Caterpillar Hydraulic Excavator 6030, 6030FS OPERATING INSTRUCTIONS MANUAL BI651388 – PDF DOWNLOAD

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Caterpillar Hydraulic Excavator 6030, 6030FS OPERATING INSTRUCTIONS MANUAL BI651388 – PDF DOWNLOAD

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Caterpillar Hydraulic Excavator 6030, 6030FS OPERATING INSTRUCTIONS MANUAL BI651388 – PDF DOWNLOAD

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Caterpillar Hydraulic Excavator 6030, 6030FS OPERATING INSTRUCTIONS MANUAL BI651388 – PDF DOWNLOAD

OPERATING INSTRUCTIONS RH120E
Introduction
PREFACE
About this Operating Instructions

• 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 mining- 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.

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TABLE OF CONTENTS:

Caterpillar Hydraulic Excavator 6030 6030FS OPERATING INSTRUCTIONS MANUAL BI651388 – PDF DOWNLOAD

TITLEPAGE....................................................................................................................................................................  1
1 INTRODUCTION............................................................................................................................................................... 13
	PREFACE ................................................................................................................................................................. 15
		About this Operating Instructions ................................................................................................................................... 15
		Further machine documentation ....................................................................................................................................... 15
	WARRANTY ................................................................................................................................................................ 16
	FUNDAMENTAL SAFETY INSTRUCTIONS.......................................................................................................................................... 17
		Warnings and symbols ................................................................................................................................................ 17
		Contents of the Declaration of Conformity ........................................................................................................................... 17
	DESIGNATED USE........................................................................................................................................................... 18
		Noise emissions ..................................................................................................................................................... 19
		Vibration data ...................................................................................................................................................... 19
	ORGANIZATIONAL MEASURES.................................................................................................................................................. 20
		Selection and qualification of personnel; basic responsibilities..................................................................................................... 21
		Safety instructions governing specific operational phases............................................................................................................ 21
		Special work in conjunction with utilization of the machine and maintenance and repairs as well as troubleshooting during work; disposal of parts and consumables.... 22
		Warning of special dangers........................................................................................................................................... 23
		Gas, dust, steam and smoke .......................................................................................................................................... 23
		Hydraulic equipment ................................................................................................................................................. 24
	FIRE AND EXPLOSION HAZARD................................................................................................................................................ 25
	NOTES ................................................................................................................................................................... 27
2 OPERATION.................................................................................................................................................................. 29
	OPERATION - SAFETY INSTRUCTIONS ......................................................................................................................................... 31
		Operating Instructions, where to store it in the driver’s cab ....................................................................................................... 32
	FIRE AND EXPLOSION HAZARD................................................................................................................................................ 33
	DESCRIPTION OF THE EXCAVATOR............................................................................................................................................. 34
		Excavator layout..................................................................................................................................................... 35
		Undercarriage ....................................................................................................................................................... 36
		Superstructure ...................................................................................................................................................... 36
		Drive ............................................................................................................................................................... 36
		Hydraulic system .................................................................................................................................................... 36
		Control and Monitoring Platform (CAMP) .............................................................................................................................. 36
		Board-Control-System (BCS) .......................................................................................................................................... 37
		Demand control / Zero-flow regulation................................................................................................................................ 37
		Automatic reset to idling............................................................................................................................................ 37
		Electrical system ................................................................................................................................................... 37
		Signs ............................................................................................................................................................... 38
		Entering and leaving the machine Safety instructions................................................................................................................. 45
		Access ladder lighting .............................................................................................................................................. 45
		Swinging ladder ..................................................................................................................................................... 46
		Folding ladder (optional) ........................................................................................................................................... 47
		Escape ladder (optional) ............................................................................................................................................ 48
		Switching the cab interior lighting on and off ...................................................................................................................... 49
		Switching the maintenance lights on and off ......................................................................................................................... 50
		Emergency shut-off function ......................................................................................................................................... 51
		Shutting off the supply voltage (battery main switch) ............................................................................................................... 52
		Driver’s seat  ...................................................................................................................................................... 53
		Reducing the operators exposure to vibrations ....................................................................................................................... 55
		Trainer's / instructor's seat ....................................................................................................................................... 55
		Fire extinguisher.................................................................................................................................................... 56
		Fire extinguisher (option) .......................................................................................................................................... 56
		Automatic fire-extinguishing system (optional) ...................................................................................................................... 57
		Windscreen washer ................................................................................................................................................... 57
		Harness (optional) .................................................................................................................................................. 58
	MONITORING, WARNING AND CONTROL ELEMENTS ................................................................................................................................ 62
		Engine 1 (LH), control and monitoring ............................................................................................................................... 69
		Engine 2 (RH), control and monitoring ............................................................................................................................... 71
	PUTTING THE MACHINE INTO OPERATION ...................................................................................................................................... 88
		Reducing the operator's exposure to noise ........................................................................................................................... 88
		Refuelling .......................................................................................................................................................... 88
		Back-up heating (option), filling in fuel ........................................................................................................................... 89
		Service station (tanklift) .......................................................................................................................................... 89
		Switching the electrical system on and off .......................................................................................................................... 95
		Engines, emergency shut-off ......................................................................................................................................... 95
		Preheating system for engine and hydraulic oil (optional) ........................................................................................................... 96
		Fuel preheating system (optional) ................................................................................................................................... 97
	STARTING AND STOPPING THE ENGINES ....................................................................................................................................... 98
		Starting the engines ................................................................................................................................................ 98
		Starting the left-hand engine........................................................................................................................................ 98
		Starting the right-hand engine....................................................................................................................................... 98
		Engines – adjusting the speed ....................................................................................................................................... 99
		Starting the engines at low temperatures ............................................................................................................................ 99
		Shutting off the engines ............................................................................................................................................100
		Shutting off the left-hand engine....................................................................................................................................100
		Shutting off the right-hand engine...................................................................................................................................100
	AIR CONDITIONER (OPTION) ................................................................................................................................................101
		Back-up heating driver’s cab (option) ...............................................................................................................................101
		Back-up heating (option) ............................................................................................................................................102
	MAXIMUM MACHINE INCLINATIONS, INFORMATION ...............................................................................................................................103
	TRAVELLING, SAFETY INSTRUCTIONS .........................................................................................................................................104
	TRAVELLING ..............................................................................................................................................................105
		Superstructure basic position .......................................................................................................................................105
		Travelling forwards/backwards .......................................................................................................................................105
		Superstructure holding brake ........................................................................................................................................109
		Track parking brake .................................................................................................................................................109
	TRANSPORTING THE MACHINE ................................................................................................................................................110
		Transport - Safety instructions .....................................................................................................................................110
	WORKING OPERATION - SAFETY INSTRUCTIONS .................................................................................................................................111
	WORKING OPERATION .......................................................................................................................................................113
		Before starting work ................................................................................................................................................113
		Activating the electronic excavator control .........................................................................................................................113
		Swinging the superstructure .........................................................................................................................................114
		Braking the superstructure ..........................................................................................................................................114
		Working .............................................................................................................................................................115
		After daily operation ...............................................................................................................................................116
	OPTIONAL EQUIPMENT ......................................................................................................................................................117
		Water spraying system ...............................................................................................................................................117
		Additional silencers ................................................................................................................................................117
	ASSEMBLING WORKING EQUIPMENT - SAFETY INSTRUCTIONS ......................................................................................................................118
		Securing the machine ................................................................................................................................................119
	CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS) ..........................................................................................................120
	ON-BOARD CRANE (OPTIONAL) ...............................................................................................................................................121
		Monitoring, warning and control elements ............................................................................................................................121
		On-board crane, putting into operation ..............................................................................................................................122
		On-board crane, drive unit ..........................................................................................................................................122
		On-Board crane, – blocking the boom in position of rest .............................................................................................................123
		Checking the on-board crane .........................................................................................................................................123
	NOTES ...................................................................................................................................................................125
3 INSPECTION AND SERVICING...................................................................................................................................................127
	INSPECTION AND SERVICING - SAFETY INSTRUCTIONS ..........................................................................................................................129
	INSPECTION AND SERVICING WORK, FIRE AND EXPLOSION HAZARD ................................................................................................................135
	INSPECTION AND SERVICING PLANS - INSTRUCTIONS ...........................................................................................................................137
		Intervals............................................................................................................................................................137
		Change of engine oil l...............................................................................................................................................137
		Air-intake system ...................................................................................................................................................137
		Oils / Greases ......................................................................................................................................................137
		Cleaning jobs .......................................................................................................................................................137
		Components ..........................................................................................................................................................137
		Plan V ..............................................................................................................................................................139
		Plan N ..............................................................................................................................................................141
		Plan T and W ........................................................................................................................................................143
		Plan A – E ..........................................................................................................................................................145
	LUBRICATING CHART – GREASE ..............................................................................................................................................152
		Lubricating chart – Grease (legend) .................................................................................................................................153
		Filling quantities – Grease .........................................................................................................................................153
	INSPECTION PLAN - OIL ...................................................................................................................................................154
		Inspection plan – Oil (legend) ......................................................................................................................................155
		Filling quantities - oil ............................................................................................................................................156
		Filling quantities - other...........................................................................................................................................156
	LUBRICANTS ..............................................................................................................................................................157
		Notes on the selection of oils and greases ..........................................................................................................................157
		Avoid mixing of different hydraulic fluids ..........................................................................................................................157
		I. Oils for combustion engines ......................................................................................................................................158
		II. Oils for hydraulic system .......................................................................................................................................159
		III.a Oils for pump gearboxes and travel gearboxes ..................................................................................................................160
		III.b Oils for swing gearboxes ......................................................................................................................................161
		V. Greases for bearings, swing rings and track system (Central lubrication system) ..................................................................................162
		Grease for idlers, track rollers and support rollers (Lifetime lubrication) .........................................................................................163
		Coolant for use on all combustion engines ...........................................................................................................................164
	SERVICING WORK ..........................................................................................................................................................165
		Hose line for oil and cooling liquid changes ........................................................................................................................165
	ENGINE ..................................................................................................................................................................166
		Engine - Safety instructions ........................................................................................................................................166
		Checking the engine oil level / Topping up  .........................................................................................................................167
		Checking the oil level in the engine oil reservoir / topping up (optional) ..........................................................................................168
		Changing the engine oil .............................................................................................................................................169
		Draining the oil off the engine oil reservoir (optional) ............................................................................................................171
		Replacing the oil filters ...........................................................................................................................................172
		Engine oil reservoir, filling in engine oil .........................................................................................................................172
		Replacing the oil filters (oil interval prolonging) .................................................................................................................173
		Centrifuge (optional) ...............................................................................................................................................174
		Cold-starting fluid (ether) - Replacing the pressure vessel .........................................................................................................175
	COOLING SYSTEM ..........................................................................................................................................................176
		Radiators ...........................................................................................................................................................176
		Cooling liquid change ...............................................................................................................................................178
		Water filter, replace ...............................................................................................................................................179
	AIR-INTAKE SYSTEM .......................................................................................................................................................180
		Main filter elements ................................................................................................................................................180
		Safety filter element, replace ......................................................................................................................................183
		Air-intake lines ....................................................................................................................................................184
		Dust collection .....................................................................................................................................................184
	FUEL SYSTEM .............................................................................................................................................................185
		Fuel system - Safety instructions ...................................................................................................................................185
		Fuel filters, replace ...............................................................................................................................................185
		Venting the fuel system .............................................................................................................................................186
		Cleaning the fuel tanks .............................................................................................................................................186
		Water trap (option)..................................................................................................................................................188
	ELECTRICAL SYSTEM  ......................................................................................................................................................190
		Electrical system - Safety instructions .............................................................................................................................190
		Alternator - Instructions ...........................................................................................................................................190
		Electrical circuit diagrams .........................................................................................................................................190
		Electrical system switch-cabinets ...................................................................................................................................190
		Replacing lamps and bulbs ...........................................................................................................................................190
		Charging batteries inside the machine, safety instructions ..........................................................................................................191
		Battery .............................................................................................................................................................192
		Switchgear cabinet ..................................................................................................................................................194
		Equipotential bonding ...............................................................................................................................................196
		Floodlight projector, replacing the lamp ............................................................................................................................198
		Lighting systems in LED technonogy, instructions ....................................................................................................................200
	HYDRAULIC SYSTEM ........................................................................................................................................................201
		Hydraulic system - Safety instructions ..............................................................................................................................201
		Depressurizing the hydraulic system .................................................................................................................................201
		Checking the hydraulic oil level ....................................................................................................................................202
		Hydraulic oil return-flow filters (hydraulic oil reservoir), replace ................................................................................................204
		Bypass valves (hydraulic oil reservoir), replace ....................................................................................................................206
		Replacing the hydraulic oil return-flow filters (filter housing) ....................................................................................................207
		Bypass valves (filter housing - cooling system), replace ............................................................................................................208
		Breather filter, replace ............................................................................................................................................209
		Filter (servo circuit), replace .....................................................................................................................................210
		High-pressure filter for working hydraulics, replace ................................................................................................................211
		High-pressure filters for swing circuit, replace ....................................................................................................................212
		Filter pump control, clean ..........................................................................................................................................213
		Changing the hydraulic oil ..........................................................................................................................................214
		Avoid mixing of different hydraulic fluids ..........................................................................................................................214
		Venting the hydraulic system.........................................................................................................................................218
		Cleaning the hydraulic oil cooler....................................................................................................................................219
		Electronic excavator control.........................................................................................................................................220
		Pressure accumulators - Emergency lowering and servo circuit ........................................................................................................221
	PUMP TRANSFER GEARBOX ...................................................................................................................................................222
		Checking the gearbox oil level / Topping up with oil ................................................................................................................222
		Gearbox venting .....................................................................................................................................................224
		Pump transfer gearbox lube oil filters ..............................................................................................................................225
	SWING GEARBOX ...........................................................................................................................................................226
		Gearbox - Checking the oil level / Topping up with oil ..............................................................................................................226
		Changing the gearbox oil ............................................................................................................................................226
		Gearbox venting .....................................................................................................................................................227
	SWING GEARBOX ...........................................................................................................................................................228
		Gearbox - Checking the oil level / Topping up with oil ..............................................................................................................228
		Changing the gearbox oil ............................................................................................................................................229
		Gearbox venting .....................................................................................................................................................230
	TRAVEL GEARBOX P/N 2712182 ..............................................................................................................................................231
		Travel gearbox, checking the oil level / Topping up with oil ........................................................................................................231
		Travel gearbox, changing oil ........................................................................................................................................232
		Pre-chamber / spur gear section, Changing the oil ...................................................................................................................232
		Brake chamber, Changing oil .........................................................................................................................................233
		Breather filter .....................................................................................................................................................233
	TRAVEL GEARBOX P/N 3683493 ..............................................................................................................................................234
		Travel gearbox - Checking the oil level / Topping up with oil .......................................................................................................234
		Brake chamber - Checking the oil level / Topping up with oil ........................................................................................................234
		Travel gearbox - Changing oil .......................................................................................................................................235
		Brake chamber - Changing oil ........................................................................................................................................236
		Breather filter .....................................................................................................................................................236
	CRAWLER TRACKS ..........................................................................................................................................................237
		Track roller, Support roller ........................................................................................................................................238
		Track tensioner .....................................................................................................................................................239
		Pressure-accumulator inspection regulations .........................................................................................................................240
		Checking the gas charging pressure in the pressure accumulator.......................................................................................................240
	SWING RING ..............................................................................................................................................................241
		Swing ring - Instructions............................................................................................................................................241
		Bearing races........................................................................................................................................................241
	CENTRAL LUBRICATING SYSTEM ..............................................................................................................................................243
		Design ..............................................................................................................................................................243
		Function ............................................................................................................................................................244
		Filling up the grease container .....................................................................................................................................245
		Breather filter grease container, check / replace ...................................................................................................................245
		Checking the greasing pressure ......................................................................................................................................246
		Unblocking a grease line ............................................................................................................................................246
		Oilfilter replace (hydraulic circuit grease pump) ...................................................................................................................247
		Grease filter replace (filling the grease container) ................................................................................................................248
		Grease filter replace (Grease lines) ................................................................................................................................248
	OTHER MAINTENANCE .......................................................................................................................................................249
		Engine ..............................................................................................................................................................249
		Heating and air conditioning ........................................................................................................................................249
		Reservoirs for used grease at the A-frame, emptying .................................................................................................................250
		Hydraulic ladder ....................................................................................................................................................250
		Pressure-accumulator inspection regulations .........................................................................................................................251
		Extract from the German regulations..................................................................................................................................251
		Checking the gas charging pressure in the pressure accumulator.......................................................................................................251
	ON-BOARD CRANE, DRIVE UNIT ..............................................................................................................................................252
		On-board crane, greasing.............................................................................................................................................252
		On-Board crane, checking tightness of fastening bolts ...............................................................................................................253
	PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING ..............................................................................................................254
		Putting the excavator out of operation...............................................................................................................................254
		Battery storage......................................................................................................................................................254
		Recommissioning......................................................................................................................................................254
	NOTES  ..................................................................................................................................................................255
4 REPAIR WORK................................................................................................................................................................257
	REPAIR WORK - SAFETY INSTRUCTIONS........................................................................................................................................259
	REPAIR WORK, FIRE AND EXPLOSION HAZARD ..................................................................................................................................261
	REPAIR WORK, ENGINE .....................................................................................................................................................262
	ELECTRICAL SYSTEM .......................................................................................................................................................263
		Assisted starting (with jumper cables) – Safety instructions ........................................................................................................263
		Assisted starting (with jumper cables)...............................................................................................................................263
		Starting the engine with jumper cables (external batteries ..........................................................................................................263
	HYDRAULIC SYSTEM ........................................................................................................................................................265
		Repair instructions .................................................................................................................................................265
		Hydraulic hoses – Instructions  .....................................................................................................................................265
	PRESSURE ACCUMULATORS - SAFETY INSTRUCTIONS..............................................................................................................................266
	WELDING OPERATIONS - SAFETY INSTRUCTIONS ................................................................................................................................267
	DISPOSAL AT THE END OF THE SERVICE LIFE  ................................................................................................................................268
		Dismantling and removal instructions ................................................................................................................................268
		Risk of deflagrations ...............................................................................................................................................268
		Risk of fire ........................................................................................................................................................268
		Disposing of the machine without polluting the environment ..........................................................................................................269
		Further hazardous substances ........................................................................................................................................269
		Appropriate disposal of batteries ...................................................................................................................................270
	NOTES ...................................................................................................................................................................271
5 ANNEX......................................................................................................................................................................273
	BOARD-CONTROL-SYSTEM ....................................................................................................................................................275
		BCS III, what’s that? ...............................................................................................................................................275
		The keys on the front side ..........................................................................................................................................276
		Other elements on the front side ....................................................................................................................................276
		BCSIII, the start screen ............................................................................................................................................277
		Information given on the start screen, top section ..................................................................................................................278
		Information given on the start screen, central section ..............................................................................................................279
		Information given on the start screen, lower section ................................................................................................................280
		Information given on the “Service” screen ...........................................................................................................................281
		Engine data screen ..................................................................................................................................................282
		Hydraulic data screen ...............................................................................................................................................283
		Lubrication data screen .............................................................................................................................................284
		Controls adjustment data screen .....................................................................................................................................285
		View documents screen ...............................................................................................................................................286
		Signal table screen .................................................................................................................................................287
		Signal table screen, location .......................................................................................................................................288
		Signal table screen, diagram ........................................................................................................................................289
		Signal table screen, diagram configuration ..........................................................................................................................290
		Code table screen ...................................................................................................................................................291
		BCS III, interfaces .................................................................................................................................................292
		USB interface, data storage .........................................................................................................................................292
		Saving data to a USB stick ..........................................................................................................................................293
		Saving data to a USB stick, continued ...............................................................................................................................294
		Saving data to a USB stick, continued ...............................................................................................................................295
		BCSIII, cleaning ....................................................................................................................................................296
		BCSIII, disposal ....................................................................................................................................................296
	TROUBLESHOOTING .........................................................................................................................................................297
		Instructions on troubleshooting .....................................................................................................................................297
		Layout of the fault table ...........................................................................................................................................297
		Possible causes .....................................................................................................................................................297
		Measures ............................................................................................................................................................297
		Section .............................................................................................................................................................297
	FAULT TABLES ............................................................................................................................................................298
		Combustion engine - Fault table .....................................................................................................................................298
		Working hydraulics – Fault table ....................................................................................................................................299
		Track drive – Fault table ...........................................................................................................................................300
		Swing mechnism – Fault table ........................................................................................................................................301
		Central lubricating system – Fault table ............................................................................................................................302
	HYDRAULIC CIRCUIT DIAGRAM ...............................................................................................................................................304
	ABBREVIATIONS ...........................................................................................................................................................305
		ABBREVIATIONS........................................................................................................................................................306
	TECHNICAL DATA ..........................................................................................................................................................307
		Product Specification Sheet
.........................................................................................................................................309
	NOTES ...................................................................................................................................................................319
6 INDEX......................................................................................................................................................................321

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