Cat 6030, 6030FS Hydraulic Shovel Operation and Maintenance Manual BI651379 – PDF DOWNLOAD

Description

Cat 6030, 6030FS Hydraulic Shovel Operation and Maintenance Manual BI651379 – PDF DOWNLOAD

FILE DETAILS:

Cat 6030 6030FS Hydraulic Shovel Operation and Maintenance Manual BI651379 – PDF DOWNLOAD

Language : English
Pages : 346
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Cat 6030 6030FS Hydraulic Shovel Operation and Maintenance Manual BI651379 – 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

• 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 Operation and Maintenance Manual BI651379 – PDF DOWNLOAD

INTRODUCTION 1-1
PREFACE __ 1-1
Further machine documentation _______ 1-1
WARRANTY 1-2
FUNDAMENTAL SAFETY INSTRUCTIONS ____ 1-3
Warnings and symbols 1-3
DESIGNATED USE, UNAUTHORIZED USE ___ 1-4
Noise emission information ___ 1-5
Vibration information ___ 1-5
ORGANIZATIONAL MEASURES _______ 1-6
Selection and qualification of personnel; basic responsibilities 1-7
Safety instructions governing specific operational phases 1-7
Special work in conjunction with utilization of the machine and maintenance and repairs as well as
troubleshooting during work; disposal of parts and consumables ____ 1-8
Warning of special dangers __ 1-9
Gas, dust, steam and smoke _ 1-9
Hydraulic equipment __ 1-10
FIRE AND EXPLOSION HAZARD _____ 1-11
NOTES 1-13
2 OPERATION 2-1
OPERATION – SAFETY INSTRUCTIONS 2-3
Operation and Maintenence Manual, where to store it in the operator’s cab ____ 2-4
FIRE AND EXPLOSION HAZARD ______ 2-5
DESCRIPTION OF THE HYDRAULIC SHOVEL 2-6
Hydraulic shovel layout – upperstructure _ 2-7
Hydraulic shovel layout – undercarriage and working equipment 2-9
Undercarriage 2-10
Upperstructure 2-10
Drive _ 2-10
Hydraulic system 2-10
Control and Monitoring Platform (CAMP) ____ 2-10
Board-Control-System (BCS) 2-11
Demand control / Zero-flow regulation _ 2-11
Automatic reset to idling ____ 2-11
Electrical system 2-11
Signs _ 2-12
Entering and leaving the machine Safety instructions 2-20
Access ladder lighting 2-20
Swinging ladder (optional) __ 2-21
Folding ladder 2-22
Emergency exit in operator’s cab and escape ladder____ 2-23
Switching the cab interior lighting on and off _ 2-24
Switching the maintenance lights on and off _ 2-25
BA 6030(3 847 020.00)-EN
TABLE OF CONTENTS
vi
Emergency shut-off function _ 2-26
Putting the machine back into operation, reset of emergency shut off function _ 2-27
Battery isolator switch, shutting off supply voltage 2-28
Starter isolator switch, shutting off starter voltage 2-28
Operator’s seat 2-29
Reducing the operators exposure to vibrations __ 2-31
Trainer’s / instructor’s seat __ 2-31
Fire extinguisher 2-32
Automatic fire-extinguishing system (optional) 2-33
Windscreen washer __ 2-33
Operating hours meter 2-33
Emergency escape device / seat (optional) __ 2-34
MONITORING, WARNING AND CONTROL ELEMENTS 2-38
Engine 1 (LH), control and monitoring _ 2-45
Engine 2 (RH), control and monitoring _ 2-47
PUTTING THE MACHINE INTO OPERATION _ 2-66
Reducing the operator’s exposure to noise __ 2-66
Refuelling 2-67
Back-up heating (option), filling in fuel _ 2-67
Service station (tanklift) ____ 2-68
Emergency off switch 2-69
Switching the electrical system on and off ___ 2-74
Engines, emergency shut-off 2-74
Preheating system for engine and hydraulic oil (optional) 2-75
Fuel preheating system (optional) _____ 2-76
STARTING AND STOPPING THE ENGINES __ 2-78
Starting the engines __ 2-78
Starting the left-hand engine _ 2-78
Starting the right-hand engine 2-78
Engines – adjusting the speed _______ 2-79
Starting the engines at low temperatures ____ 2-79
Shutting off the engines ____ 2-80
Shutting off the left-hand engine ______ 2-80
Shutting off the right-hand engine _____ 2-80
AIR CONDITIONER (OPTIONAL) ______ 2-81
Back-up heating operator’s cab (optional) ___ 2-82
Back-up heating (optional) __ 2-83
MAXIMUM MACHINE INCLINATIONS, INFORMATION 2-84
TRAVELLING, SAFETY INSTRUCTIONS ____ 2-86
TRAVELLING _ 2-87
Upperstructure basic position 2-87
Travelling forwards/backwards _______ 2-87
Upperstructure holding brake 2-91
Track parking brake __ 2-91
TRANSPORTING THE MACHINE _____ 2-92
Transport – Safety instructions _______ 2-92
BA 6030(3 847 020.00)-EN
TABLE OF CONTENTS
vii
WORKING OPERATION – SAFETY INSTRUCTIONS _ 2-93
WORKING OPERATION 2-95
Before starting work __ 2-95
Activating the electronic hydraulic shovel control _ 2-95
Swinging the upperstructure _ 2-96
Braking the upperstructure __ 2-96
Working _ 2-97
Emergency lowering of the working equipment __ 2-98
After daily operation __ 2-99
ASSEMBLING WORKING EQUIPMENT – SAFETY INSTRUCTIONS 2-100
Securing the machine 2-101
CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS) ___________ 2-102
ON-BOARD CRANE (OPTIONAL) ____ 2-103
Monitoring, warning and control elements __ 2-103
On-board crane, putting into operation 2-104
On-board crane, drive unit _ 2-104
On-Board crane, – blocking the boom in position of rest 2-105
Checking the on-board crane _______ 2-105
MONITORING CAMERAS (OPTIONAL) 2-106
Monitoring cameras – function ______ 2-106
NOTES __ 2-107
3 INSPECTION AND SERVICING 3-1
INSPECTION AND SERVICING – SAFETY INSTRUCTIONS ___ 3-3
INSPECTION AND SERVICING WORK, FIRE AND EXPLOSION HAZARD ____ 3-7
INSPECTION AND SERVICING PLANS – INSTRUCTIONS 3-9
Plan V 3-11
Plan N 3-13
Plan T and W 3-15
Plan A – E 3-17
LUBRICATING CHART – GREASE ____ 3-24
Lubricating chart – Grease (legend) ___ 3-25
Filling quantities – Grease __ 3-25
INSPECTION PLAN – OIL ____ 3-26
Inspection plan – Oil (legend) 3-27
Filling quantities – oil __ 3-28
Filling quantities – other ____ 3-28
LUBRICANTS / CONSUMABLES ______ 3-29
Notes on the selection of oils and greases ___ 3-29
Avoid mixing of different hydraulic fluids 3-29
I. Oils for combustion engines ______ 3-30
II. Fluid for hydraulic system ______ 3-31
III.a Oils for pump drive gearboxes and travel gearboxes 3-32
III.b Oil for swing gearboxes ______ 3-33
V. Grease for bearings, slew rings and track system (Central lubrication system)____________ 3-34
BA 6030(3 847 020.00)-EN
TABLE OF CONTENTS
viii
Grease for idlers, track rollers and support rollers (Lifetime lubrication) ______ 3-35
Coolant for use on all combustion engines ___ 3-36
SERVICING WORK 3-37
Hose line for oil and cooling liquid changes __ 3-37
ENGINE 3-38
Engine – Safety instructions _ 3-38
Engine oil, checking the level / topping up ___ 3-39
Engine oil reservoir (optional), checking the oil level / topping up ___ 3-40
Engine oil, change ___ 3-41
Engine oil reservoir (optional), draining the oil off _ 3-43
Engine oil filter, replace 3-45
Engine oil reservoir (optional), replacing the oil filters 3-46
Cold-starting fluid (ether) – Replacing the pressure vessel 3-47
COOLING SYSTEM ___ 3-48
Temperature _ 3-48
Radiators _ 3-49
Cooling-liquid level check ___ 3-49
Cooling liquid, change 3-52
Testing the cooling liquid composition _ 3-53
AIR-INTAKE SYSTEM __ 3-54
Dust trap, cleaning ___ 3-54
Main filter elements ___ 3-55
Main filter elements, checking and cleaning __ 3-56
Safety filter element __ 3-57
Air-intake lines 3-57
FUEL SYSTEM 3-58
Fuel system – Safety instructions _____ 3-58
Fuel filter, replace 3-58
Primary fuel filter, drain water 3-59
Primary fuel filter, replace ___ 3-59
Fuel system, venting __ 3-60
Breather filter fuel tank, replace ______ 3-60
Fuel tanks, cleaning __ 3-60
Water trap (optional) __ 3-62
ELECTRICAL SYSTEM 3-64
Electrical system – Safety instructions _ 3-64
Alternator – Instructions 3-64
Electrical circuit diagrams ___ 3-64
Electrical system switch-cabinets _____ 3-64
Replacing lamps and bulbs __ 3-64
Battery 3-65
Charging batteries inside the machine, safety instructions 3-66
Removing and installing the battery ___ 3-67
Switchgear cabinet, aeration _ 3-68
Xenon floodlight projector, replacing the lamp 3-70
Lighting systems in LED technonogy, instructions 3-72
HYDRAULIC SYSTEM 3-73
Hydraulic system – Safety instructions _ 3-73
BA 6030(3 847 020.00)-EN
TABLE OF CONTENTS
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Depressurizing the hydraulic system __ 3-73
Checking the hydraulic oil level _______ 3-74
Replacing the hydraulic oil return-flow filter (hydraulic oil reservoir)__ 3-76
Bypass valves (hydraulic oil reservoir), checking / cleaning ___ 3-79
Replacing the bypass valves and sealing rings __ 3-79
Replacing the hydraulic oil return-flow filters (filter housing cooling system) ___ 3-80
Bypass valves (filter housing – cooling system), checking / replacing 3-81
Breather filter, replace 3-82
Filter (servo control circuit) __ 3-83
High-pressure filter for working hydraulics, replace __ 3-84
High-pressure filters for swing circuit, replace 3-85
Filter pump control, clean ___ 3-86
Changing the hydraulic oil ___ 3-87
Avoid mixing of different hydraulic fluids 3-87
Venting the hydraulic system 3-91
Cleaning the hydraulic oil cooler ______ 3-92
Electronic hydraulic shovel control, clean / lubricate _ 3-93
Pressure accumulator – Emergency lowering _ 3-94
PUMP TRANSFER GEARBOX 3-95
Pump gearbox, checking the oil level / Topping up with oil ___ 3-95
Pump gearbox, change oil __ 3-96
Pump gearbox, venting 3-97
Pump transfer gearbox lube oil filters __ 3-98
SWING GEARBOX 3-99
Swing gearbox, checking the oil level / Topping up with oil ___ 3-99
Swing gearbox, changing oil 3-100
Swing gearbox venting ____ 3-100
SWING GEARBOX ___ 3-101
Swing gearbox, checking the oil level / Topping up with oil __ 3-101
Swing gearbox, changing oil 3-102
Swing gearbox, venting ____ 3-103
TRAVEL GEARBOX P/N 2712182 ____ 3-104
Travel gearbox, checking the oil level / Topping up with oil __ 3-104
Travel gearbox, changing oil 3-105
Pre-chamber / spur gear section, Changing the oil _ 3-105
Brake chamber, Changing oil _______ 3-106
Breather filter 3-106
TRAVEL GEARBOX P/N 3683493 ____ 3-107
Travel gearbox – Checking the oil level / Topping up with oil 3-107
Brake chamber – Checking the oil level / Topping up with oil 3-107
Travel gearbox – Changing oil _______ 3-108
Brake chamber – Changing oil ______ 3-109
Breather filter 3-109
CRAWLER TRACKS __ 3-110
Track roller, Support roller _ 3-111
Track tensioner 3-112
Pressure-accumulator inspection regulations 3-113
Checking the gas charging pressure in the pressure accumulator__ 3-113
BA 6030(3 847 020.00)-EN
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x
SWING RING 3-114
Swing ring – Instructions ___ 3-114
Bearing races 3-114
CENTRAL LUBRICATING SYSTEM ___ 3-116
Design __ 3-116
Function 3-117
Filling up the grease container ______ 3-118
Breather filter grease container, check / replace 3-118
Checking the greasing pressure _____ 3-119
Unblocking a grease line __ 3-119
Oilfilter replace (hydraulic circuit grease pump) _ 3-120
Grease filter replace (filling the grease container) __ 3-121
Grease filter replace (Grease lines) __ 3-121
OTHER MAINTENANCE ____ 3-122
Engine __ 3-122
Heating and air conditioning 3-122
Reservoirs for used grease at the A-frame, emptying 3-123
Hydraulic ladder, pressure accumulator ____ 3-123
Pressure-accumulator inspection regulations 3-124
Extract from the German regulations _ 3-124
Checking the gas charging pressure in the pressure accumulator__ 3-124
ON-BOARD CRANE, DRIVE UNIT ____ 3-125
On-board crane, greasing __ 3-125
On-Board crane, checking tightness of fastening bolts 3-126
PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING 3-127
Putting the hydraulic shovel out of operation 3-127
Battery storage 3-127
Recommissioning ___ 3-127
NOTES __ 3-129
4 REPAIR WORK _ 4-1
REPAIR WORK – SAFETY INSTRUCTIONS ___ 4-3
CONFINED SPACES – SAFETY INSTRUCTIONS __ 4-4
REPAIR WORK, FIRE AND EXPLOSION HAZARD 4-5
REPAIR WORK, ENGINE 4-6
HYDRAULIC SYSTEM __ 4-7
Repair instructions 4-7
Hydraulic hoses – Instructions 4-7
PRESSURE ACCUMULATORS – SAFETY INSTRUCTIONS ___ 4-8
WELDING AND FLAME CUTTING WORKS – SAFETY INSTRUCTIONS_______ 4-2
DISPOSAL AT THE END OF THE SERVICE LIFE __ 4-5
Appropriate disposal of batteries ______ 4-6
BA 6030(3 847 020.00)-EN
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xi
NOTES _ 4-8
5 ANNEX _ 5-1
BOARD-CONTROL-SYSTEM __ 5-3
BCS III, what’s that? ___ 5-3
The keys on the front side ___ 5-4
Other elements on the front side ______ 5-4
BCSIII, the start screen 5-5
Information given on the start screen, top section _ 5-6
Information given on the start screen, central section _ 5-7
Information given on the start screen, lower section __ 5-8
Information given on the “Service” screen ____ 5-9
Engine data screen ___ 5-12
Hydraulic data screen 5-13
Lubrication data screen ____ 5-14
Controls adjustment data screen _____ 5-15
View documents screen ____ 5-16
Signal table screen ___ 5-17
Signal table screen, location _ 5-18
Signal table screen, diagram 5-19
Signal table screen, diagram configuration ___ 5-20
Code table screen 5-21
BCS III, interfaces 5-22
USB interface, data storage _ 5-23
Saving data to a USB stick __ 5-24
Saving data to a USB stick, continued _ 5-25
Saving data to a USB stick, continued _ 5-26
BCSIII, cleaning 5-27
BCSIII, disposal 5-27
TROUBLESHOOTING 5-28
Instructions on troubleshooting _______ 5-28
Layout of the fault table 5-28
Possible causes 5-28
Measures 5-28
Section __ 5-28
FAULT TABLES 5-29
Combustion engine – Fault table ______ 5-29
Working hydraulics – Fault table ______ 5-30
Track drive – Fault table ____ 5-31
Swing mechnism – Fault table _______ 5-32
Central lubricating system – Fault table 5-33
ENGINE MONITORING, CONTROL LAMPS __ 5-34
HYDRAULIC CIRCUIT DIAGRAM ______ 5-35
ABBREVIATIONS 5-36
ABBREVIATIONS 5-37
BA 6030(3 847 020.00)-EN
TABLE OF CONTENTS
TECHNICAL DATA 5-2
NOTES _ 5-3
6 INDEX __ 6-1

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PLEASE NOTE:

• This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
• Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.

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