PDF Operation & Maintenance Manual CAT 6030 6030FS Hydraulic Shovel - 2 MB
This is the complete Operation & Maintenance Manual for the CAT 6030 and 6030FS Hydraulic Shovels.
This essential document provides operators with detailed instructions on all machine functions and safety protocols.
It also outlines the manufacturer's recommended maintenance schedule to ensure maximum uptime and performance.
Following this manual is critical for the safe and efficient operation of these massive mining machines.
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BI015756
BA 6030(3 847 020.00)-EN
07 / 2013
Operation and
Maintenance
Manual
6030, 6030FS
Hydraulic Shovel No.
Machines from DHL30259 (MDG)
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BI015756
BA 6030(3 847 020.00)-EN
TABLE OF CONTENTS
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
xi
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BI015756
BA 6030(3 847 020.00)-EN
Introduction
Selection and qualification of per- In the event of malfunction, stop the machine im-
mediately and lock it. Have any defects rectified
sonnel; basic responsibilities immediately.
Any work on and with the machine must be exe- Start the machine from the operator's seat only.
cuted by reliable personnel only. Statutory mini-
During start-up and shut-down procedures always
mum age limits must be observed.
watch the indicators in accordance with the Opera-
Employ only trained or instructed staff and set out tion and Maintenence Manual.
clearly the individual responsibilities of the person-
Before setting the machine in motion, make sure
nel for operation, set-up, maintenance and repair.
that nobody is at risk.
Make sure that only authorized personnel works on
Before starting work or travelling with the machine,
or with the machine.
check that braking, signalling and lighting systems
Define the machine operator's responsibilities giv- are fully functional.
ing the operator the authority to refuse instructions
Before setting the machine in motion always check
by third parties that are contrary to safety.
that the accessories have been safely stowed
Do not allow persons to be trained or instructed or away.
persons taking part in a general training course to
In conditions of poor visibility and after dark always
work on or with the machine without being perma-
switch on the lighting system.
nently supervised by an experienced person.
Persons accopanying the operator must be seated
Work on the electrical system and equipment of
on the passenger seat provided for this purpose.
the machine must be carried out only by a skilled
electrician or by instructed persons under the su- When crossing underpasses and bridges or when
pervision and guidance of a skilled electrician and passing under overhead lines always make sure
in accordance with electrical engineering rules and that there is sufficient clearance.
regulations. Always keep a distance from the working face and
Work on chassis and brake systems must be per- from slopes.
formed by skilled personnel only, which has been Avoid any operation that might be a risk to machine
specially trained for such work. stability.
Work on hydraulic systems must be carried out Never travel across slopes; always keep the work-
only by personnel with special knowledge and ex- ing equipment and the load close to the ground,
perience of hydraulic equipment. especially when travelling downhill.
On sloping terrain always adapt your travelling
speed to the prevailing ground conditions.
Safety instructions governing
Before leaving the operator's seat always secure
specific operational phases the machine against inadvertent movement and
Standard operation unauthorized use. Shut off the engines.
Avoid any operational mode that might be prejudi-
cial to safety.
Before beginning work, familiarize yourself with the
surroundings and circumstances of the site, such
as obstacles in the working area and the bearing
capacity of the soil.
Take the necessary precautions to ensure that the
machine is in a safe and reliable state.
Operate the machine only if all protective and
safety-oriented devices, such as removable safety
devices, emergency shut-off equipment, sound-
proofing elements and exhausters, are in place and
fully functional.
Check the machine at least once per working shift
for obvious damage and defects. Report any
changes (incl. changes in the machine's working
behaviour) to the competent organization/person
immediately. If necessary, stop the machine imme-
diately and lock it.
1-7
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BI015756
BA 6030(3 847 020.00)-EN
Operation
OPERATION - SAFETY INSTRUC- Safety belts
TIONS For machines with safety belts for operating per-
sonnel:
Operation and Maintenence Manual Check the safety belts attached to the operator's
Never operate the machine before seat as well as at the trainer’s seat. In the event of
having read and understood the Op- damage or after an accident, have them replaced
eration and Maintenence Manual. immediately.
Apply the safety belts before starting work.
Pay special attention to:
the "Fundamental Safety Instructions" and to all
warning and instruction signs attached to the ma- State of the machine
chine. Operate the machine only in a safe state and only
Familiarize yourself with the layout, the functioning in accordance with its designated use. Always
and the sense of actuation of the control elements observe the safety instructions.
prior to starting up the machine. Always have inspection and maintenance work
Activate the control elements from the operator's carried out on schedule.
seat only. Operate the machine only with the equipment and
component combinations approved by CGM HMS
Keep the Operation and Maintenence Manual with
GmbH. Clear-cut data are given in the technical
the machine at all times.
specification.
Never install and commission other equipment
Operating personnel and component combinations without CGM HMS
GmbH having first inspected and approved the
The operating personnel must be fully informed of project.
the operation and application of this or compara-
ble machines. Before starting work or travelling with the machine,
check that the braking, signalling and lighting sys-
The necessary know-how can be acquired in sev- tems are fully functional.
eral days' instruction, e.g. by an CGM HMS GmbH
mechanic or by attending an CGM HMS GmbH Poor visibility may result in accidents. Always
operator's training course. clean the windows and the glass covers of all
lamps before starting the machine.
Check that all warning and instruction signs at-
Personal protective gear and working tached to the machine are present and legible.
clothing
Wear a safety helmet and working footwear with Entering and leaving the machine
non-slip soles. Smooth soles may slip from steps
and pedals resulting in injury or incorrect opera- Always face the machine when entering or leaving
tion. it.
Wear closely fitting working clothing when operat- Use only the ladders, steps, platforms and grab
ing the machine. Loose, wide garments may result handles provided when entering and leaving the
in control levers being inadvertently activated. machine.
Always maintain a three point contact with the
steps and grab handles.
Always keep ladders, steps and platforms in a
non-slip, safe state and remove any oil, grease,
soil, snow, ice and other foreign matter imme-
diately.
Hazard range
The hazard range is that zone around the machine
in which persons are within reach of loads or at-
tachments falling as a result of operational move-
ments by the machine, of its equipment and at-
tachments or of swinging loads.
2-3
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BI015756
BA 6030(3 847 020.00)-EN
Operation
Fig. 2-4:
2-13
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BI015756
BA 6030(3 847 020.00)-EN
Operation
Emergency exit in operator’s cab
and escape ladder
The sliding window (arrow, Fig. 2-23:) on the left-
hand side of the operator’s cab serves as an alter-
native opening / emergency exit.
To open the sliding window from inside the cab:
Lift latch (1).
Grasp handle (2) and slide window pane to the
left.
The escape ladder (arrow, Fig. 2-24:) is located
beside the operator´s cab.
Function of ladder locking as well as free move-
ment of the ladder must be regularly checked ac-
cording to the maintenance plans.
Before unlocking the ladder:
Be sure that no person is near to the Fig. 2-23:
position the ladder moves to.
Pull out locking pin (1, Fig. 2-25:). The escape
ladder is now unlocked and the release lever
(2) is free to move.
Move release lever (2) away from the machine.
The escape ladder is now free and moves
down quickly to the ground.
Swing barrier (3) to the right and use the ladder
to escape downwards.
Fig. 2-24:
Fig. 2-25:
2-23
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BI015756
BA 6030(3 847 020.00)-EN
Operation
Automatic fire-extinguishing sys- Windscreen washer
tem (optional) The fluid reservoir (1, Fig. 2-46:) of the windscreen
washer is located in the cab module. The capacity
The automatic fire-extinguishing sys- of the reservoir is indicated under "Refilling quanti-
tem prevents fire from spreading. It is, ties - Other".
however, assumed that the machine is
thoroughly cleaned of combustible
and easily flammable substances.
The hydraulic shovel operator and the maintenance
personnel must familiarize themselves with the
automatic fire-extinguishing system.
Such instruction should be given by a qualified
instructor.
The fire-extinguishing system is activated auto-
matically in an emergency.
Refill extinguishers immediately after use ready for
further deployment.
Fig. 2-46:
In an emergency the fire-extinguishing system is
actuated automatically.
Nevertheless particular extinguishing circuit e. g.
engine 1 or 2 (LH or RH) can be actuated manu-
ally. Operating hours meter
Inspection Three operating hours meters (Fig. 2-47:) are lo-
Have the extinguishing system inspected regularly cated in the left front door of the “24 Volts switch-
by an expert. This is required by authorities and gear cabinet” in the cab module.
insurance companies and is in the interest of your
own safety. 1 LH engine hours meter
Have the fire-extinguishing system 2 RH engine hours meter
checked at the prescribed intervals by 3 Travel hours meter
authorized testing agencies.
Fig. 2-47:
2-33
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BI015756
BA 6030(3 847 020.00)-EN
Operation
(Fig. 2-61:)
No. Element Function Symbol
Key-switch Switches the electrical system on and off.
32
Buzzer (inside the Gives three acoustic warning signals if a fault
33
control column) is reported. The signals appear every 30
seconds.
Socket connectors Connection of electronic devices for fault
34
diagnosis purposes.
Switch Emergency De-energizes the outputs of the electronic
35
shut-off control units:
The engines are shut off, working move-
ments no longer possible.
(see: "Emergency shut-off function").
2-43
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BI015756
BA 6030(3 847 020.00)-EN
Operation
(Fig. 2-66:)
All switches and pushbuttons have an illuminated symbol face.
The opposite side is equipped with an LED. The LED lights up when the switch / pushbutton is actuated.
No. Element Function Symbol
91 Push-button Dumper count Press the switch face with the symbol:
Resets the loaded dumper count.
92 Switch Windscreen wiper Press the switch face with the symbol:
Windscreen wiper in intermittent operation
mode.
Press the switch face without symbol:
Windscreen wiper in permanent operation
mode.
93 Pushbutton Windscreen washer Press the switch face with the symbol:
Windscreen wiper in wipe/wash operation.
94 Switch Rotary beacon (op- Press the switch face with the symbol:
tion) Rotary beacon ON.
95 Switch Lighting Press the switch face with the symbol:
Switches on the maintenance lights in the
modules.
96 Switch Lighting Press the switch face with the symbol:
Switches on the lights in the operator's cab.
97 Outlet For connecting electrical driven devices, e. g.
for charging accumulators.
Operating voltage: 12 Volts.
Maximum power output : 120 Watts.
2-53
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BI015756
BA 6030(3 847 020.00)-EN
Operation
(Fig. 2-71:)
Air conditioner
(Option. Depending on the options ordered with the machine, the described elements can be found on differ-
ent positions on the control column).
No. Element Function Symbol
Rotary switch Blower of air condi- Blower levels 1,2,3.
150
tioner
Knob Thermostat Presetting of desired temperature.
151
Rotary switch Selector Selects the following functions:
152
heating, cooling, ventilation, defrosting.
2-63
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BI015756
BA 6030(3 847 020.00)-EN
Operation
Assemblies resp. Measuring device Remarks
reservoirs
Cooling system Level indicator (4, Fig. 2-87:) Fill in cooling fluid using express couplings (2 and/or 3,
reservoir Fig. 2-89:). Stop filling when the level indicator indicates
maximum filling level. (see: chapter "Cooling system -
Cooling liquid").
Grease container – BCS display (Fig. 2-88:) BCS gives a warning if the grease container is nearly
cental lubricating empty.
system Switch on the display system with the toggle switch (23),
indicator lamp (22) comes on.
Fill in grease using express coupling (11, Fig. 2-90:).
Stop filling when the grease container is full, the indica-
tor lamp (34) lights up.
On completion of filling, switch the display system off
again with the toggle switch (23), indicator lamp (22) is
off.
Fig. 2-87: Fig. 2-89:
Fig. 2-90:
Fig. 2-88:
2-73
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BI015756
BA 6030(3 847 020.00)-EN
Operation
Back-up heating (optional)
The back-up heating is located in the module below Control unit
the operator’s cab (Fig. 2-106:). (Fig. 2-108:):
The outlets are below and behind the operator’s
seat (Fig. 2-107:). They are adjustable in several
directions.
The heating system uses the engine cooling fluid.
Therefore full heating power is available after the
engines reach their operating temperature.
Before switching on the blower, turn the valves
(arrow, Fig. 2-106:) into direction of flow.
The back-up heating control elements are located
at the control column unit (Fig. 2-108:).
Do not switch on the back-up heating
when the air conditioner is set to
”cooling”.
Fig. 2-108:
Pos. Element Function
1 Indicator lamp heating ON
2 Indicator lamp blower ON
3 Indicator lamp heating
4 Indicator lamp cooling
5 Switch heating ON
6 Switch blower ON
Fig. 2-106:
7 Indicator lamp blower level 3
8 Indicator lamp blower level 2
9 Indicator lamp blower level 1
Fig. 2-107:
2-83
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BI015756
BA 6030(3 847 020.00)-EN
Operation
WORKING OPERATION - SAFETY
INSTRUCTIONS Running-in instructions for hydraulic
cylinders
Read the sections "Fundamental
safety instructions" and "Operation, Compression of an oil/air compound in a hydraulic
safety instructions" carefully and ob- cylinder may result in detonations which might
serve the instructions given in them. damage pistons and sealing rings.
Prior to initial commissioning and/or after repairs,
run in the hydraulic cylinders as follows:
Inspect the site for underground gas, power and Start up the engines and run at low speed.
water lines before starting work. Any damage to The pressure-limiting valve in the hydraulic
such lines is a risk to life! system must not respond
Clean off any earth, mud, snow, ice, grease and oil
In the first two working cycles, retract and ex-
adhering to your working footwear before operating
tend the pistons of the hydraulic cylinders to
the machine. There is otherwise a risk of slipping
max. ½ to ¾ (not to the limit stop).
off the pedals and initiating inadvertent move-
Never change direction suddenly. The waiting
ments.
time between changes of direction must be at
Sound the horn to warn persons in the immediate least 4 seconds.
vicinity before starting work.
Stop work if anyone is in the hazard range of the In the next eight working cycles, retract and
machine. Make sure they have left the hazard extend the pistons of the hydraulic cylinders to
range before resuming work. the limit stop. The waiting time between
changes of direction must be at least 4 sec-
Never operate the machine unless it is standing on onds.
a reasonably horizontal, flat surface. The stability of
the machine is otherwise at risk. When all hydraulic cylinders have been run in,
Ensure that the attachment has adequate clear- the hydraulic shovel can operate at a higher
ance below overhead power lines and structures. engine speed.
Trenches and working faces may give way. Keep
well clear of them.
Do not operate the machine, Warming up the hydraulic system
when several track rollers or support rollers At low temperatures, bring the engines down to
have been removed; moderate speed, then activate all hydraulic func-
tions for about 10 minutes (bring to service tem-
when one or several slewing gearboxes have perature). For further instructions, see section
failed or been removed; „LUBRICANTS / CONSUMABLES“.
when one or several teeth on the backhoe or If the BCS indicates problems with the cooling liq-
on the shovel are worn or missing; uid temperature, engine oil pressure, coolant level,
alternator or hydraulic oil filter control (with hydrau-
when parts of the hardfacing layer on the lic oil at service temperature) light up:
backhoe or on the shovel are worn or missing.
Lower the working equipment and shut off engines.
Working under these circumstances results in
heavy wear and possibly in severe damage and
thus in high repair costs.
Such circumstances are considered by CGM HMS
GmbH as "unauthorized utilization".
CGM HMS GmbH refuses to assume the guaran-
tee for damage and consequential damage caused
by an abusive utilization of the machine.
2-93
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BI015756
BA 6030(3 847 020.00)-EN
Operation
ON-BOARD CRANE (OPTIONAL) Monitoring, warning and control
The on-board crane is designed for elements
lifting heavy parts only. (Fig. 2-138:)
Do not lift persons.
Observe all national directives as well
as specific regulations relevant to
crane operation.
Personel
Crane work may be carried out only by operators
who have the necessary know-how and the per-
mission to operate cranes.
If such know-how or such permission is lacking,
meticulous instruction must be given by experi-
enced personnel, e.g. from CGM HMS GmbH.
Incorrect operation of the crane may give rise to
life-threatening situations.
Fig. 2-138:
Pos. Element Function
1 Monitoring lamp Alternator
2 Warning lamp Engine oil pressure
3 Warning lamp Engine temperature
4 Monitoring lamp Air filter
5 Key-switch Electrical system ON/OFF
6 Button Start engine of drive unit
7 Monitoring lamp Preheating system (option)
8 Knob Engine speed variation
9 Monitoring lamp Crane in operation
10 Warning lamp Malfunction
11 Button EMERGENCY STOP
12 Button Emergency lowering of
winch
21 Control lever Extending and retracting of
boom extension
22 Control lever Folding the boom
23 Control lever Swinging the boom
24 Control lever Winch up / down