cab of the machine. The operating instructions must be read and put into practice by any person in charge of carrying out work with or on the machine, such as
operation, including setting-up, troubleshooting in the course of work, care, evacuation of production waste and disposal of fuels and consumables,
maintenance (inspection, servicing, repair) and / or
transport.
In addition to the operating instructions and the mandatory rules and regulations for accident prevention and environmental protection in the user’s country and at the place where the machine is to be used, the generally recognized technical rules for safe and proper working must be observed 1. The operating instructions are directed to the mining- machine specialist. They cannot provide basic know-how. This can be acquired, for example, in several days’ instruction by a qualified Bucyrus HEX mechanic or by attending an Bucyrus HEX training course for operators or maintenance personnel
- The Bucyrus HEX after-sales service will be pleased to deal with any queries you may have after reading through the operating instructions.
- All Bucyrus HEX operating manuals are issued in German and then translated. Even a good translation may give rise to questions which Bucyrus HEX will be pleased to answer.
- The operating instructions are not work instructions for carrying out major repairs. Such work is willingly done for you by the Bucyrus HEX aftersales service
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Cat 6030, 6030FS Hydraulic Shovel Operating Instructions Manual BI017763 – PDF DOWNLOAD
TITLEPAGE.................................................................................................................................................................... 3 1 INTRODUCTION............................................................................................................................................................... 15 PREFACE ................................................................................................................................................................. 17 About this Operating Instructions ................................................................................................................................... 17 Further machine documentation ....................................................................................................................................... 17 WARRANTY ................................................................................................................................................................ 18 FUNDAMENTAL SAFETY INSTRUCTIONS.......................................................................................................................................... 19 Warnings and symbols ................................................................................................................................................ 19 Contents of the Declaration of Conformity ........................................................................................................................... 19 DESIGNATED USE........................................................................................................................................................... 20 Noise emissions ..................................................................................................................................................... 21 Vibration data ...................................................................................................................................................... 21 ORGANIZATIONAL MEASURES.................................................................................................................................................. 22 Selection and qualification of personnel; basic responsibilities..................................................................................................... 23 Safety instructions governing specific operational phases............................................................................................................ 23 Special work in conjunction with utilization of the machine and maintenance and repairs as well as troubleshooting during work; disposal of parts and consumables.... 24 Warning of special dangers........................................................................................................................................... 25 Gas, dust, steam and smoke .......................................................................................................................................... 25 Hydraulic equipment ................................................................................................................................................. 26 FIRE AND EXPLOSION HAZARD................................................................................................................................................ 27 NOTES ................................................................................................................................................................... 29 2 OPERATION.................................................................................................................................................................. 31 OPERATION - SAFETY INSTRUCTIONS ......................................................................................................................................... 33 Operating Instructions, where to store it in the driver’s cab ....................................................................................................... 34 FIRE AND EXPLOSION HAZARD................................................................................................................................................ 35 DESCRIPTION OF THE EXCAVATOR............................................................................................................................................. 36 Excavator layout..................................................................................................................................................... 37 Undercarriage ....................................................................................................................................................... 38 Superstructure ...................................................................................................................................................... 38 Drive ............................................................................................................................................................... 38 Hydraulic system .................................................................................................................................................... 38 Control and Monitoring Platform (CAMP) .............................................................................................................................. 38 Board-Control-System (BCS) .......................................................................................................................................... 39 Demand control / Zero-flow regulation................................................................................................................................ 39 Automatic reset to idling............................................................................................................................................ 39 Electrical system ................................................................................................................................................... 39 Signs ............................................................................................................................................................... 40 Entering and leaving the machine Safety instructions................................................................................................................. 47 Access ladder lighting .............................................................................................................................................. 47 Swinging ladder ..................................................................................................................................................... 48 Folding ladder (optional) ........................................................................................................................................... 49 Escape ladder (optional) ............................................................................................................................................ 50 Switching the cab interior lighting on and off ...................................................................................................................... 51 Switching the maintenance lights on and off ......................................................................................................................... 52 Emergency shut-off function ......................................................................................................................................... 53 Shutting off the supply voltage (battery main switch) ............................................................................................................... 54 Driver’s seat ...................................................................................................................................................... 55 Reducing the operators exposure to vibrations ....................................................................................................................... 57 Trainer's / instructor's seat ....................................................................................................................................... 57 Fire extinguisher.................................................................................................................................................... 58 Fire extinguisher (option) .......................................................................................................................................... 58 Automatic fire-extinguishing system (optional) ...................................................................................................................... 59 Windscreen washer ................................................................................................................................................... 59 Harness (optional) .................................................................................................................................................. 60 MONITORING, WARNING AND CONTROL ELEMENTS ................................................................................................................................ 64 Engine 1 (LH), control and monitoring ............................................................................................................................... 71 Engine 2 (RH), control and monitoring ............................................................................................................................... 73 PUTTING THE MACHINE INTO OPERATION ...................................................................................................................................... 90 Reducing the operator's exposure to noise ........................................................................................................................... 90 Refuelling .......................................................................................................................................................... 90 Back-up heating (option), filling in fuel ........................................................................................................................... 91 Service station (tanklift) .......................................................................................................................................... 91 Switching the electrical system on and off .......................................................................................................................... 97 Engines, emergency shut-off ......................................................................................................................................... 97 Preheating system for engine and hydraulic oil (optional) ........................................................................................................... 98 Fuel preheating system (optional) ................................................................................................................................... 99 STARTING AND STOPPING THE ENGINES .......................................................................................................................................100 Starting the engines ................................................................................................................................................100 Starting the left-hand engine........................................................................................................................................100 Starting the right-hand engine.......................................................................................................................................100 Engines – adjusting the speed .......................................................................................................................................101 Starting the engines at low temperatures ............................................................................................................................101 Shutting off the engines ............................................................................................................................................102 Shutting off the left-hand engine....................................................................................................................................102 Shutting off the right-hand engine...................................................................................................................................102 AIR CONDITIONER (OPTION) ................................................................................................................................................103 Back-up heating driver’s cab (option) ...............................................................................................................................103 Back-up heating (option) ............................................................................................................................................104 MAXIMUM MACHINE INCLINATIONS, INFORMATION ...............................................................................................................................105 TRAVELLING, SAFETY INSTRUCTIONS .........................................................................................................................................106 TRAVELLING ..............................................................................................................................................................107 Superstructure basic position .......................................................................................................................................107 Travelling forwards/backwards .......................................................................................................................................107 Superstructure holding brake ........................................................................................................................................111 Track parking brake .................................................................................................................................................111 TRANSPORTING THE MACHINE ................................................................................................................................................112 Transport - Safety instructions .....................................................................................................................................112 WORKING OPERATION - SAFETY INSTRUCTIONS .................................................................................................................................113 WORKING OPERATION .......................................................................................................................................................115 Before starting work ................................................................................................................................................115 Activating the electronic excavator control .........................................................................................................................115 Swinging the superstructure .........................................................................................................................................116 Braking the superstructure ..........................................................................................................................................116 Working .............................................................................................................................................................117 After daily operation ...............................................................................................................................................118 OPTIONAL EQUIPMENT ......................................................................................................................................................119 Water spraying system ...............................................................................................................................................119 Additional silencers ................................................................................................................................................119 ASSEMBLING WORKING EQUIPMENT - SAFETY INSTRUCTIONS ......................................................................................................................120 Securing the machine ................................................................................................................................................121 CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS) ..........................................................................................................122 ON-BOARD CRANE (OPTIONAL) ...............................................................................................................................................123 Monitoring, warning and control elements ............................................................................................................................123 On-board crane, putting into operation ..............................................................................................................................124 On-board crane, drive unit ..........................................................................................................................................124 On-Board crane, – blocking the boom in position of rest .............................................................................................................125 Checking the on-board crane .........................................................................................................................................125 NOTES ...................................................................................................................................................................127 3 INSPECTION AND SERVICING...................................................................................................................................................129 INSPECTION AND SERVICING - SAFETY INSTRUCTIONS ..........................................................................................................................131 INSPECTION AND SERVICING WORK, FIRE AND EXPLOSION HAZARD ................................................................................................................137 INSPECTION AND SERVICING PLANS - INSTRUCTIONS ...........................................................................................................................139 Intervals............................................................................................................................................................139 Change of engine oil l...............................................................................................................................................139 Air-intake system ...................................................................................................................................................139 Oils / Greases ......................................................................................................................................................139 Cleaning jobs .......................................................................................................................................................139 Components ..........................................................................................................................................................139 Plan V ..............................................................................................................................................................141 Plan N ..............................................................................................................................................................143 Plan T and W ........................................................................................................................................................145 Plan A – E ..........................................................................................................................................................147 LUBRICATING CHART – GREASE ..............................................................................................................................................154 Lubricating chart – Grease (legend) .................................................................................................................................155 Filling quantities – Grease .........................................................................................................................................155 INSPECTION PLAN - OIL ...................................................................................................................................................156 Inspection plan – Oil (legend) ......................................................................................................................................157 Filling quantities - oil ............................................................................................................................................158 Filling quantities - other...........................................................................................................................................158 LUBRICANTS ..............................................................................................................................................................159 Notes on the selection of oils and greases ..........................................................................................................................159 Avoid mixing of different hydraulic fluids ..........................................................................................................................159 I. Oils for combustion engines ......................................................................................................................................160 II. Oils for hydraulic system .......................................................................................................................................161 III.a Oils for pump gearboxes and travel gearboxes ..................................................................................................................162 III.b Oils for swing gearboxes ......................................................................................................................................163 V. Greases for bearings, swing rings and track system (Central lubrication system) ..................................................................................164 Grease for idlers, track rollers and support rollers (Lifetime lubrication) .........................................................................................165 Coolant for use on all combustion engines ...........................................................................................................................166 SERVICING WORK ..........................................................................................................................................................167 Hose line for oil and cooling liquid changes ........................................................................................................................167 ENGINE ..................................................................................................................................................................168 Engine - Safety instructions ........................................................................................................................................168 Checking the engine oil level / Topping up .........................................................................................................................169 Checking the oil level in the engine oil reservoir / topping up (optional) ..........................................................................................170 Changing the engine oil .............................................................................................................................................171 Draining the oil off the engine oil reservoir (optional) ............................................................................................................173 Replacing the oil filters ...........................................................................................................................................174 Engine oil reservoir, filling in engine oil .........................................................................................................................174 Replacing the oil filters (oil interval prolonging) .................................................................................................................175 Centrifuge (optional) ...............................................................................................................................................176 Cold-starting fluid (ether) - Replacing the pressure vessel .........................................................................................................177 COOLING SYSTEM ..........................................................................................................................................................178 Radiators ...........................................................................................................................................................178 Cooling liquid change ...............................................................................................................................................180 Water filter, replace ...............................................................................................................................................181 AIR-INTAKE SYSTEM .......................................................................................................................................................182 Main filter elements ................................................................................................................................................182 Safety filter element, replace ......................................................................................................................................185 Air-intake lines ....................................................................................................................................................186 Dust collection .....................................................................................................................................................186 FUEL SYSTEM .............................................................................................................................................................187 Fuel system - Safety instructions ...................................................................................................................................187 Fuel filters, replace ...............................................................................................................................................187 Venting the fuel system .............................................................................................................................................188 Cleaning the fuel tanks .............................................................................................................................................188 Water trap (option)..................................................................................................................................................190 ELECTRICAL SYSTEM ......................................................................................................................................................192 Electrical system - Safety instructions .............................................................................................................................192 Alternator - Instructions ...........................................................................................................................................192 Electrical circuit diagrams .........................................................................................................................................192 Electrical system switch-cabinets ...................................................................................................................................192 Replacing lamps and bulbs ...........................................................................................................................................192 Charging batteries inside the machine, safety instructions ..........................................................................................................193 Battery .............................................................................................................................................................194 Switchgear cabinet ..................................................................................................................................................196 Equipotential bonding ...............................................................................................................................................198 Floodlight projector, replacing the lamp ............................................................................................................................200 Lighting systems in LED technonogy, instructions ....................................................................................................................202 HYDRAULIC SYSTEM ........................................................................................................................................................203 Hydraulic system - Safety instructions ..............................................................................................................................203 Depressurizing the hydraulic system .................................................................................................................................203 Checking the hydraulic oil level ....................................................................................................................................204 Hydraulic oil return-flow filters (hydraulic oil reservoir), replace ................................................................................................206 Bypass valves (hydraulic oil reservoir), replace ....................................................................................................................208 Replacing the hydraulic oil return-flow filters (filter housing) ....................................................................................................209 Bypass valves (filter housing - cooling system), replace ............................................................................................................210 Breather filter, replace ............................................................................................................................................211 Filter (servo circuit), replace .....................................................................................................................................212 High-pressure filter for working hydraulics, replace ................................................................................................................213 High-pressure filters for swing circuit, replace ....................................................................................................................214 Filter pump control, clean ..........................................................................................................................................215 Changing the hydraulic oil ..........................................................................................................................................216 Avoid mixing of different hydraulic fluids ..........................................................................................................................216 Venting the hydraulic system.........................................................................................................................................220 Cleaning the hydraulic oil cooler....................................................................................................................................221 Electronic excavator control.........................................................................................................................................222 Pressure accumulators - Emergency lowering and servo circuit ........................................................................................................223 PUMP TRANSFER GEARBOX ...................................................................................................................................................224 Checking the gearbox oil level / Topping up with oil ................................................................................................................224 Gearbox venting .....................................................................................................................................................226 Pump transfer gearbox lube oil filters ..............................................................................................................................227 SWING GEARBOX ...........................................................................................................................................................228 Gearbox - Checking the oil level / Topping up with oil ..............................................................................................................228 Changing the gearbox oil ............................................................................................................................................228 Gearbox venting .....................................................................................................................................................229 SWING GEARBOX ...........................................................................................................................................................230 Gearbox - Checking the oil level / Topping up with oil ..............................................................................................................230 Changing the gearbox oil ............................................................................................................................................231 Gearbox venting .....................................................................................................................................................232 TRAVEL GEARBOX P/N 2712182 ..............................................................................................................................................233 Travel gearbox, checking the oil level / Topping up with oil ........................................................................................................233 Travel gearbox, changing oil ........................................................................................................................................234 Pre-chamber / spur gear section, Changing the oil ...................................................................................................................234 Brake chamber, Changing oil .........................................................................................................................................235 Breather filter .....................................................................................................................................................235 TRAVEL GEARBOX P/N 3683493 ..............................................................................................................................................236 Travel gearbox - Checking the oil level / Topping up with oil .......................................................................................................236 Brake chamber - Checking the oil level / Topping up with oil ........................................................................................................236 Travel gearbox - Changing oil .......................................................................................................................................237 Brake chamber - Changing oil ........................................................................................................................................238 Breather filter .....................................................................................................................................................238 CRAWLER TRACKS ..........................................................................................................................................................239 Track roller, Support roller ........................................................................................................................................240 Track tensioner .....................................................................................................................................................241 Pressure-accumulator inspection regulations .........................................................................................................................242 Checking the gas charging pressure in the pressure accumulator.......................................................................................................242 SWING RING ..............................................................................................................................................................243 Swing ring - Instructions............................................................................................................................................243 Bearing races........................................................................................................................................................243 CENTRAL LUBRICATING SYSTEM ..............................................................................................................................................245 Design ..............................................................................................................................................................245 Function ............................................................................................................................................................246 Filling up the grease container .....................................................................................................................................247 Breather filter grease container, check / replace ...................................................................................................................247 Checking the greasing pressure ......................................................................................................................................248 Unblocking a grease line ............................................................................................................................................248 Oilfilter replace (hydraulic circuit grease pump) ...................................................................................................................249 Grease filter replace (filling the grease container) ................................................................................................................250 Grease filter replace (Grease lines) ................................................................................................................................250 OTHER MAINTENANCE .......................................................................................................................................................251 Engine ..............................................................................................................................................................251 Heating and air conditioning ........................................................................................................................................251 Reservoirs for used grease at the A-frame, emptying .................................................................................................................252 Hydraulic ladder ....................................................................................................................................................252 Pressure-accumulator inspection regulations .........................................................................................................................253 Extract from the German regulations..................................................................................................................................253 Checking the gas charging pressure in the pressure accumulator.......................................................................................................253 ON-BOARD CRANE, DRIVE UNIT ..............................................................................................................................................254 On-board crane, greasing.............................................................................................................................................254 On-Board crane, checking tightness of fastening bolts ...............................................................................................................255 PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING ..............................................................................................................256 Putting the excavator out of operation...............................................................................................................................256 Battery storage......................................................................................................................................................256 Recommissioning......................................................................................................................................................256 NOTES ..................................................................................................................................................................257 4 REPAIR WORK................................................................................................................................................................259 REPAIR WORK - SAFETY INSTRUCTIONS........................................................................................................................................261 REPAIR WORK, FIRE AND EXPLOSION HAZARD ..................................................................................................................................263 REPAIR WORK, ENGINE .....................................................................................................................................................264 ELECTRICAL SYSTEM .......................................................................................................................................................265 Assisted starting (with jumper cables) – Safety instructions ........................................................................................................265 Assisted starting (with jumper cables)...............................................................................................................................265 Starting the engine with jumper cables (external batteries ..........................................................................................................265 HYDRAULIC SYSTEM ........................................................................................................................................................267 Repair instructions .................................................................................................................................................267 Hydraulic hoses – Instructions .....................................................................................................................................267 PRESSURE ACCUMULATORS - SAFETY INSTRUCTIONS..............................................................................................................................268 WELDING OPERATIONS - SAFETY INSTRUCTIONS ................................................................................................................................269 DISPOSAL AT THE END OF THE SERVICE LIFE ................................................................................................................................270 Dismantling and removal instructions ................................................................................................................................270 Risk of deflagrations ...............................................................................................................................................270 Risk of fire ........................................................................................................................................................270 Disposing of the machine without polluting the environment ..........................................................................................................271 Further hazardous substances ........................................................................................................................................271 Appropriate disposal of batteries ...................................................................................................................................272 NOTES ...................................................................................................................................................................273 5 ANNEX......................................................................................................................................................................275 BOARD-CONTROL-SYSTEM ....................................................................................................................................................277 BCS III, what’s that? ...............................................................................................................................................277 The keys on the front side ..........................................................................................................................................278 Other elements on the front side ....................................................................................................................................278 BCSIII, the start screen ............................................................................................................................................279 Information given on the start screen, top section ..................................................................................................................280 Information given on the start screen, central section ..............................................................................................................281 Information given on the start screen, lower section ................................................................................................................282 Information given on the “Service” screen ...........................................................................................................................283 Engine data screen ..................................................................................................................................................284 Hydraulic data screen ...............................................................................................................................................285 Lubrication data screen .............................................................................................................................................286 Controls adjustment data screen .....................................................................................................................................287 View documents screen ...............................................................................................................................................288 Signal table screen .................................................................................................................................................289 Signal table screen, location .......................................................................................................................................290 Signal table screen, diagram ........................................................................................................................................291 Signal table screen, diagram configuration ..........................................................................................................................292 Code table screen ...................................................................................................................................................293 BCS III, interfaces .................................................................................................................................................294 USB interface, data storage .........................................................................................................................................294 Saving data to a USB stick ..........................................................................................................................................295 Saving data to a USB stick, continued ...............................................................................................................................296 Saving data to a USB stick, continued ...............................................................................................................................297 BCSIII, cleaning ....................................................................................................................................................298 BCSIII, disposal ....................................................................................................................................................298 TROUBLESHOOTING .........................................................................................................................................................299 Instructions on troubleshooting .....................................................................................................................................299 Layout of the fault table ...........................................................................................................................................299 Possible causes .....................................................................................................................................................299 Measures ............................................................................................................................................................299 Section .............................................................................................................................................................299 FAULT TABLES ............................................................................................................................................................300 Combustion engine - Fault table .....................................................................................................................................300 Working hydraulics – Fault table ....................................................................................................................................301 Track drive – Fault table ...........................................................................................................................................302 Swing mechnism – Fault table ........................................................................................................................................303 Central lubricating system – Fault table ............................................................................................................................304 HYDRAULIC CIRCUIT DIAGRAM ...............................................................................................................................................306 ABBREVIATIONS ...........................................................................................................................................................307 ABBREVIATIONS........................................................................................................................................................308 TECHNICAL DATA ..........................................................................................................................................................309 Product Specification Sheet .........................................................................................................................................311 NOTES ...................................................................................................................................................................321 6 INDEX......................................................................................................................................................................323
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