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

Description

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

FILE DETAILS:

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

Language : English
Pages : 252
Downloadable : Yes
File Type : PDF

DESCRIPTION:

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

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
  ma- chine.

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:

Questions? Email us: [email protected]

TABLE OF CONTENTS:

CAT 6030AC 6030ACFS Hydraulic Shovel Operation & Maintenance Manual – 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
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
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
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
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
OMM 6030AC, 6030ACFS(3 847 030.00)-EN
TABLE OF CONTENTS
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

PLEASE NOTE:

• This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
• You will be directed to the download page as soon as the purchase is completed. The whole payment and downloading process will take anywhere between 2-5 minutes
• Need any other service / repair / parts manual, please feel free to contact [email protected] . We still have 50,000 manuals unlisted

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