CAT 6030, 6030FS Hydraulic Shovel Operation & Maintenance Manual BI017763 – PDF DOWNLOAD

Description

CAT 6030, 6030FS Hydraulic Shovel Operation & Maintenance Manual BI017763 – PDF DOWNLOAD

FILE DETAILS:

CAT 6030, 6030FS Hydraulic Shovel Operation & Maintenance Manual BI017763 – PDF DOWNLOAD

Language : English
Pages : 330
Downloadable : Yes
File Type : PDF

DESCRIPTION:

CAT 6030, 6030FS Hydraulic Shovel Operation & Maintenance Manual BI017763 – PDF DOWNLOAD

PREFACE:
About this Operating Instructions:

• These operating instructions are designed to famil- iarize the operator with the machine and its
  desig- nated use.
• The operating instructions contain important in- formation 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 avail- able 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, 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 operating instructions and the mandatory rules and regulations for
  accident pre- vention 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 min- ing-machine specialist. They cannot provide
  basic know-how. This can be acquired, for example, in several days’ instruction by a
  qualified CGM HMS mechanic or by attending an CGM HMS training course for operators or
  maintenance personnel.
• The CGM HMS after-sales service will be pleased to deal with any queries you may have after read-
  ing through the operating instructions.
• All CGM HMS operating manuals are issued in German and then translated. Even a good transla-
  tion may give rise to questions which CGM HMS will be pleased to answer.
• The operating instructions are not work instruc- tions for carrying out major repairs.
  Such work is willingly done for you by the CGM HMS after-sales
  service.

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

CAT 6030, 6030FS Hydraulic Shovel Operation & Maintenance Manual BI017763 – PDF DOWNLOAD

BA RH120E(3 725 097.01)-EN v
TABLE OF CONTENTS
1 INTRODUCTION 1-1
PREFACE 1-3
About this Operating Instructions 1-3
Further machine documentation 1-3
WARRANTY 1-4
FUNDAMENTAL SAFETY INSTRUCTIONS 1-5
Warnings and symbols 1-5
Contents of the Declaration of Conformity 1-5
DESIGNATED USE 1-6
Noise emissions 1-7
Vibration data 1-7
ORGANIZATIONAL MEASURES 1-8
Selection and qualification of personnel; basic responsibilities 1-9
Safety instructions governing specific operational phases 1-9
Special work in conjunction with utilization of the machine and maintenance and repairs as well as
troubleshooting during work; disposal of parts and consumables 1-10
Warning of special dangers 1-11
Gas, dust, steam and smoke 1-11
Hydraulic equipment 1-12
FIRE AND EXPLOSION HAZARD 1-13
NOTES 1-15
2 OPERATION 2-1
OPERATION – SAFETY INSTRUCTIONS 2-3
Operating Instructions, where to store it in the driver’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
Escape ladder (optional) 2-20
Switching the cab interior lighting on and off 2-21
BI017763
OPERATING INSTRUCTIONS 6030, 6030FS
vi BA RH120E(3 725 097.01)-EN
Switching the maintenance lights on and off 2-22
Emergency shut-off function 2-23
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
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 2-60
Back-up heating (option), filling in fuel 2-61
Service station (tanklift) 2-61
Switching the electrical system on and off 2-67
Engines, emergency shut-off 2-67
Preheating system for engine and hydraulic oil (optional) 2-68
Fuel preheating system (optional) 2-69
STARTING AND STOPPING THE ENGINES 2-70
Starting the engines 2-70
Starting the left-hand engine 2-70
Starting the right-hand engine 2-70
Engines – adjusting the speed 2-71
Starting the engines at low temperatures 2-71
Shutting off the engines 2-72
Shutting off the left-hand engine 2-72
Shutting off the right-hand engine 2-72
AIR CONDITIONER (OPTION) 2-73
Back-up heating driver’s cab (option) 2-73
Back-up heating (option) 2-74
MAXIMUM MACHINE INCLINATIONS, INFORMATION 2-75
TRAVELLING, SAFETY INSTRUCTIONS 2-76
TRAVELLING 2-77
Superstructure basic position 2-77
Travelling forwards/backwards 2-77
Superstructure holding brake 2-81
Track parking brake 2-81
TRANSPORTING THE MACHINE 2-82
Transport – Safety instructions 2-82
BI017763
OPERATING INSTRUCTIONS 6030, 6030FS
BA RH120E(3 725 097.01)-EN vii
WORKING OPERATION – SAFETY INSTRUCTIONS 2-83
WORKING OPERATION 2-85
Before starting work 2-85
Activating the electronic excavator control 2-85
Swinging the superstructure 2-86
Braking the superstructure 2-86
Working 2-87
After daily operation 2-88
OPTIONAL EQUIPMENT 2-89
Water spraying system 2-89
Additional silencers 2-89
ASSEMBLING WORKING EQUIPMENT – SAFETY INSTRUCTIONS 2-90
Securing the machine 2-91
CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS) 2-92
ON-BOARD CRANE (OPTIONAL) 2-93
Monitoring, warning and control elements 2-93
On-board crane, putting into operation 2-94
On-board crane, drive unit 2-94
On-Board crane, – blocking the boom in position of rest 2-95
Checking the on-board crane 2-95
NOTES 2-97
3 INSPECTION AND SERVICING 3-1
INSPECTION AND SERVICING – SAFETY INSTRUCTIONS 3-3
INSPECTION AND SERVICING WORK, FIRE AND EXPLOSION HAZARD 3-9
INSPECTION AND SERVICING PLANS – INSTRUCTIONS 3-11
Intervals 3-11
Change of engine oil l 3-11
Air-intake system 3-11
Oils / Greases 3-11
Cleaning jobs 3-11
Components 3-11
Plan V 3-13
Plan N 3-15
Plan T and W 3-17
Plan A – E 3-19
LUBRICATING CHART – GREASE 3-26
Lubricating chart – Grease (legend) 3-27
Filling quantities – Grease 3-27
INSPECTION PLAN – OIL 3-28
Inspection plan – Oil (legend) 3-29
Filling quantities – oil 3-30
Filling quantities – other 3-30
LUBRICANTS 3-31
Notes on the selection of oils and greases 3-31
BI017763
OPERATING INSTRUCTIONS 6030, 6030FS
viii BA RH120E(3 725 097.01)-EN
Avoid mixing of different hydraulic fluids 3-31
I. Oils for combustion engines 3-32
II. Oils for hydraulic system 3-33
III.a Oils for pump gearboxes and travel gearboxes 3-34
III.b Oils for swing gearboxes 3-35
V. Greases for bearings, swing rings and track system (Central lubrication system) 3-36
Grease for idlers, track rollers and support rollers (Lifetime lubrication) 3-37
Coolant for use on all combustion engines 3-38
SERVICING WORK 3-39
Hose line for oil and cooling liquid changes 3-39
ENGINE 3-40
Engine – Safety instructions 3-40
Checking the engine oil level / Topping up 3-41
Checking the oil level in the engine oil reservoir / topping up (optional) 3-42
Changing the engine oil 3-43
Draining the oil off the engine oil reservoir (optional) 3-45
Replacing the oil filters 3-46
Engine oil reservoir, filling in engine oil 3-46
Replacing the oil filters (oil interval prolonging) 3-47
Centrifuge (optional) 3-48
Cold-starting fluid (ether) – Replacing the pressure vessel 3-49
COOLING SYSTEM 3-50
Radiators 3-50
Cooling liquid change 3-52
Water filter, replace 3-53
AIR-INTAKE SYSTEM 3-54
Main filter elements 3-54
Safety filter element, replace 3-57
Air-intake lines 3-58
Dust collection 3-58
FUEL SYSTEM 3-59
Fuel system – Safety instructions 3-59
Fuel filters, replace 3-59
Venting the fuel system 3-60
Cleaning the fuel tanks 3-60
Water trap (option) 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
Charging batteries inside the machine, safety instructions 3-65
Battery 3-66
Switchgear cabinet 3-68
Equipotential bonding 3-70
Floodlight projector, replacing the lamp 3-72
Lighting systems in LED technonogy, instructions 3-74
BI017763
OPERATING INSTRUCTIONS 6030, 6030FS
BA RH120E(3 725 097.01)-EN ix
HYDRAULIC SYSTEM 3-75
Hydraulic system – Safety instructions 3-75
Depressurizing the hydraulic system 3-75
Checking the hydraulic oil level 3-76
Hydraulic oil return-flow filters (hydraulic oil reservoir), replace 3-78
Bypass valves (hydraulic oil reservoir), replace 3-80
Replacing the hydraulic oil return-flow filters (filter housing) 3-81
Bypass valves (filter housing – cooling system), replace 3-82
Breather filter, replace 3-83
Filter (servo circuit), replace 3-84
High-pressure filter for working hydraulics, replace 3-85
High-pressure filters for swing circuit, replace 3-86
Filter pump control, clean 3-87
Changing the hydraulic oil 3-88
Avoid mixing of different hydraulic fluids 3-88
Venting the hydraulic system 3-92
Cleaning the hydraulic oil cooler 3-93
Electronic excavator control 3-94
Pressure accumulators – Emergency lowering and servo circuit 3-95
PUMP TRANSFER GEARBOX 3-96
Checking the gearbox oil level / Topping up with oil 3-96
Gearbox venting 3-98
Pump transfer gearbox lube oil filters 3-99
SWING GEARBOX 3-100
Gearbox – Checking the oil level / Topping up with oil 3-100
Changing the gearbox oil 3-100
Gearbox venting 3-101
SWING GEARBOX 3-102
Gearbox – Checking the oil level / Topping up with oil 3-102
Changing the gearbox oil 3-103
Gearbox venting 3-104
TRAVEL GEARBOX P/N 2712182 3-105
Travel gearbox, checking the oil level / Topping up with oil 3-105
Travel gearbox, changing oil 3-106
Pre-chamber / spur gear section, Changing the oil 3-106
Brake chamber, Changing oil 3-107
Breather filter 3-107
TRAVEL GEARBOX P/N 3683493 3-108
Travel gearbox – Checking the oil level / Topping up with oil 3-108
Brake chamber – Checking the oil level / Topping up with oil 3-108
Travel gearbox – Changing oil 3-109
Brake chamber – Changing oil 3-110
Breather filter 3-110
CRAWLER TRACKS 3-111
Track roller, Support roller 3-112
Track tensioner 3-113
Pressure-accumulator inspection regulations 3-114
Checking the gas charging pressure in the pressure accumulator 3-114
BI017763
OPERATING INSTRUCTIONS 6030, 6030FS
x BA RH120E(3 725 097.01)-EN
SWING RING 3-115
Swing ring – Instructions 3-115
Bearing races 3-115
CENTRAL LUBRICATING SYSTEM 3-117
Design 3-117
Function 3-118
Filling up the grease container 3-119
Breather filter grease container, check / replace 3-119
Checking the greasing pressure 3-120
Unblocking a grease line 3-120
Oilfilter replace (hydraulic circuit grease pump) 3-121
Grease filter replace (filling the grease container) 3-122
Grease filter replace (Grease lines) 3-122
OTHER MAINTENANCE 3-123
Engine 3-123
Heating and air conditioning 3-123
Reservoirs for used grease at the A-frame, emptying 3-124
Hydraulic ladder 3-124
Pressure-accumulator inspection regulations 3-125
Extract from the German regulations 3-125
Checking the gas charging pressure in the pressure accumulator 3-125
ON-BOARD CRANE, DRIVE UNIT 3-126
On-board crane, greasing 3-126
On-Board crane, checking tightness of fastening bolts 3-127
PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING 3-128
Putting the excavator out of operation 3-128
Battery storage 3-128
Recommissioning 3-128
NOTES 3-129
4 REPAIR WORK 4-1
REPAIR WORK – SAFETY INSTRUCTIONS 4-3
REPAIR WORK, FIRE AND EXPLOSION HAZARD 4-5
REPAIR WORK, ENGINE 4-6
ELECTRICAL SYSTEM 4-7
Assisted starting (with jumper cables) – Safety instructions 4-7
Assisted starting (with jumper cables) 4-7
Starting the engine with jumper cables (external batteries 4-7
HYDRAULIC SYSTEM 4-9
Repair instructions 4-9
Hydraulic hoses – Instructions 4-9
BI017763
OPERATING INSTRUCTIONS 6030, 6030FS
BA RH120E(3 725 097.01)-EN xi
PRESSURE ACCUMULATORS – SAFETY INSTRUCTIONS 4-10
WELDING OPERATIONS – SAFETY INSTRUCTIONS 4-11
DISPOSAL AT THE END OF THE SERVICE LIFE 4-12
Dismantling and removal instructions 4-12
Risk of deflagrations 4-12
Risk of fire 4-12
Disposing of the machine without polluting the environment 4-13
Further hazardous substances 4-13
Appropriate disposal of batteries 4-14
NOTES 4-15
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 5-10
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
BI017763
OPERATING INSTRUCTIONS 6030, 6030FS
xii BA RH120E(3 725 097.01)-EN
Swing mechnism – Fault table 5-29
Central lubricating system – Fault table 5-30
HYDRAULIC CIRCUIT DIAGRAM 5-32
ABBREVIATIONS 5-33
ABBREVIATIONS 5-34
TECHNICAL DATA 5-35
NOTES 5-37
6 INDEX 6-1

Contact us: [email protected]

https://vimeo.com/857811818?share=copy

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.

S.V