CAT 6030 6030FS Hydraulic Shovel Operation & Maintenance Manual 3725082 – PDF DOWNLOAD

Description

CAT 6030 6030FS Hydraulic Shovel Operation & Maintenance Manual 3725082 – PDF DOWNLOAD

FILE DETAILS:

CAT 6030 6030FS Hydraulic Shovel Operation & Maintenance Manual 3725082 – PDF DOWNLOAD

Language : English
Pages : 326
Downloadable : Yes
File Type : PDF

DESCRIPTION:

CAT 6030 6030FS Hydraulic Shovel Operation & Maintenance Manual 3725082 – PDF DOWNLOAD

PREFACE:
About this Operation and Maintenance Manual:

• These Operation and Maintenance Manual are designed to familiarize the operator with the
  machine and its designated use.
• The Operation and Maintenance Manual contain important information on how to operate the
  machine safely, properly and with maximum effi- ciency. Observing these instructions
  helps to pre- vent hazardous situations, to reduce repair costs and downtimes and to
  increase the reliability and service life of the machine.
• The Operation and Maintenance Manual must be supplemented by the respective national rules
  and regulations for accident prevention and environ- mental protection.
• The Operation and Maintenance Manual must always be available in the driver’s cab of the
  machine.

The Operation and Maintenance Manual 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, troubleshoot- ing 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 Operation and Maintenance Man- ual 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 Operation and Maintenance Manual are di- rected to the mining-machine specialist. They
  can- not provide basic know-how. This can be acquired, for example, in several days’ instruction by
  a quali- fied CGM HMS GmbH mechanic or by attending an CGM HMS GmbH training course for
  operators or maintenance personnel.
• The CGM HMS GmbH after-sales service will be pleased to deal with any queries you may
  have after reading through the Operation and Mainte- nance Manual.
• All CGM HMS GmbH Operation and Maintenance Manuals are issued in German and then trans-
  lated. Even a good translation may give rise to questions which CGM HMS GmbH will be
  pleased to answer.
• The Operation and Maintenance Manual are not work instructions for carrying out major
  repairs. Such work is willingly done for you by the CGM
  HMS GmbH after-sales service.

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

CAT 6030 6030FS Hydraulic Shovel Operation & Maintenance Manual 3725082 – PDF DOWNLOAD

1 INTRODUCTION 1-1
PREFACE 1-1
About this Operation and Maintenance Manual 1-1
Further machine documentation 1-1
WARRANTY 1-2
FUNDAMENTAL SAFETY INSTRUCTIONS 1-3
Warnings and symbols 1-3
Contents of the Declaration of Conformity 1-3
DESIGNATED USE, UNAUTHORIZED USE 1-4
Noise emissions 1-5
Vibration data 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
FIRE AND EXPLOSION HAZARD 1-11
NOTES 1-13
2 OPERATION 2-1
OPERATION – SAFETY INSTRUCTIONS 2-3
Operation and Maintenance Manual, where to store it in the operator’s cab 2-4
FIRE AND EXPLOSION HAZARD 2-5
DESCRIPTION OF THE EXCAVATOR 2-6
Excavator layout 2-7
Undercarriage 2-8
Superstructure 2-8
Drive 2-8
Hydraulic system 2-8
Control and Monitoring Platform (CAMP) 2-8
Board-Control-System (BCS) 2-9
Demand control / Zero-flow regulation 2-9
Automatic reset to idling 2-9
Electrical system 2-9
Signs 2-10
Entering and leaving the machine Safety instructions 2-17
Access ladder lighting 2-17
Swinging ladder 2-18
Folding ladder (optional) 2-19
Emergency exit in driver’s cab and escape ladder 2-20
Switching the cab interior lighting on and off 2-21
Switching the maintenance lights on and off 2-22
Emergency shut-off function 2-23
BA RH120E(3 725 082.01)-EN
TABLE OF CONTENTS
vi
Shutting off the supply voltage (battery main switch) 2-24
Driver’s seat 2-25
Reducing the operators exposure to vibrations 2-27
Trainer’s / instructor’s seat 2-27
Fire extinguisher 2-28
Fire extinguisher (option) 2-28
Automatic fire-extinguishing system (optional) 2-29
Windscreen washer 2-29
Operating hours meter 2-29
Harness (optional) 2-30
MONITORING, WARNING AND CONTROL ELEMENTS 2-34
Engine 1 (LH), control and monitoring 2-41
Engine 2 (RH), control and monitoring 2-43
PUTTING THE MACHINE INTO OPERATION 2-60
Reducing the operator’s exposure to noise 2-60
Refuelling 2-61
Back-up heating (option), filling in fuel 2-61
Service station (tanklift) 2-62
Switching the electrical system on and off 2-68
Engines, emergency shut-off 2-68
Preheating system for engine and hydraulic oil (optional) 2-69
Fuel preheating system (optional) 2-70
STARTING AND STOPPING THE ENGINES 2-72
Starting the engines 2-72
Starting the left-hand engine 2-72
Starting the right-hand engine 2-72
Engines – adjusting the speed 2-73
Starting the engines at low temperatures 2-73
Shutting off the engines 2-74
Shutting off the left-hand engine 2-74
Shutting off the right-hand engine 2-74
AIR CONDITIONER (OPTIONAL) 2-75
Back-up heating driver’s cab (optional) 2-76
Back-up heating (optional) 2-77
MAXIMUM MACHINE INCLINATIONS, INFORMATION 2-78
TRAVELLING, SAFETY INSTRUCTIONS 2-80
TRAVELLING 2-81
Superstructure basic position 2-81
Travelling forwards/backwards 2-81
Superstructure holding brake 2-85
Track parking brake 2-85
TRANSPORTING THE MACHINE 2-86
Transport – Safety instructions 2-86
WORKING OPERATION – SAFETY INSTRUCTIONS 2-87
WORKING OPERATION 2-89
Before starting work 2-89
BA RH120E(3 725 082.01)-EN
TABLE OF CONTENTS
vii
Activating the electronic excavator control 2-89
Swinging the superstructure 2-90
Braking the superstructure 2-90
Working 2-91
After daily operation 2-92
OPTIONAL EQUIPMENT 2-93
Water spraying system 2-93
Additional silencers 2-93
ASSEMBLING WORKING EQUIPMENT – SAFETY INSTRUCTIONS 2-94
Securing the machine 2-95
CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS) 2-96
ON-BOARD CRANE (OPTIONAL) 2-97
Monitoring, warning and control elements 2-97
On-board crane, putting into operation 2-98
On-board crane, drive unit 2-98
On-Board crane, – blocking the boom in position of rest 2-99
Checking the on-board crane 2-99
NOTES 2-101
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
Intervals 3-9
Change of engine oil 3-9
Air-intake system 3-9
Oils / Greases 3-9
Cleaning jobs 3-9
Components 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
BA RH120E(3 725 082.01)-EN
TABLE OF CONTENTS
viii
III.a Oils for pump distribution gearboxes and travel gearboxes 3-32
III.b Oils for swing gearboxes 3-33
V. Greases for bearings, swing rings and track system (Central lubrication system) 3-34
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
Checking the engine oil level / Topping up 3-39
Changing the engine oil 3-40
Replacing the oil filters 3-42
Engine oil reservoir, filling in engine oil 3-42
Cold-starting fluid (ether) – Replacing the pressure vessel 3-43
COOLING SYSTEM 3-44
Radiators 3-44
Cooling liquid change 3-46
AIR-INTAKE SYSTEM 3-47
Dust trap, cleaning 3-47
Main filter elements 3-48
Safety filter element 3-50
Air-intake lines 3-50
FUEL SYSTEM 3-51
Fuel system – Safety instructions 3-51
Replacing the fuel filter 3-51
Primary fuel filter, drain water 3-52
Replacing the primary fuel filter 3-52
Venting the fuel system 3-53
Cleaning the fuel tanks 3-53
Water trap (option) 3-55
ELECTRICAL SYSTEM 3-57
Electrical system – Safety instructions 3-57
Alternator – Instructions 3-57
Electrical circuit diagrams 3-57
Electrical system switch-cabinets 3-57
Replacing lamps and bulbs 3-57
Charging batteries inside the machine, safety instructions 3-58
Battery 3-59
Switchgear cabinet 3-61
Equipotential bonding 3-63
Floodlight projector, replacing the lamp 3-65
Lighting systems in LED technonogy, instructions 3-67
HYDRAULIC SYSTEM 3-68
Hydraulic system – Safety instructions 3-68
Depressurizing the hydraulic system 3-68
Checking the hydraulic oil level 3-69
Hydraulic oil return-flow filters (hydraulic oil reservoir), replace 3-71
BA RH120E(3 725 082.01)-EN
TABLE OF CONTENTS
ix
Bypass valves (hydraulic oil reservoir), replace 3-73
Replacing the hydraulic oil return-flow filters (filter housing) 3-74
Bypass valves (filter housing – cooling system), replace 3-75
Breather filter, replace 3-76
Filter (servo circuit), replace 3-77
High-pressure filter for working hydraulics, replace 3-78
High-pressure filters for swing circuit, replace 3-79
Filter pump control, clean 3-80
Changing the hydraulic oil 3-81
Avoid mixing of different hydraulic fluids 3-81
Venting the hydraulic system 3-85
Cleaning the hydraulic oil cooler 3-86
Electronic excavator control 3-87
Pressure accumulators – Emergency lowering and servo circuit 3-88
PUMP TRANSFER GEARBOX 3-89
Pump gearbox, checking the oil level / Topping up with oil 3-89
Pump gearbox, change oil 3-90
Pump gearbox, venting 3-91
Pump transfer gearbox lube oil filters 3-92
SWING GEARBOX 3-93
Swing gearbox, checking the oil level / Topping up with oil 3-93
Swing gearbox, changing oil 3-94
Swing gearbox venting 3-94
SWING GEARBOX 3-95
Swing gearbox, checking the oil level / Topping up with oil 3-95
Swing gearbox, changing oil 3-96
Swing gearbox, venting 3-97
TRAVEL GEARBOX P/N 2712182 3-98
Travel gearbox, checking the oil level / Topping up with oil 3-98
Travel gearbox, changing oil 3-99
Pre-chamber / spur gear section, Changing the oil 3-99
Brake chamber, Changing oil 3-100
Breather filter 3-100
TRAVEL GEARBOX P/N 3683493 3-101
Travel gearbox – Checking the oil level / Topping up with oil 3-101
Brake chamber – Checking the oil level / Topping up with oil 3-101
Travel gearbox – Changing oil 3-102
Brake chamber – Changing oil 3-103
Breather filter 3-103
CRAWLER TRACKS 3-104
Track roller, Support roller 3-105
Track tensioner 3-106
Pressure-accumulator inspection regulations 3-107
Checking the gas charging pressure in the pressure accumulator 3-107
SWING RING 3-108
Swing ring – Instructions 3-108
Bearing races 3-108
BA RH120E(3 725 082.01)-EN
TABLE OF CONTENTS
x
CENTRAL LUBRICATING SYSTEM 3-110
Design 3-110
Function 3-111
Filling up the grease container 3-112
Breather filter grease container, check / replace 3-112
Checking the greasing pressure 3-113
Unblocking a grease line 3-113
Oilfilter replace (hydraulic circuit grease pump) 3-114
Grease filter replace (filling the grease container) 3-115
Grease filter replace (Grease lines) 3-115
OTHER MAINTENANCE 3-116
Engine 3-116
Heating and air conditioning 3-116
Reservoirs for used grease at the A-frame, emptying 3-117
Hydraulic ladder 3-117
Pressure-accumulator inspection regulations 3-118
Extract from the German regulations 3-118
Checking the gas charging pressure in the pressure accumulator 3-118
ON-BOARD CRANE, DRIVE UNIT 3-119
On-board crane, greasing 3-119
On-Board crane, checking tightness of fastening bolts 3-120
PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING 3-121
Putting the excavator out of operation 3-121
Battery storage 3-121
Recommissioning 3-121
NOTES 3-123
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 4-9
DISPOSAL AT THE END OF THE SERVICE LIFE 4-12
Appropriate disposal of batteries 4-13
NOTES 4-15
5 ANNEX 5-1
BOARD-CONTROL-SYSTEM 5-3
BCS III, what’s that? 5-3
BA RH120E(3 725 082.01)-EN
TABLE OF CONTENTS
xi
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 5-10
Hydraulic data screen 5-11
Lubrication data screen 5-12
Controls adjustment data screen 5-13
View documents screen 5-14
Signal table screen 5-15
Signal table screen, location 5-16
Signal table screen, diagram 5-17
Signal table screen, diagram configuration 5-18
Code table screen 5-19
BCS III, interfaces 5-20
USB interface, data storage 5-20
Saving data to a USB stick 5-21
Saving data to a USB stick, continued 5-22
Saving data to a USB stick, continued 5-23
BCSIII, cleaning 5-24
BCSIII, disposal 5-24
TROUBLESHOOTING 5-25
Instructions on troubleshooting 5-25
Layout of the fault table 5-25
Possible causes 5-25
Measures 5-25
Section 5-25
FAULT TABLES 5-26
Combustion engine – Fault table 5-26
Working hydraulics – Fault table 5-27
Track drive – Fault table 5-28
Swing mechnism – Fault table 5-29
Central lubricating system – Fault table 5-30
ENGINE MONITORING, CONTROL LAMPS 5-31
HYDRAULIC CIRCUIT DIAGRAM 5-32
ABBREVIATIONS 5-33
ABBREVIATIONS 5-34
TECHNICAL DATA 5-35
NOTES 5-37
6 INDEX 6-1

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