CAT 6030 AC 6030 ACFS Hydraulic Shovel Operation & Maintenance Manual EM028802 – PDF DOWNLOAD

Description

CAT 6030 AC 6030 ACFS Hydraulic Shovel Operation & Maintenance Manual EM028802 – PDF DOWNLOAD

FILE DETAILS:

CAT 6030 AC 6030 ACFS Hydraulic Shovel Operation & Maintenance Manual EM028802 – PDF DOWNLOAD

Language : English
Pages : 264
Downloadable : Yes
File Type : PDF

DESCRIPTION:

CAT 6030 AC 6030 ACFS Hydraulic Shovel Operation & Maintenance Manual EM028802 – PDF DOWNLOAD

DHG30290; DHG30293; DHG30294; DHG30296; DHG30297; DHG30323, DHG30332, DHG30335

PREFACE:

• This Operation and Maintenance Manual is de- signed to familiarize the operator with the
  machine and its designated use.
• The Operation and Maintenance Manual contain important information on how to operate the
  ma- chine safely, properly and with maximum efficiency. Observing these instructions helps to
  prevent haz- ardous situations, to reduce repair costs and down- times 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 environmen- tal protection.
• The Operation and Maintenance Manual must al- ways be available in the operator’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, troubleshooting in the course of work, care,
evacuation of pro- duction waste and disposal of fuels and con- sumables,
■ 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 ma- chine is to be used, the generally recognized tech- nical 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 (Caterpillar Global Mining Hydraulic Mining Shovels 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 Maintenance Manual.
• All CGM HMS GmbH Operation and Maintenance Manuals are issued in German and then translated.
  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 AC 6030 ACFS Hydraulic Shovel Operation & Maintenance Manual EM028802 – PDF DOWNLOAD

1 INTRODUCTION 1-1
PREFACE 1-3
Further machine documentation 1-3
WARRANTY 1-4
FUNDAMENTAL SAFETY INSTRUCTIONS 1-5
Warnings and symbols 1-5
DESIGNATED USE 1-6
ORGANIZATIONAL MEASURES 1-7
Selection and qualification of personnel; basic responsibilities 1-8
Safety instructions governing specific operational phases 1-8
Special work in conjunction with utilization of the machine and maintenance and repairs as well as
troubleshooting during work; disposal of parts and consumables 1-9
Warning of special dangers 1-10
Gas, dust, steam and smoke 1-11
Hydraulic / pneumatc equipment 1-11
Noise 1-11
Oil, grease and other chemical substances 1-11
Transporting and recommissioning 1-11
ACCIDENT PREVENTION REGULATIONS FOR ELECTRICALLY POWERED SHOVELS 1-12
Safety instructions for shovels with electric motor 1-13
FIRE AND EXPLOSION HAZARD 1-14
NOTES 1-15
2 OPERATION 2-1
OPERATION – SAFETY INSTRUCTIONS 2-3
Operating Instructions, where to store it in the operator’s cab 2-4
FIRE AND EXPLOSION HAZARD 2-5
DESCRIPTION OF THE SHOVEL 2-6
Shovel layout 2-7
Undercarriage 2-8
Superstructure 2-8
Drive 2-8
Hydraulic system 2-8
Pump Managing System (PMS) 2-8
Stored Program Control (SPC) 2-8
Control Management System (CMS) 2-8
Demand control / Zero-flow regulation 2-9
Board-Control-System (BCS) 2-9
Electrical system 2-9
Signs 2-11
Entering and leaving the machine, Safety instructions 2-19
Access lighting 2-19
Swinging ladder 2-20
EM028802
OMM 6030AC, 6030ACFS(3 847 030.00)-EN
TABLE OF CONTENTS
vi
Folding ladder (optional) 2-21
Cab interior lamp 2-22
Servicing lighting 2-23
Illuminating the control column 2-23
EMERGENCY STOP switch 2-24
Servicing switch 2-25
Windscreen washer 2-25
Operator’s seat 2-26
Fire extinguisher 2-28
Automatic fire-extinguishing system (optional) 2-29
Trainer’s / instructor’s seat 2-29
Emergency escape device (optional) 2-30
MONITORING, WARNING AND CONTROL ELEMENTS 2-34
PUTTING THE MACHINE INTO OPERATION 2-57
Service station (tanklift) 2-57
Battery main switch, switching on and off 2-60
Electrical system (24V), switching on and off 2-60
Switching the electric motor on and off 2-61
Time-out before restart 2-62
Electric motor can not be switched on 2-63
In case of failure 2-63
Circuit breaker, switching on and off 2-64
Motor protection relay, function 2-66
Warm-up procedure for electric shovels 2-68
Air conditioner (option) 2-69
TRAVELLING THE MACHINE 2-70
Travelling, Safety Instructions 2-70
Travelling 2-71
Emergency machine drive 2-75
Locking the superstructure 2-77
Track parking brake 2-77
TRANSPORTING THE MACHINE 2-78
Transport – Safety instructions 2-78
WORKING OPERATION – SAFETY INSTRUCTIONS 2-79
Working equipment, avoid extreme positions 2-80
WORKING OPERATION 2-81
Before starting work 2-81
Swinging the superstructure 2-81
Braking the superstructure 2-81
Working 2-82
Emergency lowering of the working equipment 2-83
After daily operation 2-83
ASSEMBLING WORKING EQUIPMENT – SAFETY INSTRUCTIONS 2-84
Securing the machine 2-85
EM028802
OMM 6030AC, 6030ACFS(3 847 030.00)-EN
TABLE OF CONTENTS
vii
CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS) 2-86
ON-BOARD CRANE (OPTIONAL) 2-87
On-board crane, monitoring, warning and control elements 2-87
On-board crane, putting into operation 2-88
On-board crane, drive unit 2-88
On-Board crane, – blocking the boom in position of rest 2-89
On-board crane, checking 2-89
Monitoring cameras 2-90
NOTES 2-91
3 INSPECTION AND SERVICING 3-1
SAFETY INSTRUCTIONS FOR SHOVELS WITH ELECTRIC MOTOR 3-3
INSPECTION AND SERVICING – SAFETY INSTRUCTIONS 3-5
FIRE AND EXPLOSION HAZARD 3-11
INSPECTION AND SERVICING PLANS – INSTRUCTIONS 3-13
Intervals 3-13
Oils / Greases 3-13
Cleaning jobs 3-13
Components 3-13
Plan V 3-15
Plan N 3-17
Plan T and W 3-19
Plan A – E 3-21
LUBRICATING CHART – GREASE 3-26
Lubricating chart – Grease (legend) 3-26
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
Avoid mixing of different hydraulic fluids 3-31
II. Oil for hydraulic system 3-32
III.a Oils for pump gearbox 3-33
III.b Oils for swing gearboxes 3-34
III.c Oils for travel gearboxes Fehler! Textmarke nicht definiert.
V. Greases for bearings and slewing rings Fehler! Textmarke nicht definiert.
SERVICING WORK 3-37
Hose line for oil change 3-37
ELECTRIC MOTOR 3-38
Electric motor – Safety instructions 3-38
Cleaning the electric motor 3-38
Electric motor, greasing 3-39
EM028802
OMM 6030AC, 6030ACFS(3 847 030.00)-EN
TABLE OF CONTENTS
viii
ELECTRICAL SYSTEM 3-40
Electrical system – Safety instructions 3-40
Battery 3-41
Switchgear cabinet 3-43
Slip ring maintenance 3-46
Floodlight projector, replacing the lamp 3-47
HYDRAULIC SYSTEM 3-49
Hydraulic system – Safety instructions 3-49
Depressurizing the hydraulic system 3-49
Checking the hydraulic oil level 3-50
Changing the hydraulic oil return-flow filter (hydraulic oil reservoir) 3-52
Bypass valves (hydraulic oil reservoir) 3-54
Replacing the hydraulic oil return-flow filters (filter housing) 3-55
Bypass valves (filter housing – cooling system) 3-56
Breather filter 3-57
Filter (control circuit and auxiliary control circuit) 3-58
High-pressure filter for working hydraulics 3-59
High-pressure filters for slewing circuit 3-60
High-pressure filters for feeding circuits and slewing pumps 3-61
Changing the hydraulic oil 3-62
Venting the hydraulic system 3-65
Cleaning the hydraulic oil cooler 3-66
Electronic shovel control 3-67
Pressure accumulator – Emergency lowering 3-68
Pressure accumulator – Servo control- and feeding circuit 3-68
PUMP DRIVE GEARBOX 3-70
Checking the gearbox oil level / Topping up with oil 3-70
Gearbox venting 3-72
Pump drive gearbox lube oil filters 3-73
SLEWING GEARBOX 3-74
Gearbox – Checking the oil level / Topping up with oil 3-74
Changing the gearbox oil 3-74
Gearbox venting 3-75
SWING GEARBOX 3-76
Gearbox – Checking the oil level / Topping up with oil 3-76
Changing the gearbox oil 3-77
Gearbox venting 3-78
TRAVEL GAERBOX 3-79
Gearbox – Checking the oil level / Topping up with oil 3-79
Travel gearbox – Changing oil 3-80
Pre-chamber – Changing the oil Fehler! Textmarke nicht definiert.
Brake chamber – Changing oil 3-81
Breather filter 3-81
CRAWLER TRACKS 3-82
Track roller, Support roller 3-83
Track tensioner 3-84
Pressure-accumulator inspection regulations 3-85
Checking the gas charging pressure in the pressure accumulator 3-85
EM028802
OMM 6030AC, 6030ACFS(3 847 030.00)-EN
TABLE OF CONTENTS
ix
SWING RING 3-86
Swing ring – Instructions 3-86
Bearing races 3-86
CENTRAL LUBRICATING 3-88
Design 3-88
Function 3-89
Replacing the grease drum 3-90
Checking the greasing pressure 3-91
Unblocking a grease line. 3-91
Oilfilter (hydraulic circuit grease pump) 3-92
Grease filter (grease lines) 3-93
OTHER MAINTENANCE 3-94
Cleaning the cooling system 3-94
Heating and air conditioning 3-94
Air intake filters 3-94
HYDRAULIC LADDER 3-95
Pressure-accumulator inspection regulations 3-96
Extract from the German regulations 3-96
Checking the gas charging pressure in the pressure accumulator 3-96
PUTTING THE SHOVEL OUT OF OPERATION AND RECOMMISSIONING 3-97
Putting the shovel out of operation 3-97
Battery storage 3-97
Recommissioning 3-98
NOTES 3-1
4 REPAIR WORK 4-1
SAFETY INSTRUCTIONS FOR SHOVELS WITH ELECTRIC MOTOR 4-3
REPAIR WORK – SAFETY INSTRUCTIONS 4-4
FIRE AND EXPLOSION HAZARD 4-5
HYDRAULIC SYSTEM 4-6
Repair 4-6
Hydraulic hoses – Instructions 4-6
PRESSURE ACCUMULATORS – SAFETY INSTRUCTIONS 4-7
WELDING AND FLAME CUTTING WORKS – SAFETY INSTRUCTIONS 4-8
DISPOSAL AT THE END OF THE SERVICE LIFE 4-11
Appropriate disposal of batteries 4-12
NOTES 4-13
5 ANNEX 5-1
TROUBLESHOOTING 5-3
Instructions on troubleshooting 5-3
Layout of the fault table 5-3
Possible causes 5-3
Measures 5-3
EM028802
OMM 6030AC, 6030ACFS(3 847 030.00)-EN
TABLE OF CONTENTS
x
Section 5-3
FAULT TABLES 5-4
Working hydraulics – Fault table 5-4
Track drive – Fault table 5-5
Swing mechnism – Fault table 5-6
Central lubricating system – Fault table 5-7
HYDRAULIC CIRCUIT DIAGRAM 5-8
ABBREVIATIONS 5-9
NOISE AND VIBRATION INFORMATION 5-11
Noise emission information 5-11
Vibration information 5-11
PRODUCT SPECIFICATION SHEET 5-12
NOTES 5-13
6 INDEX 6-1

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