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
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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
operation, including setting-up, troubleshooting 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 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.
IMAGES PREVIEW OF THE MANUAL:
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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S.M