Cat 6030 Hydraulic Shovel Operation and Maintenance Manual BI015826 – PDF DOWNLOAD

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Cat 6030 Hydraulic Shovel Operation and Maintenance Manual BI015826 – PDF DOWNLOAD

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Cat 6030 Hydraulic Shovel Operation and Maintenance Manual BI015826 – PDF DOWNLOAD

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

DESCRIPTION:

Cat 6030 Hydraulic Shovel Operation and Maintenance Manual BI015826 – PDF DOWNLOAD

OPERATING INSTRUCTIONS RH200
Introduction
PREFACE

• 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

• 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 construction- 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.
• The documentation relating to the machine is listed according to scope, quantity and language in the shipping note of the machine or in the covering letter if supplied separately. The operating instructions and spare-parts list are marked with the serial number of the machine. On taking receipt of the consignment, please check that the documentation is complete and in the language requested by you.

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TABLE OF CONTENTS:

Cat 6030 Hydraulic Shovel Operation and Maintenance Manual BI015826 – PDF DOWNLOAD

1 INTRODUCTION................................................................................................................................................................ 13
	PREFACE .................................................................................................................................................................. 15
	WARRANTY ................................................................................................................................................................. 16
	FUNDAMENTAL SAFETY INSTRUCTIONS .......................................................................................................................................... 17
		Warnings and symbols ................................................................................................................................................. 17
	DESIGNATED USE ........................................................................................................................................................... 18
	ORGANIZATIONAL MEASURES .................................................................................................................................................. 19
		Personal protective equipment and the working clothing ............................................................................................................... 19
		Selection and qualification of personnel; basic responsibilities ..................................................................................................... 20
		Safety instructions governing specific operational phases ............................................................................................................ 20
		Special work in conjunction with utilization of the machine and maintenance and repairs as well as troubleshooting during work; disposal of parts and consumables .... 21
		Warning of special dangers ........................................................................................................................................... 22
		Gas, dust, steam and smoke ........................................................................................................................................... 23
		Hydraulic equipment .................................................................................................................................................. 23
	FIRE AND EXPLOSION HAZARD ................................................................................................................................................ 24
	NOTES .................................................................................................................................................................... 25
2 OPERATION................................................................................................................................................................... 27
	OPERATION - SAFETY INSTRUCTIONS .......................................................................................................................................... 29
		Operating Instructions, where to store it in the driver’s cab ........................................................................................................ 30
	OPERATION, FIRE AND EXPLOSION HAZARD ..................................................................................................................................... 31
	DESCRIPTION OF THE EXCAVATOR ............................................................................................................................................. 32
		Excavator layout ..................................................................................................................................................... 33
		Undercarriage ........................................................................................................................................................ 34
		Superstructure........................................................................................................................................................ 34
		Drive................................................................................................................................................................. 34
		Hydraulic system...................................................................................................................................................... 34
		Pump Managing System (PMS)............................................................................................................................................ 34
		Stored Program Control (SPC) ......................................................................................................................................... 34
		Central Management System (CMS) ...................................................................................................................................... 34
		Demand control / Zero-flow regulation ................................................................................................................................ 35
		Automatic engine speed reduction ..................................................................................................................................... 35
		Board-Control-System (BCS) ........................................................................................................................................... 35
		Electrical system .................................................................................................................................................... 35
		Signs and labels ..................................................................................................................................................... 37
		Entering and leaving the machine, Safety instructions................................................................................................................. 38
		Access ladder lighting ............................................................................................................................................... 38
		Folding ladder (optional) ............................................................................................................................................ 39
		Swinging ladder (optional) ........................................................................................................................................... 40
		Switching the cab interior lighting on and off ....................................................................................................................... 41
		Switching the maintenance lights on and off .......................................................................................................................... 42
		Illuminating the control column ...................................................................................................................................... 42
		EMERGENCY STOP switch ................................................................................................................................................ 43
		Windscreen washer .................................................................................................................................................... 43
		Driver’s seat  ....................................................................................................................................................... 44
		Fire extinguisher .................................................................................................................................................... 46
		Fire extinguisher (option) ........................................................................................................................................... 46
		Automatic fire-extinguishing system (optional)........................................................................................................................ 47
		Harness (optional) ................................................................................................................................................... 48
	MONITORING, WARNING AND CONTROL ELEMENTS ................................................................................................................................. 52
	PUTTING THE MACHINE INTO OPERATION ....................................................................................................................................... 84
		Refuelling ........................................................................................................................................................... 84
		Service station (tanklift) ........................................................................................................................................... 84
		Switching the electrical system on and off ........................................................................................................................... 90
	STARTING AND STOPPING THE ENGINES ........................................................................................................................................ 91
		Starting the engines ................................................................................................................................................. 91
		Starting the engines at low temperatures ............................................................................................................................. 92
	AIR CONDITIONER (OPTION).................................................................................................................................................. 94
		Back-up heating (option) ............................................................................................................................................. 95
	DRIVING, SAFETY INSTRUCTIONS ............................................................................................................................................. 97
	TRAVELLING ............................................................................................................................................................... 98
		Superstructure basic position ........................................................................................................................................ 98
		Travelling forwards/backwards ........................................................................................................................................ 98
		Emergency machine drive ..............................................................................................................................................102
		Superstructure holding brake .........................................................................................................................................104
		Track parking brake ..................................................................................................................................................104
	TRANSPORTING THE MACHINE .................................................................................................................................................105
		Transport - Safety instructions ......................................................................................................................................105
	WORKING OPERATION - SAFETY INSTRUCTIONS ..................................................................................................................................106
		Running-in instructions for hydraulic cylinders ......................................................................................................................106
		Warming-up phase for the hydraulic system ............................................................................................................................106
		Avoid extreme positions of the working equipment .....................................................................................................................107
	WORKING OPERATION ........................................................................................................................................................108
		Before starting work .................................................................................................................................................108
		Switching on the electronic excavator control ........................................................................................................................108
		Swinging the superstructure ..........................................................................................................................................108
		Braking the superstructure ...........................................................................................................................................108
		Working movements ....................................................................................................................................................109
		After daily operation ................................................................................................................................................110
	ASSEMBLING WORKING EQUIPMENT - SAFETY INSTRUCTIONS .......................................................................................................................111
		Securing the machine .................................................................................................................................................113
	CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS) ...........................................................................................................114
	NOTES ....................................................................................................................................................................115
3 INSPECTION AND SERVICING....................................................................................................................................................117
	INSPECTION AND SERVICING - SAFETY INSTRUCTIONS ...........................................................................................................................119
	INSPECTION AND SERVICING WORK, FIRE AND EXPLOSION HAZARD .................................................................................................................125
	INSPECTION AND SERVICING PLANS - INSTRUCTIONS ............................................................................................................................127
		Intervals.............................................................................................................................................................127
		Change of engine oil l................................................................................................................................................127
		Air-intake system ....................................................................................................................................................127
		Oils / Greases .......................................................................................................................................................127
		Cleaning jobs ........................................................................................................................................................127
		Components ...........................................................................................................................................................127
		Plan V ...............................................................................................................................................................129
		Plan N ...............................................................................................................................................................131
		Plan T and W .........................................................................................................................................................133
		Plan A – E ...........................................................................................................................................................135
	LUBRICATING CHART – GREASE (LOADING BUCKET) ..............................................................................................................................142
		Lubricating chart – Grease (legend) ..................................................................................................................................143
		Filling quantities - Grease...........................................................................................................................................143
	INSPECTION PLAN - OIL ....................................................................................................................................................144
		Inspection plan – Oil (legend) .......................................................................................................................................145
		Filling quantities - oil .............................................................................................................................................146
		Filling quantities - other............................................................................................................................................146
	LUBRICANTS ...............................................................................................................................................................147
		Notes on the selection of oils and greases ...........................................................................................................................147
		I. Oils for combustion engines .......................................................................................................................................148
		II. Oils for hydraulic system ........................................................................................................................................149
		III.a Oils for pump gearboxes ........................................................................................................................................150
		III.b Oils for swing gearboxes .......................................................................................................................................151
		III.c Oils for travel gearboxes ......................................................................................................................................152
		V. Greases for bearings and swing rings ..............................................................................................................................153
	SERVICING WORK ...........................................................................................................................................................154
		Hose line for oil and cooling liquid changes .........................................................................................................................154
	ENGINE ...................................................................................................................................................................155
		Engine - Safety instructions .........................................................................................................................................155
		Checking the engine oil level / Topping up  ..........................................................................................................................156
		Changing the engine oil ..............................................................................................................................................157
		Replacing the oil filters ............................................................................................................................................159
		Cold-starting fluid (ether) - Replacing the pressure vessel ..........................................................................................................160
	COOLING SYSTEM ...........................................................................................................................................................161
		Radiators ............................................................................................................................................................161
		Cooling liquid, change ...............................................................................................................................................163
	AIR-INTAKE SYSTEM ........................................................................................................................................................164
		Dust trap, cleaning  .................................................................................................................................................164
		Main filter elements .................................................................................................................................................165
		Safety filter element ................................................................................................................................................167
		Air-intake lines .....................................................................................................................................................167
	FUEL SYSTEM ..............................................................................................................................................................168
		Fuel system - Safety instructions ....................................................................................................................................168
		Replacing the fuel filter ............................................................................................................................................168
		Primary fuel filter, drain water .....................................................................................................................................169
		Replacing the primary fuel filter ....................................................................................................................................169
		Venting the fuel system ..............................................................................................................................................170
		Cleaning the fuel tanks ..............................................................................................................................................170
		Water trap (option)...................................................................................................................................................172
	ELECTRICAL SYSTEM  .......................................................................................................................................................174
		Electrical system - Safety instructions ..............................................................................................................................174
		Alternator - Instructions ............................................................................................................................................174
		Battery ..............................................................................................................................................................175
		Switchgear cabinet aeration ..........................................................................................................................................177
		Equipotential bonding ................................................................................................................................................179
		Floodlight projector, replacing the lamp .............................................................................................................................181
	HYDRAULIC SYSTEM .........................................................................................................................................................183
		Hydraulic system - Safety instructions ...............................................................................................................................183
		Depressurizing the hydraulic system ..................................................................................................................................183
		Checking the hydraulic oil level .....................................................................................................................................184
		Changing the hydraulic oil return-flow (hydraulic oil reservoir) .....................................................................................................186
		Bypass valves (hydraulic oil reservoir) ..............................................................................................................................188
		Replacing the hydraulic oil return-flow filters (filter housing) .....................................................................................................189
		Bypass valves (filter housing - cooling system) ......................................................................................................................190
		Breather filter ......................................................................................................................................................191
		Filter (servo circuit)................................................................................................................................................192
		High-pressure filter for working hydraulics ..........................................................................................................................193
		High-pressure filters for swing circuit ..............................................................................................................................194
		Filter pump control, clean ...........................................................................................................................................195
		Changing the hydraulic oil ...........................................................................................................................................196
		Venting the hydraulic system..........................................................................................................................................199
		Cleaning the hydraulic oil cooler.....................................................................................................................................200
		Electronic excavator control..........................................................................................................................................201
		Pressure accumulator - Emergency lowering ............................................................................................................................202
	PUMP TRANSFER GEARBOX ....................................................................................................................................................203
		Checking the gearbox oil level / Topping up with oil .................................................................................................................203
		Gearbox venting ......................................................................................................................................................205
		Pump transfer gearbox lube oil filters ...............................................................................................................................206
	SWING GEARBOX ............................................................................................................................................................207
		Swing gearbox - Checking the oil level / Topping up with oil .........................................................................................................207
		Swing gearbox - Changing the gearbox oil .............................................................................................................................207
		Swing gearbox, venting ...............................................................................................................................................208
	SWING GEARBOX ............................................................................................................................................................209
		Swing gearbox - Checking the oil level / Topping up with oil .........................................................................................................209
		Swing gearbox, changing oil ..........................................................................................................................................210
		Swing gearbox, venting ...............................................................................................................................................211
	TRAVEL GEARBOX ...........................................................................................................................................................212
		Gearbox - Checking the oil level / Topping up with oil ...............................................................................................................212
		Travel gearbox - Changing oil ........................................................................................................................................213
		Pre-chamber - Changing the oil .......................................................................................................................................213
		Brake chamber - Changing oil .........................................................................................................................................214
		Breather filter ......................................................................................................................................................214
	CRAWLER TRACKS ...........................................................................................................................................................215
		Track roller, Support roller .........................................................................................................................................216
		Track tensioner ......................................................................................................................................................217
		Pressure-accumulator inspection regulations ..........................................................................................................................218
		Checking the gas charging pressure in the pressure accumulator........................................................................................................218
	SWING RING ...............................................................................................................................................................219
		Swing ring – Instructions ............................................................................................................................................219
		Bearing races.........................................................................................................................................................219
	CENTRAL LUBRICATING ......................................................................................................................................................221
		Design ...............................................................................................................................................................221
		Function .............................................................................................................................................................222
		Filling up the grease container ......................................................................................................................................223
		Breather filter ......................................................................................................................................................223
		Checking the greasing pressure .......................................................................................................................................224
		Unblocking a grease line..............................................................................................................................................225
		Oilfilter (hydraulic circuit grease pump) )...........................................................................................................................226
		Grease filter (Filling the grease container) .........................................................................................................................227
		Grease filter (Grease lines) .........................................................................................................................................228
	OTHER MAINTENANCE ........................................................................................................................................................229
		Other maintenance, engine ............................................................................................................................................229
		Heating and air conditioning .........................................................................................................................................229
	HYDRAULIC LADDER .........................................................................................................................................................230
		Pressure-accumulator inspection regulations  .........................................................................................................................231
		Extract from the German regulations...................................................................................................................................231
		Checking the gas charging pressure in the pressure accumulator .......................................................................................................231
	ON-BOARD CRANE (OPTIONAL) ................................................................................................................................................232
		Monitoring, warning and control elements .............................................................................................................................232
		Checking the on-board crane...........................................................................................................................................232
		Drive unit ...........................................................................................................................................................233
		On-board crane........................................................................................................................................................233
		On-Board crane, checking tightness of fastening bolts ................................................................................................................234
	PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING ...............................................................................................................235
		Putting the excavator out of operation ...............................................................................................................................235
		Battery storage ......................................................................................................................................................235
		Recommissioning ......................................................................................................................................................236
	NOTES  ...................................................................................................................................................................237
4 REPAIR WORK.................................................................................................................................................................239
	REPAIR WORK - SAFETY INSTRUCTIONS.........................................................................................................................................241
	REPAIR WORK, FIRE AND EXPLOSION HAZARD ...................................................................................................................................243
	REPAIR WORK, ENGINE.......................................................................................................................................................244
	ELECTRICAL SYSTEM ........................................................................................................................................................245
		Assisted starting (with jumper cables) – Safety instructions .........................................................................................................245
		Assisted starting (with jumper cables)................................................................................................................................245
		Starting the engine with jumper cables (external batteries ...........................................................................................................245
	HYDRAULIC SYSTEM..........................................................................................................................................................247
		Repair instructions ..................................................................................................................................................247
		Hydraulic hoses – Instructions  ......................................................................................................................................247
	PRESSURE ACCUMULATORS - SAFETY INSTRUCTIONS...............................................................................................................................248
	WELDING OPERATIONS - SAFETY INSTRUCTIONS .................................................................................................................................249
	NOTES ....................................................................................................................................................................251
5 ANNEX.......................................................................................................................................................................253
	TROUBLESHOOTING ..........................................................................................................................................................255
		Instructions on troubleshooting ......................................................................................................................................255
		Layout of the fault table ............................................................................................................................................255
		Possible causes ......................................................................................................................................................255
		Measures .............................................................................................................................................................255
		Section ..............................................................................................................................................................255
	FAULT TABLES .............................................................................................................................................................256
		Combustion engine - Fault table ......................................................................................................................................256
		Working hydraulics – Fault table .....................................................................................................................................257
		Track drive – Fault table ............................................................................................................................................258
		Swing mechnism – Fault table .........................................................................................................................................259
		Central lubricating system – Fault table .............................................................................................................................260
	HYDRAULIC CIRCUIT DIAGRAM ................................................................................................................................................261
	ABBREVIATIONS ............................................................................................................................................................263
		ABBREVIATIONS.........................................................................................................................................................264
	ENGINE MONITORING, CONTROL LAMPS .........................................................................................................................................265
	TECHNICAL DATA ...........................................................................................................................................................266
	NOTES ....................................................................................................................................................................275
6 INDEX.......................................................................................................................................................................277

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