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Cat 6030, 6030FS Hydraulic Shovel Operation and Maintenance Manual BI651398 – PDF DOWNLOAD
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Description
Cat 6030, 6030FS Hydraulic Shovel Operation and Maintenance Manual BI651398 – PDF DOWNLOAD
FILE DETAILS:
Cat 6030, 6030FS Hydraulic Shovel Operation and Maintenance Manual BI651398 – PDF DOWNLOAD
Language : English
Pages : 326
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Cat 6030, 6030FS Hydraulic Shovel Operation and Maintenance Manual BI651398 – PDF DOWNLOAD
OPERATING INSTRUCTIONS RH120E
Introduction
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.
- 1 Complies with VDMA recommendation “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 BI651398 – PDF DOWNLOAD
TITLEPAGE.................................................................................................................................................................... 1 1 INTRODUCTION............................................................................................................................................................... 13 PREFACE ................................................................................................................................................................. 15 About this Operation and Maintenance Manual ......................................................................................................................... 15 Further machine documentation ....................................................................................................................................... 15 WARRANTY ................................................................................................................................................................ 16 FUNDAMENTAL SAFETY INSTRUCTIONS.......................................................................................................................................... 17 Warnings and symbols ................................................................................................................................................ 17 Contents of the Declaration of Conformity ........................................................................................................................... 17 DESIGNATED USE, UNAUTHORIZED USE ........................................................................................................................................ 18 Noise emissions ..................................................................................................................................................... 19 Vibration data ...................................................................................................................................................... 19 ORGANIZATIONAL MEASURES.................................................................................................................................................. 20 Selection and qualification of personnel; basic responsibilities..................................................................................................... 21 Safety instructions governing specific operational phases............................................................................................................ 21 Special work in conjunction with utilization of the machine and maintenance and repairs as well as troubleshooting during work; disposal of parts and consumables.... 22 Warning of special dangers........................................................................................................................................... 23 FIRE AND EXPLOSION HAZARD................................................................................................................................................ 25 NOTES ................................................................................................................................................................... 27 2 OPERATION.................................................................................................................................................................. 29 OPERATION - SAFETY INSTRUCTIONS ......................................................................................................................................... 31 Operation and Maintenance Manual, where to store it in the operator’s cab ........................................................................................... 32 FIRE AND EXPLOSION HAZARD................................................................................................................................................ 33 DESCRIPTION OF THE EXCAVATOR............................................................................................................................................. 34 Excavator layout..................................................................................................................................................... 35 Undercarriage ....................................................................................................................................................... 36 Superstructure ...................................................................................................................................................... 36 Drive ............................................................................................................................................................... 36 Hydraulic system .................................................................................................................................................... 36 Control and Monitoring Platform (CAMP) .............................................................................................................................. 36 Board-Control-System (BCS) .......................................................................................................................................... 37 Demand control / Zero-flow regulation ............................................................................................................................... 37 Automatic reset to idling............................................................................................................................................ 37 Electrical system ................................................................................................................................................... 37 Signs ............................................................................................................................................................... 38 Entering and leaving the machine Safety instructions................................................................................................................. 45 Access ladder lighting .............................................................................................................................................. 45 Swinging ladder ..................................................................................................................................................... 46 Folding ladder (optional) ........................................................................................................................................... 47 Emergency exit in driver’s cab and escape ladder .................................................................................................................... 48 Switching the cab interior lighting on and off ...................................................................................................................... 49 Switching the maintenance lights on and off ......................................................................................................................... 50 Emergency shut-off function ......................................................................................................................................... 51 Shutting off the supply voltage (battery main switch) ............................................................................................................... 52 Driver’s seat ...................................................................................................................................................... 53 Reducing the operators exposure to vibrations ....................................................................................................................... 55 Trainer's / instructor's seat ....................................................................................................................................... 55 Fire extinguisher.................................................................................................................................................... 56 Fire extinguisher (option) .......................................................................................................................................... 56 Automatic fire-extinguishing system (optional) ...................................................................................................................... 57 Windscreen washer ................................................................................................................................................... 57 Operating hours meter ............................................................................................................................................... 57 Harness (optional) .................................................................................................................................................. 58 MONITORING, WARNING AND CONTROL ELEMENTS ................................................................................................................................ 62 Engine 1 (LH), control and monitoring ............................................................................................................................... 69 Engine 2 (RH), control and monitoring ............................................................................................................................... 71 PUTTING THE MACHINE INTO OPERATION ...................................................................................................................................... 88 Reducing the operator's exposure to noise ........................................................................................................................... 88 Refuelling .......................................................................................................................................................... 89 Back-up heating (option), filling in fuel ........................................................................................................................... 89 Service station (tanklift) .......................................................................................................................................... 90 Switching the electrical system on and off .......................................................................................................................... 96 Engines, emergency shut-off ......................................................................................................................................... 96 Preheating system for engine and hydraulic oil (optional) ........................................................................................................... 97 Fuel preheating system (optional) ................................................................................................................................... 98 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 (OPTIONAL) ..............................................................................................................................................103 Back-up heating driver’s cab (optional) .............................................................................................................................104 Back-up heating (optional) ..........................................................................................................................................105 MAXIMUM MACHINE INCLINATIONS, INFORMATION ...............................................................................................................................106 TRAVELLING, SAFETY INSTRUCTIONS .........................................................................................................................................108 TRAVELLING ..............................................................................................................................................................109 Superstructure basic position .......................................................................................................................................109 Travelling forwards/backwards .......................................................................................................................................109 Superstructure holding brake ........................................................................................................................................113 Track parking brake .................................................................................................................................................113 TRANSPORTING THE MACHINE ................................................................................................................................................114 Transport - Safety instructions .....................................................................................................................................114 WORKING OPERATION - SAFETY INSTRUCTIONS .................................................................................................................................115 WORKING OPERATION .......................................................................................................................................................117 Before starting work ................................................................................................................................................117 Activating the electronic excavator control .........................................................................................................................117 Swinging the superstructure .........................................................................................................................................118 Braking the superstructure ..........................................................................................................................................118 Working .............................................................................................................................................................119 After daily operation ...............................................................................................................................................120 OPTIONAL EQUIPMENT ......................................................................................................................................................121 Water spraying system ...............................................................................................................................................121 Additional silencers ................................................................................................................................................121 ASSEMBLING WORKING EQUIPMENT - SAFETY INSTRUCTIONS ......................................................................................................................122 Securing the machine ................................................................................................................................................123 CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS) ..........................................................................................................124 ON-BOARD CRANE (OPTIONAL) ...............................................................................................................................................125 Monitoring, warning and control elements ............................................................................................................................125 On-board crane, putting into operation ..............................................................................................................................126 On-board crane, drive unit ..........................................................................................................................................126 On-Board crane, – blocking the boom in position of rest .............................................................................................................127 Checking the on-board crane .........................................................................................................................................127 NOTES ...................................................................................................................................................................129 3 INSPECTION AND SERVICING...................................................................................................................................................131 INSPECTION AND SERVICING - SAFETY INSTRUCTIONS ..........................................................................................................................133 INSPECTION AND SERVICING WORK, FIRE AND EXPLOSION HAZARD ................................................................................................................137 INSPECTION AND SERVICING PLANS - INSTRUCTIONS ...........................................................................................................................139 Intervals............................................................................................................................................................139 Change of engine oil ................................................................................................................................................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 / CONSUMABLES ................................................................................................................................................159 Notes on the selection of oils and greases ..........................................................................................................................159 Avoid mixing of different hydraulic fluids ..........................................................................................................................159 I. Oils for combustion engines ......................................................................................................................................160 II. Fluid for hydraulic system ......................................................................................................................................161 III.a Oils for pump distribution 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 Changing the engine oil .............................................................................................................................................170 Replacing the oil filters ...........................................................................................................................................172 Engine oil reservoir, filling in engine oil .........................................................................................................................172 Cold-starting fluid (ether) - Replacing the pressure vessel .........................................................................................................173 COOLING SYSTEM ..........................................................................................................................................................174 Radiators ...........................................................................................................................................................174 Cooling liquid change ...............................................................................................................................................176 AIR-INTAKE SYSTEM .......................................................................................................................................................177 Dust trap, cleaning ................................................................................................................................................177 Main filter elements ................................................................................................................................................178 Safety filter element ...............................................................................................................................................180 Air-intake lines ....................................................................................................................................................180 FUEL SYSTEM .............................................................................................................................................................181 Fuel system - Safety instructions ...................................................................................................................................181 Replacing the fuel filter ...........................................................................................................................................181 Primary fuel filter, drain water ....................................................................................................................................182 Replacing the primary fuel filter ...................................................................................................................................182 Venting the fuel system .............................................................................................................................................183 Cleaning the fuel tanks .............................................................................................................................................183 Water trap (option) .................................................................................................................................................185 ELECTRICAL SYSTEM ......................................................................................................................................................187 Electrical system - Safety instructions .............................................................................................................................187 Alternator - Instructions ...........................................................................................................................................187 Electrical circuit diagrams .........................................................................................................................................187 Electrical system switch-cabinets ...................................................................................................................................187 Replacing lamps and bulbs ...........................................................................................................................................187 Charging batteries inside the machine, safety instructions ..........................................................................................................188 Battery .............................................................................................................................................................189 Switchgear cabinet ..................................................................................................................................................191 Equipotential bonding ...............................................................................................................................................193 Floodlight projector, replacing the lamp ............................................................................................................................195 Lighting systems in LED technonogy, instructions ....................................................................................................................197 HYDRAULIC SYSTEM ........................................................................................................................................................198 Hydraulic system - Safety instructions ..............................................................................................................................198 Depressurizing the hydraulic system .................................................................................................................................198 Checking the hydraulic oil level ....................................................................................................................................199 Hydraulic oil return-flow filters (hydraulic oil reservoir), replace ................................................................................................201 Bypass valves (hydraulic oil reservoir), replace ....................................................................................................................203 Replacing the hydraulic oil return-flow filters (filter housing) ....................................................................................................204 Bypass valves (filter housing - cooling system), replace ............................................................................................................205 Breather filter, replace ............................................................................................................................................206 Filter (servo circuit), replace .....................................................................................................................................207 High-pressure filter for working hydraulics, replace ................................................................................................................208 High-pressure filters for swing circuit, replace ....................................................................................................................209 Filter pump control, clean ..........................................................................................................................................210 Changing the hydraulic oil ..........................................................................................................................................211 Avoid mixing of different hydraulic fluids ..........................................................................................................................211 Venting the hydraulic system.........................................................................................................................................215 Cleaning the hydraulic oil cooler....................................................................................................................................216 Electronic excavator control.........................................................................................................................................217 Pressure accumulators - Emergency lowering and servo circuit ........................................................................................................218 PUMP TRANSFER GEARBOX ...................................................................................................................................................219 Pump gearbox, checking the oil level / Topping up with oil ..........................................................................................................219 Pump gearbox, change oil ............................................................................................................................................220 Pump gearbox, venting ...............................................................................................................................................221 Pump transfer gearbox lube oil filters ..............................................................................................................................222 SWING GEARBOX ...........................................................................................................................................................223 Swing gearbox, checking the oil level / Topping up with oil .........................................................................................................223 Swing gearbox, changing oil .........................................................................................................................................224 Swing gearbox venting ...............................................................................................................................................224 SWING GEARBOX ...........................................................................................................................................................225 Swing gearbox, checking the oil level / Topping up with oil .........................................................................................................225 Swing gearbox, changing oil .........................................................................................................................................226 Swing gearbox, venting ..............................................................................................................................................227 TRAVEL GEARBOX P/N 2712182 ..............................................................................................................................................228 Travel gearbox, checking the oil level / Topping up with oil ........................................................................................................228 Travel gearbox, changing oil ........................................................................................................................................229 Pre-chamber / spur gear section, Changing the oil ...................................................................................................................229 Brake chamber, Changing oil .........................................................................................................................................230 Breather filter .....................................................................................................................................................230 TRAVEL GEARBOX P/N 3683493 ..............................................................................................................................................231 Travel gearbox - Checking the oil level / Topping up with oil .......................................................................................................231 Brake chamber - Checking the oil level / Topping up with oil ........................................................................................................231 Travel gearbox - Changing oil .......................................................................................................................................232 Brake chamber - Changing oil ........................................................................................................................................233 Breather filter .....................................................................................................................................................233 CRAWLER TRACKS ..........................................................................................................................................................234 Track roller, Support roller ........................................................................................................................................235 Track tensioner .....................................................................................................................................................236 Pressure-accumulator inspection regulations .........................................................................................................................237 Checking the gas charging pressure in the pressure accumulator.......................................................................................................237 SWING RING ..............................................................................................................................................................238 Swing ring - Instructions............................................................................................................................................238 Bearing races........................................................................................................................................................238 CENTRAL LUBRICATING SYSTEM ..............................................................................................................................................240 Design ..............................................................................................................................................................240 Function ............................................................................................................................................................241 Filling up the grease container .....................................................................................................................................242 Breather filter grease container, check / replace ...................................................................................................................242 Checking the greasing pressure ......................................................................................................................................243 Unblocking a grease line ............................................................................................................................................243 Oilfilter replace (hydraulic circuit grease pump) ...................................................................................................................244 Grease filter replace (filling the grease container) ................................................................................................................245 Grease filter replace (Grease lines) ................................................................................................................................245 OTHER MAINTENANCE .......................................................................................................................................................246 Engine ..............................................................................................................................................................246 Heating and air conditioning ........................................................................................................................................246 Reservoirs for used grease at the A-frame, emptying .................................................................................................................247 Hydraulic ladder ....................................................................................................................................................247 Pressure-accumulator inspection regulations ........................................................................................................................248 Extract from the German regulations..................................................................................................................................248 Checking the gas charging pressure in the pressure accumulator ......................................................................................................248 ON-BOARD CRANE, DRIVE UNIT ..............................................................................................................................................249 On-board crane, greasing.............................................................................................................................................249 On-Board crane, checking tightness of fastening bolts ...............................................................................................................250 PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING ..............................................................................................................251 Putting the excavator out of operation...............................................................................................................................251 Battery storage......................................................................................................................................................251 Recommissioning......................................................................................................................................................251 NOTES ..................................................................................................................................................................253 4 REPAIR WORK................................................................................................................................................................255 REPAIR WORK - SAFETY INSTRUCTIONS........................................................................................................................................257 CONFINED SPACES - SAFETY INSTRUCTIONS ...................................................................................................................................258 REPAIR WORK, FIRE AND EXPLOSION HAZARD ..................................................................................................................................259 REPAIR WORK, ENGINE......................................................................................................................................................260 HYDRAULIC SYSTEM ........................................................................................................................................................261 Repair instructions .................................................................................................................................................261 Hydraulic hoses – Instructions .....................................................................................................................................261 PRESSURE ACCUMULATORS - SAFETY INSTRUCTIONS..............................................................................................................................262 WELDING AND FLAME CUTTING WORKS - SAFETY INSTRUCTIONS ...................................................................................................................263 DISPOSAL AT THE END OF THE SERVICE LIFE .................................................................................................................................266 Appropriate disposal of batteries ...................................................................................................................................267 NOTES ...................................................................................................................................................................269 5 ANNEX......................................................................................................................................................................271 BOARD-CONTROL-SYSTEM ....................................................................................................................................................273 BCS III, what’s that? ...............................................................................................................................................273 The keys on the front side ..........................................................................................................................................274 Other elements on the front side ....................................................................................................................................274 BCSIII, the start screen ............................................................................................................................................275 Information given on the start screen, top section ..................................................................................................................276 Information given on the start screen, central section ..............................................................................................................277 Information given on the start screen, lower section ................................................................................................................278 Information given on the “Service” screen ...........................................................................................................................279 Engine data screen ..................................................................................................................................................280 Hydraulic data screen ...............................................................................................................................................281 Lubrication data screen .............................................................................................................................................282 Controls adjustment data screen .....................................................................................................................................283 View documents screen ...............................................................................................................................................284 Signal table screen .................................................................................................................................................285 Signal table screen, location .......................................................................................................................................286 Signal table screen, diagram ........................................................................................................................................287 Signal table screen, diagram configuration ..........................................................................................................................288 Code table screen ...................................................................................................................................................289 BCS III, interfaces .................................................................................................................................................290 USB interface, data storage .........................................................................................................................................290 Saving data to a USB stick ..........................................................................................................................................291 Saving data to a USB stick, continued ...............................................................................................................................292 Saving data to a USB stick, continued ...............................................................................................................................293 BCSIII, cleaning ....................................................................................................................................................294 BCSIII, disposal ....................................................................................................................................................294 TROUBLESHOOTING .........................................................................................................................................................295 Instructions on troubleshooting .....................................................................................................................................295 Layout of the fault table ...........................................................................................................................................295 Possible causes .....................................................................................................................................................295 Measures ............................................................................................................................................................295 Section .............................................................................................................................................................295 FAULT TABLES ............................................................................................................................................................296 Combustion engine - Fault table .....................................................................................................................................296 Working hydraulics – Fault table ....................................................................................................................................297 Track drive – Fault table ...........................................................................................................................................298 Swing mechnism – Fault table ........................................................................................................................................299 Central lubricating system – Fault table ............................................................................................................................300 ENGINE MONITORING, CONTROL LAMPS ........................................................................................................................................301 HYDRAULIC CIRCUIT DIAGRAM ...............................................................................................................................................302 ABBREVIATIONS ...........................................................................................................................................................303 ABBREVIATIONS........................................................................................................................................................304 TECHNICAL DATA ..........................................................................................................................................................305 Product Specification Sheet..........................................................................................................................................307 NOTES ...................................................................................................................................................................317 6 INDEX......................................................................................................................................................................319
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