CAT 6030, 6030FS Hydraulic Shovel Operation & Maintenance Manual BI015756 – PDF DOWNLOAD
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CAT 6030, 6030FS Hydraulic Shovel Operation & Maintenance Manual BI015756 – PDF DOWNLOAD
Language : English
Pages : 346
Downloadable : Yes
File Type : PDF
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DESCRIPTION:
CAT 6030, 6030FS Hydraulic Shovel Operation & Maintenance Manual BI015756 – PDF DOWNLOAD
PREFACE:
- These operation and maintenance manual is de- signed to familiarize the operator with the
machine and its designated use.
The Operation and Maintenence 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 Maintenence Manual must be supplemented by the respective national rules
and regulations for accident prevention and environ- mental protection.
The Operation and Maintenence Manual must al- ways be available in the operator’s cab of the
ma- chine.
The Operation and Maintenence 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, troubleshoot- ing in the course of work, care,
evacuation of production waste and disposal of fuels and consumables,
▪ maintenance (inspection, servicing, repair) and / or
▪ transport.
- In addition to the Operation and Maintenence 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 machine is to be used, the generally recognized technical rules for safe
and proper working must be observed ¹. - The Operation and Maintenence 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 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 Main- tenence Manual.
CGM HMS GmbH =
Caterpillar Global Mining Hydraulic mining Shovels GmbH. - All CGM HMS GmbH operating manuals are is- sued 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 Maintenence 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.
TABLE OF CONTENTS:
CAT 6030, 6030FS Hydraulic Shovel Operation & Maintenance Manual BI015756 – PDF DOWNLOAD
1 INTRODUCTION 1-1
PREFACE 1-1
Further machine documentation 1-1
WARRANTY 1-2
FUNDAMENTAL SAFETY INSTRUCTIONS 1-3
Warnings and symbols 1-3
DESIGNATED USE, UNAUTHORIZED USE 1-4
Noise emission information 1-5
Vibration information 1-5
ORGANIZATIONAL MEASURES 1-6
Selection and qualification of personnel; basic responsibilities 1-7
Safety instructions governing specific operational phases 1-7
Special work in conjunction with utilization of the machine and maintenance and repairs as well as
troubleshooting during work; disposal of parts and consumables 1-8
Warning of special dangers 1-9
Gas, dust, steam and smoke 1-9
Hydraulic equipment 1-10
FIRE AND EXPLOSION HAZARD 1-11
NOTES 1-13
2 OPERATION 2-1
OPERATION – SAFETY INSTRUCTIONS 2-3
Operation and Maintenence Manual, where to store it in the operator’s cab 2-4
FIRE AND EXPLOSION HAZARD 2-5
DESCRIPTION OF THE HYDRAULIC SHOVEL 2-6
Hydraulic shovel layout – upperstructure 2-7
Hydraulic shovel layout – undercarriage and working equipment 2-9
Undercarriage 2-10
Upperstructure 2-10
Drive 2-10
Hydraulic system 2-10
Control and Monitoring Platform (CAMP) 2-10
Board-Control-System (BCS) 2-11
Demand control / Zero-flow regulation 2-11
Automatic reset to idling 2-11
Electrical system 2-11
Signs 2-12
Entering and leaving the machine Safety instructions 2-20
Access ladder lighting 2-20
Swinging ladder (optional) 2-21
Folding ladder 2-22
Emergency exit in operator’s cab and escape ladder 2-23
Switching the cab interior lighting on and off 2-24
Switching the maintenance lights on and off 2-25
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Emergency shut-off function 2-26
Putting the machine back into operation, reset of emergency shut off function 2-27
Battery isolator switch, shutting off supply voltage 2-28
Starter isolator switch, shutting off starter voltage 2-28
Operator’s seat 2-29
Reducing the operators exposure to vibrations 2-31
Trainer’s / instructor’s seat 2-31
Fire extinguisher 2-32
Automatic fire-extinguishing system (optional) 2-33
Windscreen washer 2-33
Operating hours meter 2-33
Emergency escape device / seat (optional) 2-34
MONITORING, WARNING AND CONTROL ELEMENTS 2-38
Engine 1 (LH), control and monitoring 2-45
Engine 2 (RH), control and monitoring 2-47
PUTTING THE MACHINE INTO OPERATION 2-66
Reducing the operator’s exposure to noise 2-66
Refuelling 2-67
Back-up heating (option), filling in fuel 2-67
Service station (tanklift) 2-68
Emergency off switch 2-69
Switching the electrical system on and off 2-74
Engines, emergency shut-off 2-74
Preheating system for engine and hydraulic oil (optional) 2-75
Fuel preheating system (optional) 2-76
STARTING AND STOPPING THE ENGINES 2-78
Starting the engines 2-78
Starting the left-hand engine 2-78
Starting the right-hand engine 2-78
Engines – adjusting the speed 2-79
Starting the engines at low temperatures 2-79
Shutting off the engines 2-80
Shutting off the left-hand engine 2-80
Shutting off the right-hand engine 2-80
AIR CONDITIONER (OPTIONAL) 2-81
Back-up heating operator’s cab (optional) 2-82
Back-up heating (optional) 2-83
MAXIMUM MACHINE INCLINATIONS, INFORMATION 2-84
TRAVELLING, SAFETY INSTRUCTIONS 2-86
TRAVELLING 2-87
Upperstructure basic position 2-87
Travelling forwards/backwards 2-87
Upperstructure holding brake 2-91
Track parking brake 2-91
TRANSPORTING THE MACHINE 2-92
Transport – Safety instructions 2-92
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WORKING OPERATION – SAFETY INSTRUCTIONS 2-93
WORKING OPERATION 2-95
Before starting work 2-95
Activating the electronic hydraulic shovel control 2-95
Swinging the upperstructure 2-96
Braking the upperstructure 2-96
Working 2-97
Emergency lowering of the working equipment 2-98
After daily operation 2-99
ASSEMBLING WORKING EQUIPMENT – SAFETY INSTRUCTIONS 2-100
Securing the machine 2-101
CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS) 2-102
ON-BOARD CRANE (OPTIONAL) 2-103
Monitoring, warning and control elements 2-103
On-board crane, putting into operation 2-104
On-board crane, drive unit 2-104
On-Board crane, – blocking the boom in position of rest 2-105
Checking the on-board crane 2-105
MONITORING CAMERAS (OPTIONAL) 2-106
Monitoring cameras – function 2-106
NOTES 2-107
3 INSPECTION AND SERVICING 3-1
INSPECTION AND SERVICING – SAFETY INSTRUCTIONS 3-3
INSPECTION AND SERVICING WORK, FIRE AND EXPLOSION HAZARD 3-7
INSPECTION AND SERVICING PLANS – INSTRUCTIONS 3-9
Plan V 3-11
Plan N 3-13
Plan T and W 3-15
Plan A – E 3-17
LUBRICATING CHART – GREASE 3-24
Lubricating chart – Grease (legend) 3-25
Filling quantities – Grease 3-25
INSPECTION PLAN – OIL 3-26
Inspection plan – Oil (legend) 3-27
Filling quantities – oil 3-28
Filling quantities – other 3-28
LUBRICANTS / CONSUMABLES 3-29
Notes on the selection of oils and greases 3-29
Avoid mixing of different hydraulic fluids 3-29
I. Oils for combustion engines 3-30
II. Fluid for hydraulic system 3-31
III.a Oils for pump drive gearboxes and travel gearboxes 3-32
III.b Oil for swing gearboxes 3-33
V. Grease for bearings, slew rings and track system (Central lubrication system) 3-34
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Grease for idlers, track rollers and support rollers (Lifetime lubrication) 3-35
Coolant for use on all combustion engines 3-36
SERVICING WORK 3-37
Hose line for oil and cooling liquid changes 3-37
ENGINE 3-38
Engine – Safety instructions 3-38
Engine oil, checking the level / topping up 3-39
Engine oil reservoir (optional), checking the oil level / topping up 3-40
Engine oil, change 3-41
Engine oil reservoir (optional), draining the oil off 3-43
Engine oil filter, replace 3-45
Engine oil reservoir (optional), replacing the oil filters 3-46
Cold-starting fluid (ether) – Replacing the pressure vessel 3-47
COOLING SYSTEM 3-48
Temperature 3-48
Radiators 3-49
Cooling-liquid level check 3-49
Cooling liquid, change 3-52
Testing the cooling liquid composition 3-53
AIR-INTAKE SYSTEM 3-54
Dust trap, cleaning 3-54
Main filter elements 3-55
Main filter elements, checking and cleaning 3-56
Safety filter element 3-57
Air-intake lines 3-57
FUEL SYSTEM 3-58
Fuel system – Safety instructions 3-58
Fuel filter, replace 3-58
Primary fuel filter, drain water 3-59
Primary fuel filter, replace 3-59
Fuel system, venting 3-60
Breather filter fuel tank, replace 3-60
Fuel tanks, cleaning 3-60
Water trap (optional) 3-62
ELECTRICAL SYSTEM 3-64
Electrical system – Safety instructions 3-64
Alternator – Instructions 3-64
Electrical circuit diagrams 3-64
Electrical system switch-cabinets 3-64
Replacing lamps and bulbs 3-64
Battery 3-65
Charging batteries inside the machine, safety instructions 3-66
Removing and installing the battery 3-67
Switchgear cabinet, aeration 3-68
Xenon floodlight projector, replacing the lamp 3-70
Lighting systems in LED technonogy, instructions 3-72
HYDRAULIC SYSTEM 3-73
Hydraulic system – Safety instructions 3-73
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Depressurizing the hydraulic system 3-73
Checking the hydraulic oil level 3-74
Replacing the hydraulic oil return-flow filter (hydraulic oil reservoir) 3-76
Bypass valves (hydraulic oil reservoir), checking / cleaning 3-79
Replacing the bypass valves and sealing rings 3-79
Replacing the hydraulic oil return-flow filters (filter housing cooling system) 3-80
Bypass valves (filter housing – cooling system), checking / replacing 3-81
Breather filter, replace 3-82
Filter (servo control circuit) 3-83
High-pressure filter for working hydraulics, replace 3-84
High-pressure filters for swing circuit, replace 3-85
Filter pump control, clean 3-86
Changing the hydraulic oil 3-87
Avoid mixing of different hydraulic fluids 3-87
Venting the hydraulic system 3-91
Cleaning the hydraulic oil cooler 3-92
Electronic hydraulic shovel control, clean / lubricate 3-93
Pressure accumulator – Emergency lowering 3-94
PUMP TRANSFER GEARBOX 3-95
Pump gearbox, checking the oil level / Topping up with oil 3-95
Pump gearbox, change oil 3-96
Pump gearbox, venting 3-97
Pump transfer gearbox lube oil filters 3-98
SWING GEARBOX 3-99
Swing gearbox, checking the oil level / Topping up with oil 3-99
Swing gearbox, changing oil 3-100
Swing gearbox venting 3-100
SWING GEARBOX 3-101
Swing gearbox, checking the oil level / Topping up with oil 3-101
Swing gearbox, changing oil 3-102
Swing gearbox, venting 3-103
TRAVEL GEARBOX P/N 2712182 3-104
Travel gearbox, checking the oil level / Topping up with oil 3-104
Travel gearbox, changing oil 3-105
Pre-chamber / spur gear section, Changing the oil 3-105
Brake chamber, Changing oil 3-106
Breather filter 3-106
TRAVEL GEARBOX P/N 3683493 3-107
Travel gearbox – Checking the oil level / Topping up with oil 3-107
Brake chamber – Checking the oil level / Topping up with oil 3-107
Travel gearbox – Changing oil 3-108
Brake chamber – Changing oil 3-109
Breather filter 3-109
CRAWLER TRACKS 3-110
Track roller, Support roller 3-111
Track tensioner 3-112
Pressure-accumulator inspection regulations 3-113
Checking the gas charging pressure in the pressure accumulator 3-113
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SWING RING 3-114
Swing ring – Instructions 3-114
Bearing races 3-114
CENTRAL LUBRICATING SYSTEM 3-116
Design 3-116
Function 3-117
Filling up the grease container 3-118
Breather filter grease container, check / replace 3-118
Checking the greasing pressure 3-119
Unblocking a grease line 3-119
Oilfilter replace (hydraulic circuit grease pump) 3-120
Grease filter replace (filling the grease container) 3-121
Grease filter replace (Grease lines) 3-121
OTHER MAINTENANCE 3-122
Engine 3-122
Heating and air conditioning 3-122
Reservoirs for used grease at the A-frame, emptying 3-123
Hydraulic ladder, pressure accumulator 3-123
Pressure-accumulator inspection regulations 3-124
Extract from the German regulations 3-124
Checking the gas charging pressure in the pressure accumulator 3-124
ON-BOARD CRANE, DRIVE UNIT 3-125
On-board crane, greasing 3-125
On-Board crane, checking tightness of fastening bolts 3-126
PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING 3-127
Putting the hydraulic shovel out of operation 3-127
Battery storage 3-127
Recommissioning 3-127
NOTES 3-129
4 REPAIR WORK 4-1
REPAIR WORK – SAFETY INSTRUCTIONS 4-3
CONFINED SPACES – SAFETY INSTRUCTIONS 4-4
REPAIR WORK, FIRE AND EXPLOSION HAZARD 4-5
REPAIR WORK, ENGINE 4-6
HYDRAULIC SYSTEM 4-7
Repair instructions 4-7
Hydraulic hoses – Instructions 4-7
PRESSURE ACCUMULATORS – SAFETY INSTRUCTIONS 4-8
WELDING AND FLAME CUTTING WORKS – SAFETY INSTRUCTIONS 4-2
DISPOSAL AT THE END OF THE SERVICE LIFE 4-5
Appropriate disposal of batteries 4-6
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NOTES 4-8
5 ANNEX 5-1
BOARD-CONTROL-SYSTEM 5-3
BCS III, what’s that? 5-3
The keys on the front side 5-4
Other elements on the front side 5-4
BCSIII, the start screen 5-5
Information given on the start screen, top section 5-6
Information given on the start screen, central section 5-7
Information given on the start screen, lower section 5-8
Information given on the “Service” screen 5-9
Engine data screen 5-12
Hydraulic data screen 5-13
Lubrication data screen 5-14
Controls adjustment data screen 5-15
View documents screen 5-16
Signal table screen 5-17
Signal table screen, location 5-18
Signal table screen, diagram 5-19
Signal table screen, diagram configuration 5-20
Code table screen 5-21
BCS III, interfaces 5-22
USB interface, data storage 5-23
Saving data to a USB stick 5-24
Saving data to a USB stick, continued 5-25
Saving data to a USB stick, continued 5-26
BCSIII, cleaning 5-27
BCSIII, disposal 5-27
TROUBLESHOOTING 5-28
Instructions on troubleshooting 5-28
Layout of the fault table 5-28
Possible causes 5-28
Measures 5-28
Section 5-28
FAULT TABLES 5-29
Combustion engine – Fault table 5-29
Working hydraulics – Fault table 5-30
Track drive – Fault table 5-31
Swing mechnism – Fault table 5-32
Central lubricating system – Fault table 5-33
ENGINE MONITORING, CONTROL LAMPS 5-34
HYDRAULIC CIRCUIT DIAGRAM 5-35
ABBREVIATIONS 5-36
ABBREVIATIONS 5-37
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TECHNICAL DATA 5-2
NOTES 5-3
6 INDEX 6-1
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