CAT 6030 6030 FS Hydraulic Shovel Operation & Maintenance Manual - PDF DOWNLOAD

BA 6030(3 847 020.00)-EN 07 / 2013

Operation and Maintenance Manual 6030, 6030FS Hydraulic Shovel Machines from DHL30259 (MDG)

No.

BA 6030(3 847 020.00)-EN

Published by:

Caterpillar Global Mining HMS GmbH Dept. Technical Publications D-44149 Dortmund, Karl-Funke-Straße 36 Tel. 49 (0) 231 922-4340 Fax 49 (0) 231 922-5005 E-Mail dokumentation-HEX@cat.com https://mining.cat.com www.bucyrus-hex.de

© Copyright Caterpillar Global Mining Hydraulic Mining Shovels GmbH 2013. The reproduction, distribution and utilization of this manual / file as well as the communication of its content to others without express authorization is prohibited. Offenders will be held liable for the payment of damages. All rights reserved in the event of the grant of a patent, utility model or design.

Printed in Germany

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The Operation and Maintenance Manual is in 6 sections; the sections are designed for different target groups: Operation and Maintenence Manual

Target group

Part 1 INTRODUCTION FUNDAMENTAL SAFETY INSTRUCTIONS

Operating personnel + Inspection and servicing personnel + Repair personnel

Part 2 OPERATION

Operating personnel The operating personnel must have knowhow relevant to the operation and the application of this or comparable machines.

Part 3 INSPECTION AND SERVICING

Inspection and servicing personnel

Part 4 REPAIR WORK

Repair personnel

The inspection and servicing personnel must have know-how relevant to the inspection and servicing of this or comparable machines.

The repair personnel must have know-how and experience relevant to the repair of this or comparable machines.

Part 5 ANNEX

Part 6 INDEX

Operating personnel + Inspection and servicing personnel + Repair personnel Operating personnel + Inspection and servicing personnel + Repair personnel

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TABLE OF CONTENTS TABLE OF CONTENTS 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 v

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TABLE OF CONTENTS 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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TABLE OF CONTENTS 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 vii

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TABLE OF CONTENTS 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 viii

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TABLE OF CONTENTS 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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TABLE OF CONTENTS 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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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

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TABLE OF CONTENTS TECHNICAL DATA _________________________________________________________________ 5-2 NOTES __________________________________________________________________________ 5-3 6 INDEX ___________________________________________________________________________ 6-1

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Introduction 1 INTRODUCTION Operation and Maintenence Manual

Target group

Part 1 INTRODUCTION FUNDAMENTAL SAFETY INSTRUCTIONS

Operating personnel + Inspection and servicing personnel + Repair personnel

Part 2 OPERATION

Operating personnel The operating personnel must have knowhow relevant to the operation and the application of this or comparable machines.

Part 3 INSPECTION AND SERVICING

Inspection and servicing personnel

Part 4 REPAIR WORK

Repair personnel

The inspection and servicing personnel must have know-how relevant to the inspection and servicing of this or comparable machines.

The repair personnel must have know-how and experience relevant to the repair of this or comparable machines.

Part 5 ANNEX

Part 6 INDEX

Operating personnel + Inspection and servicing personnel + Repair personnel Operating personnel + Inspection and servicing personnel + Repair personnel

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Introduction

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Introduction PREFACE These operation and maintenance manual is designed to familiarize the operator with the machine and its designated use.

The Operation and Maintenence Manual 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 Operation and Maintenence Manual must be supplemented by the respective national rules and regulations for accident prevention and environmental protection.

The Operation and Maintenence Manual must always be available in the operator's cab of the machine.

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

All CGM HMS GmbH operating manuals are issued in German and then translated. Even a good translation may give rise to questions which CGM HMS GmbH will be pleased to answer.

The Operation and 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.

Further machine documentation 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 Operation and Maintenence Manual, the spare-parts list and the Service Manuals are marked with the serial number of the machine.

The documentation supplied with your machine is rather comprehensive. Therefore, it has been split up in several volumes: Volume 1: the present Operation and Maintenence Manual,

operation, including setting-up, troubleshooting in the course of work, care, evacuation of production waste and disposal of fuels and consumables,

Volume 2:

spare-parts catalog of the machine,

Volume 3:

cross reference list of spare parts,

Volume 4:

electrical circuit diagram and key,



maintenance (inspection, servicing, repair) and / or

Volume 5:

documentation of the engine and of other components,



transport.

Volume 6:

Service Manual Part 1

Volume 7:

Service Manual Part 2



In addition to the Operation and Maintenence Manual 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 1 observed .

The Operation and Maintenence Manual 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 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 Maintenence Manual.

Depending on the size of your machine, the documentation can also consist of more volumes.

If you cannot find the information you are looking for in the present Operation and Maintenence Manual please check also the other volumes of the documentation.

The Service Manual Part 1 also provides information on how to assemble the machine, on functions of the hydraulic system, on hydraulic circuit diagrams etc.

On taking receipt of the consignment, please check that the documentation is complete and in the language requested by you.

CGM HMS GmbH = Caterpillar Global Mining Hydraulic mining Shovels GmbH.

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Complies with VDMA recommendation "Operating instructions" 1-1

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Introduction WARRANTY The warranty of CGM HMS GmbH presupposes among other things that the servicing works as described in the Operation and Maintenence Manual have been performed: 

Do not operate the machine  when components / assemblies are defective or missing, 

by your Caterpillar dealer

or 

in a workshop authorized in writing by CGM HMS GmbH,

and 

by using the original spare parts of CGM HMS GmbH.

The proper execution of the servicing works must be documented on the CGM HMS GmbH checklists.

if one or several of such components of which more than one are installed in the machine have been removed.

In cases of doubt seek advice from your Caterpillar dealer.

CGM HMS GmbH refuses to assume the guaranteee for damage and consequential damage caused by an abusive utilization of the machine.

Therefore: Do not operate the machine,  when several track rollers or support rollers have been removed; 

when one or several slewing gearboxes have failed or been removed;



when one or several teeth on the backhoe or on the shovel are worn or missing;



when parts of the hardfacing layer on the backhoe or on the shovel are worn or missing.

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 "abusive utilization".

Why? The machines have been designed and built on the basis of detailed calculations and so that all of the components installed absorb the occurring forces and are thus loaded to an equal extent.

Example: If the machine is used for working with, for instance, one or even several track rollers removed, the forces must be absorbed by the remaining track rollers. These are then overloaded or loaded to a greater extent than calculated.

The consequences are higher wear and consequential damage to the track rollers, but also to other components of the machine: chassis, travel gearbox and crawler track.

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Introduction FUNDAMENTAL SAFETY INSTRUCTIONS Complies with VDMA recommendation "Operation and Maintenence Manual"

Content of EC-Conformity Declaration according to EC Machine Directive 2006/42/EC:

Warnings and symbols The following signs are used in the Operation and Maintenence Manual to designate instructions of particular importance: Precautionary rules and measures designed to protect the machine operator and other persons from lifethreatening danger or injuries and to prevent extensive damage.

Inhalt der EG-Konformitätserklärung gem. EG-Maschinenrichtlinie 2006/42/EG: Hersteller: / Manufacturer: / Κατασκευαστής: CGM HMS GmbH GmbH Karl-Funke-Straße 36 D-44149 Dortmund Deutschland / Germany

Information and precautionary measures designed to prevent damage to the machine or other property.

Telefon / Telephone: +49 231-922-3 Telefax / Telefax: +49-231-922-5300 Der Hersteller bescheinigt, daß die Maschine The manufacturer certifies that the machine Art : Groß-Hydraulikbagger Category : Hydraulic excavator Typ : / Type : 6030 / 6030FS der EG-Richtlinie 2006/42/EG entspricht. is in conformity with EC Directive 2006/42/EC. Dokumentationsbevollmächtigter: / Authorised person for documents: Herr Uwe Friedhoff (Konstruktion) Mr.Uwe Friedhoff (Design Department) Datum: / Date: 14.03.2012 Unterschrieben von : / Signed by: Konstruktionsleitung / Head of Design Dept. / Leitung QM Support / Head of QM Support

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Introduction DESIGNATED USE, UNAUTHORIZED USE The machine has been built in accordance with state-of-art standards and the recognized safety rules. Nevertheless, its use may constitute a risk to life and limb for the user or third parties or cause damage to the machine and to other material property (acceptable risk)

Using the hydraulic shovel or its attachments for purposes other than or extending beyond those stated above, e.g.:  for lifting or transporting persons, 

as a working platform,



for lifting crane loads without the equipment being approved for this purpose,



for driving in posts, sheetpiles supports, etc. without the equipment being approved for this purpose,



for moving material to the side (sweeping),



for breaking down rocks by beating with the shovel or the backhoe,

With attached shovel equipment, the machine is to be used solely for loosening and loading of:



for fitting or reparing of other machines

 sand, oil sand,

is contrary to its designated use and considered as "unauthorized use".

An acceptable risk is present, e.g.: loose material or material to be loaded may drop out of the bucket or backhoe while the working equipment is being swivelled.

The machine must be used only in technically perfect condition in accordance with its designated use and the instructions set out in the Operation and Maintenence Manual, and only by safety-conscious persons who are fully aware of the risks involved in operating the machine. Any functional disorders, especially those affecting the safety of the machine, should therefore be rectified immediately.

 gravel,  blasted rock,  ore,

Lifting eyes on the lower carriage -

are settled for transporting with a crane only.

-

must not be used for towing a machine.

 coal, and other raw materials.

With attached backhoe equipment, the machine can additionally also be used for excavating and loading of excavatable soils and other raw materials.

Operating the machine within the limits of the desigated use also involves observing the instructions set out in the Operation and Maintenence Manual and complying with the inspection and maintenance directives.

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Improper use may involve a life-threatening risk for operators or other personnel or may cause injury or extensive damage.

The manufacturer/supplier cannot be held liable for any damage resulting from other than the designated use. The risk involved in such misuse lies with the user.

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Introduction Noise emission information

Vibration information

Noise emission data are specified in acc. with EC Machine Directive 2006/42/EC, Annex I, Section 1.7.4.2.u)

On the condition that the excavator is used within the limits of its designated use, the installation of seats for operators in conformity with ISO 7096 ensures that the weighted vibration accelerations awz (measured in compliance with ISO 2631 Part I) fulfil the requirements with respect to the protection against whole-body vibrations in acc. with EC Vibration Directive 2002/44/EG.

Sound power level: LWA = 114,9 dB(A).

Sound pressure level at operator's seat: LpA = 78 dB(A).

The vibrations transferred are indicated in acc. with EC Machine Directive 2006/42/EG, Annex I; Section 3.6.3.1, resp. with the "Regulations for noise and vibration at the place of work", Section 4, as of 18.12.2008.

The effective value of the weighted acceleration to which the wole body is exposed, does not exceed 2 0.5 m/s .

The measurement uncertainty is ±3% (tolerance of the measuring instruments).

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Introduction ORGANIZATIONAL MEASURES The Operation and Maintenence Manual must always be at hand at the place of use of the machine, e.g. by stowing them in the place provided for such purpose.

In addition to the Operation and Maintenence Manual, observe and instruct the user in all other generally applicable legal and other mandatory regulations relevant to accident prevention and environmental protection.

These compulsory regulations may also deal with the handling of hazardous substances, issuing and/or wearing of personal protective equipment or traffic regulations.

The Operation and Maintenence Manual must be supplemented by instructions covering the duties involved in supervising and notifying special organizational features, such as job organization, working sequences or the personnel entrusted with the work.

Personnel entrusted with work on the machine must have read the Operation and Maintenence Manual and in particular the chapter on safety before beginning work. Reading the Operation and Maintenence Manual after work has begun is too late. This applies especially to persons working only occasionally on the machine, e.g. during setting up or maintenance.

Check - at least from time to time - whether the personnel is carrying out the work in compliance with the Operation and Maintenence Manual and paying attention to risks and safety factors.

For reasons of security, long hair must be tied back or otherwise secured, garments must be closefitting and no jewellery, such as rings, may be worn. Injury may result from being caught up in the machinery or from rings catching on moving parts.

Use protective equipment wherever required by the circumstances or by law.

Personal protective equipment and the working clothing Depending on the cleaning, servicing and/or repair activities to be performed, the personal protective equipment and the working clothing may consist of the following items: 

fall arresters



protective suit



helmet



goggles - e. g. for cleaning work - or for welding work



protective gloves - e.g. for work on hot units - for grinding and welding work



protective working gloves - e.g. for fitting work - for grinding and welding work



ear protectors

Observe all safety instructions and warnings attached to the machine.

See to it that safety instructions and warnings attached to the machine are always complete and perfectly legible.

In the event of safety-relevant modifications or changes in the behaviour of the machine during operation, stop the machine immediately and report the malfunction to the competent authority/person.

Never make any modifications, additions or conversions which might affect safety without the supplier's approval. This also applies to the installation and adjustment of safety devices and valves as well as to welding work on load-bearing elements.

Use only the original sparts parts of CGM HMS GmbH. They are the only ones to fulfill the technical specifications of the machine.

Replace hydraulic hoses within stipulated and appropriate intervals, even if no safety-relevant defects have been detected.

Adhere to prescribed intervals or those specified in the Operation and Maintenence Manual for routine checks and inspections.

For the execution of maintenance work, tools and workshop equipment adapted to the task on hand are absolutely indispensable.

The personnel must be familiar with the location and operation of fire extinguishers.

Observe all fire-warning and fire-fighting procedures.

1-6

BA 6030(3 847 020.00)-EN

Introduction Selection and qualification of personnel; basic responsibilities

In the event of malfunction, stop the machine immediately and lock it. Have any defects rectified immediately.

Any work on and with the machine must be executed by reliable personnel only. Statutory minimum age limits must be observed.

Start the machine from the operator's seat only.

Employ only trained or instructed staff and set out clearly the individual responsibilities of the personnel for operation, set-up, maintenance and repair.

Make sure that only authorized personnel works on or with the machine.

Define the machine operator's responsibilities giving the operator the authority to refuse instructions by third parties that are contrary to safety.

Do not allow persons to be trained or instructed or persons taking part in a general training course to work on or with the machine without being permanently supervised by an experienced person.

Work on the electrical system and equipment of the machine must be carried out only by a skilled electrician or by instructed persons under the supervision and guidance of a skilled electrician and in accordance with electrical engineering rules and regulations.

Work on chassis and brake systems must be performed by skilled personnel only, which has been specially trained for such work.

Work on hydraulic systems must be carried out only by personnel with special knowledge and experience of hydraulic equipment.

Safety instructions governing specific operational phases Standard operation

During start-up and shut-down procedures always watch the indicators in accordance with the Operation and Maintenence Manual.

Before setting the machine in motion, make sure that nobody is at risk.

Before starting work or travelling with the machine, check that braking, signalling and lighting systems are fully functional.

Before setting the machine in motion always check that the accessories have been safely stowed away.

In conditions of poor visibility and after dark always switch on the lighting system.

Persons accopanying the operator must be seated on the passenger seat provided for this purpose.

When crossing underpasses and bridges or when passing under overhead lines always make sure that there is sufficient clearance.

Always keep a distance from the working face and from slopes.

Avoid any operation that might be a risk to machine stability.

Never travel across slopes; always keep the working equipment and the load close to the ground, especially when travelling downhill.

On sloping terrain always adapt your travelling speed to the prevailing ground conditions.

Before leaving the operator's seat always secure the machine against inadvertent movement and unauthorized use. Shut off the engines.

Avoid any operational mode that might be prejudicial 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, soundproofing 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 immediately and lock it.

1-7

BA 6030(3 847 020.00)-EN

Introduction Special work in conjunction with utilization of the machine and maintenance and repairs as well as troubleshooting during work; disposal of parts and consumables Observe the adjusting, maintenance and inspection activities and intervals set out in the Operation and Maintenence Manual, including information on the replacement of parts and equipment. These activities may be executed by skilled personnel only.

Brief operating personnel before beginning special operations and maintenance work, and appoint a person to supervise the activities.

In any work concerning the operation, conversion or adjustment of the machine and its safetyoriented devices or any work related to maintenance, inspection and repair, always observe the start-up and shut-down procedures set out in the Operation and Maintenence Manual and the information on maintenance work.

Ensure that the maintenance area is adequately secured.

If the machine is completely shut down for maintenance and repair work, it must be secured against inadvertent starting by:  removing the ignition key and  attaching a warning sign.

Carry out maintenance and repair work only if the machine is positioned on stable and level ground and has been secured against inadvertent movements.

To avoid the risk of accidents, individual parts and large assemblies being moved for replacement purposes should be carefully attached to lifting tackle and secured. Use only suitable and technically perfect lifting gear and suspension systems with adequate lifting capacity. Never work or stand under suspended loads.

The fastening of loads and the instructing of crane operators should be entrusted to experienced persons only. The marshaller giving the instructions must be within sight or sound of the operator.

For carrying out overhead assembly work always use specially designed or otherwise safety-oriented ladders and working platforms. Never use machine parts as a climbing aid Wear a safety harness when carrying out maintenance work at heights above 1 m.

Wear an approved harness equipped with fall arresters and safety lines.

1-8

Keep all handles, steps, handrails, platforms, landings and ladders free from dirt, snow and ice.

Clean the machine, especially connections and threaded unions, of any traces of oil, fuel or preservatives before carrying out maintenance/repair.

Never use aggressive detergents. Use lint-free cleaning rags.

Before cleaning the machine with water, steam jet (high-pressure cleaning) or detergents, cover or tape up all openings which - for safety and functional reasons - must be protected against water, steam or detergent penetration. Special care must be taken with electric motors and switch-gear cabinets.

Ensure during cleaning of the machine that the temperature sensors of the fire-warning and firefighting systems do not come into contact with hot cleaning agents as this might activate the firefighting system.

Exhaust pipes and turbo chargers in the engine compartments are covered with special heatinsulating material. This material must not be spray-washed with steam-jet cleaners or highpressure cleaners. It will be damaged. Therefore cover all the insulating material with plastic foils before using steam-jet cleaners or high-pressure cleaners inside the engine compartments.

After cleaning remove all covers and tapes applied for that purpose.

After cleaning, examine all fuel, lubricant, brake and hydraulic fluid lines for leaks, loose connections, chafe marks and damage. Any defect found must be rectified without delay.

Always tighten any screwed connections that have been loosened during maintenance and repair.

Any safety devices removed for set-up, maintenance or repair purposes must be refitted and checked immediately upon completion of maintenance and repair work.

Ensure that all consumables and replaced parts are disposed of safely and with minimum environmental impact.

BA 6030(3 847 020.00)-EN

Introduction Warning of special dangers

Gas, dust, steam and smoke

Electric energy

Always start and operate the engine in a wellvented area;

Use only original fuses with the specified current rating. Switch off the machine immediately if trouble occurs in the electrical system.

When working with the machine, maintain a safe distance from overhead electric lines. If work is to be carried out close to overhead lines, the working equipment must be kept well away from them.

Caution, danger! Check out the prescribed safety distances.

If your machine comes into contact with a live wire  do not leave the machine  drive the machine out of the hazard zone; warn others against approaching and touching the machine  have the live wire de-energized  do not leave the machine until the damaged or contacted line has been safely de-energized.

The electrical equipment of machines is to be inspected and checked at regular intervals. Defects such as loose connections or scorched cables must be rectified immediately.

High-voltage system Floodlamps equipped with gaz discharge lamps (Xenon) require a high-voltage supply (ca. 25 kV).

If in an enclosed area, vent the exhaust to the outside; Do not modify or tamper with the exhaust system Diesel engine exhaust and some of its constituents are known to cause cancer, birth defects, and other reproductive harm Operate fuel-operated heating systems only on adequately ventilated premises. Before starting the machine on enclosed premises, make sure that there is sufficient ventilation.

Observe the regulations in force at the respective site.

Carry out welding, flame-cutting and grinding work on the machine only if this has been expressly authorized, as there may be a risk of explosion and fire.

Before carrying out welding, flame-cutting and grinding operations, clean the machine and its surroundings from dust and other inflammable substances and make sure that the premises are adequately ventilated (risk of explosion).

CALIFORNIA Proposition 65 Warning Diesel fuel and Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

The high voltage is generated by a ballast unit.

Switch off the electrical system of the hydraulic shovel before touching the lamp or the ballast unit.

Battery Warning! Battery Posts, terminals and related accessories contain lead and lead compounds, chemicals known to cause cancer and reproductive harm. Wash hands after handling.

1-9

BA 6030(3 847 020.00)-EN

Introduction Hydraulic equipment

Ether

Check all lines, hoses and screwed connections regularly for leaks and obvious damage. Repair damage immediately. Splashed oil may cause injury and fire.

The machine can be equipped with pressure vessels for cold-starting fluid (ether) installed in the engine compartment. Ether is toxic and highly flammable; the vessels are under pressure. These pressure vessels can explode if exposed to high temperatures (above 49°C / 120°F) or in the event of damage. Protect the vessels against damage and high temperatures.

Depressurize all system sections and pressure pipes (hydraulic system) to be removed in accordance with the specific instructions for the unit concerned before carrying out any repair work.

Hydraulic lines must be laid and fitted properly.

Ensure that no connections are interchanged. The fittings, lengths and quality of the hoses must comply with the technical requirements.

Noise During operation, all sound baffles of the machine must be closed.

Always wear the prescribed ear protectors.

Oil, grease and other chemical substances When handling oil, grease or other chemical substances, observe the product-related safety regulations (see safety specifications).

Be careful when handling hot consumables (risk of burning or scalding).

Do not store pressure vessels with cold-starting fluid (ether) on the hydraulic shovel.

Do not eat, drink or smoke when replacing pressure vessels with cold-starting fluid (ether). Observe the instructions on the pressure vessels.

Provide for sufficient ventilation (see also Part 3 "Inspection and servicing").

Do not open empty cold-starting fluid pressure vessels (ether). Have the vessels disposed of properly.

For further details please refer to the instructions and safety data-sheets of the manufacturer / supplier of pressure vessels with cold starting fluid (ether).

Transporting and recommissioning The machine must be loaded and transported only in accordance with the Operation and Maintenence Manual.

Use only appropriate means of transport and lifting gear of adequate capacity.

The recommisioning procedure must be strictly in accordance with the Operation and Maintenence Manual.

1-10

BA 6030(3 847 020.00)-EN

Introduction FIRE AND EXPLOSION HAZARD Safety instructions Prior to commencing work, obtain informationon the national and corporate rules for the prevention of accidents and avoiding fires.

Pay particular attention to hazards caused by combustible and easily flammable substances.

Obtain information on the safe handling of the fire extinguishers to be used.

Avoid smoking and open fire on, next to and below the hydraulic shovel.

Combustible and easily flammable substances or liquids increase the fire and explosion hazard.

Do not store or transport flammable substances on the hydraulic shovel during the work. This is also valid for pressure vessels containing flammable substances as, for instance, spray oil or coldstarting fluid (ether). They are heat-sensitive and can explode even if exposed only to intensive sunlight.

Clean the hydraulic shovel carefully, if oil, grease, fuel, detergents or cold-starting fluid have been spilt over the machine. If possible, use a steam-jet cleaner for cleaning.

These substance can also ignite themselves if they come close to hot units or objects as, for instance, a turbocharger.

Even battery gases can ignite in open flames or fire.

Place suitable fire guardings (fire barriers) if open fire or flying sparks cannot be avoided during repair work.

Apply special protection to cables, cable ducts as well as to hose and pipe lines.

If necessary, also cover the ground with fireprotective blankets.

The engine compartment can be equipped with pressure vessels containing cold-starting fluid (ether). Ether is toxic and highly flammable; the vessels are under pressure. These pressure vessels can explode if exposed to high temperatures (above 49°C / 120°F) or in the event of damage.

Protect the pressure vessels against damage before beginning to work in or close to the engine compartment.

Ensure sufficient ventilation.

Clean the hydraulic shovel before starting a job.

Do not keep any fire extinguishers that are not suitable or have not been tested.

Do not extinguish flammable liquids with water.

Use:  dry-powder, 

carbon-dioxide or



foam extinguishing compounds.

When getting into contact with burning substances, the fire-fighting water would abruptly evaporate and distribute the substance such as oil over a wide area. Water causes short-circuits in the electrical system thus possibly entailing new hazards.

Call the fire brigade.

Have all your welding, flame cutting and grinding work approved.

Avoid parking the hydraulic shovel in places where  combustible substances such as coal dust or tar are present. 

open or smouldering fire may occur.

Remove the hydraulic shovel from such an area where combustible or easily flammable liquids have spilled from the hydraulic shovel onto the ground.

Flying sparks (caused by welding, flame cutting, grinding, electrical short-circuit) may cause fire on the ground that can spread to the hydraulic shovel.

1-11

BA 6030(3 847 020.00)-EN

Introduction

1-12

BA 6030(3 847 020.00)-EN

Introduction NOTES ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ...................................................................................................................................................................

1-13

BA 6030(3 847 020.00)-EN

Introduction

1-14

BA 6030(3 847 020.00)-EN

Operation 2 OPERATION Operation and Maintenence Manual

Target group

Part 1 INTRODUCTION FUNDAMENTAL SAFETY INSTRUCTIONS

Operating personnel + Inspection and servicing personnel + Repair personnel

Part 2 OPERATION

Operating personnel The operating personnel must have knowhow relevant to the operation and the application of this or comparable machines.

Part 3 INSPECTION AND SERVICING

Inspection and servicing personnel

Part 4 REPAIR WORK

Repair personnel

The inspection and servicing personnel must have know-how relevant to the inspection and servicing of this or comparable machines.

The repair personnel must have know-how and experience relevant to the repair of this or comparable machines.

Part 5 ANNEX

Part 6 INDEX

Operating personnel + Inspection and servicing personnel + Repair personnel Operating personnel + Inspection and servicing personnel + Repair personnel

2-1

BA 6030(3 847 020.00)-EN

Operation

2-2

BA 6030(3 847 020.00)-EN

Operation OPERATION - SAFETY INSTRUCTIONS

Safety belts

Operation and Maintenence Manual

Check the safety belts attached to the operator's seat as well as at the trainer’s seat. In the event of damage or after an accident, have them replaced immediately.

Never operate the machine before having read and understood the Operation and Maintenence Manual.

Pay special attention to: the "Fundamental Safety Instructions" and to all warning and instruction signs attached to the machine.

Familiarize yourself with the layout, the functioning and the sense of actuation of the control elements prior to starting up the machine.

Activate the control elements from the operator's seat only.

Keep the Operation and Maintenence Manual with the machine at all times.

Operating personnel The operating personnel must be fully informed of the operation and application of this or comparable machines.

The necessary know-how can be acquired in several days' instruction, e.g. by an CGM HMS GmbH mechanic or by attending an CGM HMS GmbH operator's training course.

Personal protective gear and working clothing

For machines with safety belts for operating personnel:

Apply the safety belts before starting work.

State of the machine Operate the machine only in a safe state and only in accordance with its designated use. Always observe the safety instructions.

Always have inspection and maintenance work carried out on schedule.

Operate the machine only with the equipment and component combinations approved by CGM HMS GmbH. Clear-cut data are given in the technical specification.

Never install and commission other equipment and component combinations without CGM HMS GmbH having first inspected and approved the project.

Before starting work or travelling with the machine, check that the braking, signalling and lighting systems are fully functional.

Poor visibility may result in accidents. Always clean the windows and the glass covers of all lamps before starting the machine.

Check that all warning and instruction signs attached to the machine are present and legible.

Wear a safety helmet and working footwear with non-slip soles. Smooth soles may slip from steps and pedals resulting in injury or incorrect operation.

Entering and leaving the machine

Wear closely fitting working clothing when operating the machine. Loose, wide garments may result in control levers being inadvertently activated.

Use only the ladders, steps, platforms and grab handles provided when entering and leaving the machine.

Always face the machine when entering or leaving it.

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 immediately.

Hazard range The hazard range is that zone around the machine in which persons are within reach of loads or attachments falling as a result of operational movements by the machine, of its equipment and attachments or of swinging loads.

2-3

BA 6030(3 847 020.00)-EN

Operation Persons within the hazard zone Always use the horn to warn persons in the immediate vicinity of the machine before starting up the machine.

Operation and Maintenence Manual, where to store it in the operator’s cab

Ensure that no one sets foot in the hazard zone of the machine. Interrupt work until such persons have left the hazard zone.

One copy of the Operation and Maintenence Manual for the machine must be available in the operator’s cab during operation.

Replace Operation and Maintenence Manual if lost, damaged or unreadable.

Marshallers The marshaller must keep outside the hazard zone.

The binder with the Operators Instructions can be stored in the tray (Fig. 2-1:).

Have a marshaller to assist you:  when you have no clear overview over the hazard zone of the machine, 

when reversing,



when shunting.

Use only those communication signals which you and the marshaller understand, or use aids for communication (e.g. walkie-talkie/camera). Calls cannot be understood by the marshaller because of the noise made by the machine during operation.

Keep in constant contact with the marshaller.

Stop the machine immediately if you lose contact with the marshaller.

Securing the machine Secure the machine as described under "Securing the machine" before:  mounting or dismantling the attachment, 

parking the machine after daily operation,



carrying out any servicing or repair work.

2-4

Fig. 2-1:

BA 6030(3 847 020.00)-EN

Operation FIRE AND EXPLOSION HAZARD Safety instructions Prior to commencing work, obtain informationon the national and corporate rules for the prevention of accidents and avoiding fires.

Pay particular attention to hazards caused by combustible and easily flammable substances.

Obtain information on the safe handling of the fire extinguishers to be used.

Avoid smoking and open fire on, next to and below the hydraulic shovel.

Combustible and easily or highly inflammable substances or liquids increase the risk of fire and explosion Do not store or transport flammable substances on the hydraulic shovel during the work. This is also valid for pressure vessels containing flammable substances as, for instance, spray oil or coldstarting fluid (ether). They are heat-sensitive and can explode even if exposed only to intensive sunlight.

Clean the hydraulic shovel carefully, if oil, grease, fuel, detergents or cold-starting fluid have been spilt over the machine. If possible, use a steam-jet cleaner for cleaning.

These substance can also ignite themselves if they come close to hot units or objects as, for instance, a turbocharger.

Clean rubber or electrical with compressed air only.

Ensure sufficient ventilation.

Even battery gases can ignite in open flames or fire.

Avoid parking the hydraulic shovel in places where  combustible substances such as coal dust or tar are present. 

Remove the hydraulic shovel from such an area where combustible or easily flammable liquids have spilled from the hydraulic shovel onto the ground.

Flying sparks (caused by welding, flame cutting, grinding, electrical short-circuit) may cause fire on the ground that can spread to the hydraulic shovel.

Clean the hydraulic shovel before starting work.

Place suitable fire guardings (fire barriers) if open fire or flying sparks cannot be avoided during repair work.

If necessary, also cover the ground with fireprotective blankets.

Apply special protection to cables, cable ducts as well as to hose and pipe lines.

The engine compartment can be equipped with pressure vessels containing cold-starting fluid (ether). Ether is toxic and highly flammable; the vessels are under pressure. These pressure vessels can explode if exposed to high temperatures (above 49°C / 120°F) or in the event of damage.

Protect the pressure vessels against damage before beginning to work in or close to the engine compartment.

Ensure sufficient ventilation.

Do not keep any fire extinguishers that are not suitable or have not been tested.

Do not extinguish flammable liquids with water.

Use:  dry-powder, carbon-dioxide or foam extinguishing compounds.

When getting into contact with burning substances, the fire-fighting water would abruptly evaporate and distribute the substance such as oil over a wide area. Water causes short-circuits in the electrical system thus possibly entailing new hazards.

Call the fire brigade.

Have all your welding, flame cutting and grinding work approved before starting work.

open or smouldering fire may occur.

2-5

BA 6030(3 847 020.00)-EN

Operation DESCRIPTION OF THE HYDRAULIC SHOVEL

Fig. 2-2:

2-6

BA 6030(3 847 020.00)-EN

Operation Hydraulic shovel layout - upperstructure Fig. 2-2:

29 – Swing gear 31 – Operator`s cab

Upperstructure

32 – Dashboard and BCS display

10 – Engine

33 – Control cabinets (inside cab module)

11 – Radiator (engine cooling liquid)

34 – Additional heater (optional, inside cab module)

12 – Reservoir (cooling liquid)

35 – Fire-extinguisher

13 – Air-intake system

36 – Control cabinet with battery main switch

14 – Exhaust system

37 – Batteries

15 – Fuel tank

38 – Service-station, (tanklift)

16 – Hydraulic oil reservoir

39 – Ladder

17 – Hydraulic oil cooler

40 – Hydraulic ladder

18 – Engine oil reservoir (optional)

41 – Grease container for central lubrica-

19 – Pump drive gearbox

ting system

20 – Working pump

42 – Tool cabinet (optional)

21 – Cooling oil pump

43 – Counterweight

22 – Servo system pump

44 – Hydraulic On-board crane (optional)

23 – Servo system pump

45 – Drive unit (On-board crane, optional)

24 – Gearbox circulating pump

46 – Operator’s seat

25 – Swing pump

47 – Trainer’s / Instructor’s seat

26 – Fan drive pump (cooler, hydraulic oil)

49 – Air conditioner

27 – Fan drive pump (radiator, engine cooling

50 – Cabinet with battery isolator and starter

liquid)

isolator switches.

28 – Emergency ladder

2-7

BA 6030(3 847 020.00)-EN

Operation

Fig. 2-3:

2-8

BA 6030(3 847 020.00)-EN

Operation Hydraulic shovel layout – undercarriage and working equipment Fig. 2-3:

Undercarriage 1 – Track drive 2 – Idler 3 – Track roller 4 – Support roller 5 – Crawler track 6 – Track tensioner 7 – Swing ring 30 – Travel block and rotor

Loading bucket 51 – Boom 52 – TriPower linkage 53 – Stick 54 – Bottom-dump bucket 55 – Boom cylinder 56 – Stick cylinder 57 – Tipping cylinder 58 – Bottom-dump cylinder 64 – Control valves 65 – Quick-action valve

Backhoe bucket 53 – Stick 55 – Boom cylinder 56 – Stick cylinder 59 – Monoblock boom 60 – Backhoe bucket 61 – Backhoe cylinder 62 – Toggle link 63 – Toggle lever 64 – Control valves 65 – Quick-action valve

2-9

BA 6030(3 847 020.00)-EN

Operation Undercarriage The undercarriage of the hydraulic shovel serves as a stable base and for travelling. The crawler tracks are driven hydraulically with oil motors and travel gearboxes. Undercarriage and upperstructure are connected by means of a swing ring.

Upperstructure The upperstructure accommodates the drive and part of the hydraulic and electrical equipment.

Drive The drive unit comprises diesel engines, pump drive gearboxes, hydraulic pumps, hydraulic cylinders and hydraulic motors.

Hydraulic system All working and travelling movements are performed hydraulically. The movements are controlled by servovalves. The working commands are initiated by hand and transmitted to the valves via control circuits. The oil supply from the upperstructure to the undercarriage is ensured by the rotor.

The hydraulic system is overload-protected by pressure-relief valves. The hydraulic pumps are supplied with oil from a hydraulic reservoir.

2-10

Control and Monitoring Platform (CAMP) The electronic CAMP system ensures the control and monitoring of all electrical and hydraulical functions of the shovel.

Four interconnected electronic units ensure optimal use of the installed engine power. Microprocessors are used to adapt the power output of the hydraulic pumps optimally to actual operating conditions. The machine is thus prevented from demanding more hydraulic power than the diesel engines can provide.

The desired working movements are detected by microcontrollers which permanently sense the position of hand levers and pedals.

As soon as movement is detected, the corresponding signals are transmitted to the electronic units. These units activate the drive control in order to provide the hydraulic energy needed for working.

Only then do they activate the electro-hydraulic valves which control the execution of the working movements.

BA 6030(3 847 020.00)-EN

Operation Board-Control-System (BCS) The BCS is a micro-processor-controlled system for the acquisition and processing of measuring data. It's function consists in collecting data of the hydraulic shovel operating conditions and to evaluate, store and display these data to the hydraulic shovel operator. For this purpose, the BCS is connected via a bus system to the Control and Monitoring Platform (CAMP). An interface with the outside world ensures the transfer of stored data and software updating.

The measured values (actual values) from the sensors and transducers installed in the hydraulic shovel are compared to the predefined reference values. Inadmissible deviations are indicated as fault messages on a display screen. Sensor or transducer defects or defective connecting cables are detected and indicated by plain-text messages.

The data from the engine electronics are acquired, processed and displayed in the same way.

Critical states of operation are brought to the operator's attention by means of optical and acoustic warning signals.

The display screen of the BCS is a touch-screen with a surface sensitive to the touch. This feature supports the hydraulic shovel operator or the service technician in navigating through the menus of the BCS sorftware.

For further information in this respect, please refer to section 5 in this Operation and Maintenence Manual or to the brochure "Board-Control-System – Operation and Maintenence Manual"

Demand control / Zero-flow regulation In the fine-control range, swivelling of the hydraulic pumps, and thus the variation of oil flow, are proportional to control lever and pedal valve travel.

This means that during the work, the pumps supply only as much hydraulic oil as required to perform the working movement. In the neutral position of the control levers, the pumps are automatically swivelled to zeroflow.

These special features offer the following advantages:  reduced fuel consumption 

minimum power losses



reduced temperature of the hydraulic oil



greater service life of hydraulic pumps and diesel engines.

Automatic reset to idling If no servovalves are actuated by the control pedals or levers for more than 8 seconds (factory-set value, adjustable), the engine is automatically set back to idling speed (factory setting ca. 1000 rpm, adjustable). This feature, too, contributes to reducing the fuel consumption.

Electrical system The electrical system operates on 24 volts.

2-11

BA 6030(3 847 020.00)-EN

Operation Signs Warning and instruction signs Observe the warning and instruction signs attached to the machine.

Keep the signs legible and clean.

Replace signs immediately if they have become illegible.

New warning and instruction signs can be ordered from the CGM HMS GmbH Spare Parts Service.

The ordering part numbers are set out in the spareparts list of the machine.

Fig. 2-4: - Fig. 2-9: shows the location of warning and instruction signs on the machine.

2-12

BA 6030(3 847 020.00)-EN

Operation

Fig. 2-4:

2-13

BA 6030(3 847 020.00)-EN

Operation

Fig. 2-5:

2-14

BA 6030(3 847 020.00)-EN

Operation

Fig. 2-6:

2-15

BA 6030(3 847 020.00)-EN

Operation

Fig. 2-7:

2-16

BA 6030(3 847 020.00)-EN

Operation

Fig. 2-8:

2-17

BA 6030(3 847 020.00)-EN

Operation

Fig. 2-9:

2-18

BA 6030(3 847 020.00)-EN

Operation

Machine number

Engine number

The identification plate with the machine number (Fig. 2-10:) is attached to the front side of the Aframe (arrow, Fig. 2-11:).

The serial number plate (1, Fig. 2-12:) for the diesel engines are located on the diesel engines.

Fig. 2-10:

Fig. 2-12:

Engine information plate The engine information plate (2, Fig. 2-13:) is located on the right side of the engine. The plate gives information about the engine like horsepower, high idle, full load engine speed and others.

Fig. 2-11:

Fig. 2-13:

Component numbers Other larger units also have identification plates indicating, among other things, their serial number.

On steel components, the CGM HMS GmbH part number or the serial number may be stamped into the metal at a clearly visible place.

2-19

BA 6030(3 847 020.00)-EN

Operation Entering and leaving the machine Safety instructions Risk of injury due to slipping.

Access ladder lighting The access ladder of the machine can be illuminated.

Clean off oil, grease, soil, mud, snow, ice and other substances from footwear, grab handles, ladders and steps.

From outside: The pull-switch (2, Fig. 2-15:) of the lighting system is located beneath the upperstructure. The lights are switched on from the ground by means of the pull-rope.

Keep ladders, steps, platforms and grab handles in a non-slippery condition.

From the cab: The switch is located besides the door (arrow, Fig. 2-16:).

For entering and leaving use only the ladders, steps, platforms and grab handles provided (see: illustration in Fig. 2-14:).

The lighting remains on during a presettable ON time. The ON time of the lighting is factory-adjusted to three minutes.

Always face the machine when entering or leaving it.

Always maintain a three point contact with the steps and grab handles.

Fig. 2-15:

Fig. 2-14:

Fig. 2-16:

2-20

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Operation Swinging ladder (optional) Raising resp. lowering the swinging ladder (Fig. 2-17:).

Lowering the swinging ladder (from the upper carriage)  Start an engine.  Push switch (1, Fig. 2-18:) downwards to position “ DOWN “ and hold.

The swinging ladder is lowered (Fig. 2-17:).

The swinging ladder can also be lowered when the engine ist stopped.

Fig. 2-17:

Raising the swinging ladder (from the upper carriage)  Start an engine.  Push switch (1, Fig. 2-18:) upwards to position “ UP “ and hold.

The swinging ladder is raised (Fig. 2-19:).

Fig. 2-19:

Fig. 2-18:

The upper carriage can only be swung when the folding ladder is raised completely (Fig. 2-19:).

2-21

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Operation Folding ladder Raising resp. lowering the folding ladder (Fig. 2-20:).

Lowering the folding ladder (from the upper carriage)  Start an engine.  Push switch (1, Fig. 2-21:) downwards to position “ DOWN “ and hold.

The folding ladder is lowered (Fig. 2-20:).

The folding ladder can also be lowered when the engine is stopped.

Fig. 2-20:

Raising the folding ladder (from the upper carriage)  Start an engine.  Push switch (1, Fig. 2-21:) upwards to position “ UP “ and hold.

The folding ladder is raised (Fig. 2-18:).

Fig. 2-21:

The upper carriage can only be swung when the folding ladder is raised completely (Fig. 2-18:).

2-22

Fig. 2-22:

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 lefthand side of the operator’s cab serves as an alternative 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 movement of the ladder must be regularly checked according to the maintenance plans.

Before unlocking the ladder: Be sure that no person is near to the position the ladder moves to.

Fig. 2-23:

 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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Operation Switching the cab interior lighting on and off The cab interior lighting can be switched on and off with the switches (arrow, Fig. 2-26:), (96, Fig. 2-27:) and (arrow, Fig. 2-28:) The cab interior light is supplied with power even when the electrical system is shut down.

When leaving the machine, the interior light must therefore be switched off. The batteries could be discharged if the interior light is allowed to remain on for a prolonged period.

Fig. 2-26:

Fig. 2-27:

Fig. 2-28:

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Operation Switching the maintenance lights on and off The maintenance lights in the various modules can be activated from a central point with the switches (arrow, Fig. 2-29:) or (95, Fig. 2-30:).

The invidual modules are also equipped with switches, for example the engine module: Switch at the switchgear cabinet behind the hydraulic oil reservoir (1, Fig. 2-31:).

Fig. 2-29:

Fig. 2-30:

Fig. 2-31:

2-25

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Operation Emergency shut-off function

Emergency shut off switch in cab

The emergency shut-off function can be triggered from six different places on the machine:  by pressing the switch (red) on the front panel of the control column (35, Fig. 2-32:),  by pressing the switch (red) at the entrances to the engine compartments on the right-hand and on the left-hand side (arrow, Fig. 2-33:),  by pressing the switch (red) on the control cabinet in the engine module (arrow,  by pulling the pull-switch between the left fuel tank and the counterweight (arrow, Fig. 2-35:),  by pressing the switch (red) on the control box at the servicestation (tanklift) (arrow, Fig. 2-36:).

The emergency shut-off function disconnects all power outputs of the electronic control units. In this case, all engines are shut off so that no working movements can be performed anymore.

Fig. 2-32:

Emergency shut off switch at the engine compartments

The power supply of the electronic control units of the engines and of the machine is, however, not interrupted. For this reason, the trouble shooting and failure analisis functions continue to remain active.

Other auxiliary functions such as:  the fire extinguishing system,  the service station (tank-lift) and,  the radio, the cab interior lighting and the access ladder lighting and maintenance lighting remain functional as well.

The emergency shut-off function can also be triggered before maintenance operations are performed on the machine. For this purpose, one of the switches is depressed and secured with a padlock. Any inadvertent starting of the engine is thus prevented.

Fig. 2-33:

Emergency shut off switch on the control cabinet engine module

Fig. 2-34

(continued next page)

2-26

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Operation Emergency shut off switches, continued

Putting the machine back into operation, reset of emergency shut off function

Emergency shut off pull switch between left fuel tank and counterweight

The machine can only be put back into operation when all switches listed above are again in their basic position (i.e. not actuated).

Additionally the Reset button (arrow, Fig. 2-37:) has to be pushed. The Reset button is located in the front door of the 24Volt-control cabinet in the cab module.

Fig. 2-35:

Emergency shut off switch on the servicestation (tanklift) Fig. 2-37:

Fig. 2-36:

2-27

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Operation Battery isolator switch, shutting off supply voltage The battery isolator switch (1, Fig. 2-39:) is located inside the control cabinet on the deck of the engine module (Fig. 2-38:).

The supply voltage is shut off when the battery isolator switch has been turned to position “OFF”.

This function shuts off the complete electrical system of the machine by disconnecting the two poles from the batteries (battery main switch).

In this case, all engines are shut off so that no working movements can be performed anymore.

The power supply of the electronic control units of the engines and of the machine is shut off after a brief delay. The delay ensures that the current operating data can be saved and the systems shut down properly.

Lock the battery isolator switch in position “OFF” by means of a padlock.

The machine can only be put back into operation when the battery isolator switch is unlocked and switched in the “ON” position. A green LED located near the switch comes on.

Fig. 2-38:

Starter isolator switch, shutting off starter voltage The starter isolator switch (2, Fig. 2-40:) is located inside the control cabinet on the deck of the engine module (Fig. 2-38:).

After turning the “Starter Isolator” switch to position “OFF” the engines could not be started.

All other sections of the electrical system are supplied with voltage.

Fig. 2-39:

This is to ensure personal safety during testing and trouble shooting purposes.

Lock the starter isolator switch in position “OFF” by means of a padlock.

The engines can only be put back into operation when the starter isolator switch is unlocked and switched into the “ON” position. A green LED located near the switch comes on.

Fig. 2-40:

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Operation Operator’s seat The operator’s seat (Fig. 2-41: and Fig. 2-42:) can be adjusted in several positions.

Never adjust the seat while driving. Concentrate on the road to avoid accidents.

Before carrying out any seat adjustments stop the machine and set the control levers to "0"

Fig. 2-41:

2-29

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Operation

Fig. 2-42:

2-30

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Operation Reducing the operators exposure to vibrations Vibrations, oscillations and movements of the machine cannot be avoided when the machine is in operation. They also have an effect on the operator.

These effects on the operator can however be avoided, if the operator’s seat is adjusted correctly.

Therefore, make use of the seat's various adjustment features (see Fig. 2-41: and Fig. 2-42:): 

shock absorption (Absorber),



body weight setting (Weight adjustment),



horizontal movement damping (Fore/aft isolator).

Trainer's / instructor's seat For operator training / instructing purposes it is often required that a trainer / instructor accompanies the operator in the cab.

For the safety of the trainer / instructor during hydraulic shovel operation the cab is equipped with a second seat. This seat is installed behind the operator's seat (Fig. 2-43:).  Sit down on this seat and do not forget to fasten the seat-belt (if installed, see arrow, Fig. 2-43:).  Do not leave this seat during the training / instruction session and / or as long as the machine is in operation.

Adjust the seat before beginning work to suit your personal requirements. Check whether all adjustments are functional. If this is not possible, have the seat checked and repaired as soon as possible.

Fig. 2-43:

2-31

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Operation Fire extinguisher

Extinguishing agent

The hydraulic shovel is equipped with two fire extinguishers (arrow, Fig. 2-44:).

Each fire-extinguisher is filled with 12 kg (26.4 lb) Glutex. This extinguishing agent is used for fighting fires of classes A, B and C. Fires are extinguished fast, perfectly and without residues.

Handling

Fig. 2-44:

The hydraulic shovel operator and the maintenance personnel must inform themselves about how to handle the fire-extinguisher in order to be able to act fast and efficiently in case of beginning fires.

Such instruction should be given by a qualified instructor.

Fig. 2-45:

 Pull out securing pin (2, Fig. 2-45:).  Strike knob (3) hard, then release again.  Operate the extinguishing gun.

Inspection Have the extinguisher inspected at regular intervals by an expert. This is required by local authorities and insurance companies and is in the interest of your own safety.

Have the fire-extinguisher checked at the prescribed intervals by authorized testing agencies.

2-32

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Operation Automatic fire-extinguishing system (optional) The automatic fire-extinguishing system prevents fire from spreading. It is, however, assumed that the machine is thoroughly cleaned of combustible and easily flammable substances.

Windscreen washer The fluid reservoir (1, Fig. 2-46:) of the windscreen washer is located in the cab module. The capacity of the reservoir is indicated under "Refilling quantities - Other".

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 automatically in an emergency.

Refill extinguishers immediately after use ready for further deployment.

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 manually.

Inspection Have the extinguishing system inspected regularly by an expert. This is required by authorities and insurance companies and is in the interest of your own safety.

Have the fire-extinguishing system checked at the prescribed intervals by authorized testing agencies.

Fig. 2-46:

Operating hours meter Three operating hours meters (Fig. 2-47:) are located in the left front door of the “24 Volts switchgear cabinet” in the cab module. 

1



LH engine hours meter



2



RH engine hours meter



3



Travel hours meter

Fig. 2-47:

2-33

BA 6030(3 847 020.00)-EN

Operation Emergency escape device / seat (optional) Elements of the harness (Fig. 2-48:- Fig. 2-50:) Pos. Designation 1

Back support

2

Shoulder belt

3

Shoulder belt

4

Loop (chest belt)

5

Loop (chest belt)

6

Loop (back support)

11

Holding device

12

Fall arrester

13

Guidance line

14

Hanging up line

15

Handbag with harness

16

Snap hook

17

Hook safety device

Fig. 2-49:

Fig. 2-50:

Important hints Read and observe also: Operation and Maintenence Manual of the supplier.

Fig. 2-48:

Before using operator shall have received adequate training.

The harness must be used by one person only.

He is responsible for the appropriate use and maintenance.

Visual inspection is recommended prior to each use; if necessary it must be checked by an expert.

Harness must be checked annualy (every 12 month) by an expert.

2-34

BA 6030(3 847 020.00)-EN

Operation Taking on harness  Take harness out of handbag (15, Fig. 2-51:)

 Pull loop (6) of the back support (1) between your legs to the front (Fig. 2-53:)  Pull loop (5, Fig. 2-54:) through loop (6).

Fig. 2-51:

 Take on shoulder belts (2 and 3, Fig. 2-52:)

Fig. 2-54:

 Pull loop (4, Fig. 2-54:) through loop (5).  Press the hooking safety device (17, Fig. 2-54:) of the snap hook (16).

Fig. 2-52:

 Pull back support (1, Fig. 2-52:) behind your body (Fig. 2-53:) The loops (4 and 5) are in front of your body.

Fig. 2-55:

Fig. 2-53:

2-35

BA 6030(3 847 020.00)-EN

Operation

 Hang up loop (4, Fig. Fig. 2-56:) into snap hook (16)

Fig. 2-56:

 Release hooking safety device (17, Fig. 2-57:)

Fig. 2-57:

2-36

If you have the harness put on in such a way in case of danger you can escape from the hydraulic shovel (Fig. Fig. 2-58:).

Fig. 2-58:

BA 6030(3 847 020.00)-EN

Operation

This page intentionally left blank.

2-37

BA 6030(3 847 020.00)-EN

Operation MONITORING, WARNING AND CONTROL ELEMENTS

Fig. 2-59:

2-38

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Operation (Fig. 2-59:) BCS, Board-Control-System No. 1

2

3

4

Element BCS

Function Electronic system for measured data acquisition and processing

Board Control System, acquisition and display of important operating data of the hydraulic shovel

Monitor

BCS

The monitor displays collected operating data, warning messages and – if needed – instruction for help.

Push-button

Navigation in menus Control of cursor movements, program selection within the BCS, confirmation of inputs / displayed values (Enter), quitting of menus / sub-menus Numeric keypad Input of numeric values.

Push-button

Symbol

The surface of the monitor is sensitive to the touch (touch-screen technology). A touchscreen permits selecting menus and programs by touching graphic control symbols and to recall, for instance operating data of the hydraulic shovel.

For further information please refer to section 5 of this Operation and Maintenence Manual, chapter “Board-Control-System”.

2-39

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Operation

Fig. 2-60

2-40

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Operation (Fig. 2-60:) BCS, Board Control System, display screen example (For further information please refer to section 5 of this Operation and Maintenence Manual, chapter “BoardControl-System”).

No. 1

2

3

4 5 6

Element

Function

Status line

Indicates activated functions and operating hours.

The symbols displayed are those of the switches in the control column

Touch-screen Monitor

BCS

Indicates collected operating data graphically and / or numerically, displays warning messages, fault messages and – if needed – instructions for help.

Pushbutton

Navigation in menus

Control of cursor movements, program selection within the BCS, confirmation of inputs / displayed values (Enter), quitting of menus / sub-menus

Push-button

Numeric keypad

Input of numeric values.

Touch-screen buttons Status line

Examples Fault messages

Symbol

Displays fault messages as a code number and as plain text. The "Fault" button permits displaying further fault messages stored in the system.

2-41

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Operation

Fig. 2-61:

2-42

BA 6030(3 847 020.00)-EN

Operation (Fig. 2-61:)

No. 32 33

34 35

Element

Function

Key-switch

Switches the electrical system on and off.

Buzzer (inside the control column)

Gives three acoustic warning signals if a fault is reported. The signals appear every 30 seconds.

Socket connectors

Connection of electronic devices for fault diagnosis purposes.

Switch

Emergency shut-off

Symbol

De-energizes the outputs of the electronic control units: The engines are shut off, working movements no longer possible. (see: "Emergency shut-off function").

2-43

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Operation

Fig. 2-62:

2-44

BA 6030(3 847 020.00)-EN

Operation (Fig. 2-62:)

Engine 1 (LH), control and monitoring 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. 41

42

43

44

45

46

47

48

Element

Function

Push-button

Start

Starting of the engine. For starting, press the push-button face with the symbol.

Push-button

Stop

Stopping of the engine. For stopping, press the push-button face with the symbol.

Push-button

Idle

Stopping of the engine with an after-run delay of 5 min. For delayed stopping, press the push-button face with the symbol (“Idle Shut Down”).

Warning lamp

Engine oil pressure

Lit up when the engine oil pressure is too low.

Warning lamp

Alternator

Lit up when the batteries are not being charged or in the event of an alternator defect.

Warning lamp

Engine oil temperature

Lit up when the engine oil temperature is too high.

Warning lamp

Cooling liquid temperature

Lit up when the engine cooling liquid temperature is too high.

Switch

Engine speed

Press switch face without symbol: the speed of the engine increases.

Symbol

Press the switch face with the symbol: the speed of the engine reduces.

49

50

Diagnosis lamp

Diagnosis lamp

Engine monitoring

Engine monitoring

Lits up when malfunctions occur on the engine. The indication uses so-called flashcodes (see section 5 of this Operation and Maintenence Manual: “Engine monitoring, Control lamps”).

Check the BCS display for further fault messages and give an information to the responsible service personnel.

STOP! Lits up when a serious fault occurs on the engine. The diagnosis lamp (49) provides the event code at the same time (flashing). (see part 5 of this Operation and Maintenence Manual: “Engine monitoring, Control lamps”).

Shut off the engine immediately.

Check the BCS display for further fault messages and give an information to the responsible service personnel.

2-45

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Operation

Fig. 2-63:

2-46

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Operation (Fig. 2-63:)

Engine 2 (RH), control and monitoring 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. 51

52

53

54

55

56

57

58

Element

Function

Push-button

Start

Starting of the engine. For starting, press the push-button face with the symbol.

Push-button

Stop

Stopping of the engine. For stopping, press the push-button face with the symbol.

Push-button

Idle

Stopping of the engine with an after-run delay of 5 min. For delayed stopping, press the push-button face with the symbol (“Idle Shut Down”).

Warning lamp

Engine oil pressure

Lit up when the engine oil pressure is too low.

Warning lamp

Alternator

Lit up when the batteries are not being charged or in the event of an alternator defect.

Warning lamp

Engine oil temperature

Lit up when the engine oil temperature is too high.

Warning lamp

Cooling liquid temperature

Lit up when the engine cooling liquid temperature is too high.

Switch

Engine speed

Press switch face without symbol: the speed of the engine increases.

Symbol

Press the switch face with the symbol: the speed of the engine reduces.

59

60

Diagnosis lamp

Diagnosis lamp

Engine monitoring

Engine monitoring

Lits up when malfunctions occur on the engine. The indication uses so-called flashcodes (see section 5 of this Operation and Maintenence Manual: “Engine monitoring, Control lamps”).

Check the BCS display for further fault messages and give an information to the responsible service personnel.

STOP! Lits up when a serious fault occurs on the engine. The diagnosis lamp (59) provides the event code at the same time (flashing). (see part 5 of this Operation and Maintenence Manual: “Engine monitoring, Control lamps”).

Shut off the engine immediately.

Check the BCS display for further fault messages and give an information to the responsible service personnel.

2-47

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Operation

Fig. 2-64:

2-48

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Operation (Fig. 2-64:) 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. 61

Element Push-button

Function Upperstructure holding brake

Symbol

Blocks the upperstructure.

Press this button when the upperstructure is stationary.

Do not use this button while the upperstructure is still in motion.

Risk of damage to the brake and the slewing gearboxes.

Not connected.

62 63

Switch

Excavator parking brake

Not actuated: The parking brake is applied automatically ca. 5 secs after the hydraulic shovel has stopped moving.

The parking brake is released automatically when the "Travel" function is activated.

Press the switch face with the symbol: The parking brake is applied permanently.

The hydraulic shovel cannot be moved.

Actuate this switch only when the hydraulic shovel is stationary.

Do not use this switch while the hydraulic shovel is still in motion.

Risk of damage to the brakes and the travel gearboxes.

64

Push-button

Central greasing system reset

Reset function of the central greasing system control (Press for at least 3 sec.).

Press switch face without symbol: Resets the control of the upperstructure.

Press the switch face with the symbol: Resets the control of the undercarriage.

65

Push-button

Emergency lowering Lowering of the working equipment in an emergency situation. For instance, if the engines have failed.

For more information refer to chapter “Emergency lowering of the working equipment”.

66

Switch

Automatic speed reduction

Reduces the speed of the diesel engines to -1 about 1000 min , if no working movement is being executed during about 8 seconds.

2-49

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Operation

Fig. 2-65:

2-50

BA 6030(3 847 020.00)-EN

Operation (Fig. 2-65:) 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. 71

72

Element

Function

Switch

Servo-control

Press the switch face with the symbol: The electro-hydraulic servo-control is enabled.

Switch

Travelling speed

Not actuated: st 1 travelling stage travelling forwards / backwards is possible

Symbol

Press the switch face with the symbol: nd 2 travelling stage, only parallel forward travel is possible. in case of backward travel and cornering, the machine switches back automatically into the st 1 travelling stage.

Not connected.

73 74

Monitoring lamps

Engine oil interval prolongation

Not connected.

75 76

81 82 83 84 85 86

Lamp is lit up, when the right or the left pump of the prolongation system is running.

Push-button

When the machine has to be manoeuvered out of dangerous situations

Press the switch face with the symbol: The machine can be driven and the upperstructure be slewed although these functions are automatically deactivated.

Use this function only in dangerous situations to manouever yourself or the machine out of hazard zones. Risk of damaging parts of the machine, e.g. the hydraulic ladder or the tanklift.

Switch

Floodlamps

Switches the floodlamps on the operator´s cab on and off.

Switch

Floodlamps

Switches the floodlamps on the hydraulic oil cooler module on and off.

Switch

Floodlamps

Switches the floodlamps on the cab module on and off.

Switch

Floodlamps

Switches the floodlamps on the boomon and off.

Switch

Floodlamps rear

Switches the floodlamps on the counterweight on and off.

Switch

Not connected.

2-51

BA 6030(3 847 020.00)-EN

Operation

Fig. 2-66:

2-52

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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

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.

Symbol

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 (option)

Press the switch face with the symbol: 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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Operation

Fig. 2-67:

2-54

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Operation (Fig. 2-67:) No.

Element

101

Push-button

(Free for options)

102

Push-button

Stick floating position (shovel equipment only)

Function Can be used as a push-to-speak button on a radio, or to switch over from one camera to another one.

Button is pressed: The stick cylinders are pressurized on retracting.

Symbol

Press button (102) only in position "0" of control lever (115).

103

Push-button

Boom floating position

Button is pressed: The boom cylinders are pressurized on retracting.

Press button (103) only in position "0" of control lever (116).

104 105

111 112 113 114 115

116

117 118

119

120

Push-button

Warning signal

Push-button inside the seat

Electronic hydraulic shovel control (servocontrol)

Pedal Pedal

Shovel trap (shovel equipment only) Travel, left track

Pedal

Travel, right track

Button is pressed: Acoustic warning signal / horn is activated.

Button in the seat.

The electronic hydraulic shovel control (servocontrol) is activated when the operator sits down on the seat.

The electronic hydraulic shovel control (servocontrol) is deactivated when he leaves the seat.

Forwards – shovel trap is opened; Backwards – shovel trap is closed.

Forwards – forward travel Backwards – backward travel.

Forwards – forward travel; Backwards – backward travel.

Footrest Forwards – raising the stick Backwards – lowering the stick.

To the left / right – slewing and braking of the upperstructure.

Forwards – lowering the boom; Backwards – raising the boom.

To the left – backwards tipping of shovel / bucket; To the right – dumping of shovel / bucket.

Not used on this machine.

Control lever

Control lever

Push-button Thumb wheel

Push-button

Thumb wheel

Turn forwards – shovel trap is opened; Turn backwards – shovel trap is closed.

Function can be overridden with pedal 111.

(Thumb wheel is spring centered).

To the left – automatically stopped stick- and/or By-pass for the automatically switch off for backhoe cylinders can be driven slowly to the stick- and /or backhoe limit stopps.

To the right – Each press on the button increcylinders (Option) ments the loaded dumper count for by "1".

(Count reset with button (91)) Not used on this machine.

Shovel trap (shovel equipment only)

2-55

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Operation

Fig. 2-68:

2-56

BA 6030(3 847 020.00)-EN

Operation (Fig. 2-68:) (Engine 1 (left) monitoring) Function

No.

Element

121

Monitoring device

Engine monitoring Indicates different parameters on the display (E) (engine 1 left) Use push buttons (C and D) to scroll through parameter list.

Indicator lamps (A and B) lit when an active fault occurs.

122

Thermometer

Engine temperature (engine 1 left)

123

Pressure gauge

Engine oil pressure Indicates the oil pressure in the diesel engine lubricating system. (engine 1 left)

124

Warning device

Engine monitoring (engine 1 left)

Symbol

Indicates the cooling-water temperature.

Gives an acoustic warning signal if a fault is reported, e.g. 

Engine oil pressure too low,



Engine temperature too high.

Lower the equipment to the ground and shut off engine immediately if the warning device (124) sounds. The warning device (124) continues to sound until the fault has been rectified.

Lits up when engine is in idle phase.

125

Indicator lamp

Idle (engine 1 left)

126

Warning lamp

Cooling water level Lits up when the cooling-water level is too low. (engine 1 left)

127

Warning lamp

Alternator (engine 1 left)

Lits up when the batteries are not recharged.

2-57

BA 6030(3 847 020.00)-EN

Operation

Fig. 2-69:

2-58

BA 6030(3 847 020.00)-EN

Operation (Fig. 2-69:) (Engine 2 (right) monitoring) Function

No.

Element

131

Monitoring device

Engine monitoring Indicates different parameters on the display (E) (engine 2 right) Use push buttons (C and D) to scroll through parameter list.

Indicator lamps (A and B) lit when an active fault occurs.

132

Thermometer

Engine temperature (engine 2 right)

133

Pressure gauge

Engine oil pressure Indicates the oil pressure in the diesel engine lubricating system. (engine 2 right)

134

Warning device

Engine monitoring (engine 2 right)

Symbol

Indicates the cooling-water temperature.

Gives an acoustic warning signal if a fault is reported, e.g. 

Engine oil pressure too low,



Engine temperature too high.

Lower the equipment to the ground and shut off engine immediately if the warning device (134) sounds. The warning device (134) continues to sound until the fault has been rectified.

Lits up when engine is in idle phase.

135

Indicator lamp

Idle (engine 2 right)

136

Warning lamp

Cooling water level Lits up when the cooling-water level is too low. (engine 2 right)

137

Warning lamp

Alternator (engine 2 right)

Lits up when the batteries are not recharged.

2-59

BA 6030(3 847 020.00)-EN

Operation

Fig. 2-70:

2-60

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Operation (Fig. 2-70:) (Options. Depending on the options ordered with the machine, the described elements can be found on different positions on the control column).

Nr. 140 141 142

143

144

Element

Funksjon Auxiliary heating (option) Auxiliary heating blower (option) Auxiliary heating (option)

Auxiliary heating for operator’s cab ON / OFF. Blower levels 1,2,3.

Switch

Fuel Pre-heating (option)

Switches the fuel pre-heating function of RH engine on and off.

Switch

Fuel Pre-heating (option)

Switches the fuel pre-heating function of LH engine on and off.

Switch Switch Switch

Symbol

Auxiliary heating for operator’s cab ON / OFF. Automatic regulation.

2-61

BA 6030(3 847 020.00)-EN

Operation

Fig. 2-71:

2-62

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 different positions on the control column).

No. 150 151 152

Function

Element

Blower levels 1,2,3.

Knob

Blower of air conditioner Thermostat

Rotary switch

Selector

Selects the following functions: heating, cooling, ventilation, defrosting.

Rotary switch

Symbol

Presetting of desired temperature.

2-63

BA 6030(3 847 020.00)-EN

Operation

Fig. 2-72 :

2-64

BA 6030(3 847 020.00)-EN

Operation (Fig. 2-72) Air filter monitoring (Option. Depending on the options ordered with the machine, the described elements can be found on different positions on or near the control column).

No.

Element

Function

191

Underpressure Air filters (left engine 1, gauge outside)

192

Underpressure Air filters (left engine 1, gauge inside)

193

Underpressure Air filters (right engine gauge 2, inside)

194

Underpressure Air filters (right engine gauge 2, outside)

Indicates the underpressure in the air filters.

Underpressure must be less than 635 mm (25 inches) water column.

Otherwise clean / replace the filterelements.

Indicates the underpressure in the air filters.

Underpressure must be less than 635 mm (25 inches) water column.

Otherwise clean / replace the filterelements.

Indicates the underpressure in the air filters.

Underpressure must be less than 635 mm (25 inches) water column.

Otherwise clean / replace the filterelements.

Indicates the underpressure in the air filters.

Underpressure must be less than 635 mm (25 inches) water column.

Otherwise clean / replace the filterelements.

Symbol

2-65

BA 6030(3 847 020.00)-EN

Operation PUTTING THE MACHINE INTO OPERATION

Reducing the operator's exposure to noise

Before daily start-up, carry out works in accordance with servicing plan T (see: Part 3 "Inspection and servicing").

All noise protection devices of the machine must be in place and fully functional when the machine is in operation.

Increased fire and explosion hazard will exist.

Prior to your daily start-up, make sure the machine has been cleaned of combustible and easily flammable substances.

e.g. 

doors, flaps and covers of the engine compartments must be closed,



access doors to the compartments of the radiator fans must not be left open,



the cab door must be closed,



the exhaust silencer must be checked for holes,



the screwed conections of all components fastend with screws must be checked for tightness. Loose components tend to vibrate and to rattle, thus increasing the noise level.

Wear ear protectors when leaving the operator's cab with the engines on and running.

2-66

BA 6030(3 847 020.00)-EN

Operation Refuelling Refuelling - Safety instructions

Back-up heating (option), filling in fuel

Fuels and fuel gases are inflammable.

The fuel reservoir for the back-up heating system is located in the module below the operator’s cab (Fig. 2-73:).

Avoid open flames and stop smoking.

Fill in clean fuel through the filler neck.

Explosion hazard. Risk of fire.

Fuel may cause skin injury. Wear protective gloves or use a barrier cream.

Stand working equipment on the ground.

Shut off the engines.

Fuel is to be filled in using the service station (tanklift), see the following chapter "Service station (tanklift), Fuel Tank".

Do not spill fuel and do not allow fuel to penetrate into the soil. Fuel pollutes the environment.

Wipe off spilt fuel immediately with cleaning rags or soak up with binding agents.

Fuel and cleaning material must be disposed of without polluting the environment.

Report fuel accidents immediately to the owner of the machine or his representative.

Fig. 2-73:

Check the grounding straps (equipotential bonding) at the tank lift regularly for proper fastening.

Grounding straps can remove voltages and prevent fire during refuelling only when properly fastened.

2-67

BA 6030(3 847 020.00)-EN

Operation Service station (tanklift) The hydraulic shovel is equipped with a central service station (Fig. 2-74: resp. Fig. 2-75:) for refuelling. A service vehicle is needed for filling and/or draining of the fluids.

The service station is accessible from the ground below the upperstructure.

Risk of injury. Always stay clear of the moving service station.

The service station is moved downwards and upwards by means of a hydraulic driven cylinder.

The up and down movement of the service station is initiated the switch (1, Fig. 2-75:). The switch is located in a control box at the hydraulic ladder (arrow).

To lower the service station:  Push momentary switch (1, Fig. 2-75:) downwards and hold until the service station is in its lower position.

Fig. 2-74:

To bring the service station in the upmost position:  Push switch (1) upwards. Service station is moved upwards until it reaches its upmost position.

With switch (1) in its middle position, movement of the service station is stopped.

Fig. 2-75:

2-68

BA 6030(3 847 020.00)-EN

Operation Express couplings are provided for refilling / draining the following consumables (fluids).

Note: Connections used may vary depending on how the machine is equipped.

Pos. Consumable Express Fig. coupling for 2-76: Diesel fuel for lefthand Filling 1 and righthand fuel tank Cooling fluid for leftFilling and/or 2 hand engine draining Cooling fluid for Filling and/or 3 righthand engine draining Gearbox oil for left Filling and/or 4 pump drive gearbox draining Gearbox oil for right Filling and/or 5 pump drive gearbox draining Tank for engine oil Filling and/or 6 interval prolongation draining lefthand engine.

Tank for engine oil Filling and/or 7 interval prolongation draining righthand engine.

Engine oil for lefthand Filling and/or 8 engine draining Engine oil for Filling and/or 9 righthand engine draining Hydraulic oil tank Filling and/or 10 draining Grease container Filling 11 Swing gear (optional) Filling 12

Refilling and draining For filling in or for draining consumables / fluids, unscrew the cap of the corresponding express coupling (Fig. 2-76:).

Attach express coupling of filling hose from the service vehicle to the corresponding express coupling at the service station. Fill in or drain off consumable / fluid.

Take off filling hose and refit cap on the express coupling.

Emergency off switch The control box at the service station is equipped with an emergency off switch (Fig. 2-77:).

In case of emergency press the button. The electrical system is switched off.

Fig. 2-77:

Fig. 2-76:

2-69

BA 6030(3 847 020.00)-EN

Operation

Assemblies resp. reservoirs Fuel tank

Fig. 2-78:

2-70

Measuring device

Remarks

BCS fuel indicator (Fig. 2-78:)

Switch on the monitoring system by using toggle switch (23, Fig. 2-79:). The indicator light (22) comes on.

Fill in fuel using express coupling (1).

The indicator light (32) comes on when the LH fuel tank is full.

Stop filling when the fuel tank is full.

The indicator light (33) comes on when the RH fuel tank is full.

Stop filling when the fuel tank is full.

Switch off the monitoring system by using toggle switch (23), indicator light (22) is off.

Fig. 2-79:

BA 6030(3 847 020.00)-EN

Operation

Assemblies resp. reservoirs Pump drive gearboxes

Measuring device

Remarks

Dipstick (1, Fig. 2-80:)

Engines

Dipstick (Fig. 2-82:)

Engine oil tank (option)

Monitoring lamps (1 and 2, Fig. 2-83:)

Fill in gear oil using express couplings (4 and 5, Fig. 2-81:).

Stop filling when the oil reaches the "max" mark on the dipstick (see: Part 3, chapter "Pump drive gearbox Checking the gearbox oil level/Filling in oil").

Fill in engine oil using express couplings (8 and 9, Fig. 2-83:).

Stop filling when the oil reaches the "max" mark on the dipstick (see: chapter "Engine - engine oil level/filling in oil").

Small amounts of oil can be filled in through the filler neck at the engine.

Fill in engine oil using express couplings (6 and 7, Fig. 2-83:).

Stop filling when monitoring lamps (1 and / or 2) lit up, (see: chapter "Engine , filling in oil").

Fig. 2-80:

Fig. 2-82:

Fig. 2-81:

Fig. 2-83:

2-71

BA 6030(3 847 020.00)-EN

Operation

Assemblies resp. reservoirs

Measuring device

Remarks

Hydraulic oil tank

Inspection glass (1, Fig. 2-84:), signs (2. Fig. 2-84: and Fig. 2-85:)

Checking the oil level: Extend the piston rods of stick and bucket cylinders halfway.

Stand working equipment on the ground.

Check oil level at an oil temperature of ca. 50 °C / 122°F, with the engines stationary.

Fill in oil through express coupling (10, Fig. 2-86:) when the oil level in the inspection glass has dropped below the "min" mark on sign (2).

Stop filling if the acoustic warning signal “Travel Alarm” sounds and oil reaches the "max" mark on sign (2) near the inspection glass (see: chapter "Hydraulic system Checking the hydraulic oil level / Refilling hydraulic oil").

Fig. 2-84:

Fig. 2-85:

2-72

Fig. 2-86:

BA 6030(3 847 020.00)-EN

Operation

Assemblies resp. reservoirs

Measuring device

Remarks

Cooling system reservoir

Level indicator (4, Fig. 2-87:) Fill in cooling fluid using express couplings (2 and/or 3, 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 indicator 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. 2-88:

Fig. 2-89:

Fig. 2-90:

2-73

BA 6030(3 847 020.00)-EN

Operation Switching the electrical system on and off The electrical system is switched on with keyswitch (32, Fig. 2-91:).  Insert key into key-switch and turn to the right.

If the electrical system cannot be switched on, check first whether the battery main switch is on (see: "Battery isolator switch, shutting off supply voltage").

Fig. 2-91:

2-74

Engines, emergency shut-off In an emergency, the engines can be stopped out of full load.

To do so:  Depress the emergency shut-off switch (35, Fig. 2-92:). The engines are stopped. (see the chapter "Emergency shut-off function").  Switch off the electrical system with key-switch (32).

Fig. 2-92:

BA 6030(3 847 020.00)-EN

Operation Preheating system for engine and hydraulic oil (optional) Preheating system for engine and hydraulic oil, function The preheating system consists of heating elements for engine oil, engine coolant and hydraulic oil.

At low outside temperatures, the system facilitates starting of the engine and ensures that the hydraulic system reaches its operating temperature faster.

The preheating system is operated electrically with an external supply voltage. This voltage is available at a socket outlet at the service-station (tanklift) (Fig. 2-93:).

(The system has been set at the factory for a standard supply of 400 volts, threephase AC. Other voltages are available on request as well as socket outlets meeting other standards).

When the temperatures of the engine oil, engine coolant and the hydraulic oil are below -10°C / 14°F:  Connect the system to the external power supply.  Switch on the preheating system with switch (1, Fig. 2-94:).

The pilot lamp (2, Fig. 2-94:) lights up.  Switch off the preheating system with switch (1, Fig. 2-94:) when the engine and the hydraulic system have reached a temperature above 0°C / 32°F. The pilot lamp (2, Fig. 2-94:) goes out.  Switch on the fuel preheating system (see "Fuel preheating system (option)").

Switching the preheating system for engine and hydraulic oil on and off Risk of an electric shock.

Check first: Insulation of the socket outlet on the machine in good condition?

Insulation of the connecting cable in good condition?

Connect the system to the power supply only if the insulation of the components is in perfect condition.

Observe the national safety regulations to be applied in the presence of electric current.

Fig. 2-93:

Switch and pilot lamp are located at the switchgear cabinet in the engine module behind the hydraulic oil reservoir (Fig. 2-94:).

Fig. 2-94:

2-75

BA 6030(3 847 020.00)-EN

Operation Fuel preheating system (optional) Fuel preheating system, function At temperatures below 0°C / 32°F, the paraffin particles contained in the diesel fuel begin to clump together. They form flakes which clog up the fuel lines and the filters. Starting of the engine is then no longer possible.

To prevent this, the diesel fuel must be preheated.

Preheating is effeceted by means of two heating elements in the fuel line. The heating elements are attached to the engines.

They are equipped with internal thermostats ensuring an automatic temperature regulation.

Switch on the fuel preheating only after preheating of the engine and of the hydraulic oil is terminated (see "Preheating system for engine and hydraulic oil (option)").

The preheating time is dependent on the outside temperature.

Fig. 2-95:

Switching the fuel preheating system on and off  Switch on the ignition by turning key-switch (32, Fig. 2-95:) to position 1.  At temperatures below 0°C / 32°F, switch on the fuel preheating: switch (144, Fig. 2-96:) for the lefthand engine, switch (143) for the righthand engine.

The pilot lamp located above the resp. switch lights up.  After a short time start up the engines (see also "Starting and stopping the engines").  Switch off the fuel preheating with switches (143 and 144), when the engines has reached their operating temperatures.

The pilot lamp (Fig. 2-96:) goes out.

2-76

Fig. 2-96:

BA 6030(3 847 020.00)-EN

Operation

This page intentionally left blank.

2-77

BA 6030(3 847 020.00)-EN

Operation STARTING AND STOPPING THE ENGINES Starting the engines

Starting the left-hand engine

Exhaust gases from diesel engines and some of their constituents may cause cancer, birth defects and other reproductive harm.

Start and operate combustion engines only on well-ventilated premises. In closed rooms, exhaust gases must be evacuated to the outside.

Do not work on the exhaust system an do not make any modifications to it.

All control levers and pedals must be in position "0".

Pull out all emergency shut-off switches.

Fig. 2-97:

Pull out both switches for the battery main switch.

Check for persons on the machine. Do not start engines until all persons have left the machine.

Starting the right-hand engine

Activate the horn before you start the engines to give a warning signal to people around.

Start the engines one after another.  Switch on the electrical system with key-switch (32).

Warning lamps (44 – 47, Fig. 2-97:) and (54 – 57, Fig. 2-98:) light up.  Press button (41, Fig. 2-97:) to start the lefthand engine. Release button (41) as soon as the engine has fired.

Warning lamps (44 – 47) go out.  Press button (51, Fig. 2-98:) to start the righthand engine. Release button (51) as soon as the engine has fired.

Warning lamps (54 – 57) go out.

2-78

Fig. 2-98:

BA 6030(3 847 020.00)-EN

Operation Repeat the starting procedure if one of the engines does not fire. Repeat starting procedure not more often than three to four times. Do not operate the starter for more than 10 seconds.

If warning lamps (44 – 47, Fig. 2-97:) or (54 – 57, Fig. 2-98:) do not go out or when the BCS (Fig. 2-99:) displays a fault message after starting, the engine concerned must be stopped immediately.

Locate the cause of the fault and rectify before restarting the engine.

Do not run engines at full load unless they have been allowed to run for at least 3 minutes at idling.

Starting the engines at low temperatures If the machine is used in low temperatures, the engine may be equipped with a cold-starting device.

The pressure vessel containing the cold-starting fluid (ether) can be installed in or near the engine compartment.

The vessel is screwed into an electro-mechanical metering valve. When the engine is started at temperatures below 0°C (32°F), this valve is activated automatically by the engine electronics and injects a precisely metered amount of cold-starting fluid into the air intake duct of the engine.

Ether is toxic and highly inflammable. Safety instructions and information concerning the handling of pressure vessels for cold-starting fluids (ether) can be found in the following chapters: "Fundamental safety instructions", "Inspection and servicing - Safety instructions", "Cold-starting fluid (ether) - Replacing the pressure vessel".

Fig. 2-99:

Engines – adjusting the speed Adjust the speed of the left-hand engine with switch (48, Fig. 2-97:).

Adjust the speed of the right-hand engine with switch (58, Fig. 2-98:).  Press the switch face without symbol the engine speed is raised up to maximum speed.  Press the switch face with the symbol the engine speed is reduced to idling speed.

2-79

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Operation Shutting off the engines

Shutting off the left-hand engine

During interruptions of the work and after the work, stand working equipment on the ground.

Do not shut off the engines before the working equipment rests on the ground.

Do not shut off the engine out of full load. The engine should be run at no more than one-half of the rated rpm for another 5 minutes to allow the lubricating oil and the cooling liquid to dissipate the combustion heat from the combustion chamber and from bearings and shafts.  Reduce the speed of the engines to idling by pressing the left side of the speed adjusting switches (48, Fig. 2-100:) and (58, Fig. 2-101:).  Press button (42, Fig. 2-100:) for the left-hand engine. The left-hand engine is stopped.

Warning lamps (44 – 47) light up.

Fig. 2-100:

Shutting off the right-hand engine

 Press button (52, Fig. 2-101:) for the right-hand engine. The right-hand engine is stopped.

Warning lamps (54 – 57) light up.  Switch off the electrical system with key-switch (32).

Warning lamps (44 – 47, Fig. 2-100:) and (54 – 57, Fig. 2-101:) go out.

The engines will be shut off with a delay of a few seconds. During this time, the current operating data are saved and the electronic units shut down.

Fig. 2-101:

2-80

BA 6030(3 847 020.00)-EN

Operation AIR CONDITIONER (OPTIONAL) Control unit (SIGMA dual) The air conditioning system (single or dual) is installed under the cab roof (Fig. 2-102:).

The illustration (Fig. 2-103:) shows a control unit for a dual air conditioner.

The control unit of a single air conditioning system contains the control elements only once.

Do not switch on the air conditioner when the backup heating is set to ”heating”.

Control unit (Fig. 2-103:) Unit 1 Pos. Element 1 Rotary switch 2

Thermostat

3

Rotary switch

Unit 2 Pos. Element 4 Rotary switch 5

Thermostat

6

Rotary switch

Function selects the intensity level of the blower (3 levels) sets the desired temperature inside the cab selects the desired control function (heating, cooling, ventilation, defrosting)

Function selects the intensity level of the blower (3 levels) sets the desired temperature inside the cab selects the desired control function (heating, cooling, ventilation, defrosting)

Fig. 2-102:

Fig. 2-103:

2-81

BA 6030(3 847 020.00)-EN

Operation Back-up heating operator’s cab (optional) The back-up heating for the operator’s cab is located in the module below the operator’ cab (Fig. 2-104:). The heating consists of one or two heating units (1) and the fuel reservoir (2).  Switch on the back-up heating using switch (142, Fig. 2-105:). The pilot lamp above switch (142) lights up.

The heating system has an automatic regulation.

Do not switch on the back-up heating when the air conditioner is set to ”cooling”.

Fig. 2-104:

Fig. 2-105:

2-82

BA 6030(3 847 020.00)-EN

Operation Back-up heating (optional) The back-up heating is located in the module below the operator’s cab (Fig. 2-106:).

Control unit (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

7

Indicator lamp

blower level 3

8

Indicator lamp

blower level 2

9

Indicator lamp

blower level 1

Fig. 2-106:

Fig. 2-107:

2-83

BA 6030(3 847 020.00)-EN

Operation MAXIMUM MACHINE INCLINATIONS, INFORMATION The machine must not exceed the inclinations indicated for working, travelling and servicing operations and during downtimes. The values specified in the tables below (next page) are valid for all types of working equipment.

If the maximum inclinations are exceeded, there is a risk of severe damage to the engines due to insufficient lubrication. In the event of extreme inclinations the machine can topple over.

Instruction sign “Maximum inclination” This sign is attached inside the operators cab.

Observe all the warning and instruction signs attached to the machine.

Keep the signs legible and clean.

Replace signs immediately if they have become illegible.

The working performance of the machine is especially economical when the machine stands on firm and level ground.

A loss of performance and higher wear must be accepted when the machine works in an inclined position, e.g. when building a ramp or when slewing uphill.

For the building of ramps, the values specified in the table "Maximum inclinations during working operations" may be exceeded. In this case, however, a reduced service life of the components can be expected.

During downtimes, the machine must be parked in such a way that its inclination does not exceed 3° / 5.2 %.

Fig. 2-109

2-84

BA 6030(3 847 020.00)-EN

Operation

Maximum machine inclinations during working operations:

forward inclination

rearward inclination

side inclination

5° / 8.7%

5° / 8.7%

5° / 8.7%

Maximum machine inclinations during travelling: Type

Engine

forward deg / %

rearward deg / %

side deg / %

6030, 6030FS

QSK19

30° / 57.7%

30° / 57.7%

30° / 57.7%

C27

20° / 36.4%

20° / 36.4%

20° / 36.4%

Maximum machine inclinations during maintenance operations:

forward inclination

rearward inclination

side inclination

0° - 2° / 3.4%

0° - 2° / 3.4%

0° - 2° / 3.4%

2-85

BA 6030(3 847 020.00)-EN

Operation TRAVELLING, SAFETY INSTRUCTIONS Have the attachment raised only so far as to permit the machine to be driven under overhead power lines without any risk.

Close the cab door.

If the machine is fitted with a safety belt for the operator, fasten the belt.

If the upperstructure is turned by more than 90° from the BASIC POSITION, the hydraulic shovel travels in the opposite direction to that selected.

If the position of the upperstructure in relation to the undercarriage is not exactly known, touch the accelerator lightly to see which direction the machine takes, before initiating the full travelling movement.

Never drive across slopes.

Take the utmost care on slippery, greasy ground.

Sound the horn to warn persons in the immediate vicinity before starting travelling.

Do not exceed the maximum machine inclination (see “Maximum machine inclinations” chapter).

Fig. 2-111:

Running-in specifications for components of the crawler tracks: Prior to initial commissioning and/or after repair work, run in the idlers, track rollers and support rollers as follow:  Raise the equipment (Fig. 2-110: and Fig. 2-111:)  Drive the hydraulic shovel in reverse approx. 50 m (164 ft).  Drive the hydraulic shovel in forwards approx. 50 m (164 ft).  Stop the hydraulic shovel.  Measure the temperature at each dler, track roller and support roller with an infrared thermometer. (at a temperature of approx. 100° C (212°F) wait for idlers, track rollers and support rollers to cool down).  Repeat this running-in procedure up to 10 times.  Check all idlers, track rollers and support rollers for leaks.

Fig. 2-110:

The engines must be at operating temperature before being subjected to full load.

If the machine is to be driven a longer distance, the upperstructure must be secured against turning by means of the upperstructure holding brake.

2-86

BA 6030(3 847 020.00)-EN

Operation TRAVELLING

Travelling forwards/backwards

Upperstructure basic position

Travelling forwards:  depress pedals (112 and 113) forwards.

Travel direction and sense of actuation of pedals (112 and 113, Fig. 2-113:) are identical only when the hydraulic shovel is in its BASIC POSITION (Fig. 2-112:).

The hydraulic shovel travels in the direction of the idler (2, Fig. 2-112:).

Travelling backwards:  depress pedals (112 and 113, Fig. 2-113:) backwards.

The hydraulic shovel travels in the direction of the drive sprocket (4, Fig. 2-112:).

During travelling, an acoustic warning signal sounds (Travel Alarm).

Fig. 2-112:

If the upperstructure is swung out of its basic position by more than 90° (Fig. 2-114:), the hydraulic shovel moves in a direction opposite to that expected when pedals (112 and 113, Fig. 2-113:) are depressed.

Fig. 2-114:

The pedals return automatically to their "0" positions when released.

Reverse the hydraulic shovel only over short distances and with the assistance of marshallers because of restricted rear-view conditions.

Do not travel across slopes.

When travelling uphill or downhill, the travel drive must always be at the rear.

Travel only in the basic position of the hydraulic shovel and only forwards.

Be extremely careful on slippery and greasy ground.

Fig. 2-113:

If the operator is not completely sure of the position of the upperstructure with regard to the understructure, pedals (112 and 113) should be depressed slightly in order to find out which way the hydraulic shovel moves before initiating the full travelling movement.

Do not exceed the maximum machine inclination (see “Maximum machine inclinations” chapter).

All instructions with regard to travelling speed regulation and travel direction control are applicable only as long as the crawler tracks have sufficient grip and do not slip.

2-87

BA 6030(3 847 020.00)-EN

Operation Regulating the travelling speed Travelling on level ground Regulate the travelling speed with  pedals (112 and 113, Fig. 2-115:) and  Switch (72, Fig. 2-116:) to the left (slow gear).

All forward/reverse travel movements are possible with this gear.  Switch (72, Fig. 2-116:) to the right (fast gear).

The hydraulic shovel can be driven only parallel forwards with this fast gear.

The travel gearbox changes automatically into st the 1 gear as soon as another travelling function (e.g. reversing, cornering) is initiated.

Change speed range only when the hydraulic shovel is stationary.

Fig. 2-116:

Press engine speed regulator switches (48 and 58) to the left (full-throttled position).

Travelling uphill and downhill Read and observe the "Travelling Safety instructions" chapter.

Do not exceed the maximum machine inclination (see “Maximum machine inclinations” chapter).  Depress padals (112 and 113, Fig. 2-115:) fully to the limit stop.  Regulate the travel speed only with the engines speed control.

When travelling downhill, the travel retarder valve acts as a speed limiter.

The travel retarder valve works correctly if pedals (112 and 113) are fully depressed down to the limit stop.

Fig. 2-115:

2-88

Should the travelling speed become too high when travelling downhill release pedals (112 and 113) to stop the hydraulic shovel.

BA 6030(3 847 020.00)-EN

Operation Cornering Never use the working equipment to raise one side of the undercarriage and then turn the undercarriage by initiating the swinging and/or the travelling function.

To take a right-hand corner forwards  depress only pedal(112, Fig. 2-117:) forwards.

To take a lefthand corner forwards  depress only pedal (113) forwards.

Turning To turn to the right  depress pedal (112) forwards and pedal (113) backwards.

To turn to the left  depress pedal (113) forwards and pedal (112) backwards.

This way of working is contrary to the hydraulic shovel's designated use.

There is a risk of accident. Moreover, the tracks, swing gear, roller bearing swing ring, backhoe or bucket back-wall and the front part of the bucket are subjected to inadmissibly high stresses.

Fig. 2-118:

Fig. 2-117:

Note Change the position of the undercarriage - parallel or perpendicular to the working face - only by cornering forwards/backwards (Fig. 2-118:).

Cornering to the left: forwards

from pos. 1 to pos. 2

backwards

from pos. 2 to pos. 3

forwards

from pos. 3 to pos. 4

The same procedure should be adopted if the hydraulic shovel is to be driven out of depressions (Fig. 2-119:): Cornering to the left

from pos. 1 to pos. 2

Cornering to the right

from pos. 2 to pos. 3

Fig. 2-119:

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Operation Travelling over long distances Travel only forwards with the hydraulic shovel in its basic position.

Travelling backwards over longer distances could damage parts of the undercarriage.

Backhoe equipment (Fig. 2-121:):  Fully extend boom cylinder 1.  Extend backhoe cylinder 2,  extend stick cylinder 3, to such an extent as to reach the position of the equipment shown in (Fig. 2-121:).

Read and observe the "Travelling – Safety instructions" chapter.

Do not exceed the maximum machine inclination (see “Maximum machine inclinations” chapter).

When travelling, pay attention to sufficient headroom, e. g. under cable bridges or high-tension cables.

Keep the loading or the backhoe bucket close to the ground. For a more uniform loading of the tracks, the equipment must, however, be kept at a steep angle (Fig. 2-120: / Fig. 2-121:).

Fig. 2-121:

Lower the equipment when travelling underneath obstacles.

If the equipment position must be changed:  stop the hydraulic shovel,  change the position,  continue to travel.

Fig. 2-120:

Face shovel equipment (Fig. 2-120:):  Fully extend boom cylinder (1).  Retract bucket cylinder 2,  retract stick cylinder 3 to such an extent as to reach the position of the equipment (Fig. 2-120:).

2-90

After travelling for 15 minutes without interruption, stop the hydraulic shovel and check the temperature of the track rollers.

If the temperature does not exceed approx. 100° C (212°F):  Continue travelling.

In case of higher temperatures:  Stop travelling. Resume travelling only after the track rollers have cooled down to approx. 40° C (104°F).

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Operation Upperstructure holding brake

Track parking brake

The hydraulic shovel is equipped with three upperstructure holding brakes which are integrated in the swing gearboxes. The upperstructure holding brakes lock the upperstructure with respect to the undercarriage.

The hydraulic shovel is equipped with 4 travelling gear brakes which are integrated in the travel drives.

The gearbox brakes are holding brakes.

Do not press the button unless the upperstructure is stationary. Do not use this button while the upperstructure is still in motion. Risk of damage to the brakes and the slewing gears.

Apply the holding brake:  when the hydraulic shovel is parked,  when travelling longer distances.  To apply the holding brakes, press switch (61, Fig. 2-122:).

The travelling gear brakes are parking brakes.

They protect the hydraulic shovel from rolling forwards or backwards. When the machine is parked, travel brakes are activated automatically. The brakes are deactivated during operation of the machine.

Note: As travel brakes are deactivated, machine could slightly move in direction of excavating during operation.

Whenever loading operation is interrupted, stand working equipment on the ground. This avoids slight movement of the machine and possible consequential damage of lowered ladder, in case ignition remains engaged.

Fig. 2-122: Fig. 2-123:

For Service and Maintenance purposes the travelling gear brakes can also be applied with switch (63, Fig. 2-123:).

Actuate this switch only when the hydraulic shovel is stationary. Do not use this switch while the hydraulic shovel is still in motion. Risk of damage to the brakes and the travel gearboxes.

Press the switch face with the symbol (63): The parking brake is applied permanently. The hydraulic shovel cannot be moved.

For more detailed information refer to the Service Manual, chapters eight and nine.

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Operation TRANSPORTING THE MACHINE Transport - Safety instructions The machine must be loaded and transported only after all safety regulations have been observed and complied with.

Entrust loading and transporting of the machine to a company experienced in the transport of heavy equipment.

The responsability for loading and transporting lies with the transport company or their representative.

Remove oil, grease, soil, mud, snow, ice and other materials from the hydraulic shovel's crawler tracks and from ramps and loading platforms of the transport vehicle to minimize slipping.

Transport The dimensions and the service weight of the fully assembled hydraulic shovel do not allow the hydraulic shovel to be transported in an undismantled state on a low-bed trailer over public roads.

Therefore, the following components and modules must be dismantled beforehand.

Suspensions points as well as the center of gravity are marked on the modules (see example, Fig. 2-124:).

Dimensions and weights of the machines modules can be found in the annex, chapter “Technical Data” as well as in the “Service Manual”.

Secure the transport vehicle against rolling away.

Use only tying equipment of sufficient strength (the weights and dimensions of the hydraulic shovel are set out in the "Product Specification Sheet") which can be found in the annex.

Fig. 2-124:

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Operation WORKING OPERATION - SAFETY INSTRUCTIONS Read the sections "Fundamental safety instructions" and "Operation, safety instructions" carefully and observe the instructions given in them.

Inspect the site for underground gas, power and water lines before starting work. Any damage to such lines is a risk to life!

Clean off any earth, mud, snow, ice, grease and oil adhering to your working footwear before operating the machine. There is otherwise a risk of slipping off the pedals and initiating inadvertent movements.

Sound the horn to warn persons in the immediate vicinity before starting work.

Stop work if anyone is in the hazard range of the machine. Make sure they have left the hazard range before resuming work.

Never operate the machine unless it is standing on a reasonably horizontal, flat surface. The stability of the machine is otherwise at risk.

Ensure that the attachment has adequate clearance below overhead power lines and structures.

Running-in instructions for hydraulic cylinders Compression of an oil/air compound in a hydraulic cylinder may result in detonations which might damage pistons and sealing rings.

Prior to initial commissioning and/or after repairs, run in the hydraulic cylinders as follows:  Start up the engines and run at low speed.

The pressure-limiting valve in the hydraulic system must not respond  In the first two working cycles, retract and extend the pistons of the hydraulic cylinders to max. ½ to ¾ (not to the limit stop).

Never change direction suddenly. The waiting time between changes of direction must be at least 4 seconds.  In the next eight working cycles, retract and extend the pistons of the hydraulic cylinders to the limit stop. The waiting time between changes of direction must be at least 4 seconds.  When all hydraulic cylinders have been run in, the hydraulic shovel can operate at a higher engine speed.

Trenches and working faces may give way. Keep well clear of them.

Do not operate the machine, 

when several track rollers or support rollers have been removed;



when one or several slewing gearboxes have failed or been removed;



when one or several teeth on the backhoe or on the shovel are worn or missing;



when parts of the hardfacing layer on the backhoe or on the shovel are worn or missing.

Warming up the hydraulic system At low temperatures, bring the engines down to moderate speed, then activate all hydraulic functions for about 10 minutes (bring to service temperature). For further instructions, see section „LUBRICANTS / CONSUMABLES“.

If the BCS indicates problems with the cooling liquid temperature, engine oil pressure, coolant level, alternator or hydraulic oil filter control (with hydraulic oil at service temperature) light up: 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 guarantee for damage and consequential damage caused by an abusive utilization of the machine.

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Operation Avoid extreme positions of the attachment Parts of the attachment may damage the machine if they are moved into extreme positions (see illustrations Fig. 2-125 - Fig. 2-129).

Work carefully, avoiding extreme positions of this kind.

Fig. 2-127

Fig. 2-125

Fig. 2-128

Fig. 2-126

Fig. 2-129

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Operation WORKING OPERATION Before starting work Prior to initial commissioning and after repairs on the central lubricating system or the hydraulic cylinders, move the unloaded equipment for abt.

5 minutes.

This is required to ensure an adequate supply of grease to the cylinder bearings when the work starts.

Warming up: At low outside temperatures it is necessary to run the hydraulic system up to operating temperature.

The temperatures at which warming up is necessary depend on the type of hydraulic oil used; see also "Oils for hydraulic systems".  Run the diesel engines at ca. 2/3 full speed and start to perform no-load working movements for abt. 10 minutes with the hydraulic shovel.

Activating the electronic hydraulic shovel control The hydraulic shovel can execute working movements only after the electronic hydraulic shovel control (servo-control) has been activated.

The servo-control block is enabled by switch (71, Fig. 2-130:).

At the beginning of the work, the electronic hydraulic shovel control (servo-control) is activated by a contact in the operator's seat (105):  Electronic hydraulic shovel control ON The operator is sitting on his seat.  Elektronic hydraulic shovel control is OFF The operator's seat is empty.

Fig. 2-130:

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Operation Swinging the upperstructure Swinging of the upperstructure is possible onlywhen: 

the upperstructure holding brake is released and



the hydraulic shovel operator is sitting on his seat and



the hydraulic ladder is raised and



the servicestation (tanklift) is raised and



the BCS swing circuit test was successful.

 To swing the upperstructure to the right move control lever to the right (115, Fig. 2-131:).  To swing the upperstructure to the left move control lever to the left (115).

After releasing, the control lever returns automatically to position "0".

Releasing the control lever (115) is not sufficient to brake the upperstructure automatically. In order to brake the upperstructure, the control lever must be moved in the direction opposite the swing movement (reversing).

Fig. 2-131:

Braking the upperstructure The upperstructure can only be braked by moving control lever (115) in the direction opposite the swing movement (reversing).

The upperstructure does not stop automatically by simply releasing the swing control lever (115).

To brake the upperstructure, the swing control lever (115) must be moved in opposite direction.

In an emergency, activate the holding brake by pressing switch (61, Fig. 2-132:).

Fig. 2-132:

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Operation Working When released, all control levers for working operation return automatically to position "0".

Level a surface only in the bucket's digging direction. Never "beat" or "sweep" with the bucket.

Do not level off a surface with the front shell of the face shovel open.

Close face shovel completely before beginning to dig.

Sound the horn to warn persons in the immediate vicinity before starting work.

Do not exceed the maximum machine inclination (see “Maximum machine inclinations” chapter).

Extending and retracting the shovel or backhoe stick

Fig. 2-133:

 To extend the stick: push control lever (115, Fig. 2-133:) forwards.  To retract the stick: pull control lever (115) backwards.  To retract the stick with pressure: (only on face shovel equipment) depress button (102) and push control lever (115) backwards.

Opening and closing the face shovel  To open the shovel: press pedal (111, Fig. 2-133:) forwards or press button (117) to the left.  To close the shovel: press pedal (111) backwards or press button (117) to the right.

Fig. 2-134:

Raising and lowering the boom  To raise the boom: pull control lever (116, Fig. 2-134:) backwards.  To lower the boom: push control lever (116) forwards.  To lower the boom with pressure: depress button (103) and push control lever (116) forwards.

Filling and emptying the shovel or the backhoe bucket  To fill/tip back the shovel / backhoe bucket: shift control lever (116, Fig. 2-134:) to the left.  To empty the bucket by dumping/tipping: shift control lever (116) to the right.

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Operation Emergency lowering of the working equipment In case of a failing out of the electronic hydraulic shovel control and / or the engines, lower the equipment as follows:  Sit down on the operator’s seat. Switch inside seat (105, Fig. 2-135:) is activated then.  Switch on the electric system with key-switch (32).  Operate switch (71), hydraulic servo system is activated then.  Operate switch (65, Fig. 2-136:) and hold.  Push control lever (116) forwards to lower the working equipment to ground.  Contact the responsible service personnel as soon as possible.

Fig. 2-135:

Fig. 2-136:

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Operation After daily operation Parking the machine  Park the machine on level and stable ground.

This is particularly important in winter to avoid freezing of the tracks.  Stand the working equipment on the ground.  Shut off the engines.  Shift both control levers into all directions todepressurize the hydraulic cylinders.  Withdraw the key from the electrical system key-switch.

Escaping oil pollutes the environment.

Repair leaks immediately (or have them repaired).

Report oil accidents to the responsible person.  Check the upperstructure, undercarriage and the working equipment for damage and all steel components for cracks or fractures.  Report detected damage immediately to the responsible person.  Clean off gross dirt, ice and snow from the fins and the fan wheel of the hydraulic oil cooler.

 Close the cab window.  Lock the cab door and all lockable hatches and covers on the machine.  Clean the machine of coarse dirt as well as of combustible and easily flammable substances, if possible with a stream jet (rubber parts and electric components with compressed air - refer to information label). Otherwise, the fire and explosion hazard will exist.  Fill up the fuel tanks.  Inspect the engines, the hydraulic system, the track rollers, support rollers, idlers and gearboxes visually for leaks.

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Operation ASSEMBLING WORKING EQUIPMENT - SAFETY INSTRUCTIONS

Tools and auxiliaries

Personel

Metal splinters may cause injury when accessory bolts are being driven in or out. A brass or copper mandrel should therefore be used for this purpose, and goggles must be worn.

Assembly work may be carried out only by operating or maintenance personnel who have the necessary know-how at their disposal.

If such know-how is lacking, meticulous instruction must be given by experienced personnel, e.g. from CGM HMS GmbH. The operating manual, and in particular the section headed "Fundamental Safety Instructions", must have been read and understood.

Only such persons may start up the machine during assembly work in order to adjust the attachments.

Incorrect operation of the machine or the attachments may give rise to life-threatening situations.

Personal protective equipment and working clothes Wear closely fitting working clothing when working on the machine. Loose, wide garments may catch on machine parts and result in injury.

Wear your personal protective equipment: a safety helmet, safety goggles, safety footwear and gloves.

When carrying out work on the working equipment, f.ex. on the monobloc boom (Fig. 3-116:), use a fall arrester. Falling down from great hight may cause severe injuries. Connect the fall arrester to the safety line on the monobloc boom (arrow, Fig. 3-116:).

Tools, hoists, slings, trestles and other devices must be in a reliable, safe state.

Use only the steps, platforms and handrails when climbing onto or off the machine.

Always keep steps and platforms in a non-slip state. Remove any oil, grease, earth, clay, snow, ice and other foreign matter immediately.

Securing the working equipment Stand working equipment on the ground in such a way that no movements can be made if mechanical or hydraulic connections become detached.

Secure any equipment or component which is to be mounted or dismantled, or whose position is to be changed, with hoists or appropriate slinging/supporting devices to prevent them from moving, slipping or falling inadvertently.

Securing the machine Carry out work on the attachment only if the machine is secured as described in the "Securing the machine" section.

Selecting the attachments The machine can be equipped with various attachments. The components of the attachments are assembled with hydraulic cylinders and connectors. Components can be combined in various ways for optimum adaptation of the attachments to the specific application.

Operate the machine only with the equipment and component combinations expressly approved by CGM HMS GmbH for this type of machine.

Never install and commission other equipment and component combinations without CGM HMS GmbH first having inspected and approved the project in writing.

Protective roof against falling objects Fig. 2-137:

2-100

The machine is equipped with an integrated cabprotection roof (FOPS).

BA 6030(3 847 020.00)-EN

Operation Securing the machine Risk of injury

Secure the machine as described below:  before carrying out any fitting and modification work on the working equipment,

The machine must not be started by unauthorized persons.



Therefore, secure the machine.

 Park the machine on level and stable ground.

Observe the accident prevention regulations.

Depressurize pipeline systems, on which work is to be carried out, by appropriate measures.

Protective shrouds of moving machine parts may only be opened or removed when the drive unit is stationary and protected against inadvertent starting.

before carrying out any servicing and repair work on the machine.

 Stand the working equipment on the ground.  Shut off the engines.  Depressurize the hydraulic system.  Withdraw the key from the key-switch.

Before carrying out fitting works, the machine and the equipment must be protected against inadvertent starting by placing chocks under the tracks and by standing the working equipment on the ground.

Hydraulic and lubricating systems: Close all open bores, pipe and hose connections with pressureresistant plugs.

Refill collected hydraulic oil back into the hydraulic system only through the return-flow filters. Dispose of non re-usable oils without polluting the environment.

All components of CGM HMS GmbH machines have been carefully purpose-coordinated. Troublefree operation and a long service life can only be achieved with original CGM HMS GmbH spare parts.

Respect the sequence of working operations when fitting or replacing the attachments. The sequence has been determined and tested by qualified experts.

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Operation CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS) Use "GLEITMO 815" anti-corrosive agent only.

Other agents are not approved by CGM HMS GmbH. All pins and bearings (bushings and hubs) of the working equipment or in equipment componenents must be treated with "GLEITMO 815" anti-corrosive agent before fitting.

Doing so  permits easy fitting and dismantling 

protects against rust, oxidation and similar wear



prevents seizing and fretting corrosion in nonmoving parts of bearings.

This is achieved by aluminium and copper particles forming a protective layer on the metal. This layer removes surface irregularities and does not sweat, seize or harden.

Part no. for "GLEITMO 815" is 2764305, available from CGM HMS GmbH Spare-Parts Service.

2-102

Application of GLEITMO 815  Clean off grease, oil, dirt and corrosion protection agents from pins and bearings using white spirit or diesel fuel.

Rust patches must be thoroughly removed, if any.

All parts must present a dry, bright metal surface.  Apply a thin layer of GLEITMO 815 on pins and all bearings using a brush or a spray can. Pin shafts and bearings must be completely covered by the protective layer.

If the protective layer of a pin already treated with GLEITMO 815 is damaged, these areas must be touched up before fitting the part.  Fitting and securing of pins If the pin is too heavy to be fitted manually, apply GLEITMO 815 at first only on abt. a quarter of the pin's length.

Then position pin by means of a lifting gearready for fitting.

Apply GLEITMO 815 on the remaining length of pin shaft, fit pin and secure.

BA 6030(3 847 020.00)-EN

Operation ON-BOARD CRANE (OPTIONAL) The on-board crane is designed for lifting heavy parts only.

Monitoring, warning and control elements (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 permission to operate cranes.

If such know-how or such permission is lacking, meticulous instruction must be given by experienced personnel, e.g. from CGM HMS GmbH. Incorrect operation of the crane may give rise to life-threatening situations.

Fig. 2-138:

Pos. 1 2 3 4 5 6 7 8 9 10 11 12

Element Monitoring lamp Warning lamp Warning lamp Monitoring lamp Key-switch Button Monitoring lamp Knob Monitoring lamp Warning lamp Button Button

21

Control lever

22 23 24

Control lever Control lever Control lever

Function Alternator Engine oil pressure Engine temperature Air filter Electrical system ON/OFF Start engine of drive unit Preheating system (option) Engine speed variation Crane in operation Malfunction EMERGENCY STOP Emergency lowering of winch Extending and retracting of boom extension Folding the boom Swinging the boom Winch up / down

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Operation On-board crane, putting into operation Risk of serious injuries due to movements of the crane.

Put the crane into operation only after all persons have left the danger area.

Do not exceed the maximum lifting capacity (observe the lift capacity chart attached to the boom).

On-board crane, drive unit The drive unit (Fig. 2-139:) supplies the crane with hydraulic power. So the on-board crane is functional without the shovel’s engines running.

The drive unit comprises the diesel engine, fuel tank, starter batteries and the hydraulic system.

The drive unit is equipped with an Emergency OFF push switch (arrow, Fig. 2-139:).

In case of emergency push switch, the engine of the drive unit comes to standstill.

Prior to each deployment: Carry out all maintenance work as listed in the “Inspection and Servicing Plans “T” and “W”.

To start the drive unit:  Turn key-switch (5, Fig. 2-138:) to position ON.  Press button (6), engine will start.

The crane control unit is equipped with an Emergency OFF push switch (11).

In case of emergency push switch, the engine of the drive unit comes to standstill.

After finishing work block the boom, then stop the engine (see chapter “On-board crane, - blocking the boom in position of rest”).

2-104

Fig. 2-139:

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Operation On-Board crane, – blocking the boom in position of rest Movements and accelerations produced by working operations of the machine can cause damage to the slewing drive of the on-board crane, if the crane is not blocked.

The hydraulic on-board crane must therefore be blocked in its position of rest.

Risk of serious injuries due to movements of the crane.

Put the crane into operation only after all persons have left the danger area.

To block the boom:  Retract the boom completely.  Slew the boom in the direction of the blocking device (Fig. 2-140:) and lower it.  Withdraw the cotter pin at the tip of the boom.  Extend the boom carefully until the tip engages the blocking device (arrow, Fig. 2-140:).  Reinsert and lock the the cotter pin.

Checking the on-board crane Extract from the inspection and testing regulations The on-board crane is approved in accordance with the Accident Prevention Regulations for Cranes (BGV D6, applicable only in Germany).

The on-board crane must be inspected regularly in accordance with the regulations in force in the country of use.

The inspections must be requested by the user of the crane. The expert or specialist entrusted with the inspection can be appointed at the user's discretion.

The user must ensure, however, that the appointed person meets the requirements.

The user is obliged to make available all documents required for the inspection and to ensure the smooth running of the inspection. He is furthermore obliged to provide, if required, crane operators and auxiliary personnel and the required test loads.

The result of the inspection is to be documented in an inspection record signed by the inspector.

The inspection record serves as proof on the part of the user that the inspections have been carried out. The inspection record must contain all data required for crane identification and for the performance of further regular inspections.

Fig. 2-140:

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Operation MONITORING CAMERAS (OPTIONAL) Monitoring cameras – function This excavator is equipped with two monitoring cameras: 

one mounted on the counterweight, looking backwards;



one mounted on the hydraulic oil cooler module, looking to the right.

The two cameras and the belonging LCD-diplay are operational after the electrical system of the machine has been activated with the key operated switch.

Both cameras transmit their images to the same LCD-display. The display is mounted near the control column.

For toggling between the camera images beeing displayed, press the key in the left joystick (arrow, Fig. 2-138:).

Additional information can be found in the manuals of the camera manufacturer (see Volume 5 of the Technical Documentation "Components").

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Fig. 2-141:

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Operation NOTES ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ...................................................................................................................................................................

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Operation

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Inspection and servicing 3 INSPECTION AND SERVICING

Operation and Maintenence Manual

Target group

Part 1 INTRODUCTION FUNDAMENTAL SAFETY INSTRUCTIONS

Operating personnel + Inspection and servicing personnel + Repair personnel

Part 2 OPERATION

Operating personnel The operating personnel must have knowhow relevant to the operation and the application of this or comparable machines.

Part 3 INSPECTION AND SERVICING

Inspection and servicing personnel

Part 4 REPAIR WORK

Repair personnel

The inspection and servicing personnel must have know-how relevant to the inspection and servicing of this or comparable machines.

The repair personnel must have know-how and experience relevant to the repair of this or comparable machines.

Part 5 ANNEX

Part 6 INDEX

Operating personnel + Inspection and servicing personnel + Repair personnel Operating personnel + Inspection and servicing personnel + Repair personnel

3-1

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Inspection and servicing

3-2

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Inspection and servicing INSPECTION AND SERVICING SAFETY INSTRUCTIONS Operating manual No inspection and servicing work must be carried out until the operating manual has been read and understood.

Pay special attention to: „Fundamental safety instructions" and all warnings and safety instructions attached to the machine.

The operating manual lists all jobs to be done. The descriptions of job sequences, however, provide only experienced personnel with the necessary instructions.

The operating manual must be kept with the machine at all times.

Inspection and servicing personnel Inspection and servicing personnel must have the necessary know-how on the inspection and servicing of this or comparable machines.

The necessary know-how can be acquired in a several day's instruction, e.g. by an CGM HMS GmbH mechanic or by attending an CGM HMS GmbH training course.

Personal protective equipment and working clothing Wear closely fitting working clothing when working on the machine. Loose, wide garments may catch on machine parts and result in injury.

Wear a safety helmet, safety footwear, gloves and, in the event of high noise levels, ear protectors.

Securing the working equipment Stand working equipment on the ground in such a way that no movements can be made if mechanical or hydraulical connections become detached.

Secure any equipment or component which is to be mounted or dismantled, or whose position is to be changed, with hoists or appropriate slinging / supporting devices to prevent them from moving, slipping or falling inadvertently.

Securing the machine Carry out servicing work only if the machine is secured as described in the section "Securing the machine".

Climbing onto and off the machine Use only the ladders, steps, platforms and handrails provided when climbing onto or off the machine.

Always keep ladders, steps, platforms and handrails in a non-slip, safe state and remove any oil, grease, soil, clay, snow, ice and other foreign matter immediately.

Always maintain a three point contact with the steps and grab handles.

Always face the machine when climbing on and off.

Checking the state of tools Use only fully functional, reliable tools.

Select the right tool for the job.

Wrenches of the wrong size, for example, may slip and cause injury.

Cleaning jobs Prior to commencing work, clean your working area, if necessary and possible, with a stream jet (rubber parts and electric components with compressed air - refer to information label).

Exhaust pipes and turbo chargers in the engine compartments are covered with special heatinsulating material. This material must not be spraywashed with steam-jet cleaners or highpressure cleaners. It will be damaged. Therefore cover all the insulating material with plastic foils before using steam-jet cleaners or high-pressure cleaners inside the engine compartments.

Use only lint-free cleaning rags when working on the hydraulic system or the engines.

Cleaning agents and solvents may give off harmful, readily flammable vapours. Never work with such agents except on well ventilated premises; never inhale the vapours and never smoke.

Prevent solvents and cleaning agents from coming into contact with your skin.

Wear gloves.

Observe the instructions on the packaging.

3-3

BA 6030(3 847 020.00)-EN

Inspection and servicing Handling flammable liquids

Visible oil losses

When handling flammable liquids:  never smoke,

Have any visible leakage repaired immediately.



keep away from unshielded light sources and naked flames,

Fuel and other consumables often have low flash points and are readily ignited. Never attempt to extinguish burning liquids with water.

Use:  dry powder, 

carbon dioxide or



foam extinguishers.

Water used for extinguishing purposes would vapourize instantaneously on contact with burning substances and spread burning oil, for example, over a wide area. Water generates short circuits in the electrical system, possibly producing hazards.

Notify the fire brigade.

Fastening and securing elements Check fastening and securing elements, e.g. bolts, nuts, washers, before using them again.

Replace any damaged parts.

Escaping oil is an environmental hazard.

Soak up any oil that has escaped with a binding agent.

Sweep up binding agent and dispose of it separately from other waste.

Relieving residual pressure in the hydraulic system Only unpressurized hydraulic systems may be opened. Even when a machine is parked on a horizontal surface with ist attachments supported on the ground and its driving motors switched off, there may still be substantial residual pressure in parts of the hydraulic system, e.g. primary pressure from the last hydraulic movements prior to stopping the machine.

Residual pressure is reduced only gradually. If an intervention into the hydraulic system is to be undertaken immediately after stopping, the system must be depressurzized: (do not leave the operator's seat)  Stand working equipment on the ground,  Shut off the engines,

Spare parts Use only the original sparts parts of CGM HMS GmbH. They are the only ones to fulfill the technical specifications of the machine.

Handling oils and greases Hot lubricant or hydraulic oil emerging uncontrolled from the system may result in severe burns.

Never set foot withing reach of the emerging oil jet.

Avoid contact with the skin. Wear gloves and firm protective clothing.

 Move all control levers and pedals repeatedly into all ndirections.

Screwed connections, piping, hydraulic hoses Repair any leakage in the piping and hose system immediately.

A fine, highly pressurized jet of hydraulic oil can penetrate the skin.

Never search for leakages with the fingers, but use a piece of cardboard and always wear goggles.

Used oil may be harmful to the skin.

If oil has penetrated into the skin, consult a doctor immediately.

Clean soiled skin thoroughly with warm soapy water and apply a barrier cream. Never use fuels or solvents for cleaning the skin.

Never repair damaged piping; always replace them.

If you have swallowed any oil, avoid vomiting but consult a doctor immediately.

Replace hydraulic hoses immediately on detecting any damage or moist areas.

Tighten leaking screw plugs only when the system is depressurized.

Escaping oil is an environmental hazard.

3-4

BA 6030(3 847 020.00)-EN

Inspection and servicing

Non-polluting disposal Dispose of oils, greases, cooling liquids, detergents, solvents and oil-containing components, such as filters, cleaning rags, replaced wearing parts and unusable machine parts, without polluting the environment and separately from other waste.

Do not dispose of these substances together with household wastes.

Engine exhaust gases Start and operate combustion engines only on wellventilated premises.

In closed rooms, exhaust gases must be evacuated to the outside; Do not work on the exhaust system an do not make any modifications to it;.

Fill these substances into the containers provided for such purposes.

Exhaust gases from diesel engines and some of their constituents may cause cancer, birth defects and other reproductive harm.

Like any other oil, also bio-degradable, "environmental-friendly" hydraulic oil must be disposed of separately.

Handling batteries

Do not allow oils and oily wastes to penetrate into the soil or into water. They are an environmental hazard.

Used pressure vessels for cold-starting fluid (ether) must be disposed of properly. Contact the supplier with regard to disposal / return of the vessels.

Even apparently empty pressure vessels can contain rests of ether and therefore explode if they are damaged or heated up above 49°C / 120°F. They must therefore be handled in the same way as full pressure vessels. 

Do not keep them on the machine.



Do not damage or open the vessels.



Do not expose the vessels to great heat or direct sunlight.



Do not dispose of in fire.



Keep the vessels in a place inaccessible to unauthorized persons.



Dispose of the vessels properly.

Seals After replacing parts or after opening housings replace seals. Always use new seals and gaskets.

Clean sealing faces prior to assembly.

Individual spares may contain asbestos. Such spares or their packaging are marked with: Never process spares containing asbestos mechanically. Inhaling asbestos dust is a health hazard.

Clean sealing faces prior to assembly.

Battery Posts, terminals and related accessories contain lead and lead compounds, chemicals known to cause cancer and reproductive harm.

Wash hands after handling.

Batteries give off explosive gases.

Never handle batteries close to naked flames and unshielded light sources, never smoke.

Battery acid is toxic and corrosive.

Avoid any contact with the skin, mouth, eyes and clothing. Avoid spilling battery acid or inhaling the vapours.

Wear gloves, firm protective clothing and goggles / face protection shield when handling batteries.

If the skin is splashed with acid, rinse thoroughly with running water and consult a doctor.

If the eyes are splashed with acid, rinse thoroughly with running water and consult a doctor immediately.

Never set tools down on the battery. They may induce a short circuit, causing irreparable damage to the battery and injuring persons.

Never wear metal necklaces, bracelets or watchstraps when working on the battery. The metal parts may induce a short-circuit resulting in burns.

Dispose of used batteries separately from other waste in the interests of environmental protection.

Before working on the electrical system Before performing work on the electrical system where tools, spare parts, etc. can come into contact with electrical conductors or contacts, the battery must be disconnected.

Disconnect first the negative and then the positive terminal.

After the work: Reconnect first the positive and then the negative terminal.

3-5

BA 6030(3 847 020.00)-EN

Inspection and servicing Handling of cold-starting fluid (ether)

Filters

The engine compartment can be equipped with pressure vessels containing cold-starting fluid (ether).

Replace / clean all filter elements or filter cartridges within the specified periods.

Ether is toxic and highly flammable; the vessels are under pressure. These pressure vessels can explode if exposed to high temperatures (above 49°C / 120°F) or in the event of damage.

Protect the pressure vessels against damage before beginning to work in or close to the engine compartment.

Read and observe the instructions on the pressure vessels.

For further details please refer to the instructions and safety data-sheets of the manufacturer / supplier of pressure vessels with cold starting fluid (ether).

Provide for sufficient ventilation.

Do not eat, drink or smoke when replacing an empty vessel.

Do not inhale the vapours of escaping cold-starting fluid.

In contact with the skin, ether can cause frostbites and irritations. Avoid skin contact.

All filters are coordinated carefully with the equipment. Original CGM HMS GmbH parts must be used to ensure smooth running and a long service life of the engine and the hydraulic units.

Sealing elements When dismantling parts, watch for sealing elements.

Check sealing elements prior to installation and replace any that are even slightly damaged.

When assembling, ensure a perfect fit.

Oil-level check and oil change Position the machine horizontally.

Change the oil when the machine is at operating temperature. Warm oil flows better and carries suspended particles (carbon or abraded matter) better.

Wear suitable protective gloves and goggles.

Even apparently empty pressure vessels can still contain rests of ether and therefore explode if they are damaged or heated up above 49°C. They must therefore be handled in the same way as full pressure vessels. 

Do not keep them on the machine.



Do not damage or open the vessels.



Do not expose the vessels to great heat or direct sunlight.



Do not dispose of in fire.



Keep the vessels in a place inaccessible to unauthorized persons.



Dispose of the vessels properly.

Selecting oils and greases Use the recommended qualities only, matching viscosities with the temperature level.

3-6

Lubricating Clean the lubricating nipple, then lubricate as scheduled.

After servicing To prevent corrosion, coat all bright metal parts with a grease film.

On completing work, re-install all protective devices.

Never start up the drive motors while work is being done on the machine.

Carry out performance tests with the machine.

BA 6030(3 847 020.00)-EN

Inspection and servicing INSPECTION AND SERVICING WORK, FIRE AND EXPLOSION HAZARD Safety instructions Prior to commencing work, obtain informationon the national and corporate rules for the prevention of accidents and avoiding fires.

Pay particular attention to hazards caused by combustible and easily flammable substances.

Obtain information on the safe handling of the fire extinguishers to be used.

Avoid smoking and open fire on, next to and below the hydraulic shovel.

Even battery gases can ignite in open flames or fire.

Combustible and easily or highly inflammable substances or liquids increase the risk of fire and explosion. This is also valid for pressure vessels containing flammable substances as, for instance, spray oil or cold-starting fluid (ether). They are heat-sensitive and can explode even if exposed only to intensive sunlight.

These substance can also ignite themselves if they come close to hot units or objects as, for instance, a turbocharger.

Do not store these substances on the hydraulic shovel. If combustible, easily or highly flammable substances or liquids were used during maintenance operations, they must be completely removed from the hydraulic shovel at the end of the work.

Place suitable fire guardings (fire barriers) if open fire or flying sparks cannot be avoided during repair work.

If necessary, also cover the ground with fireprotective blankets.

Apply special protection to cables, cable ducts as well as to hose and pipe lines.

Have all your welding, flame cutting and grinding work approved before starting work.

The engine compartment can be equipped with pressure vessels containing cold-starting fluid (ether). Ether is toxic and highly flammable; the vessels are under pressure. These pressure vessels can explode if exposed to high temperatures (above 49°C / 120°F) or in the event of damage.

Protect the pressure vessels against damage before beginning to work in or close to the engine compartment.

Ensure sufficient ventilation.

Do not keep any fire extinguishers that are not suitable or have not been tested.

Do not extinguish flammable liquids with water.

Use:  dry-powder, carbon-dioxide or foam extinguishing compounds.

When getting into contact with burning substances, the fire-fighting water would abruptly evaporate and distribute the substance such as oil over a wide area. Water causes short-circuits in the electrical system thus possibly entailing new hazards.

Call the fire brigade.

Clean the hydraulic shovel carefully after the maintenance, if oil, grease, fuel, detergents or coldstarting fluid have been spilt over the machine. If possible, use a steam-jet cleaner for cleaning.

Avoid parking the hydraulic shovel in places where  combustible substances such as coal dust or tar are present. 

open or smouldering fire may occur.

Remove the hydraulic shovel from such an area where combustible or easily flammable liquids have spilled from the hydraulic shovel onto the ground.

Flying sparks (caused by welding, flame cutting, grinding, electrical short-circuit) may cause fire on the ground that can spread to the hydraulic shovel.

3-7

BA 6030(3 847 020.00)-EN

Inspection and servicing

3-8

BA 6030(3 847 020.00)-EN

Inspection and servicing INSPECTION AND SERVICING PLANS - INSTRUCTIONS Intervals The inspection and Servicing plan lists all jobs which have to be done on the machine at regular intervals.

The individual inspection and Servicing plans are marked with letters providing a link between the operating hours (OH) recorded by the hours-run meter of the machine and the inspection and sServicing plans.

Plan V N

Do all jobs .... ...once prior to initial commissioning. ...after initial commissioning and during the running-in period (up to 100 OH). ...every 10 OH or every working shift 1) T 2 ...every 60 OH or weekly .

W ...after every 250 OH. A ...after every 500 OH. B ...after every 1000 OH. C ...after every 5000 OH. D ...after every 10000 OH. E OH = Bh = Operating hours

Air-intake system The air filter must be serviced only if the BCS so indicates. Replace the filter elements after one year at the latest.

Oils / Greases For the specification of oils and greases to be used refer to the „LUBRICANTS / CONSUMABLES“ section.

The numerals mentioned in the "Oil / Grease" column in the inspection and Servicing plans have the following meaning: Oils for combustion engines and compressors Oils for hydraulic systems II IIIa, b, c Oils for gearboxes Greases for bearings and swing rings V I

Cleaning jobs Cleaning jobs, especially on cooling systems, must be done at shorter intervals if the machine is exposed to severe dust build-up.

Components Change of engine oil The intervals stated for changing the engine oil apply to fuels with a sulphur content of  0.5% and a permanent ambient temperature down to –10° C (14 °F).

In case of higher sulphur content and/or a permanent ambient temperature of below –10° C (14 °F), shorter intervals are required.

The maintenance intervals for components, e.g. engine and gearbox, are listed in the following CGM HMS GmbH maintenance schedules.

It is possible that the manufacturer's documentation for these components states intervals deviating from the above-mentioned intervals.

In such case, only the maintenance intervals specified by CGM HMS GmbH shall apply.

If the engine oil change intervals are not reached within 6 months, the oil must be changed at least after 6 months.

2

Whichever comes first.

3-9

BA 6030(3 847 020.00)-EN

Inspection and servicing

3-10

BA 6030(3 847 020.00)-EN

Inspection and servicing Plan V Plan V – Once prior to initial commissioning Page 1 of 2 Location

Servicing work

Engine Engine oil tank (optional) Cooling system Cooling liquid Electrical system Battery Lighting

Check oil level Check oil level

Monitoring, warning and control elements BCS Slewing system Hydraulic system Hydraulic oil reservoir Hydraulic cylinders Pump drive gearbox - Pre-chambers - Expansion reservoir Swing gearbox (Gearbox P/N 3692960) Swing gearbox (Gearbox P/N 3676892) - Expansion reservoirs Travel gearbox (Gearbox P/N 2712182) - Pre-chamber (spur gear section) - Brake chambers Travel gearbox (Gearbox P/N 3683493) - Brake chambers

Quantity/ No. 2 2

Check

2

Check liquid level Check operation

4

Check function of monitoring, warning and control elements Check emergency OFF function Check function Perform „Slew brake Test“ (see chapter „Service – Slew Brake Test“) Check function of working and travelling movement Check pressure (see Service Manual) Check oil level Vent (see chapter “Venting hydraulic system“) Check oil level Check oil level Check oil level Check oil level Check oil level Check oil level Check oil level Check oil level Check oil level Check oil level

1

1 2 2 2 2 2 2 2x1 2x2 2 2x2

3-11

BA 6030(3 847 020.00)-EN

Inspection and servicing

Plan V – Once prior to initial commissioning Page 2 of 2 Location Undercarriage Track roller Support roller Track tension Idler Central lubricating system Grease container Greasing and pause cycles Level control Service – Station (tanklift) Air conditioner (optional) Compressor Hydraulic ladder - Lubricating points On-board crane (optional) - Fastening bolts - Bearings - Joint (column / boom) - Cylinder bearing - Swing ring Hydraulic oil reservoir Crane drive engine - Battery Escape ladder - Locking device - Ladder Harness (optional) - Harness holding device on cab roof All lines, fittings and connections All articutated joints and hinges

3

Servicing work

Check for leaks and free movement 3 Check grease filling, fill in grease Check for leaks and free movement Check grease filling, fill in greaseFehler!

Textmarke nicht definiert.

Check pressure (see Service Manual) Check for leaks and free movement

2x7 2x2 2 2

Check filling level Check setting Check function Check operation Check oil level Lubricate Check for tightness Lubricate Lubricate Lubricate Grease Check oil level (see “On-Board Crane“ Operation and Maintenance Manual) Check oil level (see “Crane drive Engine“ Operation and Maintenance Manual) Check liquid level Check function Check function Check free movement Check completeness and condition Check for tightness Inspect visually for leaks, wearing marks Lubricate

Valid for machines with automatic greasing system for the undercarriage

3-12

Quantity/ No.

16 4 2 5 1 1 1 2

BA 6030(3 847 020.00)-EN

Inspection and servicing Plan N Plan N – After initial commissioning and during the running-in period (after approx. 100 OH) Page 1 of 2 Location

Servicing work

Engine (After 20 - 40 OH, cf. Engine Operation and Maintenance Manual) V-belts, Poly-V-belts - Bearing, Fastening bolts Cooling system Cooling liquid

Check tension, check condition Check for tightness

Radiator - Bearing - Fastening bolts Hydraulic system Oil cooler - Bearing - Fastening bolts Return-flow filter Magnetic rod Filter housing (cooling system) - Return-flow filter - Magnetic rod Pressure accumulator – emergency lowering Pressure accumulator - hydraulic ladder (optional) Pressure accumulator – track tension Pump drive gearbox - Pre-chambers - Fastening bolts Swing gearbox (Gearbox P/N 3692960) - Fastening bolts Swing gearbox (Gearbox P/N 3676892) - Brake chamber - Fastening bolts Travel gearbox (Gearbox P/N 2712182) - Pre-chamber (spur gear section) - Brake chambers - Fastening bolts Travel gearbox (Gearbox P/N 3683493) - Brake chambers - Fastening bolts

4

Quantity/ No.

Carry out cooling liquid analysis after 250 OH (see: Engine Operation and Maintenance Manual) Check for tightness (see Service Manual)

Check for tightness (see Service Manual) Replace Clean

7 1

Replace Clean Check function Check function

2 2 1 1

Check function Change oil Change oil Check for tightness (see Service Manual) Change oil Check for tightness (see Service Manual) Change oil Change oil Check for tightness (see Service Manual) Change oil Change oil Change oil Check for tightness (see Service Manual) Change oil Change oil Check for tightness (see Service Manual)

2 4 2 4 2x3 2

4

4

2 4 2 4

2 4 2x1 4 2x2 4

2 4 2x2

see: “Refilling quantities – Oil“ table

3-13

BA 6030(3 847 020.00)-EN

Inspection and servicing Plan N – After initial commissioning and during the running-in period (after approx. 100 OH) Page 2 of 2 Location

Servicing work

Swing ring Fastening bolts (swing ring, undercarriage and Check for tightness (see Service Manual) Upperstructure) Upperstructure Fastening bolts, especially at upperstructure / Check for tightness (see Service Manual) pedestal / operator’s cab Inspect visually for leaks, wearing marks All lines, fittings and connections

3-14

Quantity/ No.

BA 6030(3 847 020.00)-EN

Inspection and servicing Plan T and W Plan T - Every 10 OH or every working shift (whichever comes first) Plan W - Every 60 OH or every working week (whichever comes first) Page 1 of 2 Location

Servicing work

Engine Engine monitoring (Board Control System) Cooling system Cooling fluid level Radiator Fuel system Fuel filter Water trap (optional) Fuel tank

Check oil level

Air-intake system Intake and clean-air lines - Dust trap - Cyclon prefilter Electrical system Lighting Switchgear cabinet - Breather filter - Dust trap - EMERGENCY OFF button Monitoring, warning and control elements BCS Hydraulic system Hydraulic oil reservoir Oil cooler Fan wheel Pump drive gearbox - pre-chambers expansion reservoir Oil filter (tell-tale)

Quantity/ No. 2

Plan T 

Plan W 





2 2

 

 

2x1 2x1

  

  

 

   





 

  

 

 

 

      

Check monitoring display Check Check / clean Drain off water Drain off water Drain off water and sediment if necessary Check BCS – indication Check for tightness and leaks Remove dust Check, remove dust

1 4x1 4x1

Check operation Remove dust Check function Check function of monitoring, warning and control elements Check function Check function of working and travelling movement Inspect visually for leaks Check oil level Check / clean Check condition Check oil level Check oil level Check

1 5

1 2 2 2 2 2x1

 

3-15

BA 6030(3 847 020.00)-EN

Inspection and servicing Plan T - Every 10 OH or every working shift (whichever comes first) Plan W - Every 60 OH or every working week (whichever comes first) Page 2 of 2 Location

Servicing work Check oil level

Quantity/ No. 2

Plan T 

Plan W 

Swing gearbox (Gearbox P/N 3692960) Swing gearbox (Gearbox P/N 3676892) - Expansion reservoirs Travel gearbox Undercarriage Tracks

Check oil level Check for leaks

4 2

 

 

Inspect track tension visually

2





Track roller

Check for leaks and free movement

2x7



Support roller

Check for leaks and free movement

2x2



Idler

Check for leaks and free movement

2



Face shovel

Check housing of clamshell cylinders for accumulated soil, clean if necessary

Central lubricating system Grease container Lubricating points Air conditioner (optional) 5 On-board crane (optional) Fastening bolts Crane drive engine Hydraulic oil reservoir - Reflow filter Reservoirs for used grease at the A-frame Escape ladder - Locking device - Ladder Harness (optional) - Harness holding device on cab roof Fire extinguisher Automatic fire-extinguishing system (optional) All lines, fittings and connections Excavator

5 Before each deployment of the crane

3-16

2x1

Check filling level Check visually (see: “Air Conditioning manual)

1

Check for tightness Check oil level (see: “Crane drive Engine“ Operation and Maintenance Manual) Check oil level Check contamination indicator Check, depollute used grease

16 1

Inspect visually for leaks, wearing marks Inspect visually, overall cleaning









  

1 1 2

Check function Check free movement Check completeness and condition Check for tightness Check condition Check control module



2 1



   

   

 

 



 

BA 6030(3 847 020.00)-EN

Inspection and servicing Plan A – E Plan A – after every 250 OH (at 250, 750, 1250 … OH)

Plan B – after every 500 OH (at 500, 1500, 2500 … OH)

Plan C – after every 1000 OH (at 1000, 2000, 3000, 4000 … OH)

Plan D – after every 5000 OH (at 5000, 15000, 25000 … OH)

Plan E – after every 10000 OH (at 10000, 20000, 30000, … OH) Page 1 of 7 Location Servicing in acc. with W or T Monitoring, warning and control elements - Joystick - Control spool, plate and cardan joint - Pedal - Control spool (machine with face shovel) - Control spool (machine with backhoe bucket) Operator’s cab - Fastening bolts to cab module

6

Servicing work

Quant. / No.

grease lightly

2x4

6







grease lightly

3x2

6







grease lightly

2x2

6













Check for tightness (see Service Manual for tightening torque)

Plan Plan Plan Plan Plan A B C D E     

apply a thin layer of low temperature grease

3-17

BA 6030(3 847 020.00)-EN

Inspection and servicing Plan A – after every 250 OH (at 250, 750, 1250 … OH)

Plan B – after every 500 OH (at 500, 1500, 2500 … OH)

Plan C – after every 1000 OH (at 1000, 2000, 3000, 4000 … OH)

Plan D – after every 5000 OH (at 5000, 15000, 25000 … OH)

Plan E – after every 10000 OH (at 10000, 20000, 30000, … OH) Page 2 of 7 Location Servicing in acc. with W or T Engine Inspection and servicing

Oil filter V-belt V-belt - Bearing - Fastening bolts - Rubber bearing Crank case breather Groundscrew engine electronics Starter Water pump Turbo charger

Servicing work

See: “Engine Operating and Maintenance Manual”

Carry out analysis of engine oil Change oil Clean Replace Check tension Check condition Check tightness Check condition Clean Check, clean, fasten Check Check Check

After 3000 OH:

See: Engine Operating and Maintenance Manual

Crankshaft Electronic Unit Injector Engine speed sensors Engine timing sensors Engine Valve Lash Engine Valve Rotators

Inspect Vibration damper Inspect/Adjust Check/Clean/Adjust Check/Clean/Adjust Inspect/Adjust Inspect

7

see: “Refilling quantities – Oil“ table

3-18

Quant. / No.

Plan Plan Plan Plan Plan A B C D E     

2











2x1 7 2

 

 

2x2



  

     

     

     

 

   

   

   

  

  

  

  

2x1 2x1



BA 6030(3 847 020.00)-EN

Inspection and servicing Plan A - after every 250 OH (at 250, 750, 1250 ... OH)

Plan B - after every 500 OH (at 500, 1500, 2500 ... OH)

Plan C - after every 1000 OH (at 1000, 2000, 3000, 4000 ... OH)

Plan D - after every 5000 OH (at 5000, 15000, 25000 ... OH)

Plan E - after every 10000 OH (at 10000, 20000, 30000, ... OH) Page 3 of 7 Location

Servicing work

Cooling system Radiator - Check tightness - Fastening bolts - Rubber bearing Cooling liquid ELC (see: Engine Operation and Maintenance Manual)

Inspect visually for leaks Clean

Quant. / No.

Plan Plan Plan Plan Plan A B C D E  

 

Check tightness Check condition Carry out cooling liquid analysis (after 1 year at the latest)

 

 

 

  

  

  

  

  

   

   

   

   

8

Change Check Check for leaks Check tightness

1

Replace Replace Clean Replace

2x1 2x1 2x1 2x1

Check / replace

2x2

9







Safety filter element

Replace

2x2

10







Air-intake lines and clean-air lines Intercooler Hoses

Check for tightness and leaks







Check / clean Replace







 

 

Electrical system Battery cable connections

Check for tightness











Battery

Check fluid level

4









Clean

1









Replace

1





Anti-freeze Lines Hose clamps Fuel system Fuel filter Primary fuel filter Water trap (optional) Breather filter fuel tank Air-intake system Main filter element





  

  

Switchgear cabinet - Breather filter - Filter element

8

Cooling-liquid (ELC) replacement after 12000 OH or after 6 years.

9

Replacement of main filter element after one year resp. after 3 cleaning cycles

10

Replacement of safety filter element after one year resp. after 3 cleaning cycles of the main filter element at the latest 3-19

BA 6030(3 847 020.00)-EN

Inspection and servicing

Plan A - after every 250 OH (at 250, 750, 1250 ... OH)

Plan B - after every 500 OH (at 500, 1500, 2500 ... OH)

Plan C - after every 1000 OH (at 1000, 2000, 3000, 4000 ... OH)

Plan D - after every 5000 OH (at 5000, 15000, 25000 ... OH)

Plan E - after every 10000 OH (at 10000, 20000, 30000, ... OH) Page 4 of 7 Location

Servicing work

Hydraulic system

Check pressure (see: Service Manual)







Check for tightness (see Service Manual) Check condition Replace Replace







7 4

 

  

  

Check / clean Check / clean filter sieve

1 4

 

 

 

2 2 2 2x1 1 1 2x2 2 1 11 12 1

  

        

          

Oil cooler bearing - Fastening bolts - Rubber bearing Return-flow filter High-pressure filter for working hydraulics Magnetic rod Bypass valve hydraulic oil reservoir Filter housing (cooling system) - Return-flow filter - Bypass valve - Magnetic rod Filter for pilot control circuit Filter (control circuit) Filter (auxiliary control circuit) Filter (swing pump feed circ.)

Breather filter Hydraulic oil reservoir Pressure accumulators Cylinder (seals and guide rings)

11

Replace Check sieve / clean Check / clean Replace Replace Replace Replace Replace Carry out oil analysis Change oil Check pressure (see: Service Manual) Replace

Quant. / No.

Plan Plan Plan Plan Plan A B C D E



 



see: “Refilling quantities – Oil“ table

12

Unless it is regulary analyzed, the hydraulic oil must be changed every 5000 OH or after 3 years at the latest

3-20

BA 6030(3 847 020.00)-EN

Inspection and servicing

Plan A – after every 250 OH (at 250, 750, 1250 … OH)

Plan B – after every 500 OH (at 500, 1500, 2500 … OH)

Plan C – after every 1000 OH (at 1000, 2000, 3000, 4000 … OH)

Plan D – after every 5000 OH (at 5000, 15000, 25000 … OH)

Plan E – after every 10000 OH (at 10000, 20000, 30000, … OH) Page 5 of 7 Location

Servicing work

Pump drive gearbox

Carry out oil analysis Change oil Clean Replace Change oil Clean Check tightness Check for contamination and damage Replace

- Breather filter - Pre-chamber - Breather filter Fastening srews Oil filter

Travel gearbox (Gearbox P/N 2712182) - Magnetic rod Pre-chamber / spur wheel section - Magnetic rod Brake chambers Breather filter Travel gearbox (Gearbox P/N 3683493) - Magnetic rod Brake chambers Breather filter

13

Quant. / No. 2 13 2 2x1 2x1 2x3 2x1 2x1

Plan Plan Plan Plan Plan A B C D E                         

2x1

Carry out oil analysis Check oil level Change oil Clean Check oil level

2 2 13 2 2x6 2x1

Change oil Clean Check oil level Change oil Clean Replace

2x1 2x1 2x2 13 2x2 2x3 2x3

Carry out oil analysis Check oil level Change oil Clean Check oil level Change oil Clean Replace

2 2 13 2 2x6 2x2 13 2x2 2x3 2x3

 

 



 



 

13

  

 



  





    

    

     

     

       

       

see: “Refilling quantities – Oil“ table

3-21

BA 6030(3 847 020.00)-EN

Inspection and servicing

Plan A – after every 250 OH (at 250, 750, 1250 … OH)

Plan B – after every 500 OH (at 500, 1500, 2500 … OH)

Plan C – after every 1000 OH (at 1000, 2000, 3000, 4000 … OH)

Plan D – after every 5000 OH (at 5000, 15000, 25000 … OH)

Plan E – after every 10000 OH (at 10000, 20000, 30000, … OH) Page 6 of 7 Location

Servicing work

Swing gearbox

Carry out oil analysis Change oil Replace Change oil

- Breather filter - Brake chamber (Gearbox P/N 3676893 only) Swing ring Gearing / pinion Fastening bolts (swing ring, undercarriage and upperstructure) Undercarriage Diaphragm accumulator - Diaphragm Central lubricating system Oilfilter (hydraulic circuit grease pump) Grease filter (filling grease container) Grease filter (grease lines) Breather filter Air conditioner (optional)

- Filter mats

Check grease filling Check condition Check for tightness (see: Service Manual) Check wear (see: Service Manual) Check pressure (see: Service Manual) Replace (see: Service Manual) Check function

Quant. / No. 2 14 2 2x1 14 2

Plan Plan Plan Plan A B C D          

1

2

 

  

  





















2 

Plan E    



Replace

1





Replace

1





Replace Check / replace Carry out all maintenance accord. to manufacturers manual) Clean, replace if damaged

2 1 1



 

 























Hydraulic ladder - Greasing point

14

Lubricate

see: “Refilling quantities – Oil“ table

3-22

BA 6030(3 847 020.00)-EN

Inspection and servicing Plan A - after every 250 OH (at 250, 750, 1250 ... OH)

Plan B - after every 500 OH (at 500, 1500, 2500 ... OH)

Plan C - after every 1000 OH (at 1000, 2000, 3000, 4000 ... OH)

Plan D - after every 5000 OH (at 5000, 15000, 25000 ... OH)

Plan E - after every 10000 OH (at 10000, 20000, 30000, ... OH) Page 7 of 7 Location On-board crane (Option) 15 - Bearing - Joint (column / boom) – Cylinder bearing – Swing ring Hydraulic system – Return-flow filter – Breather filter

Crane drive engine - Oil filter – Fastening bolts – Fuel filter – Air filter – Battery cable connection

Steel components

Modules – Fastening bolts All articulated joints and hinges

Servicing work

Lubricate Lubricate Lubricate Grease Change oil Replace Replace see: “On-Board Crane“ Operation and Maintenance Manual Clean Change oil Replace Check for tightness Replace Replace Check for tightness see: “Crane Drive Engine“ Operation and Maintenance Manual Visual inspection acc. to "Structural Inspection Report every 500 OH" 17 If any suspect areas have been found additional testing is required: For detailed crack analysis prepare the surface of the relevant area to be inspected and carry out the dye penetrant, magnetic powder or ultrasonic test.

Check for tightness (see Service Manual) Grease

15

Do all servicing jobs at least once a year and when necessary

16

see: “Refilling quantities – Oil“ table

Menge / No.

Plan Plan Plan Plan Plan A B C D E

4 2 5 1 16 1 1 1 





































1 16 1 1 1 1 1 2

17

"Structural Inspection Reports" for inspections every 500 OH can be downloaded from the CGM HMS website www.bucyrus-HEX.de, section "Support, Warranty".

3-23

BA 6030(3 847 020.00)-EN

Inspection and servicing LUBRICATING CHART – GREASE

Fig. 3-1:

3-24

BA 6030(3 847 020.00)-EN

Inspection and servicing Lubricating chart – Grease (legend) No. Greasing point 1

Central lubricating system – grease container

3

Hydraulic ladder (optional) - greasing point

4

Hydraulic on-board crane

5

Number

Lubricant properties

1

V 18 V 18

Grease every .... operating hours 10 1000 250

- Bearing - Joint (column / boom)

4 2

- Cylinder bearing

5

- Swing ring

1

V

250 250

18

250

Graphitespray

250

V 18

1000 1000

Monitoring, warning and control elements - Joysticks - Pedals

19

2x4 19 3x2

All other greasing points are supplied with grease by the central lubricating system.

Filling quantities – Grease Greasing point Central lubricating system – grease container (different containers available) Internal gearing – Roller-bearing swing ring Idler (permanent grease filling) Track rollers (permanent grease filling, if not connected to the central greasing system, optional) Support rollers (permanent grease filling)

18

see: "LUBRICANTS / CONSUMABLES" section.

19

apply a thin layer of low temperature grease

Lubricant properties

V 18

Tribol CGM HMS GmbH part no. 2764564

Filling quant. in kg lb 180 / 500

397 / 1102

appr. 150 2 x appr. 4.4

appr. 331 2 x appr. 9.7

14 x appr. 14

14 x appr. 31

4 x appr. 1.3

4 x appr. 3

3-25

BA 6030(3 847 020.00)-EN

Inspection and servicing INSPECTION PLAN - OIL

Fig. 3-2:

3-26

BA 6030(3 847 020.00)-EN

Inspection and servicing Inspection plan – Oil (legend) No. Location

Lubricant 20 properties

I II III.a

1

Engine

2

2

Hydraulic system

1

3

Pump drive gearbox

2

3 4

- Pre-chambers Swing gearbox (Gearbox P/N 3692960) Swing gearbox (Gearbox P/N 3676892 only) - Expansion reservoir - Expansion reservoir brake chamber Travel gearbox

2x5 2

- Pre-chamber, spur gear section (Gearbox P/N 2712182 only) - Brake chambers

2x1

5

6

7

20

Number

2 2

III.b III.b

2

III. a

2x2

Check oil level every ... OH 10

Change oil every ... OH 250

10

10000

60

1000

10 10

1000 1000

10 10

1000 1000

500

5000

500

5000

500

5000

10

250

10

1000

21

On-board crane (optional) - Crane drive engine

1

- Hydraulic oil reservoir

1

I II

22 23

see: "LUBRICANTS / CONSUMABLES" section

21

Change hydraulic oil every 5000 OH unless the oil is analyzed at regular intervals, but not later than every 3 years.

22

Change oil at least once a year.

23

Change hydraulic oil at least once a year.

3-27

BA 6030(3 847 020.00)-EN

Inspection and servicing Filling quantities - oil Location Engine (with filter changed)

Filling quantity litres gal 2 x approx. 68 2 x approx. 18

Engine oil tank (optional)

2 x approx. 260

2 x approx. 68.7

Hydraulic oil reservoir Hydraulic system Pump transfer gearbox - Pre-chambers (Working pumps)

approx. 2500 approx. 3500 2 x approx. 15.5 4 x approx. 1,4

approx. 660 approx. 925 2 x approx. 4.1 4 x approx. 0.37

- Pre-chambers (Hydraulic pumps) Swing gearbox (Gearbox P/N 3692960)

2 x approx. 0.2 2 x approx. 38

2 x approx. 0.05 2 x approx. 10

Swing gearbox (Gearbox P/N 3676892) - Brake chambers Travel gearbox (Gearbox P/N 2712182) - Pre-chamber, spur gear section

2 x approx. 26 2 x approx. 6 2 x approx. 60 2 x approx. 7

2 x approx. 6.9 2 x approx. 1.6 2 x approx. 17.4 2 x approx. 1.9

- Brake chambers

4 x approx. 0,5

4 x approx. 0.13

Travel gearbox (Gearbox P/N 3683493) - Brake chambers On-board crane (optional) - Crane drive engine

2 x approx. 94 4 x approx. 1

2 x approx. 24.8 4 x approx. 0.26

III.a

approx. 5,5

approx. 1.45

approx. 50

approx. 13.2

I II

- Hydraulic oil reservoir

Oil

I I II III.a III.b III.b III.a

Filling quantities – other Location

Filling quantity litres

gal

2 x approx. 150

2 x approx. 41

Fuel tank

2 x approx.

2680

2 x approx. 708

Fuel tank, crane drive engine (optional)

approx. 20

approx. 5.3

Screen washer

approx. 13

approx. 3.4

Cooling system - engine

3-28

BA 6030(3 847 020.00)-EN

Inspection and servicing LUBRICANTS / CONSUMABLES Notes on the selection of oils and greases Original CGM HMS GmbH oils and greases Besides regular and careful maintenance, the quality of the oils and greases used in the machine has a decisive influence on high performance, reliability and long service life of a machine and of its units and assemblies.

The lubricants tables in the CGM HMS GmbH Operation and Maintenence Manual contain specifications for the oils and greases that are approved for use in CGM HMS GmbH machines. These oils and greases are especially adapted to CGM HMS GmbH machines and their units and assemblies.

Other oils and greases which do not fulfil the requirements of the specifications can be the cause of premature wear or of damage to and failures of machine units and assemblies.

For this reason, CGM HMS GmbH only approves the use of the specified oils and greases.

All other qualities are not approved.

Alternative oils and greases The oils and greases filled into the machine must meet at least the specifications mentioned in the lubricants tables of the CGM HMS GmbH Operation and Maintenence Manual.

In the event of damage to the machine or to its units and assemblies caused by the use of alternative oils and greases that are not compatible with CGM HMS GmbH specifications, CGM HMS GmbH does not assume any responsibility and does not accept any warranty claims.

Avoid mixing of different hydraulic fluids The machine has been run in at the factory with BM Long Term Hydraulic Fluid HSS (Part-No. 2482971). CGM HMS GmbH recommends using this high-grade hydraulic fluid also in operation as it has been made especially for use in these machines to which it is also perfectly adapted.

If oil analyses are performed regularly and with positive results, the BM Long Term Hydraulic Fluid can remain in the machine for up to 10 000 operating hours.

If an alternative hydraulic fluid is to be used, it must fulfil the same specifications. Please note that the change interval for alternative fluids is fixed at 5 000 operating hours.

There is an increased risk of damage to hydraulic components, if different hydraulic fluids are mixed during topping up as well as when changing over to a fluid of a different type or from another manufacturer.

For topping up, it is therefore necessary to use only same hydraulic fluid as the one that is already in the hydraulic system.

When changing over to an alternative hydraulic fluid, please observe that there is always a small amount of old fluid remaining in the hydraulic system even after the system has been emptied. The mixing of this residual amount of old fluid with the new alternative fluid reduces the properties of the fluid dramatically and can cause damage to components of the hydraulic system in operation.

To avoid this result, the change-over to the alternative fluid must be performed in strict compliance with the manufacturer's prescriptions. The manufacturer must confirm that his hydraulic fluid is compatible with the BM Long Term Hydraulic Fluid.

The remaining amount of old fluid must not exceed 2% of the total volume. This can only be achieved by repeated flushing with the total fluid volume.

If the remaining amount of fluid exceeds 2% of the total volume, the fluid becomes a detrimental "mixed fluid".

The operation of the system with mixed fluids must by all means be avoided.

CGM HMS GmbH assumes no warranty for damage caused as a result of the machine having been operated with consumables of inappropriate specification or with mixed fluids.

3-29

BA 6030(3 847 020.00)-EN

Inspection and servicing

I.

Fig. 3-3:

3-30

Oils for combustion engines

BA 6030(3 847 020.00)-EN

Inspection and servicing

II.

Fluid for hydraulic system

Fig. 3-4:

3-31

BA 6030(3 847 020.00)-EN

Inspection and servicing

III.a Oils for pump drive gearboxes and travel gearboxes

Fig. 3-5:

3-32

BA 6030(3 847 020.00)-EN

Inspection and servicing

III.b Oil for swing gearboxes

Fig. 3-6:

3-33

BA 6030(3 847 020.00)-EN

Inspection and servicing

V. Grease for bearings, slew rings and track system (Central lubrication system)

Fig. 3-7:

3-34

BA 6030(3 847 020.00)-EN

Inspection and servicing

Grease for idlers, track rollers and support rollers (Lifetime lubrication)

Fig. 3-8:

3-35

BA 6030(3 847 020.00)-EN

Inspection and servicing

Coolant for use on all combustion engines

Fig. 3-9:

3-36

BA 6030(3 847 020.00)-EN

Inspection and servicing SERVICING WORK Hose line for oil and cooling liquid changes Collect escaping oil and cooling liquid and discard without polluting the environment.

The engines, the hydraulic oil reservoir, the pump drive gearboxes, the swing gearboxes and the radiators (engine cooling liquid) can moreover be equipped with automatic drain valves (1, Fig. 3-11:).

These automatic drain valves permit oil- and cooling-liquid changes without polluting the environment.

Carry out oil changes when the machine is at operating temperature; warm oil drains away more easily.

Filling and draining can be done by means of a hose through the service station (tanklift) (Fig. 3-10:).

For filling and draining, a flexible hose is connected to the express coupling on the service station and to the service vehicle at the other end.

The filling operations require an overpressure, whereas the draining operations require low pressure.

Fig. 3-11:

Change oil or cooling liquid as follows:  Place a collecting recipient for used oil or cooling liquid under the corresponding automatic drain valve. For the recipient capacity refer to the "Refilling quantities - Oil" table or to the "Refilling quantities - Other" table.  Unscrew protective cap from automatic drain valve.  Screw on hose line (2) to open the valve, so that the oil or the cooling liquid can flow out.  When the oil or the cooling liquid has drained away, unscrew hose line to allow the valve to close automatically.  Screw protective cap back in place.

Fig. 3-10:

3-37

BA 6030(3 847 020.00)-EN

Inspection and servicing ENGINE Engine - Safety instructions Start and operate combustion engines only on well-ventilated premises.

Attention, Ether!

In closed rooms, exhaust gases must be evacuated to the outside.

The engine compartment can be equipped with pressure vessels containing cold-starting fluid (ether).

Do not work on the exhaust system an do not make any modifications to it.

Exhaust gases from diesel engines and some of their constituents may cause cancer, birth defects and other reproductive harm.

Read and observe: "Inspection and Servicing – Safety Instructions" and the engine Operation and Maintenence Manual.

Risk of injury from hot or rotating parts of the engine.

Shut off engines and allow to cool down.

Secure the machine as described in the "Securing the machine" section.

Skin contact with cooling liquid is a potential health hazard.

Protect the skin from potentially harmful contact with engine oil.

Wear protective gloves and firm working clothing.

Ether is toxic and highly flammable; the vessels are under pressure.

These pressure vessels can explode if exposed to high temperatures (above 49°C / 120°F) or in the event of damage.

Protect the pressure vessels against damage before beginning to work in or close to the engine compartment.

Secure the machine as described in section “Securing the machine” before starting Inspection and Servicing.

“Retensioning the alternator belt”, “Checking and adjusting the valve clearance”, these and other servicing works are described in the engine manufacturer's Operation and Maintenence Manual.

Before cleaning the engines Exhaust pipes and turbo chargers in the engine compartments are covered with special heat-insulating material.

This material must not be spraywashed with steam-jet cleaners or high-pressure cleaners. It will be damaged.

Therefore cover all the insulating material with plastic foils before using steam-jet cleaners or high-pressure cleaners inside the engine compartments.

3-38

BA 6030(3 847 020.00)-EN

Inspection and servicing Engine oil, checking the level / topping up The engine oil temperature is constantly monitored by the BCS (Fig. 3-12:) when the machine is in operation. It can be displayed on the BCS screen.

 Draw out dipstick a second time. The oil level should now lie between the marks (arrows, Fig. 3-13:). If the oil level is at the "min" mark or below, top up with engine oil through filler tube (2, Fig. 3-14:).

The actual pressure and temperature of the engine oil is also displayed on the screen (Fig. 3-12:).

BCS give acoustic warnings to the operator if the engine oil temperature too high or the oil pressure is too low.

Fig. 3-14: Fig. 3-12:

Engine oil can also be filled in from the service station (Fig. 3-15:) through  express coupling (8) for the lefthand engine, 

express coupling (9) for the righthand engine,

(see chapter "Engine oil, change").

Fig. 3-13:

 Park the machine on a horizontal surface and secure against inadvertent movements.  Shut off engines.  Draw out oil dipstick (2, Fig. 3-14:).

Fig. 3-15:

 Wipe oil off the dipstick with a clean, lintfree cleaning rag and re-insert.

3-39

BA 6030(3 847 020.00)-EN

Inspection and servicing Engine oil reservoir (optional), checking the oil level / topping up  Park the machine on a horizontal surface and secure against inadvertent movements.  Shut off engines.  Unlock the oil dipstick (Fig. 3-16:) and withdraw.  Wipe oil off the dipstick with a clean, lintfree cleaning rag and re-insert.  Draw out dipstick a second time. The oil level should lie at the mark. If the oil level is below, the engine oil is filled in from the service station (Fig. 3-17:) through - express coupling (6) for the lefthand engine oil reservoir, - express coupling (7) for the righthand engine oil reservoir.

Fig. 3-16:

A description of the Service Station can be found in Part 2 of this manual, chapter “Service Station (tanklift)”.

Fig. 3-17:

3-40

BA 6030(3 847 020.00)-EN

Inspection and servicing Engine oil, change Risk of scalding from hot engine oil.

Read and observe: "Inspection and servicing – Safety instructions".

The engines may also be hot. Wear protective gloves and firm working clothing.

Collect escaping oil and discard without polluting the environment.

Drawing off engine oil with the service station  Bring engine oil to operating temperature.  Park the machine on a horizontal surface and secure.  Shut off the engines.  Draw off the engine oil through: 

A description of the Service Station can be found in Part 2 of this manual, chapter “Service Station (tanklift)”.

express coupling (8, Fig. 3-18:) for the lefthand engine,



express coupling (9) for the righthand engine.

Draining off engine oil

After the engine oil has been drawn off:  Replace the engine oil filters.

 Bring engine oil to operating temperature.  Park the machine on a horizontal surface and secure.  Shut off the engines.  Place a collecting recipient for used oil under the oil sump.

(The required recipient capacity is set out in the "Filling quantities - Oil" table).

 Unscrew cap of express coupling and connect hose line of the service vehicle.

 Remove the hose line. The express coupling closes automatically.  Screw on protective cap.  Fill in fresh engine oil.

 Drain oil from the engine through express coupling located at the lowest part of the oil sump.  Unscrew cap of express coupling.  Connect the hose line.

The hose line and its use are described in the "Hose line for oil and cooling liquid changes" section.

After draining of the oil:  Replace the engine oil filters.  Remove the hose line.

The automatic drain coupling closes automatically.

Fig. 3-18:

 Screw on protective cap.

3-41

BA 6030(3 847 020.00)-EN

Inspection and servicing Filling in engine oil  Fill in engine oil through filler tube (1, Fig. 3-19:) until the oil level has reached the "max" mark (Fig. 3-20:) on dipstick (2, Fig. 3-19:).

Filling in engine oil through the service station Fill in engine oil through:  express coupling (8, Fig. 3-21:) for the lefthand engine, 

express coupling (9) for the righthand engine,

until the oil level has reached the "max." mark (Fig. 3-20:) on dipstick (2, Fig. 3-19:).  Unscrew cap of express coupling and connect filling hose of the service vehicle.  Start the engines and allow to run at idling for abt. 2 minutes.

Fig. 3-19:

 Check oil level at dipstick (2, Fig. 3-19:) and top up with oil to the "max" mark (Fig. 3-20:) if required.  Remove the filling hose.

The express coupling closes automatically.  Screw on protective cap.

Fig. 3-20:

Fig. 3-21:

3-42

BA 6030(3 847 020.00)-EN

Inspection and servicing Engine oil reservoir (optional), draining the oil off Risk of scalding from hot engine oil.

Read and observe: "Inspection and servicing – Safety instructions".

Draining the oil off the engine oil reservoir  Bring engine oil to operating temperature.  Park the machine on a horizontal surface and secure engine oil reservoir.  Shut off the engines.

The engine oil reservoirs may also be hot. Wear protective gloves and firm working clothing.

Collect escaping oil and discard without polluting the environment.

Draw off engine oil with the service station (Fig. 3-22:) through  express coupling (6) for the lefthand engine oil reservoir, 

A description of the Service Station can be found in Part 2 of this manual, chapter “Service Station (tanklift)”.

express coupling (7) for the righthand engine oil reservoir.

 Unscrew cap of express coupling and connect hose line of the service vehicle.  Drain the engine oil reservoir.  Remove the hose line.

The express coupling closes automatically.  Screw on protective cap.  After the engine oil has been drawn off: Replace the engine oil filter.

Fig. 3-22:

3-43

BA 6030(3 847 020.00)-EN

Inspection and servicing Filling in engine oil The engine oil is filled in with the service station (Fig. 3-23:) through  express coupling (6) for the lefthand engine oil reservoir, 

express coupling (7) for the righthand engine oil reservoir,

until the oil level has reached the mark on dipstick (Fig. 3-24:).  Unscrew cap of express coupling and connect hose line of the service vehicle.  Fill in engine oil.  Check oil level and top up with engine oil until the oil level has reached the mark on dipstick (Fig. 3-24:).

Fig. 3-23:

 Remove the hose line.

The express coupling closes automatically.  Screw on protective cap.

Fig. 3-24:

3-44

BA 6030(3 847 020.00)-EN

Inspection and servicing Engine oil filter, replace Risk of scalding from hot engine oil.

Read and observe: "Inspection and servicing – Safety instructions".

Oil filters Carry out servicing of the oil filters (Fig. 3-25:) in accordance with the engine Operation and Maintenence Manual.

Replacement:  Shut off the engines.

The filter housing may also be hot. Wear protective gloves and firm working clothing.

Collect escaping oil and discard with-out polluting the environment.

 Unscrew the filters.  Install new filter together with slightly oiled sealing ring and tighten by hand.

Thereafter:  Start the engines and allow to run at idling for a short while.  Check filters for leaks, shut off engines.  Check oil level after 10 minutes, top up if neccessary.

Fig. 3-25:

3-45

BA 6030(3 847 020.00)-EN

Inspection and servicing Engine oil reservoir (optional), replacing the oil filters Risk of scalding from hot engine oil.

Read and observe: "Inspection and servicing – Safety instructions".

The filter housing may also be hot. Wear protective gloves and firm working clothing.

Collect escaping oil and discard with-out polluting the environment.

Replacing the oil filter The filterelements are placed in the engine compartments, at the wall of the counterweight (arrow, Fig. 3-26:).

Carry out servicing of the oil filters together with the engine oil reservoir.

Replacement:  Shut off the engines.  Unscrew the filters.  Install new filter together with slightly oiled sealing ring and tighten by hand.

Thereafter:  Allow engines to run at idling for a short while and check filters for tightness and leaks before shutting off the engines.  Check oil level after abt. 10 minutes and top up, if required.

3-46

Fig. 3-26:

BA 6030(3 847 020.00)-EN

Inspection and servicing Cold-starting fluid (ether) - Replacing the pressure vessel

If the machine is used in low temperatures, the engine may be equipped with a cold-starting device.

Read and observe: "Inspection and servicing Safety instructions"

The pressure vessel containing the cold-starting fluid (ether) can be installed in or near the engine compartment.

Risk of injury Cold-starting fluid is composed mainly of ether.

Ether is toxic when the mists and vapours are inhaled. Ether is harmful to the eyes, the skin, the respiratory system and the central nervous system.

Prolonged inhalation of ether can be fatal.

The vessel is screwed onto an electro-mechanical metering valve. At temperatures below 0°C (32°F), this valve is activated automatically by the engine electronics and injects a precisely metered amount of cold-starting fluid into the air intake duct of the engine.

Replacing the pressure vessel:  Remove the clamp around the pressure vessel.

In contact with the skin, ether can cause frostbites and irritations.

 Unscrew the pressure vessel carefully from the metering valve.

Ether is toxic and highly flammable; the vessels are under pressure.

 Remove the used seal from the metering valve.

These pressure vessels can explode if exposed to high temperatures (above 49°C/ / 120°F) or in the event of damage.

 Insert a new seal into the valve (supplied with the new pressure vessel).

Before replacing an empty pressure vessel: Read and observe the instructions on the pressure vessels.

For further details please refer to the instructions and safety data-sheets of the manufacturer / supplier of pressure vessels with cold starting fluid (ether).

 Screw the new pressure vessel onto the metering valve and tighten by hand.  Fasten the clamp round the pressure vessel.

Even apparently empty pressure vessels can contain rests of ether and therefore explode if they are damaged or heated up above 49°C / 120°F. They must therefore be handled in the same way as full pressure vessels.  Do not keep them on the machine. 

Do not damage or open the vessels.



Do not expose the vessels to great heat or direct sunlight.



Do not dispose of in fire.

Do not inhale the vapours of escaping cold-starting fluid (ether).



Keep the vessels in a place unaccessible to unauthorized persons.

Avoid skin contact. Wear suitable protective gloves and goggles.



Dispose of the vessels properly.

Provide for sufficient ventilation of the surroundings.

Do not eat, drink or smoke when replacing an empty vessel.

3-47

BA 6030(3 847 020.00)-EN

Inspection and servicing COOLING SYSTEM

Temperature

Risk of scalding from hot cooling liquid.

The cooling liquid circuit is controlled by a thermostat. The max. admissible temperature is ca. 100° C (212°F).

Read and observe: "Inspection and servicing - Safety instructions".

In case of higher temperatures, the BCS displays a warning on the screen (Fig. 3-27:).

Secure the machine as described in the "Securing the machine" section.

Shut off the engines and allow to cool down.

Collect escaping cooling liquid and discard without polluting the environment.

Protect the skin from contact with cooling liquid.

Skin contact with cooling liquid is a potential health hazard.

Wear protective gloves and firm working clothing.

Fig. 3-27:

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Inspection and servicing Radiators The radiators are located on the upperstructure in the counterweight module.

Weekly checks:  Check radiator fins for dirt and clean, if required.

Cooling-liquid level check An insufficient cooling-liquid level is displayed on the BCS screen (Fig. 3-28:).

The level indicator (4, Fig. 3-29:) at the expansion reservoirs shows the liquid level as well.

The cooling-liquid level should be between the “FULL” and the “LOW” marking. Top up with cooling liquid, if required (see “Topping up cooling liquid”).

Fig. 3-28:

Fig. 3-29:

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Inspection and servicing Topping up cooling liquid Fill cooling liquid through filler tube (1, Fig. 3-30:) or through express couplings of the Service-Station (2 and 3, Fig. 3-31:) into the cooling system (see “Topping up cooling liquid using the ServiceStation”).

The radiator caps (1, Fig. 3-30:) are accessible from above.

Risk of scalding from hot cooling liquid under pressure.

Before opening the radiator cap: Release pressure by lifting the red lever on top of the radiator cap.

Open radiator cap cautiously.

Fig. 3-31:

 Turn radiator cap (1) back to the first notch.

For topping up of the cooling system use specially prepared cooling liquid CAT ELC, CGM HMS GmbH Part No. 2482777 only.

 When the pressure has been released turn cap into the "open" position and remove.

This gives an anti-freeze protection down to -37 °C / -34.6°F.

Do not fill in cold cooling liquid when the engine is at operating temperature.

Before refilling, allow engine to cool down to below 50° C (122°F).

For use at lower temperatures, ask your Caterpillar dealer.

After filling in cooling liquid allow the engines to run for short period to eliminate air voids before topping up with cooling liquid to the lower edge of the filler tube.  Remove hose from express coupling.

The express coupling closes automatically.  Screw on protective cap.

In case of significant cooling-liquid losses, the whole cooling system must be checked for leaks.

Check regularly:  all lines for leaks and all hose clamps for tightness.

Checking the SCA concentration

Fig. 3-30:

3-50

Observe the instructions of the engine manufacturer with regard to the SCA concentration (see “Engine Operation and Maintenance Manual”).

BA 6030(3 847 020.00)-EN

Inspection and servicing Topping up cooling liquid using the Service-Station A description of the Service Station can be found in Part 2 of this manual, chapter “Service Station (tanklift)”.

The cooling liquid can also be filled in with the service station (Fig. 3-32:) through  express coupling (2) for the lefthand engine, 

express coupling (3) for the righthand engine.

 Prior to topping up cooling liquid release pressure from the cooling system.

To do so move lever of the ball valves in the direction of the arrow (Fig. 3-32:).

The pressure is released then and the express couplings are then accessible.  Remove cap of express coupling. Connect the filling hose of the service vehicle.

The hose line and its use are described in the "Hose line for oil and cooling liquid changes" section.  Fill with coolant until the cooling-liquid level lies between the “FULL” and the “LOW” marking of the level indicator at the expansion reservoirs.

Fig. 3-32:

 Remove hose.

The express coupling closes automatically.  Push on protective cap.  Close ball valves (Fig. 3-32:).

3-51

BA 6030(3 847 020.00)-EN

Inspection and servicing Cooling liquid, change Risk of scalding from hot cooling liquid.

Read and observe: Inspection and servicing – Safety instructions.

The radiators may also be hot. Wear protective gloves and firm working clothing.

Drawing off cooling liquid Cooling liquid can be drained from the cooling system by means of the express couplings located at the counterweight, below the engine cooling radiators.

The cooling liquid can also be drawn off faster with the service station (Fig. 3-33:) through  express coupling (2) for the lefthand cooling circuit, express coupling (3) for the righthand cooling circuit.

Collect escaping cooling liquid and discard without polluting the environment.



Only use “ELC” cooling liquid, see: “Topping up cooling liquid” and the engine manufacturers recommendations. Do not use pure water.

A description of the Service Station can be found in Part 2 of this manual, chapter “Service Station (tanklift)”.

The cooling liquid must be analized and changed after 12000 operating hours or after six years at the latest.

 Prior to drawing off cooling liquid release pressure from the cooling system.

To do so move lever of the ball valves in the direction of the arrow (Fig. 3-33:).

The pressure is released then and the express couplings are then accessible.  Remove cap of express coupling. Connect hose line of the service vehicle.

The hose line and its use are described in the "Hose line for oil and cooling liquid changes" section.  Draw off cooling liquid.  Fill in fresh cooling liquid, see “Filling in cooling liquid”.

Fig. 3-33:

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BA 6030(3 847 020.00)-EN

Inspection and servicing Filling in cooling liquid A description of the Service Station can be found in Part 2 of this manual, chapter “Service Station (tanklift)”.  Shut off the engines.  Fill in cooling liquid with the service station (Fig. 3-34:) through: 

express coupling (2) for the lefthand cooling circuit,

express coupling (3) for the righthand cooling circuit.  Check ball valves (Fig. 3-34:).

They must be open. The express couplings are then accessible. 

 Remove cap of express coupling.

Connect hose of the service vehicle.

The hose line and its use are described in the "Hose line for oil and cooling liquid changes" section.

Fig. 3-34:

 Fill with coolant until the cooling-liquid level lies between the “FULL” and the “LOW” marking of the level indicator at the expansion reservoirs (4, Fig. 3-35:).  Remove hose from express coupling.

The coupling closes automatically.  Push on protective cap.  Close ball valves (Fig. 3-34:).

The cooling liquid can also be filled in through filler neck (1, Fig. 3-35:).

Fig. 3-35:

Testing the cooling liquid composition The “Engine Operating and Maintenance Manual” contain a detailed description of how to prepare and test the cooling liquid composition. In case of imminent frost check that the factory-adjusted antifreeze concentration is sufficient for the expected temperatures.

Check the cooling liquid in the cooling system regularly to ensure that the ELC is sufficiently concentrated to prevent corrosion under the corresponding operating conditions.

3-53

BA 6030(3 847 020.00)-EN

Inspection and servicing AIR-INTAKE SYSTEM Risk of injury when falling down.

Put on your fall protection equipment before entering the upperstructure.

Risk of injury caused by hot parts of the engine exhaust system.

Let exhaust cool down.

Dust trap, cleaning The dust trap (arrow,Fig. 3-37:) collects dust and dirt that infiltrates the air filter housing.  To remove dust and dirt, squeeze the flexible part of the dust trap several times.

Dust and dirt will be detached and come off.

Read and observe the "Engine - Safety instructions" chapter.

Do not start the engine when parts of the air-intake system have been detached.

Engine damage may occur if the engine is allowed to draw in unfiltered air.

Secure the machine as described in the "Securing the machine" section.

Each engine is equipped with two dry-air filters (Fig. 3-36:) consisting of pre-cleaner, main filter element and safety filter element.

Fig. 3-37:

Fig. 3-36:

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BA 6030(3 847 020.00)-EN

Inspection and servicing Main filter elements

Removal and installation

Insufficient air-intake performance, caused by a contaminated main filter element, is displayed on the BCS-screen (Fig. 3-38:).

 Loosen clamps (1, Fig. 3-39:) at the air filter housing and remove cover (2).

Clean or renew main filter elements only if the BCS displays a warning on the screen (Fig. 3-38:) with the engines running at high speed.

New or cleaned main filter elements should always be at hand to shorten excavator downtimes.

 Withdraw main filter element (3).

Do not remove safety filter element (4).  Replace or clean main filter element.  Before installing the filter element, clean contact faces at cover (2, Fig. 3-39:) and at filter housing.  Put on cover (2) using clamps (1).

Fig. 3-38:

Fig. 3-39:

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BA 6030(3 847 020.00)-EN

Inspection and servicing Main filter elements, checking and cleaning  Examine the filter paper of the element with a lamp which is introduced into the element (Fig. 3-40:). Any damage is then clearly visible.

Replace damaged or deformed elements immediately.

 Check element seal. When the seal is damaged, the filter element must be replaced, too.

Cleaning with compressed air is suitable if the filter element is to be re-used immediately.  Blow filter element (Fig. 3-41:) clean with dry compressed air from the inside by moving the compressed-air gun up and down.

Fig. 3-40:

The pressure at the nozzle must not exceed 3 bars / 43 psi.

Cleaning is terminated when all visible dust has been blown out of the filter element.

Never clean filter element by beating against hard objects.

 Replace the main filter element after 1000 operating hours or 3 cleaning cycles; and, after one year of operation at the latest.

Fig. 3-41:

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BA 6030(3 847 020.00)-EN

Inspection and servicing Safety filter element

Air-intake lines

Removal and installation

At regular intervals:

 Replace the safety filter elements (4, Fig. 3-42:) after 1000 operating hours or 3 cleaning cycles of the main filter elements. After one year of operation at the latest.

 Check intake lines for leaks and hose clamps for tightness.

Never clean the safety filter element, but always renew.

 Replace hoses between filter housing and engine.

During all work on the air-intake system ensure proper sealing to prevent unfiltered air from reaching the engines.

 Remove cover (2, Fig. 3-42:) and main filter element (3) as described above.  Withdraw safety filter element (4).  Clean the air filter housing.  Install the new safety filter element and a cleaned or a new main filter element.

Fig. 3-42:

3-57

BA 6030(3 847 020.00)-EN

Inspection and servicing FUEL SYSTEM Fuel system - Safety instructions Read and observe the "Inspection and servicing – Safety instructions" chapter.

Fuel filter, replace Read and observe the "Inspection and servicing – Safety instructions" chapter.

Collect escaping fuel and discard without polluting the environment.

Before working on the fuel system: 

shut off the engines,



secure the machine as described in the "Securing the machine" section,



keep away naked flames,



do not smoke.

Collect escaping fuel and discard without polluting the environment.

Avoid skin contact with diesel fuel.

Diesel fuel may cause skin injury.

Wear firm working clothing.

Wear protective gloves or use a barrier cream.

Fig. 3-43:

 Relieve residual fuel pressure from the fuel system by carefully loosen one of the fuel supply connections at the filter head (1, Fig. 3-43:).  Unscrew fuel filter (2).  Clean gasket sealing surface at the filter head.  Do not fill new filter with fuel. This prevents the injection system from beeing contaminated by unfiltered fuel after fuel filter change.  Apply clean diesel fuel to the new filter gasket and screw it onto the filter head by hand. Continue to tighten filter by a further ½ to ¾ turn.

Tightening the filter element with a tool may damage or deform the filter head.

For further information see:“Engine Operating and Maintenance Manual”.

3-58

BA 6030(3 847 020.00)-EN

Inspection and servicing Primary fuel filter, drain water

Primary fuel filter, replace

Read and observe the "Inspection and servicing – Safety instructions" chapter.

Read and observe the "Inspection and servicing – Safety instructions" chapter.

Collect escaping fuel and discard without polluting the environment.

Collect escaping fuel and discard without polluting the environment.  Open valve (3, Fig. 3-44:) and drain off fuel.  Close valve (3).  Remove the fuel filter bowl (2) and wash the fuel filter bowl with clean diesel fuel.  Unscrew primary fuel filter (1).  Clean gasket sealing surface at the filter head.  Do not fill new primary filter with fuel. This prevents the injection system from beeing contaminated by unfiltered fuel after fuel filter change.

Fig. 3-44:

The primary fuel filter (1, Fig. 3-44:) serves also as a water separator:  Open valve (3) and drain off water until fuel emerges.  Close valve (3).

For further information see:“Engine Operation and Maintenence Manual“.

 Apply clean diesel fuel to the new primary filter gasket and screw it onto the filter head by hand. Continue to tighten filter by a further ½ to ¾ turn Tightening the filter element with a tool may damage or deform the filter head.

 Screw fuel filter bowl (2) onto the new primary fuel filter (1) by hand.

Tightening the fuel filter bowl with a tool may cause damage or destroys the filter bowl.

 Vent fuel filters, see "Venting the fuel system".  Start engine and check fuel system for leaks.

For further information see:“Engine Operation and Maintenence Manual“.

3-59

BA 6030(3 847 020.00)-EN

Inspection and servicing Fuel system, venting

Fuel tanks, cleaning

Venting fuel filters

Explosion hazard.

 Place a collecting recipient under the air bleed valve (1, Fig. 3-45:).

Read and observe the "Inspection and servicing. Safety instructions" chapter.

 Unscrew air bleed valve (1) and switch on the pre-fuel pump with switch (2).  Close air bleed valve (1) and switch off pre-fuel pump (2) when fuel emerges at the air bleed valve without any bubbles.

Do not use white spirit, paraffin oil or other solvents.

For flushing and cleaning use diesel fuel.

Avoid skin contact.

Skin contact with diesel fuel may cause skin injury.

Wear firm working clothing.

Wear protective gloves or use a barrier ccream.

Fuel must be prevented from penetrating into the soil. Keep fuel for re-use or discard without polluting the environment.  Use up as much fuel as possible.  Check how much fuel remains in the tank and place a collecting recipient of sufficient size under the drain plugs of the tanks.

Fig. 3-45:

Breather filter fuel tank, replace The fuel tanks are vented with breather valves (Fig. 3-46:).

 Loosen drain plugs (5, Fig. 3-47:) at the bottom of the fuel tank and drain off fuel.  Flush tank with diesel fuel.  Screw drain plugs back in place.

 Replace breather valves regularly according to the maintenance plan.

To do so unscrew cap (1) of breather valve and replace with a new one. The filter element is integrated in the cap.

Fig. 3-47:

Fig. 3-46:

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BA 6030(3 847 020.00)-EN

Inspection and servicing  Fill in fuel through the strainer in filler tube (1, Fig. 3-48:)  Fuel can also be filled into both fuel tanks through the service station (1, Fig. 3-49:).

A description of the Service Station can be found in Part 2 of this manual, chapter “Service Station (tanklift)”.  Unscrew cap of express coupling.

Connect filling hose of the service vehicle.  Fill in fuel. The filling level is displayed on the BCS screen (Fig. 3-50:).  Remove filling hose.

The express coupling closes automatically.

Fig. 3-48:

 Screw on protective cap.

Fig. 3-49:

Fig. 3-50:

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Inspection and servicing Water trap (optional)

Draining off water

Water contained in the fuel is removed by the water trap (Fig. 3-51:).

Carry out the following works in accordance with the servicing schedule and at regular intervals:  Loosen venting plug (9, Fig. 3-52:) and leave drain valve (3) open until there is no more water in the diesel fuel flowing out of the valve.

Collect escaping liquid in a recipient suitable for diesel fuel and discard without polluting the environment.

Fig. 3-51:

Fig. 3-52:

The liquid flowing out of the valve flushes and cleans the filter element(6) von from top to bottom.  Close drain valve (3) and tighten venting plug (9).

3-62

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Inspection and servicing Checking / cleaning the filter element

 Clean recipient (1) and filter housing (4).  Loosen flange (2).

Replace filter element (6, Fig. 3-53:) only when the suction resistance is too high.

 Take off recipient (1) and clean with diesel fuel  Check cover sealing and replace, if necessary.  Attach recipient (1) with flange (2) at filter housing (4).

Check for proper sealing.

Fig. 3-53:

 Loosen venting plug (9) and leave drain valve (3) open until the reservoir is completely empty.

Collect escaping liquid in a recipient suitable for diesel fuel and discard without polluting the environment.  Remove cover (5).  Remove spring holder (7) and filter element (6) from filter housing (4).  Check / replace filter element (6).  Clean filter housing (4) using diesel fuel.  Check cover sealing and replace,if necessary.  Insert filter element (6) and spring housing (7) into filter housing (4).  Fasten cover (5) on filter housing (4).

Check for proper sealing.

3-63

BA 6030(3 847 020.00)-EN

Inspection and servicing ELECTRICAL SYSTEM Electrical system - Safety instructions Risk of injury caused by battery acid and gases and short circuits.

Read and observe the "Inspection and servicing – Safety instructions" chapter.

Carry out every work on the electrical / electronical systems only if you are a qualified electrician and after having received special trainings.

Electrical circuit diagrams The electrical circuit diagrams and wiring diagrams are annexed to the spare-parts list. Further information can be found in the CGM HMS GmbH Service Manual "Working with circuit diagrams".

Electrical system switch-cabinets The electrical system switch-cabinets are located in the cab module, in the pump compartment and behind the hydraulic reservoir. The cabinets are described in the spare-parts list (electrical circuit diagram) together with the designation of the electrical components.

Wear goggles, working gloves and firm working clothing.

Fuses and their function are listed on a sheet inside the switch-cabinets in the cab module.

Carry out voltage and continuity checks only by means of a test lamp or a measuring instrument.

Do not check by "touching ground" with a bare wire. The short-circuit thus produced damages the alternator and the electronic modules of the PMS.

Use only original fuses with the specified current rating.

Alternator - Instructions Never disconnect cables from the alternator, regulator and the battery when the engine is running to avoid damage to the alternator and regulator.

Do not interchange the cables when connecting the battery (observe polarity).

Carry out voltage and continuity checks only by means of a test lamp or a measuring instrument.

Do not check by "touching ground" with a bare wire. The short-circuit thus produced damages the alternator and the regulator.

Cables and cable lugs must not get in contact with other metal parts. Replace broken or damaged cables and the respective cable lugs.

3-64

Replacing lamps and bulbs If a bulb does not work after replacement, the pertaining fuses, connection cables and contacts must be checked.

Xenon-working floodlights are operated with high voltage.

Read and observe the chapter: “Floodlight projector, replacing the lamp”.

Floodlights working with LED-technology do not have replaceable lamps / bulbs. The floodlight must be replaced if defective.

BA 6030(3 847 020.00)-EN

Inspection and servicing Battery Warning! Battery Posts, terminals and related accessories contain lead and lead compounds, chemicals known to cause cancer and reproductive harm.

Wash hands after handling.

Checking the battery fluid level (Not applicable in case of maintenance-free batteries).  Unscrew caps (Fig. 3-54:).  If checking inserts are provided, the battery acid must reach up to their bottom.  If no checking inserts are provided, insert a clean wooden rod into the battery until it contacts the upper edge of the cell plates. The rod must be moistened over at least 10 mm / 0.4“.

Removing and installing the battery The acid temperature must be 20 ° C / 68° F.  Unscrew caps of the battery (Fig. 3-54:).  Measure the acid density of the battery using a commercial acid tester (Fig. 3-54:).

The acid density measured is in direct correlation with the battery charge.

Acid density kg / dm3 Charge Normal Tropical conditicondition ons 1,28 1,23 fully charged 1,20 1,12 half charged, recharge 1,12 1,08 discharged, recharge immediately

 If the fluid level is too low, top up with distilled water only.

Fig. 3-54:

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Inspection and servicing Charging batteries inside the machine, safety instructions Explosion hazard.

Battery gases are highly flammable.

Keep any potential ignition sources, such as unshielded lights or burning cigarettes, away from the batteries.

Risk of injury from acid splashes and battery gases.

Wear safety goggles or a face protection shield and acid proof protective gloves.

Do not lean over the batteries while charging.

The batteries of the machine can also be charged while installed in the machine.

For this purpose, the arm of the service station (Fig. 3-55:) is equipped with a socket outlet for a charging cable.

Charging the batteries  Cut out the battery main switch.  For battery ventilation unscrew the cover of the battery cabinet.  Connect the charging cable to the socket outlet (Fig. 3-55:).  Switch on the charger and watch the charging process.

Stop the charging process: 

if the batteries are getting hot,



if acid escapes from the batteries,



if the charge current is still insignificantly low even after 15 minutes of charging.

Before starting a new charging cycle, check the batteries and the connecting cable thoroughly and replace any damaged components. It may be necessary to remove the batteries and to charge them one by one.

When the batteries are full:  Shut off the charger first before withdrawing the charging cable from the socket outlet.

Risk of fire.

Read the instructions of the charger in order to know when the charging cycle has ended.

Do not use the socket outlet (Fig. 3-55:) for jump-starting of the engines.

The batteries are fully charged, if

The connectors and the cables are not designed for the high currents flowing during the starting phase.

Check before charging why the batteries are discharged and replace the batteries if they are defective.



the charging current and voltage remain constant (for voltage-controlled chargers);



the charging current does not any rise longer for two hours (current-controlled chargers);



the charger shuts off or switches over to trickle charge (automatic chargers).

Check the connecting cables of the battery set for damage, corrosion and tight fit.

Never charge the batteries while they are frozen.

Warm them up beforehand and check for proper functioning.

Do not charge the batteries when they are warmer than "warm to the touch" (45 °C / 113 °F).

Use only approved chargers for 24 volts DC. Read and observe the instructions for the charger.

The charging cable must have a conductor cross2 section of at least 70 mm .

Fig. 3-55:

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Inspection and servicing Removing and installing the battery Read and observe the "Inspection and servicing – Safety instructions" chapter.

Wear protective gloves and firm working clothing.

Shut off the engines before removing the batteries to avoid damaging the alternator and the regulator.

Turn key in key-switch to position "0" and withdraw.

Disconnect and reconnect the terminal clamping lugs in the prescribed order.

Disconnecting and connecting in the wrong order may cause short-circuits.

The batteries (1, Fig. 3-56:) are located behind the hydraulic reservoir. The 12-volt batteries are connected in series and in parallel, so that the system voltage is 24 volts.

 Detach battery holder (3).  Disconnect the cable lug from the negative terminal of the battery.  Disconnect the cable lug from the positive terminal of the battery.  Insulate the cable lugs.  Lift battery out of battery box.

Before installing new batteries, the contact faces of the battery terminal posts and the cable lugs must be cleaned down to the bright metal.  Install the new batteries.  Connect the cable lug to the positive terminal of the battery. Tighten the clamping screws of the cable lugs. Do not use too much force to avoid deformation.  Connect the cable lug to the negative terminal of the battery.  Apply special terminal grease or acid-free vaseline on the battery terminal posts and clamping lugs. Loose or corroded clamping lugs will lead to alternator or regulator overloading.

Fig. 3-56:

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Inspection and servicing Switchgear cabinet, aeration Breather filter In the switchgear cabinet, the air is drawn in by a ventilator via the filter (Fig. 3-57:).

Emptying dust trap  Press dust trap (14, Fig. 3-57:) and hold until the dust trap is empty.

Emptying the dust collector  Loosen clamps (11, Fig. 3-57:).  Remove dust collector (12) and empty.

Fig. 3-57:

Filter element  Remove the dust collector (12, Fig. 3-57:).  Withdraw filter element (13, Fig. 3-58:).  Replace or clean filter element (13).  Refit dust collector (12, Fig. 3-57:).

Fig. 3-58:

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Inspection and servicing Checking and cleaning the filter element  Check the filter paper of the element by inserting a lamp into the element (Fig. 3-59:). Any damage can then be seen.

Replace damaged or distorted element immediately.

 Check element seal. If damaged, replace filter element too.

Cleaning with compressed air allows the filter element to be re-used immediately.  Blow filter element (Fig. 3-60:) dry with compressed air by moving the compressed-air piston up and down inside it.

Fig. 3-59:

The pressure at the nozzle must not exceed 3 bars / 43 psi.

Cleaning is completed when no more dust is seen to leave the filter element.

Never clean filter element by beating it against hard objects.

 Replace main filter element after 1000 operating hours or 3 cleaning cycles, but not later than after one year of operation.

Fig. 3-60:

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Inspection and servicing Xenon floodlight projector, replacing the lamp Safety instructions The floodlight projectors use xenon technology.

The lamp is not a usual incandescent lamp, but a gas discharge lamp which is operated with a ballast unit. The ballast unit is integrated in the floodlight projector.

When the projector is turned on, the ballast unit generates a high-voltage pulse of more than 25000 volts to start the xenon lamp.

Warning!

This high-voltage pulse can be a lifethreatening risk, if a person comes into contact with any of the live components. This can be the case, for instance,  if the lamp is operated improperly, 

if the projector housing is opened in an inapropriate way or



by sticking one's hand into an opened or damaged projector.

Protect yourself from potential risks by reading and by observing the following safety instructions.

Always switch off the projector and disconnect it from its power supply before replacing the Xenon lamp.

Allow the xenon lamp to cool off before removing it from the projector.

Wear googles and safety gloves when replacing the lamp.

Never stick your hand into the lampholder. The contacts may still be live with residual voltage.

Never switch on the projector when the xenon lamp has been removed.

There is a risk of voltage discharge and damage to the lampholder.

The glass body of the xenon lamp is filled with different gases and metal gases and is under gauge pressure (risk of injury from splinters).

If the xenon lamp breaks apart in closed room (workshop), all persons must leave the room and the room must be ventilated for at least 20 minutes to exclude any health risks caused by gases.

Further instructions Always hold the xenon lamp by the base. Never touch the glass bulb. Sweat and grease from the skin would evaporate when the lamp is in operation and obscure the reflector.

If the fingers have nevertheless come into contact with the glass bulb, the fingerprints must be removed with a clean cloth and some alcohol.

The replaced Xenon lamp must be disposed of as special waste.

Never switch on projectors when housing or electrical wiring is damaged.

Have damaged projectors be replaced by a qualified electrician as soon as possible.

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Inspection and servicing Replacing a defective Xenon-lamp Read and observe the: „Xenon floodlight projector, replacing the lamp, Safety instructions“.  Switch off the projector, shut off the engine and cut out the battery main switch.  Wait until the housing of the floodlight projector has cooled down.  Withdraw the power supply connector from the projector.

Fig. 3-61

 Remove four screws (1, Fig. 3-61) and withdraw the reflector (2) from the projector housing.  Withdraw connector (Fig. 3-62) from Xenon lamp socket.  Unscrew Xenon lamp holding clamp (Fig. 3-63).  Remove the defective Xenon lamp and replace by a new one. Do not touch the glass bulb of the lamp.  Reinstall the new lamp. Screw lamp holding clamp back in place.  Plug the power supply connector onto the lamp.  Re-assemble the housing.

Fig. 3-62

Fig. 3-63

3-71

BA 6030(3 847 020.00)-EN

Inspection and servicing Lighting systems in LED technonogy, instructions The lights of the maintenance lighting system (Fig. 3-64) as well as the working floodlights (Fig. 3-65) are equipped with lamps in LED technology (lightemitting diodes).

High-performance LEDs ensure the emission of light with high luminance. If the light is allowed to shine directly into the eyes from a short distance and over prolonged periods, there is a risk of injury to the retina.

Do not look for a prolonged period into the light cones of the LEDs. Adjust the lights in such way that they do not shine directly into the eyes and that you are not blinded by the glare.

The lights become hot in operation.

The heat is dispersed via the ribbed metal housing.

Fig. 3-64

For this reason, the housings must not be covered up and cleaning rags or similar things placed over them.

The high-performance LEDs in these lights have a very long service life and can therefore not be replaced. If one or more of these LEDs fail, the light can remain in service if the remaining luminance is still sufficient.

Fig. 3-65

3-72

BA 6030(3 847 020.00)-EN

Inspection and servicing HYDRAULIC SYSTEM Hydraulic system - Safety instructions Read and observe the "Inspection and servicing – Safety instructions" chapter.

Before working on the hydraulic system, make sure that the system is without pressure and that the residual pressures have also been eliminated.

Shut off the engines.

Risk of burning caused by hot hydraulic components (e.g. hydraulic oil reservoir, cylinder, valves).

Depressurizing the hydraulic system Hydraulic systems may only be opened if they are completely depressurized. Even when an hydraulic shovel is parked on a horizontal surface with the working equipment resting on the ground (Fig. 3-66: and Fig. 3-67:) and with its drive engines stationary, there may still be a considerable amount of residual pressure in parts of the hydraulic system, as e.g. the primary pressure resulting from the last hydraulic movements before the immobilization.

Residual pressures disappear only gradually. If work is to be carried out on the hydraulic system immediately after the immobilization, the system must be freed from pressure, i.e. depressurized:

Secure the machine as described in the "Securing the machine“ section.

Avoid skin contact with hydraulic oil.

Contact with hydraulic oil can cause skin injury.

Wear protective gloves and firm working clothing.

Fig. 3-66:

Fig. 3-67:

 Locate the system section to be opened.  Depressurize the section to be opened. If required, the necessary measures described must be combined.  Open the depressurized system section with caution.

3-73

BA 6030(3 847 020.00)-EN

Inspection and servicing Examples of system sections: 1) working hydraulics

Checking the hydraulic oil level

2) servo control circuit

 Bring hydraulic oil to operating temperature (abt. 50 °C / 122 °F).

3) precharged return-flow line

 Park the machine on a horizontal surface.

Depressurizing

 Move all hydraulic cylinders to their central positions.

 Park the hydraulic shovel on a horizontal surface.

The oil level must lie between the “min” and “max” marks of the sign (2) near the level indicator tube (1, Fig. 3-69:).

 Set the working equipment on the ground.  Shut off the drive engines, keep sitting on the operator’s seat.  Do not switch off the electrical system Sections 1 and 2: servo control and working hydraulics  Shift both control levers and all pedals repeatedly into all directions (Fig. 3-68:).

Fig. 3-69:

The hydraulic oil level is monitored by the BCS. The BCS displays a warning on the screen (Fig. 3-70:) if the hydraulic oil level is too low or too high.

Shut off the engines, locate cause and rectify.

Fig. 3-68:

Section 3: Return-flow line After shutting down the engine, the precharging pressure decreases rapidly through the precharging valve. No measures are required before opening the return-flow line.

Detailled information can be found in the Service Manual, chapter 8: Hydraulic System”.

Fig. 3-70:

3-74

BA 6030(3 847 020.00)-EN

Inspection and servicing

Fig. 3-73:

Fig. 3-71:

 Stand working equipment on the ground as shown on the sign (Fig. 3-71:).

Signs (2, Fig. 3-72:) are attached beside the inspection glass tube (1).

Hydraulic oil (oil grade see: „LUBRICANTS / CONSUMABLES“) can also be filled in by means of the service station (Fig. 3-74:).

A description of the Service Station can be found in Part 2 of this manual, chapter “Service Station (tanklift)”.  Unscrew cap of express coupling (10).

Connect filling hose express coupling of the service vehicle.  Fill in hydraulic oil until the oil level lies between the “min” and the “max” marks of sign (2) near the level indicator tube (1, Fig. 3-72:). The acoustic warning signal “Travel Alarm” sounds.  Unscrew the hose line; the express coupling closes automatically.  Screw protective cap back in place.

Fig. 3-72:

Fill in hydraulic oil through the return-flow filters:  Remove cover (16, Fig. 3-73:).  Fill in hydraulic oil through the opening until the oil level lies between the “min” and the “max” marks of the sign (2) near the level indicator tube. (oil grade see: „LUBRICANTS / CONSUMABLES“).  Before fitting the cover (16), check the sealing ring and replace, if damaged.

Fig. 3-74:

 Fit cover together with sealing ring.

3-75

BA 6030(3 847 020.00)-EN

Inspection and servicing

Replacing the hydraulic oil return-flow filter (hydraulic oil reservoir) Risk of scalding caused by hot hydraulic fluid.

The hydraulic oil reservoir itself may also be hot.

Allow hydraulic fluid to cool down before start working at the reservoir.

Read and observe the "Inspection and servicing – Safety instructions" chapter.

Removing filter elements  Loosen plug (1, Fig. 3-76:) for pressure compensation.  Remove cover (3) together with sealing ring (5), remove bracket (7).  Remove press rings (8) with O-rings (10) and (11).  Withdraw filter elements (9) from basket (12).  Check filter elements (9) for damage.

If filter elements are undamaged, insert new filter elements. Dispose of used filter elements.

If a filter element is damaged, remove the filter basket (12) and check (see: “Removing and checking the filter basket”).

Shut off the engines.

Avoid skin contact. Skin contact with hydraulic oil may cause skin injury.

Wear protective gloves, firm working clothing and protective goggles.

Collect escaping hydraulic oil and discard without polluting the environment.

The return-flow filters must be replaced:  when servicing works in accordance with the servicing plan are carried out; 

when the BCS displays a warning on the screen (Fig. 3-75:). In this case, the filter elements (9, Fig. 3-76:) are heavily contaminated;



after repairs on the hydraulic system;



in case of damage.

Fig. 3-75:

Fig. 3-76:

3-76

BA 6030(3 847 020.00)-EN

Inspection and servicing Installing filter elements  Insert new filter elements (9, Fig. 3-77:) paying attention to the correct direction (observe the “TOP” marking).  Insert new O-rings (10) and (11) into the press rings (8).  Put press rings (8) on filter elements (9).  Assemble bracket (7).  Clean the magnetic rod (17, Fig. 3-78:). The magnetic rod is located under cap (16).

If metal filings are detected, contact your Caterpillar dealer. The origin of filings must necessarily be located and rectified.

Otherwise there is a risk of extraordinarily damages in the hydraulic system.  Refit cap with magnetic rod (16).

Fig. 3-77:

 Refit cover (3) together with sealing ring (5).

Tighten bolts (18) crosswise with a torque wrench (tightening torque 79Nm / 58lbf ft).  Replace also the return-flow filter in the filter housing (cooling-system).

The return-flow filters are located under the caps (10, Fig. 3-79:).

(See: "Replacing the hydraulic oil return-flow filters (filter housing“).

Fig. 3-78:

Fig. 3-79:

3-77

BA 6030(3 847 020.00)-EN

Inspection and servicing Removing and checking the filter basket In case one of the filter elements (9, Fig. 3-81:) is damaged, remove filter basket (12) and check / clean. To do so:  Unscrew bolts (13), take away washers (15) and brackets (14).  Draw out filter basket (12) and clean with white spirit or paraffin oil.  Check the filter chamber inside the hydraulic reservoir, clean if necessary.

If considerable pollution or foreign objects are detected, contact your Caterpillar dealer. The origin of those pollution or foreign objects must necessarily be located and rectified.

Otherwise there is a risk of extraordinarily damages in the hydraulic system.  Re-assemble filter basket (12) with brackets (14), washers (15) and bolts (13).  Tighten bolts (13) using a torque wrench (tightening torque 54Nm / 40lbf ft).  Refit filter elements (9), (see: “Installing filter elements”).

3-78

Fig. 3-80:

BA 6030(3 847 020.00)-EN

Inspection and servicing Bypass valves (hydraulic oil reservoir), checking / cleaning Risk of scalding caused by hot hydraulic oil.

Read and observe the "Inspection and servicing – Safety instructions" chapter.

Shut off the engines.

The hydraulic oil reservoir itself may also be hot.

Wear protective gloves and firm working clothing.

Avoid skin contact. Skin contact with hydraulic oil may cause skin injury.

Fig. 3-81:

Collect escaping hydraulic oil and discard without polluting the environment.

Cleaning the filter screens  Remove cover (3, Fig. 3-81:) together with sealing ring (5).  Unscrew screws (22). Withdraw bypass valve.  Take off screen (23) together with sealing ring and clean in white spirit or paraffin oil. Replace, if required.  Check sealing ring for damage and replace, if required.

Fig. 3-82:

 Re-assemble the bypass valve.  Check sealing ring (24) for damage and replace, if required.  Insert bypass valve and fasten with screws (22).  Clean also the screen of the bypass valve in the filter housing (cooling-system).

The bypass valve is located under the cover (10, Fig. 3-82:). (See: "Bypass valves (filter housing - cooling-system").

Replacing the bypass valves and sealing rings  Remove bypass valve as described under "Cleaning the filter screens".  Re-assemble the bypass valve with a new screen (23, Fig. 3-81:) and a new sealing ring.  Insert bypass valve with new sealing ring (24) and fasten with screws (22).  Replace also the bypass valve and sealing ring in the filter housing (cooling-system).

The bypass valve is located under the covers (10, Fig. 3-82:). (See: "Bypass valves (filter housing - cooling-system").

3-79

BA 6030(3 847 020.00)-EN

Inspection and servicing Replacing the hydraulic oil return-flow filters (filter housing cooling system)

Replace the return-flow filters (15, Fig. 3-83:) together with the return-flow filters in the hydraulic oil reservoir.

Risk of scalding caused by hot hydraulic oil.

Read and observe the "Inspection and servicing – Safety instructions" chapter.

Shut off the engines.

The hydraulic oil reservoir itself may also be hot.

Wear protective gloves and firm working clothing.

Avoid skin contact. Skin contact with hydraulic oil may cause skin injury.

Collect escaping hydraulic oil and discard without polluting the environment.

Fig. 3-83:

 Detach covers (10) together with sealing ring (12).  Withdraw filter element (15).  Insert a new filter element.

If metal filings are detected, locate cause and rectify.

Contact your Caterpillar dealer, if required.  Refit covers (10) with new sealing ring (12).

3-80

BA 6030(3 847 020.00)-EN

Inspection and servicing Bypass valves (filter housing cooling system), checking / replacing Risk of scalding caused by hot hydraulic oil.

Read and observe the "Inspection and servicing – Safety instructions" chapter.

Shut off the engines.

Checking / Cleaning the screens Clean/replace the bypass valves (Fig. 3-84:) together with the bypass valves in the hydraulic oil reservoir.  Detach covers (10) together with sealing ring (5).  Unscrew screws (22) and withdraw bypass valve.  Take off screen (23) together with sealing ring (24) and clean in white spirit or paraffin oil; replace, if required.

The hydraulic oil reservoir itself may also be hot.

Wear protective gloves and firm working clothing.

 Re-assemble the bypass valve.

Avoid skin contact. Skin contact with hydraulic oil may cause skin injury.

 Insert bypass valve and fasten with screws (22).

Collect escaping hydraulic oil and discard without polluting the environment.

 Refit cover (10) with a new sealing ring (5).

Replacing the bypass valves and sealing rings Replace the bypass valves and sealing rings together with the bypass valves in the hydraulic oil reservoir.  Remove the bypass valve as described under "Cleaning the screens".  Re-assemble the bypass valve with a new screen (23) and a new sealing ring.  Insert bypass valve with new sealing ring (24) and fasten with screws (22).

Fig. 3-84:

 Refit cover (10) with a new sealing ring (5).

3-81

BA 6030(3 847 020.00)-EN

Inspection and servicing Breather filter, replace Risk of scalding caused by hot hydraulic oil.

Read and observe the "Inspection and servicing – Safety instructions" chapter.

Shut off the engines.

The hydraulic oil reservoir itself may also be hot.

Wear protective gloves and firm working clothing.

Avoid skin contact. Skin contact with hydraulic oil may cause skin injury.

Collect escaping hydraulic oil and discard without polluting the environment.

Replacing the filter elements Two breather filters (20, Fig. 3-85:) on top of the hydraulic tank ensure venting of the hydraulic oil tank at varying hydraulic oil levels.

Inspect and replace the filter elements according to the maintenance plans.

In case the machine is working in very dusty conditions or in an environment with high air humidity, the filter elements must be inspected and replaced in shorter intervals.

This protects the hydraulic tank from beeing contaminated.

To replace the filter elements:  Unscrew bolts (21, Fig. 3-85:) and remove holding brackets (22).  Withdraw filter elements (20).  Check foam rings on top of the filter elements, replace if damaged.  Attach new filter elements (20) with foam rings to their cylindrical connections.  Install holding brackets (22) using bolts (21).

Fig. 3-85:

3-82

BA 6030(3 847 020.00)-EN

Inspection and servicing Filter (servo control circuit)

Replacing the filter element

The control circuit (servo circuit) is equipped with a high-pressure filter (arrow, Fig. 3-86:).

Change filter element regulary and when the BCS indicates a contamination.  Unscrew filter housing (5, Fig. 3-86:).

Risk of scalding caused by hot hydraulic oil.

The filter housings themselfes may also be hot.

Wear protective gloves and firm working clothing.

Skin contact with hydraulic oil may cause skin injury.Avoid skin contact.

Read and observe the "Inspection and servicing – Safety instructions" chapter.

 Withdraw filter element (6) from filter housing (5).  Clean filter housing (5) and the sealing face at the filter head (9) with white spirit or paraffin oil.  Insert new filter element into filter housing (5) and refit to the filter head with new, lightly oiled sealing ring (8).  Check for leaks after putting the filter into operation.

 Shut off the engines.  Depressurize the hydraulic system.  Clean carefully the filter block and the filter housings.  Collect escaping hydraulic oil and discard without polluting the environment.

Fig. 3-86:

Fig. 3-87:

3-83

BA 6030(3 847 020.00)-EN

Inspection and servicing High-pressure filter for working hydraulics, replace To filter the hydraulic oil on the high-pressure side of the working hydraulic system, the machine is equipped with four high-pressure filters (arrow, Fig. 3-88:).

The filters are attached to the valve block in front of the hydraulic oil tank, they are accessible from the pump compartment.

 Place a suitable resipient under the filter housings (Fig. 3-89:).  Collect escaping hydraulic oil and used filter elements. Discard without polluting the environment.  Unscrew drain plug (11, Fig. 3-89:) and drain the hydraulic oil from the filter housing (9).  Unscrew filter housing (9) by counterclockwise rotation. Pour out the oil.  Disengage filter element (15) with a slight turn from the centering spigot in the filter head.  Check filter housing (9) as well as the used filter element surface for debris.  Clean filter housing (9) and the sealing surfaces at the filter head with white spirit or parafin oil.  Check sealing ring (14) and support ring (13) on the filter housing for position and damage.

Replace if necessary.  Install the new filter element (15) with a new seal (10) on the spigot again by slightly turning it.

Fig. 3-88:

Replacing the filter elements Risk of scalding caused by hot hydraulic oil.

The filter housings themselfes may also be hot.

 Screw in the filter housing (9) to stop. Then turn out the filter housing by an 1/8 turn so that the filter housing is not stuck due to pressure pulsation and can be easily loosened in case of maintenance works.  Check high-pressure filters for leaks after putting the hydraulic system back into operation.

Wear protective gloves and firm working clothing.

Skin contact with hydraulic oil may cause skin injury.Avoid skin contact.

Read and observe the "Inspection and servicing – Safety instructions" chapter.  Shut off the engines.  Depressurize the hydraulic system.  Clean carefully the filter block and the filter housings.

Fig. 3-89:

3-84

BA 6030(3 847 020.00)-EN

Inspection and servicing High-pressure filters for swing circuit, replace Each of the two swing circuits is equipped with a high-pressure filter (Fig. 3-90:).

The filter elements are located in the pump compartment in front of the hydraulic oil tank.

Replacing the filter elements  Unscrew filter housing (5, Fig. 3-91:) and pour out oil.  Withdraw filter element (3) from filter housing (5).  Clean filter housings and sealing faces at filter head with white spirit or paraffin oil.  Insert new filter element (3) and new sealing ring (2) into filter housing (5) and re-assemble with a new, lightly oiled sealing ring (4) to filter head (1).  Screw in the filter housing (5) to stop. Then turn out the filter housing by an 1/8 turn so that the filter housing is not stuck due to pressure pulsation and can be easily loosened in case of maintenance works.  Check the high-pressure filter for leaks after putting the hydraulic system back into operation.

Fig. 3-90:

Risk of scalding caused by hot hydraulic oil.

The filter housings themselfes may also be hot.

Wear protective gloves and firm working clothing.

Skin contact with hydraulic oil may cause skin injury.Avoid skin contact.

Read and observe the "Inspection and servicing – Safety instructions" chapter.  Shut off the engines.  Depressurize the hydraulic system.  Clean carefully the filter block and the filter housings.

Fig. 3-91:

 Collect escaping hydraulic oil and discard without polluting the environment.

3-85

BA 6030(3 847 020.00)-EN

Inspection and servicing Filter pump control, clean Each of the pump control circuits is equipped with a high-pressure filter (arrow, Fig. 3-92:).

Check filter tell-tales (1, Fig. 3-93:) regulary - at operating temperature - for indication of contamination.

If the red sector is visible through transparent cap (2), the filter element must be cleaned or changed.  Remove flange (3, Fig. 3-93:).  Pour oil out of filter pot (4) and remove filter element (5).  Clean filter element in spirits or petroleum, replace if damaged.  Clean filter head (6, Fig. 3-93:) and filter pot (4). Check o-ring (7, Fig. 3-94:) for damage; replace if necessary.

Fig. 3-92:

 Oil the o-ring lightly. Place filter element into filter pot and re-assemly.  Check filters for leakages after recommencing operation.

Filter element (5) must be changed after having been cleaned 8 - 10 times; at the latest however, after 1000 operating hours.

Fig. 3-93:

Fig. 3-94:

3-86

BA 6030(3 847 020.00)-EN

Inspection and servicing Changing the hydraulic oil Read and observe the "Inspection and servicing - Safety instructions" chapter.

Avoid mixing of different hydraulic fluids (see chapter “Avoid mixing of different hydraulic fluids” for more information).

Shut off the engines.

Risk of scalding caused by hot hydraulic oil.

The hydraulic oil reservoir itself may also be hot.

Skin contact with hydraulic oil may cause skin injury.

Avoid skin contact.

Wear protective gloves and firm working clothing.

Collect escaping oil and discard without polluting the environment.

Do not start up the drive engines when the hydraulic oil reservoir is empty. The hydraulic pumps may be destroyed if they are allowed to run dry.

Avoid mixing of different hydraulic fluids The machine has been run in at the factory with BM Long Term Hydraulic Fluid HSS (Part-No. 2482971). CGM HMS GmbH recommends using this high-grade hydraulic fluid also in operation as it has been made especially for use in these machines to which it is also perfectly adapted.

If oil analyses are performed regularly and with positive results, the BM Long Term Hydraulic Fluid can remain in the machine for up to 10 000 operating hours.

If an alternative hydraulic fluid is to be used, it must fulfil the same specifications. Please note that the change interval for alternative fluids is fixed at 5 000 operating hours.

There is an increased risk of damage to hydraulic components, if different hydraulic fluids are mixed during topping up as well as when changing over to a fluid of a different type or from another manufacturer.

For topping up, it is therefore necessary to use only same hydraulic fluid as the one that is already in the hydraulic system.

When changing over to an alternative hydraulic fluid, please observe that there is always a small amount of old fluid remaining in the hydraulic system even after the system has been emptied. The mixing of this residual amount of old fluid with the new alternative fluid reduces the properties of the fluid dramatically and can cause damage to components of the hydraulic system in operation.

To avoid this result, the change-over to the alternative fluid must be performed in strict compliance with the manufacturer's prescriptions. The manufacturer must confirm that his hydraulic fluid is compatible with the BM Long Term Hydraulic Fluid.

The remaining amount of old fluid must not exceed 2% of the total volume. This can only be achieved by repeated flushing with the total fluid volume.

If the remaining amount of fluid exceeds 2% of the total volume, the fluid becomes a detrimental "mixed fluid".

The operation of the system with mixed fluids must by all means be avoided.

CGM HMS GmbH assumes no warranty for damage caused as a result of the machine having been operated with consumables of inappropriate specification or with mixed fluids.

3-87

BA 6030(3 847 020.00)-EN

Inspection and servicing Drawing off hydaulic oil  Bring the hydraulic oil to operating temperature (abt. 50 ° C / 122°F).  Retract the hydraulic cylinders as far as possible and stand the working equipment on the ground.  Shut off the engines.  Place suitable recipients under the drain valve (1, Fig. 3-95:) of the hydraulic oil reservoir. For the required capacity refer to the "Filling quantities - Oil" table.  Drain the hydraulic oil at express coupling (1) at the bottom of the hydraulic oil reservoir.

The use of the hose line is described in the "Hose line for oil and cooling-liquid changes" section.  Unscrew the hose line; the oil drain valve closes automatically.  Screw protective cap back in place.

Drawing off hydaulic oil using the service station The hydraulic oil can also be drawn off through the service station (Fig. 3-96:).

A description of the Service Station can be found in Part 2 of this manual, chapter “Service Station (tanklift)”.  Bring hydraulic oil to operating temperature (ca. 50° C / 122°F).  Retract hydraulic cylinders as far as possible and stand working equipment on the ground.  Shut off the engines.  Unscrew cap of express coupling (10).  Connect hose line of the service vehicle.  Draw off hydraulic oil.  Remove hose line. The coupling closes automatically.  Screw on protective cap.

Fig. 3-95:

Fig. 3-96:

3-88

BA 6030(3 847 020.00)-EN

Inspection and servicing Cleaning the hydraulic oil reservoir Explosion hazard.

 Drain off hydraulic oil as described under "Draining off the hydraulic oil".

Read and observe the "Inspection and servicing - Safety instructions" chapter.

 Remove cap (3, Fig. 3-97:).

Shut off the engines.

Do not use white spirit, paraffin oil or other solvents for cleaning.

Use diesel fuel or a special flushing oil.

Skin contact with hydraulic oil may cause skin injury.

Avoid skin contact.

 Detach the return-flow filter.  Place a collecting recipient for the flushing oil under the hydraulic oil reservoir.  Clean the inside of the hydraulic oil reservoir with diesel fuel or flushing oil.

Remove all sediments and also the residues of the cleaning agent thoroughly.  Refit cap (3).

Wear protective gloves and firm working clothing.

Dispose of contaminated hydraulic oil without polluting the environment and separately from other waste.

Fig. 3-97:

3-89

BA 6030(3 847 020.00)-EN

Inspection and servicing Filling in hydraulic oil Fill in hydraulic oil through the return-flow filters.  Remove cap (16, Fig. 3-98:).  Fill in hydraulic oil through the opening until the oil level lies between the “min” and the “max” marks of the decal (2) beside the inspection glass (1, Fig. 3-99:). (oil grade see: „LUBRICANTS / CONSUMABLES“).  Vent the hydraulic system.  Check the oil level in the hydraulic oil reservoir.

Top up with oil, if required.  Refit cap (16, Fig. 3-98:).

Hydraulic oil can also be filled by means of the service station (Fig. 3-100:).  Unscrew cap of express coupling (10).  Connect filling hose express coupling of the service vehicle. Fill in hydraulic oil until the oil level lies between the “min” and the “max marks of the decal (2) beside the inspection glass (1, Fig. 3-99:). (oil grade see: „LUBRICANTS / CONSUMABLES“).  The oil level is also displayed on the BCSscreen (Fig. 3-101:).  Vent the hydraulic system.  Check the oil level in the hydraulic oil reservoir.

Top up with oil, if required.  Unscrew the hose line. The express coupling closes automatically.  Screw protective cap back in place.

Fig. 3-98:

Fig. 3-100:

Fig. 3-99:

Fig. 3-101:

3-90

BA 6030(3 847 020.00)-EN

Inspection and servicing Venting the hydraulic system Hydraulic pumps, hydraulic motors, hydraulic cylinders, travel brake valves, suction lines of hydraulic pumps, oil cooler manifolds and the servo control system must be vented  after assembly on site and prior to initial commissioning, 

before each recommissioning of the hydraulic shovel, e.g. after extensive repair work to the hydraulic system or after prolonged downtimes,



after each hydraulic oil change,



after replacement of hoses or lines.

Venting the hydraulic components 

Hydraulic pumps and hydraulic motors (with electric motors shut off):

Fig. 3-103:

Always admit oil first to that side of the cylinder where the piston (2) is. This is

Open the highest leakage oil port and fill in clean hydraulic oil up to the lower edge of the opening.

 the piston-side port (3) when the piston rod is retracted (1, Fig. 3-102:),

Check the hydraulic system under load. Pay attention to noises produced by the hydraulic pump or the hydraulic motors. Abrupt movements of the working equipment are a sign of entrapped air in the system. Remaining air pockets can be eliminated by actuating all hydraulic functions. 

 the rod-side port (4) when the piston rod is extended (1, Fig. 3-103:).

If, for assembly reasons, the piston rod is inmiddle position, admit oil first to the piston-side port (4).

When oil is admitted for the first time to the cylinder, the oil flow must be reduced. Therefore extend or retract the piston rod as slowly as possible.

Hydraulic cylinder: Before the initial admission of the cylinder with oil, the piston must be in either of the two extreme piston positions. In other words, the piston rod (1, Fig. 3-102: and Fig. 3-103:) must be either completely retracted or completely extended.

The screws/nozzles of the following components must be opened until oil emerges bubble-free from the opening: Always vent only the system section that has been opened.



the travel brake valve at the venting screw,



the oil cooler manifold at the mini-measuring ports,



the servo system at the venting screws of the control blocks (under the servo caps),



the intake line at the venting screw (with drive motors stationary).

Fig. 3-102:

3-91

BA 6030(3 847 020.00)-EN

Inspection and servicing Cleaning the hydraulic oil cooler Risk of injury from rotating cooler fan blades.

Never start cleaning work until the cooler fan blades have stopped turning.

Cleaning The hydraulic oil coolers are located in the oil cooler module.

Clean the hydraulic oil coolers at regular intervals.  Shut off the engines.  Remove any accumulated dirt.  Clean the fan blades (2, Fig. 3-104:).

Shut off the engines.

The hydraulic oil coolers reach the same temperature as the hydraulic oil. Risk of burning.

 Clean the radiators with a jet of water or compressed air from outside to inside.

Allow the hydraulic oil cooler to cool down.

 Leave hydraulic oil coolers to dry.

Wear protective gloves and firm protective clothing.

 Check the hydraulic motors (1) for free movement.

If the machine is used in places with heavily contaminated ambient air, the hydraulic oil coolers must be cleaned more often than specified in the servicing plan.

In winter-time, check that the fans (2) turn freely and that the cooling fins are free from ice and snow.

The speeds of the fan motors (1, Fig. 3-104:) are thermostat-controlled. The fan motors run at maximum speed when the hydraulic oil temperature reaches ca. 60°C / 140°F.

Fig. 3-104:

3-92

BA 6030(3 847 020.00)-EN

Inspection and servicing Electronic hydraulic shovel control, clean / lubricate Joystick At regular intervals acc. to the maintenance plans:  Loosen gaiter and move upwards.  Apply a thin layer of low temperature grease on the control spools, the actuator plate above and the cardan joint of the joysticks (arrows, Fig. 3-105:) to prevent jamming of the joysticks.

Pedal At regular intervals acc. to the maintenance plans:  Remove old grease and dirt from the control spools and the actuator plate of the pedals (arrows, Fig. 3-106:).  Apply a thin layer of low temperature grease on the control spools of the pedals to prevent jamming of the control spools.

 Refit gaiter using a cable strap.

Fig. 3-106:

Fig. 3-105:

3-93

BA 6030(3 847 020.00)-EN

Inspection and servicing Pressure accumulator - Emergency lowering To permit the working equipment to be lowered in an emergency, the machine is equipped with a pressure accumulator (1, Fig. 3-107:).

The pressure accumulator (1) is located in the upperstructure and is accessible from the ground.

Extract from the German regulations The accumulator vessel must not be subjected to welding, soldering or any other mechanical work.

Work on systems containing accumulators (repairs, connection of pressure gauges or similar work) may be carried out only when the fluid pressure has been released

Extract from the German acceptance regulations Hydraulic accumulators are pressure vessels and are therefore subject to the "Druckbehälterverordnung (DruckbehV)" [Pressure Vessel Regulations].

Their installation, equipment and operation are governed by the "Technische Regeln Druckbehälter (TRB)" [Technical Rules for Pressure Vessels]. The pressure vessels of hydraulic accumulators are classified by the admissible operating pressure p in bars, the capacity l in liters and the product of pressure and capacity p x l. Depending on the class to which the accumulator belongs, the following inspections are mandatory: Checking the gas charging pressure in the pressure accumulator

Fig. 3-107:

Pressure-accumulator inspection regulations The following regulations are applicable only in Germany. Please observe the relevant regulations in force in your own country.

Group II p  l bar and p·x l  200

3-94

After commissioning (new installation or repair), the gas charging pressure in the pressure vessel must be checked at least once during the first week. If no pressure loss is detected, the second pressure test must be performed after ca. 3 months. If no pressure loss is detected in this test either, the testing interval can be fixed at once pressure test each year.

Inspections prior to commissioning at the factory at the place of use Pressure testing Inspection certificate Prototype and pressure test (Check of correctness and certified by the manufacturer correct installation) issued by an expert

Regular inspections Inspection schedule to be drawn up by end user, based on experience with type of operation and fluid.

BA 6030(3 847 020.00)-EN

Inspection and servicing PUMP TRANSFER GEARBOX Read and observe: "Inspection and servicing - Safety instructions.

Shut off the engines.

The gearbox housings may be hot, too.

Secure the machine as described in the "Securing the machine" section.

Protect the skin from contact with gearbox oil.

Skin contact with gearbox oil is a potential health hazard.

Wear protective gloves and firm working clothing.

Pre-chamber Checking oil level The oil level in the pre-chambers is visually at the inspection glas (3, Fig. 3-109) in expansion reservoir (1).

The oil level should reach up at least to the middle of the inspection glas (3). Top up with gearbox oil, if required.

(Oil grade see: „LUBRICANTS / CONSUMABLES“ section).

Pump gearbox, checking the oil level / Topping up with oil Park the machine as described in the "Securing the machine" section.  Unscrew dipstick (1, Fig. 3-108:) and wipe.  Insert dipstick (1) fully again and withdraw a second time.

Oil level should be between the two dipstick markers. Top up with oil if required.

(Oil grade see: „LUBRICANTS / CONSUMABLES“ section).

Fig. 3-109

 Screw in dipstick (1) again.

Fig. 3-108:

3-95

BA 6030(3 847 020.00)-EN

Inspection and servicing Pump gearbox, change oil Change the oil when the machine is nearly at operating temperature. Warm oil flows better and carries suspended particles (carbon or abraded matter) better.

Filling in oil (Oil grade see: „LUBRICANTS / CONSUMABLES“ section).

Drawing off oil

 Fill in oil through the bore in breather valve (2, Fig. 3-111:).

The oil level must reach the upper mark on dipstick (1).

The gearbox oil is drained with the service station (Fig. 3-110:) through

The gearbox oil can also be filled in with the service station (Fig. 3-110:) through



express coupling (4) for the lefthand pump transfer gearbox



express coupling (4) for the lefthand pump transfer gearbox



express coupling (5) for the righthand pump transfer gearbox.



express coupling (5) for the righthand pump transfer gearbox

 Unscrew cap of express coupling and connect hose line of the service vehicle.

 Unscrew cap of express coupling and connect hose line of the service vehicle.

 Remove hose after the oil has been drawn off.

The coupling closes automatically.

 Fill in gearbox oil.

The oil level must reach the upper mark on dipstick (1, Fig. 3-111:).

 Screw on protective cap.

 Remove hose after the oil has been filled in.

The coupling closes automatically.  Screw on protective cap.

Fig. 3-110:

Fig. 3-111:

3-96

BA 6030(3 847 020.00)-EN

Inspection and servicing Pre-chambers

Pump gearbox, venting

Draining off oil

The gearbox is vented through breather valve (2, Fig. 3-113:).

Clean breather valve (2) in accordance with the servicing plan.

 Prepare a collecting recipient for used oil.

Choose the required capacity in accordance with the "Refilling quantities - Oil" table.  Screw plug (7) back in place.

 Unscrew breather filter (2), clean with white spirit or paraffin oil and blow dry with compressed air.

Filling in oil

 Screw breather filter (2) back in place.

 Unscrew plug (7, Fig. 3-112) and drain off oil.

Filling in oil see: “Checking the gearbox oil level / topping up with oil”

Fig. 3-113: Fig. 3-112

Pre-chamber venting The gearbox is vented through breather valve (2, Fig. 3-114:).

Clean breather valve (2) in accordance with the servicing plan.  Unscrew breather filter (2), clean with white spirit or paraffin oil and blow dry with compressed air.  Screw breather filter (2) back in place.

Fig. 3-114:

3-97

BA 6030(3 847 020.00)-EN

Inspection and servicing Pump transfer gearbox lube oil filters In the oil circuits of the gearbox lube oil there are two filterelements (arrows, Fig. 3-115:).

Check filter tell-tales (1, Fig. 3-116:) regulary - at operating temperature - for indication of contamination.

If the red sector is visible through transparent cap (2), the filter element must be cleaned or changed.  Remove flange (3, Fig. 3-116:).  Pour oil out of filter pot (4) and remove filter element (5).  Clean filter element in spirits or petroleum; replace if damaged  Clean filter head (6, Fig. 3-116:) and filter pot (4). Check o-ring (7, Fig. 3-117:) for damage; change if necessary.

Fig. 3-115:

 Oil the o-ring lightly. Place filter element into filter pot and re-assemly.  Check filters for leakages after recommencing operation.

Filter element (5) must be changed after having been cleaned 8 - 10 times; at the latest however, after 1000 operating hours.

Fig. 3-116:

Fig. 3-117:

3-98

BA 6030(3 847 020.00)-EN

Inspection and servicing SWING GEARBOX (For swing gearbox P/N 3692960) Read and observe: "Inspection and servicing - Safety instructions.

Swing gearbox, checking the oil level / Topping up with oil  Park the machine as described under "Securing the machine".  Screw out dipstick (1, Fig. 3-118:) and wipe clean.

Shut off the engine The gearbox housings may be hot, too.

Secure the machine as described in the "Securing the machine" section.

Protect the skin from contact with gearbox oil.

Skin contact with cooling liquid is a potential health hazard.

 Insert dipstick (1) fully again (do not screw in) and withdraw a second time.

The oil level must reach up at least to the lower mark on dipstick (1). Top up with gearbox oil, if required.

(Oil grade see “LUBRICANTS / CONSUMABLES” section).

Screw dipstick (1) back in place.

Wear protective gloves and firm working clothing.

Fig. 3-118:

3-99

BA 6030(3 847 020.00)-EN

Inspection and servicing Swing gearbox, changing oil Change the oil when the machine is nearly at operating temperature. Warm oil flows better and carries suspended particles (carbon or abraded matter) better.  Prepare a collecting recipient for used oil.

Choose the required capacity in accordance with the "Refilling quantities - Oil" table.

Draining off oil  Attach hose (8, Fig. 3-119:) to drain valve (7) and drain off oil completely.

The drain valve (7, Fig. 3-119:) is accessible from the undercarriage.

The use of the oil draining hose is described in the "Hose line for oil and cooling liquid change" chapter.

Fig. 3-119:

 Remove hose. The oil drain valve closes automatically.for oil and cooling liquid change" section.

Filling in new oil / Topping up  Unscrew plug (4, Fig. 3-120:) and fill in new oil.

(Oil grade see “LUBRICANTS / CONSUMABLES” section).  Check oil level with dipstick (1, Fig. 3-120:).  Screw in plug (4) again.

Fig. 3-120:

Swing gearbox venting The gearbox is vented through breather filter (2, Fig. 3-120:).  Clean breather filter (2) in accordance with the servicing plan.  Unscrew breather filter (2), clean in white spirit or paraffin oil and blow dry with compressed air.  Screw breather filter (2) back in place.

3-100

BA 6030(3 847 020.00)-EN

Inspection and servicing SWING GEARBOX (For swing gearbox P/N 3676892) Read and observe: "Inspection and servicing - Safety instructions.

Shut off the engines.

Swing gearbox, checking the oil level / Topping up with oil  Check the oil level visually at expansion tanks (5 and 6, Fig. 3-121:). The expansion tanks must be filled with gearbox oil up to abt. 1/3.

The oil level is visible from outside (light/dark area).

Secure the machine as described in the "Securing the machine" section.

 If necessary, unscrew cap (7) and fill in oil.

(Oil grade see “LUBRICANTS / CONSUMABLES” section).

Protect the skin from contact with gearbox oil.

Skin contact with cooling liquid is a potential health hazard.

The hoses (4, Fig. 3-121:and Fig. 3-122:) connect the gearboxes (1) with the expansion reservoirs (5 and 6).

The gearbox housings may be hot.

Wear protective gloves and firm working clothing.

Check all threaded joints for leaks.

Collect escaping oil carefully and dispose of in an environmentally acceptable manner.

These swing gearboxes have two seperated oil chambers. Each gearbox is connected to two expansion reservoirs for gearoil: 

Expansion reservoir for oil in the gearbox housing (5).



Expansion reservoir for oil in the brake chamber (6).

Fig. 3-122:

Fig. 3-121:

3-101

BA 6030(3 847 020.00)-EN

Inspection and servicing Swing gearbox, changing oil Change the oil when the machine is nearly at operating temperature. Warm oil flows better and carries suspended particles (carbon or abraded matter) better.

Gearbox housing, draining off oil  Prepare a collecting recipient for used oil.

Choose the required capacity in accordance with the "Refilling quantities - Oil" table.  Unscrew caps (7, Fig. 3-125:) from expansion reservoirs (5). Oil will escaping faster then.  Attach hose (3, Fig. 3-123:) to drain valve (2) and drain off oil completely.

The use of the oil draining hose is described in the "Hose line for oil and cooling liquid change" chapter.

The drain valve (2, Fig. 3-124:) is accessible from the undercarriage.

Fig. 3-123:

 Remove oil draining hose. The oil drain valve closes automatically.

Screw on protection cap to the drain valve.

Gearbox housing, filling in new oil / topping up  Unscrew caps (7, Fig. 3-125:) from expansion reservoirs (5) and fill in new gearbox oil.

(Oil grade see “LUBRICANTS / CONSUMABLES” section).

The expansion tanks must be filled with oil up to abt. 1/3.

The oil level is visible from outside (light/dark area).

Fig. 3-124:

 Screw caps (7) back in place.

Fig. 3-125:

3-102

BA 6030(3 847 020.00)-EN

Inspection and servicing Brake chamber, draining off oil

Swing gearbox, venting

 Prepare a collecting recipient for used oil.

Choose the required capacity in accordance with the "Refilling quantities - Oil" table.

The gearbox is vented through the caps of the expansion reservoirs (7, Fig. 3-127:).

 Unscrew caps (7, Fig. 3-127:) from expansion reservoirs (6). Oil will escaping faster then.  Unscrew plug at the upper edge of the gearbox housing (arrow, Fig. 3-126:).

Oil escapes.  Screw plug (arrow, Fig. 3-126:) back in place.

Brake chamber, filling in new oil / topping up  Fill in new gearbox oil into expansion reservoirs (6, Fig. 3-127:).

(Oil grade see “LUBRICANTS / CONSUMABLES” section).

The expansion tanks must be filled with oil up to abt. 1/3.

The oil level is visible from outside (light/dark area).

Fig. 3-127:

 Screw caps (7) back in place.

Fig. 3-126:

3-103

BA 6030(3 847 020.00)-EN

Inspection and servicing TRAVEL GEARBOX P/N 2712182 (For travel gearbox P/N 2712182 only) Risk of scalding caused by hot gearbox oil.

The gearbox housings may be hot, too.

Shut off the engines and let cool down.

Skin contact with cooling liquid is a potential health hazard. Protect the skin from contact with gearbox oil.

Wear protective gloves and firm working clothing.

Pre-chamber / spur gear section Checking the oil level / Topping up with oil  Check oil level at the inspection glass (2, Fig. 3-129:). The oil level should the center of the inspection glass.

If required screw out plug (4) and top up with oil through the opening.

(Oil grade see “LUBRICANTS / CONSUMABLES” section).  Screw in plug (4) back in place.

Secure the machine as described in the "Securing the machine" section.

Read and observe: "Inspection and servicing Safety instructions”.

Travel gearbox, checking the oil level / Topping up with oil  Move the excavator into such a position that the screw plugs (1, 2 and 3, Fig. 3-128:) are in the displayed position.  Unscrew checking screw (1).

The oil level should reach up to the lower edge of the opening. Top up with oil, if required.

(Oil grade see “LUBRICANTS / CONSUMABLES” section).  Screw checking plug (1) back in place.

Fig. 3-129:

Brake chamber - Checking the oil level / Topping up with oil  Unscrew checking screw (6, Fig. 3-129:).

The oil level should reach up to the lower edge of the opening. Top up with oil, if required (see: “Brake chamber, changing oil”).  Screw checking plug (6) back in place.

Fig. 3-128:

Fig. 3-130:

3-104

BA 6030(3 847 020.00)-EN

Inspection and servicing Travel gearbox, changing oil Change the oil when the machine is nearly at operating temperature. Warm oil flows better and carries suspended particles (carbon or abraded matter) better.

Pre-chamber / spur gear section, Changing the oil Change the oil when the machine is nearly at operating temperature. Warm oil flows better and carries suspended particles (carbon or abraded matter) better.

Draining off oil  Move the excavator into such a position that the screw plugs (1, 2 and 3, Fig. 3-131:) are in the displayed position.  Place a collecting recipient for used oil under the travel gearbox.

Choose the required capacity in accordance with the "Refilling quantities - Oil" table.  Unscrew drain plug (2) and drain off the oil completely.

Slackening plug (3) allows the oil to run out more readily.  Clean screw plugs (2 and 3)  Screw screw plug (2) back in place.

Filling in oil  Unscrew screw plugs (1 and 3).  Fill in oil through opening of plug (3) until it flows out of opening of plug (1).

(Oil grade see “LUBRICANTS / CONSUMABLES” section).

Draining off oil  Place a collecting recipient for used oil under the pre-chamber / spur gear section.

Choose the required capacity in accordance with the "Refilling quantities - Oil" table.  Unscrew drain plug (3, Fig. 3-132:) and drain off the oil completely.

Slackening plug (4) allows the oil to run out more readily.  Clean screw plugs (3 and 4)  Screw screw plug (3) back in place.

Filling in oil  Unscrew screw plug (4).  Fill in oil through opening in plug (4) until it reaches the center of inspection glas (2).

(Oil grade see “LUBRICANTS” section).  Screw plugs (4) back in place.

 Screw plugs (1 and 3) back in place.

Fig. 3-132:

Fig. 3-131:

3-105

BA 6030(3 847 020.00)-EN

Inspection and servicing Brake chamber, Changing oil Change the oil when the machine is nearly at operating temperature. Warm oil flows better and carries suspended particles (carbon or abraded matter) better.

Breather filter  Unscrew breather filter (1 and 5, Fig. 3-134:) and clean in white spirit or parafin.

Replace according to maintenance plan.

Draining off oil  Place a collecting recipient for used oil under the pre-chamber.

Choose the required capacity in accordance with the "Refilling quantities - Oil" table.  Unscrew drain plug (7, Fig. 3-133:) and drain off the oil completely.

Slackening breather filter (5) allows the oil to run out more readily.  Clean screw plug (7).  Screw screw plug (7) back in place.

Filling in oil  Unscrew screw plug (6).  Fill in oil through opening of breather filter (5) until it flows out of opening of plug (6).

(Oil grade see “LUBRICANTS / CONSUMABLES” section).  Screw plug (6) and breather filter (5) back in place.

Fig. 3-133:

3-106

Fig. 3-134:

BA 6030(3 847 020.00)-EN

Inspection and servicing TRAVEL GEARBOX P/N 3683493 (For travel gearbox P/N 3683493 only) Risk of scalding caused by hot gearbox oil.

The gearbox housings may be hot, too.

Shut off the engines and let cool down.

Brake chamber - Checking the oil level / Topping up with oil  Unscrew checking screw (6, Fig. 3-136:).

The oil level should reach up to the lower edge of the opening. Top up with oil, if required (see: “Brake chamber, changing oil”).  Screw checking plug (6) back in place.

Skin contact with cooling liquid is a potential health hazard. Protect the skin from contact with gearbox oil.

Wear protective gloves and firm working clothing.

Secure the machine as described in the "Securing the machine" section.

Read and observe: "Inspection and servicing Safety instructions.

Travel gearbox - Checking the oil level / Topping up with oil

Fig. 3-136:

 Move the excavator into such a position that the screw plugs (1, 2 and 3, Fig. 3-135:) are in the displayed position.  Unscrew checking screw (1).

The oil level should reach up to the lower edge of the opening. Top up with oil, if required.  Screw checking plug (1) back in place.

Fig. 3-135:

3-107

BA 6030(3 847 020.00)-EN

Inspection and servicing Travel gearbox - Changing oil Change the oil when the machine is at operating temperature. Warm oil flows better and carries suspended particles (carbon or abraded matter) better.

Draining off oil  Move the excavator into such a position that the screw plugs (1, 2 and 3, Fig. 3-137:) are in the displayed position.  Place a collecting recipient for used oil under the travel gearbox (Fig. 3-138:).

Choose the required capacity in accordance with the "Refilling quantities - Oil" table.

Fig. 3-137:

 Unscrew drain plug (2, Fig. 3-138:) and drain off the oil completely.

Slackening plug (1) allows the oil to run out more readily.  Clean screw plugs (1 and 2).  Screw plugs back in place.  Place a collecting recipient for used oil under the travel gearbox (Fig. 3-137:).

Choose the required capacity in accordance with the "Refilling quantities - Oil" table.  Unscrew drain plug (2, Fig. 3-137:) and drain off the oil completely.

Slackening plug (1) allows the oil to run out more readily.  Clean screw plugs (1 and 2).  Screw plug (2) back in place.

Filling in oil  Unscrew screw plug (1, Fig. 3-137:).  Fill in oil through opening of plug (1) until it flows out of opening of plug (1).

(Oil grade see “LUBRICANTS / CONSUMABLES” section).  Screw plug (1) back in place.

3-108

Fig. 3-138:

BA 6030(3 847 020.00)-EN

Inspection and servicing Brake chamber - Changing oil

Breather filter

Change the oil when the machine is at operating temperature. Warm oil flows better and carries suspended particles (carbon or abraded matter) better.

 Unscrew breather filter (1 and 5, Fig. 3-140:) and clean in white spirit or parafin.

Replace according to maintenance plan.

Draining off oil  Place a collecting recipient for used oil under the brake-chamber.

Choose the required capacity in accordance with the "Refilling quantities - Oil" table.  Unscrew drain plug (7, Fig. 3-139:) and drain off the oil completely.

Slackening breather filter (5) allows the oil to run out more readily.  Clean screw plug (7).  Screw screw plug (7) back in place.

Fig. 3-140:

Filling in oil  Unscrew screw plug (6).  Fill in oil through opening of breather filter (5) until it flows out of opening of plug (6).

(Oil grade see “LUBRICANTS” section).  Screw plug (6) and breather filter (5) back in place.

Fig. 3-139:

3-109

BA 6030(3 847 020.00)-EN

Inspection and servicing CRAWLER TRACKS

Undercarriage, lubricating system

Cleaning Clean tracks, track and support rollers, sprockets and idlers regularly and whenever required. Cleaning is especially important in winter to prevent:  the tracks from being thrown off, 

oil from leaking out of track and support rollers, sprockets and idlers,



excessive wear,



the track from breaking.

The track rollers and support rollers (1 and 2, Fig. 3-143:) are supported with grease by means of the automatic undercarriage greasing system.

Optional they could have a permanent grease filling. In this case it is necessary to press in grease filling at regular intervals.

It is necessary to be sure that there is always sufficient grease in the roller bearings.

Inspect all track and support rollers visually for leaks and free movement at regular intervals.

To clean the tracks:  raise one side of the hydraulic shovel with the working equipment and allow track to turn;  clean the side member supporting the track;  clean track and support rollers (1 and 2, Fig. 3-141:) thoroughly;  clean the sliding planes on the idler guides.

Fig. 3-142:

 Unscrew plug (6, Fig. 3-142:) from breather line.

Fig. 3-141:

 Remove dust cap (1) from coupling (2).  Remove dust cap (4) from plug (5).  Connect grease hose (3) to couling (2).  Press in grease as long as used grease emerges from breather line.  Screw on plug (6) to breather line.  Disconnect the grease hose (3).  Fix dust caps (1 and 4) back in place.

3-110

BA 6030(3 847 020.00)-EN

Inspection and servicing Track roller, Support roller Track roller fastening Check Fastening bolts (4, Fig. 3-143:) regularly for tightness:  Tighten screws with a torque wrench to the prescribed tightening torque (see: "Service Manual").

Support roller fastening Check Fastening bolts (3, Fig. 3-143:) regularly for tightness.  Tighten screws with a torque wrench to the prescribed tightening torque (see: "Service Manual").

Fig. 3-143:

3-111

BA 6030(3 847 020.00)-EN

Inspection and servicing Track tensioner Design The tracks are tensioned with the help of the hydraulic pressure created during travelling. Fig. 3-144: and Fig. 3-145: show parts of the tracks and the tensioner:

Techncal data Track tensioning pressure ca. 70 bars / 1015 psi Pressure limiting valve 330 bars / 4786 psi Gas pressure in pressure accumulator (nitrogen 50 bars / 725 psi filling pressure)

Function The tensioning system is under permanent pressure of ca. 70 bars / 1015 psi which keeps both tracks permanently tensioned. Pressure losses are compensated as soon as the engines have been started. Retensioning is not required.

For cleaning and servicing work, the tracks can be slackened.

To do so:  stop the engines.  open both pressure limiting valves (7, Fig. 3-145:) to slacken the tracks.

Fig. 3-144:

1 2 3 4 5 6 7 8 9 10

Crawler track Idler Drive sprocket Support roller Pressure accumulator Pressure cylinder Pressure limiting valve Track roller Mini- measuring port Stop cock

 After the work, screw down the pressure limiting valves (7) to the limit stop.

Fig. 3-145:

The pressure-limiting valves (7) are preset to a pressure of 330 bars / 4786 psi and sealed in this position. The lead seal must not be removed and the pressure setting of 330 bars / 4786 psi must not be changed.

The track tensioners are maintenance-free.

3-112

BA 6030(3 847 020.00)-EN

Inspection and servicing Pressure-accumulator inspection regulations The following regulations are applicable only in Germany. Please observe the relevant regulations in force in your own country.

Extract from the German regulations The accumulator vessel must not be subjected to welding, soldering or any other mechanical work.

Work on systems containing accumulators (repairs, connection of pressure gauges or similar work) may be carried out only when the fluid pressure has been relieved.

Extract from the German acceptance regulations Hydraulic accumulators are pressure vessels and are therefore subject to the "Druckbehälterverordnung (DruckbehV)" [Pressure Vessel Regulations].

Their installation, equipment and operation are governed by the "Technische Regeln Druckbehälter (TRB)" [Technical Rules for Pressure Vessels]. The pressure vessels of hydraulic accumulators are classified by the admissible operating pressure p in bars, the capacity l in liters and the product of pressure and capacity p x l. Depending on the class to which the accumulator belongs, the following inspections are mandatory:

Checking the gas charging pressure in the pressure accumulator After commissioning (new installation or repair), the gas charging pressure in the pressure vessel must be checked at least once during the first week. If no pressure loss is detected, the second pressure test must be performed after ca. 3 months. If no pressure loss is detected in this test either, the testing interval can be fixed at once pressure test each year.

The above-mentioned pressure tests are required to ensure the functioning of the track tensioner.

They are no substitute for the inspections as required by the "Pressure Vessel Regulations".

Before checking the gas charging pressure (nitrogen filling pressure) in the pressure accumulator, the track must first be slackened, i.e. the hydraulic part of the tensioning system must be depressurized. See: "Function".

Tab. 3-1

Group IV p  l bar p·x l  1000

Inspections prior to commissioning at the factory at the place of use Preliminary inspection by an Acceptance inspection by an expert expert Prototype and pressure test certified by the manufacturer (type approval) or the expert

Regular inspections Internal inspection: every 10 years for noncorrosive fluids; otherwise pressure testing every 5 years: every 10 years by an expert

3-113

BA 6030(3 847 020.00)-EN

Inspection and servicing SWING RING Read and observe: "Inspection and servicing - Safety instructions.

Internal gearing The internal gearing (1, Fig. 3-147:) and the pinion (2) are enclosed in a housing (3, Fig. 3-148:). The housing forms a grease-filled trough in which the pinion of the swing mechanism moves.

Shut off the engines.

Wear protective gloves and firm protective clothing.

Swing ring – Instructions The grease filling must be replaced:  when repairs have been carried out on the swing ring, the swing ring seals or the swing ring housing.

Remove old grease completely before filling in new grease.

If greater losses are detected, locate cause immediately to prevent damage to the swing ring.

Greases and greasy cleaning rags must not be allowed to pollute the environment. Discard grease and greasy cleaning rags separately from other waste without polluting the environment.

Bearing races The central lubricating system supplies grease continuously to the two roller bearing races and the internal gearing .

Fig. 3-147:

The grease is pumped to the greasing port of the grease trough by the distributor (Fig. 3-146:). The amount of grease used up during operation is replenished by the central lubricating system.

The housings have a check opening which is closed with a cover (2, Fig. 3-148:). For checking, the cover must be removed.

The grease is pumped to the greasing points of the bearing races by a distributor (Fig. 3-146:).

Fig. 3-148:

Fig. 3-146:

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Inspection and servicing Swing ring - Checking the grease filling Read and observe: "Inspection and servicing - Safety instructions.

Swing ring - Filling in grease Prior to initial commissioning, the grease trough of the internal gearing must be filled with grease.

Add grease when  the housing has been replaced,

Shut off the engines.

Wear protective gloves and firm protective clothing.

At regular intervals:  check internal gearing and teeth of swing mechanism pinion for condition



old grease has been removed in the course of other work.

Always fill in fresh grease by hand.

Risk of accidents. Never swing the upperstructure when refilling grease.

 check that the grease filling is sufficient.

The housing must always contain enough grease for the gearing - measured from its lower edge - to run in at least 20 mm / 0.78“ of grease over its whole circumference (Fig. 3-149:).

In the event of greater grease losses, eliminate cause immediately and add grease to prevent the internal gearing and the pinion from being damaged by continued swing movements.

Swing ring - Checking the screws for tightness The Fastening bolts of the swing ring in the upperstructure and the undercarriage are tightened with their respective torques (see: "Service Manual").

When these values are reached, the Fastening bolts are perfectly tight.

Loosen slack screws before tightening them with a torque wrench to the prescribed torques (see: "Service Manual").

Fig. 3-149:

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Inspection and servicing CENTRAL LUBRICATING SYSTEM Design The excavator is equipped with an automatic central lubricating system which provides grease regularly to all greasing points except those mentioned in the "Lubricating chart - Grease".

The central lubricating system is activated when the electrical system is switched on with the keyswitch and at least one engine is running.

All greasing points connected to the system are greased at regular intervals.

The automatic greasing is interrupted when the engines are stopped with the idle timers.

The central lubricating system is controlled electrohydraulically by the PLC (Programmable logical controller).

The PLC is located in a switch box underneath the cab.

Fig. 3-151:

If a fault occurs, BCS gives a warning on the screen (Fig. 3-151:). This happens, for example, if the filter element in the hydraulic line is contaminated.

If one of the following faults occurs, BCS gives a warning and at the same time the grease pump is switched off: 

Grease container is empty,



Greasing pressure in the grease lines is below 250 bars (3626psi).

In this cases, BCS switches off the hydraulic function of the shovel/backhoe cylinders after 15 minutes. This prevents damages from lack of greasing.

Inform the responsible maintenance personnel immediately.

Keep on working after the fault has been fixed.

Fig. 3-150:

After the fault has been fixed, actuate the "Reset" button in the control column (64, Fig. 3-150:) or the “Reset” button in the control box located at the grease container. The buttons must be actuated for at least one second.

For further information on the function and setting refer to the Service Manual, chapters 9 and 11.

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Inspection and servicing Function The grease is pumped by hydraulically driven pumps (2 and 3, Fig. 3-152:) via greasing lines from the grease container to the main distributors on the upperstructure and on the undercarriage.

Pump (2) supports greasing points on upperstructure and working equipment, pump (3) supports the undercarriage (optional).

The control elements of the lubricating system are installed on a control panel (1) attached to the grease container.

As soon as the grease container is empty, the BCS (Fig. 3-153:) gives a warning signal (fault). In the event of a fault, the "dumping” function (shovel or backhoe cylinder) is switched off automatically after 15 min.

Work can be continued when the grease container is filled with grease.

Fig. 3-152:

Fig. 3-153:

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Inspection and servicing Filling up the grease container Always refill the grease container in time to avoid air from penetrating into the greasing system. Air in the greasing system may cause malfunctions.

Fill up the grease container through the service station (Fig. 3-154:).  Switch on the indicator system with toggle switch (23, Fig. 3-154:). Monitoring lamp (22) lights up.

Breather filter grease container, check / replace Check/change the breather filter of the grease container at regular intervals.  Unscrew wing nut on top of the breather filter.  Withdraw cover (1, Fig. 3-155:) and filter element (2).

 Unscrew the cap of the express coupling (11).

 Check the filter element (2) and replace if it is soiled or damaged.

 Connect the filling hose of the service vehicle.

 Replace sealing rings of the filter element.

 When the grease container is full, the indicator lamp (34) lights up.

 Re-install breather filter.

 Switch off the indicator system with toggle switch (23). Monitoring lamp (22) is off.  Remove the filling hose.

The express coupling closes automatically.  Refit the protective cap.

Fig. 3-155:

Fig. 3-154:

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Inspection and servicing Checking the greasing pressure

Unblocking a grease line

Check regularly (accord. to the maintenance plan), whether the oil pressure indicated by pressure gauge (3, Fig. 3-156:) at the hydraulic oil filter is 55 - 60 bars / 798 - 870 psi.

In the event of faults at the central greasing system inform the responsible maintenance personnel immediately. Detailled information about the central greasing system can be found in the “Service Manual” chapter 11.

The pressure is depending on temperature and viscosity of the oil and may vary.

This oil pressure is reduced so that the pressure indicated by pressure gauge (2) is 35 – 40 bars / 507 – 580 psi and by pressure gauge (1) is 49 – 51 bar / 711 – 740 psi.

The necessary greasing pressure of 320 bar / 4641 psi for the upperstructure and 180 bar / 2611 psi for the lower carriage is generated by means of a pressure translator.

The greasing pressure for upperstructure and working equipment is indicated by pressure gauge (4). The greasing pressure for the undercarriage (optional) is indicated by pressure gauge (5).

Even when the grease pump isn’t active, there can be residual pressures in the grease lines up to 30 bars (435psi).

Relieve this residual pressure before opening a grease line.

Put the excavator back into operation only after the greasing system works properly and after having actuated the unloaded working equipment for abt. 5 minutes. This is necessary in order to supply sufficient amounts of grease to the cylinder bearings.

In the event of deviating pressure values, shut off the engines and inform the responsible maintenance personnel. The central greasing system has to be checked.

Lower oil / grease pressure means that not all of the greasing points are supplied with grease.

Higher oil / grease pressure may cause bursting of a greasing line.

Fig. 3-156:

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Inspection and servicing Oilfilter replace (hydraulic circuit grease pump) Risk of scalding caused by hot hydraulic oil.

Shut off the engines.

Read and observe the "Inspection and servicing - Safety instructions" chapter.

Replacing the filter element For filtering of the hydraulic oil, a high pressure filter is installed in the pumping line (Fig. 3-157:).

At the filter head there is a contamination indicator.

Replace filter element if a red colored pin is visible at the contamination indicator.  Relieve hydraulic pressure.  Unscrew filter housing (3).  Withdraw filter element (2) from filter housing (3).

The filter housings may also be hot. Wear protective gloves and firm working clothing.

 Clean filter housing and the sealing face at the filter head with white spirit or paraffin oil.

Skin contact with hydraulic oil may cause skin injury. Avoid skin contact.

 Insert the new filter element into filter housing and refit to the filter head with new, lightly oiled sealing ring (1).  Check for leaks after putting the filter into operation.

Fig. 3-157:

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Inspection and servicing Grease filter replace (filling the grease container)

Grease filter replace (Grease lines)

Read and observe the "Inspection and servicing –Safety instructions" chapter.

Read and observe the "Inspection and servicing –Safety instructions" chapter.

Shut off the engines.

Shut off the engines.

Replacing the filter element

Replacing the filter element

A grease filter (arrow, Fig. 3-158:) is installed in the grease filling line to the grease container.

Two grease filters (Fig. 3-159:) are installed in the greasing lines to the grease distributors.

Replace filter element regularly according to the maintenance plans.

Replace filter element regularly according to the maintenance plans.

 Unscrew filter housing (4).

 Unscrew filter housing (4).

 Withdraw filter element (2) from housing.

 Withdraw filter element (2) from housing.

 Remove the grease.

 Remove the grease.

 Clean filter housing and contact faces at the filter head with white spirit or paraffin oil.

 Clean filter housing and contact faces at the filter head with white spirit or paraffin oil.

 Insert the new filter element into filter housing and refit to the filter head with new, lightly oiled sealing rings (1 and 3).

 Insert the new filter element into filter housing and refit to the filter head with new, lightly oiled sealing rings (1 and 3).

 Check for leaks after putting the filter into operation.

 Check for leaks after putting the filter into operation.

Fig. 3-158:

Fig. 3-159:

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Inspection and servicing OTHER MAINTENANCE Engine Information about maintenance can be found in the engine Operation and Maintenence Manual.

Cooling system Check the radiators regularly.  Shut off the engines.  Remove any accumulated dirt.

Further servicing works not described are carried out by your Caterpillar dealer or the engine manufacturer.

 Clean the fan blades.

Cleaning

 Dry up coolers.

Check the engines regularly. 



If the engine is cleaned with a steam-jet cleaner, make sure that the jet is not directed towards electrical components.

If no steam-jet cleaner is available, the engines must be cleaned with suitable cleaning agents (cold cleaners).

 Clean the radiators with a jet of water or compressed-air from the outside.

Do not clean radiators with a wire brush or similar hard objects.

In case of firmly adhering dirt, remove radiator and clean.

Exhaust system Check the Fastening bolts regularly for tightness when the exhaust system is cold.

Before cleaning the engines Exhaust pipes and turbo chargers in the engine compartments are covered with special heat-insulating material.

This material must not be spraywashed with steam-jet cleaners or high-pressure cleaners. It will be damaged. Therefore cover all the insulating material with plastic foils before using steam-jet cleaners or highpressure cleaners inside the engine compartments.

Heating and air conditioning Clean or replace the filter mats in the air suction regulary.

The filter mats are located in the air conditioner housing (Fig. 3-160:) below the roof of the cab.  Open housing of air conditioner.  Clean or replace filter mats.  Close housing.

Means of fastening  Check Fastening bolts regularly for tightness.

The seating planes of the screws must be free from paint, dirt and rust.

Fig. 3-160:

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Inspection and servicing Reservoirs for used grease at the A-frame, emptying

Hydraulic ladder, pressure accumulator

Remove used grease from the reservoirs (Fig. 3-161:) regularly according to the maintenance plans.

To allow the hydraulic ladder (Fig. 3-162: and Fig. 3-163:) to be lowered in an emergency, the ladder mechanism is equipped with a pressure accumulator (1, Fig. 3-164:).

Do not re-use the grease because it is polluted.

Dispose off used grease as well as cleaning rags without polluting the environment and separately from other waste.

The pressure accumulator (1) is located in the upperstructure and is accessible from the ground.

Fig. 3-162:

Fig. 3-161:

Fig. 3-163:

Fig. 3-164:

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Inspection and servicing Pressure-accumulator inspection regulations The following regulations are applicable only in Germany. Please observe the relevant regulations in force in your own country.

Extract from the German regulations The accumulator vessel must not be subjected to welding, soldering or any other mechanical work.

Work on systems containing accumulators (repairs, connection of pressure gauges or similar work) may be carried out only when the fluid pressure has been relieved.

Extract from the German acceptance regulations Hydraulic accumulators are pressure vessels and are therefore subject to the "Druckbehälterverordnung (DruckbehV)" [Pressure Vessel Regulations].

Their installation, equipment and operation are governed by the "Technische Regeln Druckbehälter (TRB)" [Technical Rules for Pressure Vessels]. The pressure vessels of hydraulic accumulators are classified by the admissible operating pressure p in bars, the capacity l in liters and the product of pressure and capacity p x l. Depending on the class to which the accumulator belongs, the following inspections are mandatory:

3-124

Checking the gas charging pressure in the pressure accumulator After commissioning (new installation or repair), the gas charging pressure in the pressure vessel must be checked at least once during the first week. If no pressure loss is detected, the second pressure test must be performed after ca. 3 months. If no pressure loss is detected in this test either, the testing interval can be fixed at once pressure test each year.

BA 6030(3 847 020.00)-EN

Inspection and servicing ON-BOARD CRANE, DRIVE UNIT The drive unit supplies the crane with hydraulic power. The drive unit comprises the diesel engine, fuel tank, starter batteries and the hydraulic system.

Crane engine More and detailed information about the diesel engine can be found in the Operating and Maintenance Manual for the crane engine.  Before each shift check engine oil level. If necessary top up with engine oil through opening of dipstick (3, Fig. 3-165:).  After each shift fill up fuel tank (1).  Regularly check batteries (4) and cable connections.  Regularly, at least once a year: - change engine oil, - replace engine oil filter, - check / replace air filter (2), - replace fuel filter.

Do not start engine with air filter (2) removed.

Hydraulic system For more and detailed information, see crane Operation and Maintenence Manual.  Prior to each deployment, check the hydraulic oil level at the inspection glass (1, Fig. 3-166:); top up with hydraulic oil if necessary.  Check contamination of hydraulic oil filter regularly at contamination indicator (4, Fig. 3-165:).  Regularly, but at least once a year replace the hydraulic oil filter (3) and the breather filter (2).

On-board crane, greasing Servicing work  Lubricate all bearings regularly and as required, and spray swing ring with a graphite spray (Fig. 3-167:) 1 - bearing 4 lube points 2 - joint (column/boom) 2 lube points 3 - cylinder bearing 5 lube points 4 - swing ring Graphite spray

Fig. 3-165:

Fig. 3-167:

Fig. 3-166:

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Inspection and servicing On-Board crane, checking tightness of fastening bolts The hydraulic driven on-board crane (Optional) is fixed on the upperstructure of the machine by means of 16 fastening bolts. The upper and lower fastening bolts (Fig. 3-168:) are important and safety relevant components, they carry all loads and forces of the crane.

Check tightness of all fastening bolts:  in regular intervals according to the maintenance plans and 

before every start of the on-board crane.

Check tightness of the fastening bolts by means of a torque wrench. The tightening torque for fastening bolts M20, quality 10.9, lightly oiled is: 557 Nm.

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Fig. 3-168:

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Inspection and servicing PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING Putting the hydraulic shovel out of operation

Battery storage

 Park the hydraulic shovel on firm and level ground.

 Check the acid density and the electrolyte level of the battery every two weeks.

 Set the working equipment down on the ground, retracting the piston rods of the hydraulic cylinders as far as possible.

 Recharge the batteries at the latest, when the acid density has dropped to 1.23 kg/dm³.

 Set all control element to "0".

During prolonged machine downtimes, remove the batteries and store in a dry room at an ambient temperature of ca. 20°C / 68°F. Observe the following points with regard to maintenance:  Clean the batteries.

 Keep the batteries clean and dry on the outside.

 Clean the machine.  Carry out a visual inspection of the hydraulic shovel.  Remove coarse dirt, snow and ice from the fins and fan wheel of the hydraulic oil cooler.  Carry out engines preservation.  Protect all bright metal parts (e.g. piston rods) from rust and dirt.

Recommissioning  Remove the covers.  Degrease / clean all protected components.  Remove engines preservation in acc. with the engine operationg anstructions.  Check the fuel level in tanks.

 Check anti-freeze concentration of the cooling liquid to avoid freezing during the cold season.

 Check track tension (visual inspection).

 Fill up the fuel tanks.

 Check level and condition of the cooling liquid in the cooling system.

 Remove the batteries; see: "Battery storage".  Secure the machine against unauthorized starting by: withdrawing the key from the key-switch, locking the cab door, securing all lockable hatches.  Cover up all openings.

 Check grease filling in grease container.  Oil level

- drive engines, - swing gearboxes, - pump drive gearboxes, - travel gearboxes.

 Check oil level in hydraulic oil reservoir.  Check battery acid density and level.  Install batteries and reconnect.  Function checks:

- upperstructure holding brake, - track brake, - lighting system, - signalling equipment.

 Vent the hydraulic system.

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Inspection and servicing

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Inspection and servicing NOTES .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. ..............................................................................................................................................................................

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Inspection and servicing

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Repair work 4 REPAIR WORK Operation and Maintenence Manual

Target group

Part 1 INTRODUCTION FUNDAMENTAL SAFETY INSTRUCTIONS

Operating personnel + Inspection and servicing personnel + Repair personnel

Part 2 OPERATION

Operating personnel The operating personnel must have knowhow relevant to the operation and the application of this or comparable machines.

Part 3 INSPECTION AND SERVICING

Inspection and servicing personnel

Part 4 REPAIR WORK

Repair personnel

The inspection and servicing personnel must have know-how relevant to the inspection and servicing of this or comparable machines.

The repair personnel must have know-how and experience relevant to the repair of this or comparable machines.

Part 5 ANNEX

Part 6 INDEX

Operating personnel + Inspection and servicing personnel + Repair personnel Operating personnel + Inspection and servicing personnel + Repair personnel

4-1

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Repair work

4-2

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Repair work REPAIR WORK - SAFETY INSTRUCTIONS

Dismantling components

Operation and Maintenence Manual

Never do dismantling while the machine is at operating temperature.

Never carry out repair work without having read and understood the Operation and Maintenence Manual.

Oils, greases, or coolants may have a high temperature and result in burning or scalding.

Pay special attention to: "Fundamental Safety Instructions", "Inspection and servicing - safety instructions" and all warnings and safety instructions attached to the machine.

Before starting work, depressurize piping and hoses, cylinders, radiator, hydraulic tank and other systems or units.

The descriptions of job sequences provide only experienced personnel with the necessary instructions.

The operating manual must be kept with the machine at all times.

Repair personnel Repair personnel must have know-how and experience relevant to repairing this or comparable machines.

In the absence of such know-how, meticulous training must be given by experienced repair personnel, e.g. from CGM HMS GmbH.

Working in greater heights Always wear safety harnesses when working at greater heights.

Wear an approved safety harness; it must be equipped with fall arresters and safety cables.

Prestressed units

Leave time for the machine to cool down.

Replace defective components in good time to prevent major damage.

Clean the defective component carefully before dismantling it.

Mark the dismantled parts in the correct sequence to faciliate re-assembly.

When dismantling the component, close off exposed hose and piping connections, exposed drill holes and housings carefully to prevent any dirt from penetrating.

Never remove lead seals Never change rated pressure of pressure relief valves without the explicit authorization of CGM HMS GmbH. Never remove lead seals from pressure relief valves and accumulators.

After the repair work To prevent corrosion, coat all bright metal machine parts with a grease film.

Never open defective prestressed units but replace them as an entirety.

On completing the work, re-assemble all protective devices, covers and noise- and vibrationinsulation material.

In exceptional cases, open only when the system and the operating sequence are precisely known and any special tools required are available.

Never start up the drive engines while work is being done on the machine.

The operating manual contains no information on this point.

Check the repaired components and all machine functions in a trial run.

Never release the machine for recommissioning until it is fully functioning.

4-3

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Repair work CONFINED SPACES - SAFETY INSTRUCTIONS Work in confined spaces can lead to unexpected dangerous situations, such as 

the formation of flammable vapours exploding during welding operations or



the lack of oxygen and harmful gases causing loss of consciousness.

What are "confined spaces"?

Confined spaces on this machine are, for instance, components of the working equipment such as the monoblock boom, the lower part of the boom, the stick or the hydraulic reservoir (Fig. 4-1: - Fig. 4-3:).

These components are provided with manholes.

Manholes offer access to the inside of these components in order to carry out inspections or repairs such as welding work.

Fig. 4-1:

Dangerous situations can also exist in other spaces which are not very often visited or which are badly ventilated. In these spaces, harmful or flammable gases can accumulate unnoticed.

Work in such spaces may only be carried out by specially qualified persons who have been instructed as to the situational risks.

Before visiting these spaces, the following safety precautions must be taken:  The narrow space must be ventilated for a prolonged time, e.g. with a blower. Do not blow oxygen into the space. Oxygen increases the risk of fire.

Fig. 4-2:

 Use your personal protective equipment, e.g. respiratory mask.  Use a safety harness and have a second person stand by with a rescue rope attached to the harness.  Evacuate the gases produced during welding.

Fig. 4-3:

4-4

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Repair work REPAIR WORK, FIRE AND EXPLOSION HAZARD Safety instructions

Place suitable fire guardings (fire barriers) if open fire or flying sparks cannot be avoided during repair work.

If necessary, also cover the ground with fireprotective blankets.

Prior to commencing work, obtain information on the national and corporate rules for the prevention of accidents and avoiding fires.

Apply special protection to cables, cable ducts as well as to hose and pipe lines.

Pay particular attention to hazards caused by combustible and easily flammable substances.

The engine compartment can be equipped with pressure vessels containing cold-starting fluid (ether). Ether is toxic and highly flammable; the vessels are under pressure. These pressure vessels can explode if exposed to high temperatures (above 49°C / 120°F) or in the event of damage.

Protect the pressure vessels against damage before beginning to work in or close to the engine compartment.

Obtain information on the safe handling of the fire extinguishers to be used.

Avoid smoking and open fire on, next to and below the hydraulic shovel.

Even battery gases can ignite in open flames or fire.

Combustible and easily or highly inflammable substances or liquids increase the risk of fire and explosion. This is also valid for pressure vessels containing flammable substances as, for instance, spray oil or cold-starting fluid (ether). They are heat-sensitive and can explode even if exposed only to intensive sunlight.

These substance can also ignite themselves if they come close to hot units or objects as, for instance, a turbocharger.

Do not store these substances on the hydraulic shovel. If combustible, easily or highly flammable substances or liquids were used during maintenance operations, they must be completely removed from the hydraulic shovel at the end of the work.

Have all your welding, flame cutting and grinding work approved before starting work.

Ensure sufficient ventilation.

Do not keep any fire extinguishers that are not suitable or have not been tested.

Do not extinguish flammable liquids with water.

Use:  dry-powder, carbon-dioxide or foam extinguishing compounds.

When getting into contact with burning substances, the fire-fighting water would abruptly evaporate and distribute the substance such as oil over a wide area. Water causes short-circuits in the electrical system thus possibly entailing new hazards.

Call the fire brigade.

Clean the hydraulic shovel carefully after the maintenance, if oil, grease, fuel, detergents or coldstarting fluid have been spilt over the machine. If possible, use a steam-jet cleaner for cleaning.

Avoid parking the hydraulic shovel in places where  combustible substances such as coal dust or tar are present. 

open or smouldering fire may occur.

Remove the hydraulic shovel from such an area where combustible or easily flammable liquids have spilled from the hydraulic shovel onto the ground.

Flying sparks (caused by welding, flame cutting, grinding, electrical short-circuit) may cause fire on the ground that can spread to the hydraulic shovel.

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Repair work REPAIR WORK, ENGINE Read and observe the "Repair - Safety instructions" chapter and the engine Operation and Maintenence Manual before working on the engine.

The engine compartment can be equipped with pressure vessels containing cold-starting fluid (ether).

Ether is toxic and highly flammable; the vessels are under pressure. These pressure vessels can explode if exposed to high temperatures (above 49°C / 120°F) or in the event of damage. Protect the pressure vessels against damage before beginning to work in or close to the engine compartment.

Risk of injury caused by rotating or hot parts of the engine.

Shut off the engine and allow to cool down.

Before cleaning the engines Exhaust pipes and turbo chargers in the engine compartments are covered with special heat-insulating material.

This material must not be spraywashed with steam-jet cleaners or high-pressure cleaners. It will be damaged. Therefore cover all the insulating material with plastic foils before using steam-jet cleaners or highpressure cleaners inside the engine compartments.

Carry out repair work only if the machine has been secured as described in the "Securing the machine" section of these Operation and Maintenence Manual.

Check and replace V-belts only when the engine is stationary.

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Repair work HYDRAULIC SYSTEM Repair instructions

Hydraulic hoses – Instructions

Always depressurize the hydraulic system before disconnecting any hydraulic hoses or pipes.

Even hoses that have been properly stored or used are subject to natural ageing. Their useful life is therefore limited.

Read and observe also the chapters "Inspection and servicing - Safety instructions" and "Repair Safety instructions".

Replace damaged and leaking hydraulic hoses and pipes as soon as possible by new ones.

Use original spare parts from CGM HMS GmbH. They are adapted to the respective function.

Do not re-use old hoses.

Never repair damaged hoses.

Discard escaped oil and oily wastes without polluting the environment. These substances must not be allowed to penetrate into the soil.

Hydraulic hoses must replaced after a service life of six years (including a storage time of 2 years).

Check the date of manufacture on the hose or on the hose fitting regularly.

The recommended interval after which hydraulic hoses - and especially those used in harsh conditions - must be replaced depends on the number of operating hours and on pressure loading.

The use of hoses close to their recommended load limit shortens the replacement interval (e.g. high temperatures, frequent working cycles, extremely high pulse frequencies as well as multi-shift operation and round-the-clock work).

Hydraulic hoses must be replaced, if one of the following defects is detected during a visual inspection:  Damage to the outer fibre reinforcement layer reaching down to the inner layer (cuts, chafe marks, cracks). 

Embrittlement of the outer fibre reinforcement layer (cracks in the hose material).



Changes in the ususal shape of the hose under pressure or in pressureless condition in bends or curves such as detachment of fibre layers, formation of bubbles or bulges.



Leaks.



Non-observance of fitting requirements.



Damage to or deformation of hose fittings that may result in a reduction of the strength of the screwed union.



Detachment of the hose from the fitting.



Corrosion in fittings reducing the strength of the function of the fitting.

4-7

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Repair work PRESSURE ACCUMULATORS SAFETY INSTRUCTIONS The hydraulic system is equipped with pressure accumulators containing nitrogen under high initial pressure.

Even when the hydraulic pressure in the system is reduced, the nitrogen in the accumulator will remain under pressure.

The accumulators are completely safe in operation. If incorrectly handled, however, there is a risk of explosion.

So:  Never handle accumulators never weld or solder.

mechanically,

 Testing and servicing work must be carried out by experts only.  Prior to any testing and servicing work, depressurize the hydraulic part of the system.  To dismantle the accumulator, always wear goggles and working gloves.  Fill accumulator with nitrogen only, never with compressed air or oxygen.  Report any defects or damage to the machine owner without delay.  Prior to recommissioning, an inspection by a specialist or expert is essential if the accumulator was damaged or if the admissible operating temperature or operating pressure was exceeded.

Never remove or paint over warning and information plates, rating plates or type identification markings. Replace illegible or damaged plates immediately.

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Repair work WELDING AND FLAME CUTTING WORKS - SAFETY INSTRUCTIONS The present safety instructions are valid for both types of work. For easier reading, the text only uses the terms "welding work", "welding" or simply "work". These terms do however always refer to both types of work, i.e. "welding and flame-cutting work".

Read these safety instructions before starting any welding or flame-cutting operations.

Increased risk of fire during welding work Always bear in mind that the heat, the sparks or dripping red-hot metal or slag produced in the process constitute a considerable risk of fire.

The present safety instructions provide information on how to minimize the risk of fire.

Remove all combustible materials close to the welding location or cover them up with noncombustible materials.

If works in the vicinity of combustible materials cannot be avoided, further persons with fire-fighting equipment must be present on site as fireguards.

Welding work by qualified personnel only

Observe the instructions of the machine owner and of the mine.

Carry out welding work only if you have received special training and if you have been ordered to perform such work.

Health hazards

Always bear in mind that you are performing welding work on heavily loaded components. The quality of your welding work can be decisive for the operational capability of the machine and also for the health and life of persons.

Observe the health protection and accident prevention laws and regulations as well as the fire protection regulations in force in your country.

Observe all warning and instruction signs attached to the machine.

Wear the prescribed personal protective equipment such as:  protective clothing,  protective gloves,  protective mask and,  a fall-arrest system for persons working at height.

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Welding operations produce harmful gases. Do not inhale the fumes and gases and make sure the surroundings of the welding location are well ventilated or equipped with an exhaust system.

Remove all kinds of paint and all coatings as well as all residues of oils and greases from the weld area.

Do not wind the welding cables round your body or parts of your body. The electromagnetic fields produced may damage your health.

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Repair work Tanks, pressure vessels and pressure accumulators Any work on vessels containing or having contained  combustible or combustion-accelerating substances,  potentially explosive substances or  substances susceptible to develop harmful gases, fumes, mists or dusts during welding may only be carried out under expert supervision and only by experienced personnel especially assigned to such work.

This prescription applies, for instance, to all tanks and reservoirs for hydraulic fluid, engine oil, diesel fuel or lubricating grease.

Welding work on pressure vessels and pressure accumulators is forbidden.

Pressure vessels containing cold-starting fluid (ether) may be installed in or near the engine compartment.

Ether is toxic and highly flammable; the vessels are under pressure. These pressure vessels can explode if exposed to high temperatures (above 49°C / 120°F) or in the event of damage.

Slewing rings and articulated joints The welding current must not flow through ballbearing or roller-bearing slewings rings, through bolted connections or articulated joints or through hydraulic cylinders.

An electric current flowing through an air gap (e.g. in the bearing or in the articulation) produces a spark which damages the metallic surface.

The welding clamps must therefore always be connected very close to the weld area (max. 2 - 3 m away (6.6-9.8 ft)).

Information relating to the electrical system and to electronic modules Electric arc welding produces electromagnetic fields, electrostatic charges and voltage spikes which can cause damage to electronic modules.

Although the electronic modules of the machine are carefully protected against these influences, it is nevertheless necessary to take additional precautions in order to prevent such damage to the greatest possible extent.

Switch off the electrical system ("ignition OFF").

Open the battery main switch (or disconnect the starter batteries from the machine).

Protect the vessels against damage and high temperatures.

Lay the welding cables as far away from electric lines as possible.

Do not perform welding work in the vicinity of these pressure vessels before they have been covered up safely against accidental contact or flying sparks. Have the pressure vessels removed from the machine, if safe protection cannot be ensured.

If it is not possible to implement all of the abovementioned precautions, all connectors must be removed from the electronic modules before beginning any welding work.

Inform yourself about the locations in the machine where the pressure accumulators of the hydraulic system are installed. Do not perform welding work in the vicinity of these pressure accumulators before they have been covered up safely against accidental contact or flying sparks. Have the pressure accumulators removed from the machine, if safe protection cannot be ensured.

Never touch the enclosures of electrical and electronic modules with the welding electrode.

Protect withdrawn terminals and connectors from short circuits and soiling. Cover up terminals and connectors with foils or adhesive tape.

Protect electric lines against the heat emanating from the weld area.

Restore all electrical connections when the welding operations are terminated.

Never connect the ground clamp of the welding cable to the enclosures of electric or electronic modules.

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Repair work Welding on the counterweight

Welding on the cab

Counterweights may contain a build-up of flammable gases. Before starting to work, counterweights must be flushed for at least 20 minutes with compressed air in order to remove these build-ups of gas. To permit flushing, the counterweight has two bores in its upper part: a threaded bore M18x1.5 for the compressed-air line and another unthreaded bore to let the air out.

The operator’s cab is designed in such a way that it meets the FOPS (Falling Objects Protective Structure) requirements in accordance with DIN EN ISO 3449.

Detailed information / instructions on this subject can be found in Service Information 2006-33 which is available on the CGM HMS GmbH website under Maintenance & Service.

Welding on components of the working equipment and on other fully or partly closed steel structures Components may be equipped with pipelines routed inside. These lines can contain combustible substances such as hydraulic oil or lubricating grease which may be set on fire by welding operations.

Check whether pipes or hosepipes are connected to the steel component.

Depressurize these lines.

Open the screwed connections and empty the lines routed inside the component.

Start welding only after these operations have been carried out.

Electric lines may also be be laid inside partly open steel structures in order to protect them against damage. They are not always visible from each viewing direction. Electric lines may catch fire as a result of the heat produced during welding.

Therefore check carefully whether electric lines are laid in the vicinity of the weld area.

Protect electric lines against the heat produced at the weld area or have them removed before starting the welding operations.

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Welding and other mechanical work is forbidden as there is a risk of reducing the structural stability of the cab.

Further information More detailed information concerning the state-ofthe-art execution of welding operations can be found in the Service Manual "Welding for maintenance and repair".

For problems or queries please contact the competent service personnel.

If parts of the machine have to be removed or dismantled, please read and observe the chapters: "Assembly of working equipment, safety instructions", "Inspection and servicing, safety instructions", "Repair, safety instructions".

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Repair work DISPOSAL AT THE END OF THE SERVICE LIFE Dismantling and removal instructions Before beginning work, think about the risks involved, e.g.: 

Most of the machine components have considerable mass. Therefore use only lifting gear and slings of sufficient bearing capacity.



Risk of residual pressures still in the hydraulic system. Be very careful when opening hydraulic lines.

Read the following text attentively and observe the instructions given. Respecting the instructions will help you to protect yourself against health hazards and injuries and to prevent avoidable environment pollution.

Risk of deflagrations In the course of time, flammable gases may have formed or accumulated in the hollow spaces of welded constructions, e.g. the counterweight. To remove these flammable gases, the hollow spaces must be purged carefully with compressed air before work with hand grinders, flame cutters or other sparking tools is being undertaken.

Risk of fire Remainders of fuel or oils may lead to the formation of flammable gases in tanks or other hollow spaces. When these tanks or hollow bodies are cut into pieces, the gases may ignite or even explode.

For this reason, remove all fuel or oil remainders from these components and purge them carefully with compressed air in order to eliminate flammable gases (other efficient methods of removing flammable gases can also be applied) before work with hand grinders, flame cutters or other sparking tools is being undertaken.

Disposing of the machine without polluting the environment Before stripping down the machine at the end of its service life observe the following instructions: The assemblies of the machine contain various operating fluids or lubricants. These substances may pollute the environment (so-called hazardous substances) and must therefore be disposed of properly.

Observe the national laws and regulations governing the non-polluting disposal of these substances.

Remove all operating fluids from the systems, remove all lubricants and dispose of these substances properly. 

Fuel system: fuel tanks, fuel filters, fuel lines, filling station.

Auxiliary attachment and units, such as an onboard crane or an auxiliary heater have their own fuel tanks with the corresponding line systems.



Hydraulic oil: hydraulic oil reservoir, hydraulic cylinders, hydraulic motors, hosepipes, piping, hydraulic pumps, hydraulic valves, hydraulic oil filter, filling station.



Engine coolant: engine, radiator, expansion reservoir, piping and hosepipes, filling station.



Gearbox oil in slewing, travelling and transfer gearbox systems, expansion tanks, piping and hospipes, filling station; idlers, support and track rollers.



Have the refrigerant (R134A) sucked out of the air conditioner system.



Grease from the central lubricating system, grease drum, piping and hosepipes, distributors, filling station; grease accumulations in bearings of the working equipment, grease filling in the slewing ring, grease filling in track and support rollers as well as in idlers.

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Repair work Further hazardous substances

Appropriate disposal of batteries



Batteries contain lead and acid.



Electronic modules are located in switch cabinets of the cab module, the engine module, the control column.

The machine is equipped with batteries containing lead and other harmful and polluting substances.



Pressure accumulators contain nitrogen under high pressure and possibly remainders of hydraulic oil.



Lamps of Xenon working lights contain mercury.

The required electronic control circuits are integrated in the housings of the working lights.



The fluorescent lamps of the maintenance lighting (discharge types) contain mercury.



Insulating material of cables can contain PVC.



The fire extinguishing system (if installed) contains trigger charges (ATTENTION, explosion risk) on the extinguishing agent containers.

Pressure accumulators, extinguishing gas and extinguishing powder.

For more detailed information please refer to the manufacturer's safety datasheets.

Damaged or used batteries must therefore not be disposed of in the environment. They must be disposed of properly and separately from other waste.

The batteries are marked with the corresponding symbols (Fig. 4-4:).

Since batteries contain also reusable materials, they are taken back free of charge by the manufacturer, dealer or by other specialized companies.

In the European Community, the final consumer is obliged by law to to dispose of used batteries in designated waste collections centers.

Observe the current regulations and laws of your country with regard to the handling of damaged or used batteries.

Fig. 4-4:

The symbols in Fig. 4-4: have the following meaning:

4-6



Crossed-out waste bin= Do not dispose of batteries with normal household waste.



Pb……= Chemical symbol for lead.



Circle of bent arrows= Recycling symbol, ingredients of the battery can be reused.

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Repair work

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Repair work NOTES .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. ..............................................................................................................................................................................

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Repair work

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Annex 5 ANNEX Operation and Maintenence Manual

Target group

Part 1 INTRODUCTION FUNDAMENTAL SAFETY INSTRUCTIONS

Operating personnel + Inspection and servicing personnel + Repair personnel

Part 2 OPERATION

Operating personnel The operating personnel must have knowhow relevant to the operation and the application of this or comparable machines.

Part 3 INSPECTION AND SERVICING

Inspection and servicing personnel

Part 4 REPAIR WORK

Repair personnel

The inspection and servicing personnel must have know-how relevant to the inspection and servicing of this or comparable machines.

The repair personnel must have know-how and experience relevant to the repair of this or comparable machines.

Part 5 ANNEX

Operating personnel + Inspection and servicing personnel + Repair personnel

Part 6 INDEX

Operating personnel + Inspection and servicing personnel + Repair personnel

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Annex

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Annex BOARD-CONTROL-SYSTEM BCS III, what’s that?

What it is The BCSIII is the third generation of the Board Control System. This generation represents the current stage of development of this reliable monitoring and control system for hydraulic mining hydraulic shovels from CGM HMS GmbH. The BCSIII communicates with other electronic units in the hydraulic shovel and makes up the CAMP system, the Control And Monitoring Platform.

Controllers actuate and monitor functions such as the motor management, drive and control of the hydraulic pumps, the servo control and others. The controllers are basically computers that have been configured for their special application.

Other electronic units of the CAMP system that communicate with the BCSIII are located in cabinets in the module below the operator’s cab, the pump compartment and the engine compartment.

The exchange of data between sensors, controllers, the BCSIII and other involved components takes place via the CAN bus.

What it does The Board Control System, abbreviated to BCS, monitors all the essential functions of the hydraulic shovel and its components.

It releases an appropriate signal if any maximum value is exceeded and also sends a report to be archived in the memory bank.

If a normal operating status can be reached by temporarily reducing the hydraulic shovel's output, then this is monitored by BCS and done by the CAMP system.

If it is necessary for the operator to take certain action, e.g. to stop one of the engines a relevant command is sent to the BCS display screen.

BCS also gives information on servicing and trouble-shooting.

Sensors installed at various points on the hydraulic shovel constantly transmit their readings to the controllers of the CAMP system.

All essential pieces of operating data are displayed on the BCSIII screen in the form of simulated instruments as well as they are archived and can be called up as and when required.

Fig. 5-1:

Benefits for the operator Because BCS automatically warns of any abnormal conditions that require a corrective action, the operator can concentrate fully on the work in hand, and is not distracted by constantly having to keep an eye on many instruments or by having to decide upon appropriate actions to be taken in case of limit values being exceeded.

The operator and the servicing crew also have the means of calling up particular background information from the BCS archive.

The housing – installed in the control column inside the operator’s cab (Fig. 5-1:) – integrates the computer, the monitor, the control elements and the interfaces.

SIL2 functionality Safety related functions on the machine have been checked to minimize the risk of faults in their own function. Tests were performed according to the standards of functional safety (ISO 61508).

To fulfill the requirements for reaching the Safety Integrated Level 2 (SIL2) new components and electronic units had to be used on the machine.

These components and units are servo-controllers, sensors, switches, hand levers (joysticks), foot pedals and valves.

Want more information?

More detailed and more technical information for service personnel could be found in the “Service Manual”, chapter 9.

There are more extensive information given about the communicating units and about troubleshooting.

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Annex The keys on the front side

Other elements on the front side

A membrane keypad is located on the front side of the housing (Fig. 5-2:). The keys can be used to navigate through the screen pages.

(located on top of the column of keys on the right side)

The keys in the row below the screen (1 – 0) will perform the same task as the active area on the screen above.

Example: In (Fig. 5-2:) the key (1) lies directly below the active area "Service". Touching the "Service" area or pressing key "1", will take you to the same screen page.

They can also be used for numerical inputs.

The keys provided with arrows on the right side of the screen are used to navigate in a screen page.

Pressing the key with the "door symbol" gives access to the previous screen page.

Pressing the bottom key in the row confirms an input (like “Enter”).

Fig. 5-2:

5-4

The green LED lights up when the electrical system of the machine is switched on, operating voltage is available. The green LED flashes with each keypress and when the background lighting of the screen is turned off.

The yellow LED flashes if the temperature inside the device lies outside the permissible range. The automatic heating system is then active.

The brightness sensor measures the ambient brightness. The BCS automatically controls the background illumination of the screen and the illumination of the keypad.

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Annex BCSIII, the start screen The screen displays the graphical user interface of the Board Control System. The basic screen (Fig. 5-3:) appears when all electronic units of the CAMP system have started and when their self-tests have been completed.

Note: At low outside temperatures it is possible that the basic screen appears a few minutes after switching on the electrical system (warming up phase).

Starting from this basic screen, the user can access a number of other screens. This does not require an input device such as a keyboard, mouse or similar.

The BCS screen is designed as a touch-screen. By slightly touching the active areas, the user can perform activities such as changing to another screen page.

Active areas are shown on the screen as threedimensional graphics. In the basic configuration – not activated - they seem to project out of the user interface. When touched, they appear to be lowered.

Never use pointed objects such as a ball pen, screwdriver, nail or similar.

This could damage the active surface of the touch-screen.

Do not press on the sensitive areas, just slightly touch them!

Fig. 5-3:

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Annex Information given on the start screen, top section The symbols shown in the top row of the start screen (Fig. 5-4:) appear in grey colour if function is not activated, in green colour if everything is OK or in red if a warning is given. In this case more information is displayed in the red “failure row” below.

6

Operating hours meter.

7

Right engine monitoring.

8

Service station, turns to red colour if lowered. Swinging upperstructure or travelling the machine not possible then.

9

Hydraulic ladder, turns to red colour if lowered. Swinging upperstructure or travelling the machine not possible then.

1

Left engine monitoring.

2

Central lubrication system monitoring.

3

The number of dumpers you loaded is displayed here (if counted with the key in the right joystick).

10

Track parking brakes monitoring.

11

Upperstructure holding brakes monitoring.

4

Connection to Remote Service System (optional).

12

Servo-switch inside seat monitoring.

5

Hydraulic system monitoring.

Fig. 5-4:

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Annex Information given on the start screen, central section 1

Left engine data during operation: bar = engine oil pressure, Rpm = revolutions per minute, Ltr = fuel in fuel reservoir, red means: top up with fuel soon.

Water = temperature of cooling fluid in degrees Celcius, left arrowhead-shaped symbol slides up and down displaying the current temperature. The symbol showing a halfed arrowhead is a trailing pointer displaying the maximum temperature. Slide to “0” with your fingertip.

2

Hydr. Oil = Hydraulic oil temperature in degrees Celcius, displayed graphically and numerically.

V = on-board voltage, displayed graphically and numerically.

Spanner symbol = operating time until next service is to be due, symbols are red then.

3

Right engine data during operation: bar = engine oil pressure, Rpm = revolutions per minute, Ltr = fuel in fuel reservoir, red means: top up with fuel soon.

Water = temperature of cooling fluid in degrees Celcius, left arrowhead-shaped symbol slides up and down displaying the current temperature. The symbol showing a halfed arrowhead is a trailing pointer displaying the maximum temperature. Slide to “0” with your fingertip.

Fig. 5-5:

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Annex Information given on the start screen, lower section 1

2

Button “Service”.

Tapping with your fingertip opens a gate to much more information about the hydraulic shovels current behavior.

A menu will appear where you can select the section you want information about (see chapter “Service screen”).

Button “Setup”.

Tapping with your fingertip opens a login window that permits access to the BCS section that is exclusively for service personnel.

A password is needed to get access.

Fig. 5-6:

5-8

3

Button “Fault”.

Tapping this button opens a list of failures stored in the failure memory.

A detailed description can be found in the “Service Manual”, chapter 9.

4

The red “failure row”.

Here the system displayes detailed information about the failure occurred and gives instructions about what to do.

5

Tapping the button with the door icon “Exit” leaves the current screen and opens the previous screen.

6

Clock.

Can be adjusted in the “Setup” section by service personnel.

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Annex EMERGENCY STOP, RESET FUNCTION In case the Emergency Stop function has been activated by one or more of the Emergency Stop switches or by operating the battery circuit breaker, the main screen changes and displays the reset button (1, Fig. 7). The machine is inactivated then, engines cannot be started.

1

This symbol appears on the main screen, when the Emergency STOP button has been activated.

Call the responsible service personnel immediately.

The fault has to be located and eliminated.

Before being able to restart the engines the reset button, located in the front door of the 24Voltswitch cabinet (X1) must be pressed. The switch cabinet is located in the cab module.

After pushing the reset button, the green LED inside the push switch lights up. This signalizes that the Emergency Stop function is back in function again.

Fig. 5-7:

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Annex SWING CIRCUIT LOCK-OUT FUNCTION If the system detects an error with the swing function the swing circuit lock-out screen pops up on the main page displaying the faulty component(s).

Call the responsible service personnel immediately.

The fault has to be located and eliminated.

The pop-up window disappears after touching anywhere in the window. It will stay in the background until another fault happens or the operator navigates to a different screen and goes back to the main screen.

The fault can be reviewed on the “Servo Controller Menu”, available after logging in to the Setup-Level I-Menu (password required).

Fig. 5-8:

5-10

Squared symbols meanings: Green colour = OK Yellow colour = Minor fault detected, 48 hours to solve the problem before status changes to red and safe stop sequence is initiated.

Red colour = Major fault detected, safe stop sequence is initiated.

The all-over status (green, yellow, red) of the swing circuit is displayed at the end of the chain and correlates with the three conditions mentioned above.

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Annex Information given on the “Service” screen 1

2

3

Tapping on the photo of the engine opens a screen displaying current engine data (see “Engine data screen”).

Same result when tapping on button “Engine” or pressing key “1” on the housing.

Tapping on the photo of the hydraulic pumps opens a screen displaying current hydraulic data (see “Hydraulic data screen”).

Same result when tapping on button “Hydraulic” or pressing key “3” on the housing.

Tapping on the photo of the lubrication control opens a screen displaying current lubrication data (see “Lubrication data screen”).

Same result when tapping on button “Lubrication” or pressing key “5” on the housing.

4

Tapping on the photo of the control lever (joystick) opens a screen displaying control elements adjusting data (see “Controls adjustment data screen”).

Same result when tapping on button “Servosystem” or pressing key “7” on the housing.

5

Tapping on this button opens the “View documents” screen (see: “View documents screen”).

6

Adjusting screen brightness. Sliding the green button sets screen brighter / darker.

Tapping on button “Autom.” sets brightness to automatic mode.

7

Tapping on this button opens the “Signal Table” screen (see: “Signal Table screen”).

8

Tapping the button with the door icon “Exit” leaves the current screen and opens the previous screen.

Fig. 5-9:

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Annex Engine data screen This screen displays data of the left engine. Same data for the right engine are available after tapping on the button “right engine”.

1

This section of the screen displays current engine data.

2

Here the oil change interval is displayed as well as the remaining operating hours (h) until the next oil change.

After carrying out oil change tap on button “done”, this resets the graphical oil change bar and the (h) counter.

Fig. 5-10:

5-12

3

In this section information about faults and malfunctions are displayed. Fault description follows the SAE J1939 standard.

SPN Number = Suspect Parameter Number, FMI = Failure Mode Indentifier.

The “failure row” below displays a failure description.

4

All data displayed can be saved to an USBstick after tapping this button (see: “Saving data to an USB-stick”).

5

Tapping on this button opens a window displaying all the faults / malfunctions the system is able to display (see: “Code Table screen”).

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Annex Hydraulic data screen 1

This screen displays data related to the hydraulic system.

2

All data displayed can be saved to an USBstick after tapping this button (see: “Saving data to an USB-stick”).

3

Tapping the button with the door icon “Exit” leaves the current screen and opens the previous screen.

Fig. 5-11:

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Annex Lubrication data screen 1

2

This screen displays data related to the central lubrication system.

Here are information about the status of the lubricating system of the upper carriage.

3

Here you get information about the status of the lubricating system of the under carriage.

4

If the system detects faults or malfunctions in the lubrication system of the upper carriage they are marked here with a red dot.

Call the responsible service personnel.

If the system detects faults or malfunctions in the lubrication system of the under carriage they are marked here with a red dot.

Call the responsible service personnel.

5

Tapping the button with the door icon “Exit” leaves the current screen and opens the previous screen.

Fig. 5-12:

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Annex Controls adjustment data screen The characteristic curves of control levers (1, Fig. 5-13:) and control pedals (2) are adjustable by service personnel. The adjusted values are shown here graphically and numerically.

Tapping the button with the door icon “Exit” leaves the current screen and opens the previous screen.

If adjustment is needed, call the responsible service personnel.

Adjustment is to be done in the “Setup” section of BCSIII. Access to this area is for service personnel only (password required).

Fig. 5-13:

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Annex View documents screen Technical documentation for the machine is stored in memory.

Tapping on the buttons opens the appropriate pdf file and displays it on the screen by means of the build in viewer.

You can navigate inside the documents using the navigation elements known from other computer usage, like buttons, sliders, links from the contents page and so on.

Fig. 5-14:

5-16

Tapping the button with the door icon “Exit” leaves the current screen and opens the previous screen.

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Annex Signal table screen

1

This is a listing of all the signal sources that are connected to the BCS- and CAMP-system.

In the “Status” column small icons visualize the signal status: green=ok; red=malfunction.

In column “Code” you can find the identifier for the sensor or unit that helps the maintenance personnel to localize the sensor in the electric schematics (in this example the identifier for the sensor is “3B22”) .

To identify and localize sensors and units on the machine, some photos were attached. If you tap on a “Name” and then the button “Location” became readable, a photo is available. Otherwise the button is greyed.

In Fig. 5-15: ID 110 “Main Pump 1/3 Pressure” is marked and button “Location” (1) is readable. When tapping on it, a photo appears and shows where the sensor is located (see Fig. 5-16:).

2

Tapping on button “Diagram” opens a screen showing the data coming from four sensors in a diagram (see Fig. 5-17:).

3

Tapping the button with the door icon “Exit” leaves the current screen and opens the previous screen.

Fig. 5-15:

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Annex Signal table screen, location Button “Location” has been tapped, a photo appears showing where the sensor “3B22” is located at the machine.

Fig. 5-16:

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Annex Signal table screen, diagram This is a diagram showing the data coming from four signal sources (sensors) for a longer period of time.

The signal sources (channel 1-4) can be selected from a listing after tapping the “Config” button (see: “Signal table screen, diagram configuration”).

3

Rec = starts recording the data from the selected sources; Stop = stops recording data; Rev = scrolls the diagram in reverse; Fwd = scrolls the diagram forwards.

4

Diagram window, displays the data from four sources as four lines in different colours.

1

Tapping on button “Config.” opens a window listing all the signal sources available for BCS and CAMP (Fig. 5-18:).

5

Save = save data to memory; Load = load older data from memory; Delete = delete data displayed.

2

Listing of the four signal sources selected: ID, Name, actual value and value at cursor in the diagram.

6

Buttons to scroll, scale up, scale down the diagram window.

7

Tapping the button with the door icon “Exit” leaves the current screen and opens the previous screen.

Fig. 5-17:

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Annex Signal table screen, diagram configuration Button “Config.” has been tapped, a window appears displaying all the signal sources available.

In column “Channel” you can mark four signal sources whose data you want to display in the diagram (Fig. 5-17:).

Mark the line with the signal source you want and press the appopriate numeric key on the BCS housing: “1” for channel 1; “2”, “3” and “4” for the other channels.

Fig. 5-18:

5-20

1

For example: This signal source is selected and marked to be displayed on channel 3.

2

For example: This signal source is selected and marked to be displayed on channel 2.

3

Tapping the button will confirm your selection.

4

Tapping the button with the door icon “Exit” leaves the current screen and opens the previous screen.

BA 6030(3 847 020.00)-EN

Annex Code table screen Coming from the “Engine data screen” (Fig. 5-10:) after tapping the “Code Table” button.

This screen displays a listing of all available trouble codes according to the SAE J1939 standard.

Active faults or malfunctions are displayed on the “Engine data screen” with their “SPN Number” and their “FMI Number”. To get the description for the fault or malfunction, key in both numbers at (1) and tap on the button left aside.

The appropriate description will be displayed (2).

1

SPN = Suspect Parameter Number, according to SAE J1939 standard, For example: 94

2

FMI = Failure Mode Identifier, according to SAE J1939 standard, For example: 18

3

Tapping these buttons will scroll the listing: forward, reverse, to beginning, to end.

4

Tapping the button with the door icon “Exit” leaves the current screen and opens the previous screen.

Fig. 5-19:

5-21

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Annex SLEW BRAKE TEST SCREEN The slew brake test screen (Fig. 20) is available after logging in to the Setup-Level I-Menu (password required).

1

A slew brake test must be performed during commissioning of the machine and after repair work or maintainance work carried out on the slewing system.

The slew brake test should be performed at every maintenance scheduled by the customer.

Preconditions to be fulfilled before performing the slew brake test, from left to right: - swing brake applied, - servo control switch in control column must be in position OFF, - operator sitting on his seat.

Symbols change to green with precondition fulfilled.

Time limit to fulfill preconditions is 60 sec.

This is to ensure proper functioning of the slew brake system. Proper functioning of the slew brake system has influence to machine safety.

2

Button to start the test.

3

Hydraulic pressures in the units of the slewing systems, lefthand and righthand.

Before performing the slew brake test, ensure the machine is in a safe workplace where the machine can rotate 360° without hitting an obstacle. Check that all persons have left the area around the machine. Activate the horn.

4

Instructions to perform the slew brake test.

5

Instruments displaying hydraulic pressure in lefthand / righthand slewing system.

6

Indicators showing the progress during testing: - “pending”, colour red after starting the test, - “in progress”, colour yellow when 300 bar, - “passed”, colour green when test OK.

To perform the slew brake test, follow the instrucions (4) given on the screen.

Fig. 5-20:

5-22

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Annex BCS III, interfaces The BCS system comes with different data interfaces. This feature allows the communication with external electronic devices.

Three connectors are located on the right-hand side-wall of the control column (Fig. 5-21:): 1

USB 2.0, jack type A. This jack accepts, for example, a USB stick used to save operating data for evaluation on an external computer.

2

Jack D sub, 9 pins.

Used to connect a computer with a diagnosis software with access to the CAN bus. This connection is reserved for service personnel.

3

Fig. 5-21:

Ethernet, jack type RJ45.

For the connection of future extensions, for example, the remote servicing system.

USB interface, data storage A USB stick can be connected to the USB plug-in connection of type A (1, Fig. 5-21:).

Suitable are such USB sticks that would also work ® on computers with WINDOWS operating systems; they may be formatted with the NTFS or the FAT32 file system.

If a screen page displays the symbol of a USB stick, the operating data of this screen page can be saved. The BCS will create a text file.

For a detailed description see: “Saving data to a USB stick”.

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Annex Saving data to a USB stick All screens which have the “USB-stick-button” (1, Fig. 5-22:) offer the functionality to store data for external use.

All data related to the current screen will be stored to a USB stick. In this example all data from the “Service, left engine” screen will be saved to a file.

Fileformat is RTF (Rich Text Format).

The file name will be automatically created following this pattern: “Shovel type+serial number+screen name.rtf”.

For example: “RH120172_Engine_LH.rtf”.

If this file already exists, an extension with increment numbers will be added to the file name: “RH120172_Engine_LH_(1).rtf”.

“RH120172_Engine_LH_(2).rtf”. ……

Fig. 5-22:

5-24

Save data: Plug a USB stick into the USB jack (see: “BCSIII, interfaces”).

To save the data, tap on button (1, Fig. 5-22:).

The BCS system checks the USB interface before saving the data. If no USB stick is detected, a new window appears showing the folder structure on the CF-card as well as the message “Please plug a USB stick”.

If a USB stick is found, a new window appears, see next page (Fig. 5-23:).

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Annex Saving data to a USB stick, continued This window shows the current data you want to save in a file and askes for confirmation.

If you want to save the data tap on the “Yes” button (1, Fig. 5-23:). The file will be written on the USB stick.

Otherwise tap on the “No” button and return to the screen you want.

If you want to see the files stored on the USB stick, tap on the “Open” button (2).

A new window appear showing the folder / file structure on the USB stick, see next page (Fig. 5-24:).

Fig. 5-23:

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Annex Saving data to a USB stick, continued This window (Fig. 5-24:) displays the folder / file structure on the USB stick plugged into the USB jack.

Mark the file you want to see by tapping on the filename (2).

Tapping an button “show” (1) opens another window which shows the file.

Tapping the button with the door icon (3) leaves the current screen and opens the previous screen.

Fig. 5-24:

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Annex BCSIII, cleaning

BCSIII, disposal

Clean dirty screens with a soft, slightly moist cloth.

In order to remove persistent dirt, you can use in addition a conventional cleaning agent for LCD monitors.

This electronic device contains substances that might be harmful to the environment.

Never use solving or scouring cleaning agents.

This could damage the surface of the screen.

Do not use compressed air or water under pressure (high pressure cleaner or steam cleaner).

This could damage the electronic components.

The electronic components and the tubes of the background illumination contain, for example, lead (Pb) and mercury (Hg).

The background illumination lamps are CCFL-typelamps (Cold Cathode Fluorescent Lamps).

The battery for backing up the memory contains lithium.

Therefore, this device must not be disposed of with your regular household waste. It must be disposed of properly as electronic scrap.

The escaping liquid from a damaged LCD screen may be harmful.

Do not come in contact with escaping liquids. In case of skin contact, wash immediately with water and soap.

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Annex TROUBLESHOOTING Instructions on troubleshooting

Layout of the fault table

Faults are often due to the machine not being correctly operated or serviced.

Fault

For this reason, it is vital to read through the relevant section of the Operation and Maintenence Manual once again before rectifying any faults.

If you are unable to detect the cause of the fault or to rectify it, apply to the CGM HMS GmbH aftersales service.

Describe the fault and all accompanying circumstances as precisely as possible when calling on the CGM HMS GmbH after-sales service. Exact data allow for fast troubleshooting.

Never do any jobs for which you are not qualified.

The fault table lists all faults which have been reported to date and outlines their possible causes and rectifying measures. In exceptional cases, a described fault may also have a different cause.

The fault is described here as the outcome of an observation or a previous activity.

Therefore make careful observations.

Study the problem carefully. First think, then act.

Ask yourself the following questions: 

Which warning signals preceded the fault?



What repair and servicing work was carried out previously?



Has this defect already occurred?



Is it one or several simultaneously occurring faults?

Possible causes The possible causes of the observed fault are outlined in this group. They are arranged in order of probability, i.e. the possible cause occurring in most cases heads the list.

Measures This describes the troubleshooting procedure.

Section This specifies where information on troubleshooting is given in the Operation and Maintenence Manual. If there is no entry, the CGM HMS GmbH after-sales service should be consulted

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Annex FAULT TABLES Combustion engine - Fault table Fault Engine fails to start or starts only with difficulty Engine does not turn Engine starts, but runs enevenly or intermittently Engine gets too hot, temperature warning activated

Remedial action Check P Adjust Replace

E W

Top up Reduce

A S

Clean

R

Engine not working at full power Engine not working on full cylinder papacity Engine without oil pressure or oil pressure too low Engine oil comsumption too high Engine emits blue smoke Engine emits white smoke Engine emits black smoke Engine cannot be stopped Engine throttled down strongly Cause Oil level too low 

  

 

Oil level too high

  

Engine inclination too big



Engine oil of wrong SAE-class













 

Fuel quality not corresponding to specification 

Air filter contaminated / turbo-charger defective

  

Fuel filter contaminated 

Charge-air line leaking



Radiator / cooling fins contaminated



Cooling fan or water pump defective or loose



Cooling air gets too hot / heat buid-up

1) Contact the CGM HMS GmbH Service

Chapter ref.

Engine oil level

A

Engine oil level S Engine Op. P Instr.

Lubricants W Engine Op. W Instr.

Air intake syst. P Fuel filter P/W P Cooler cleaning R Engine Op. P/W Instr.

P Battery P



Battery defective or discharged



Cable connections in starter circuit loose or corroded

P

Starter defective or pinion not in mesh

P

Shut-off relay jamming

1)

 





   







   



 

Incorrect valve setting Injection line leaking

 



Injection valve defective Combustion engine blocked on output side

 



Engine Instr.

 

 PMS malfunction  Celect coding lamp flashing/lit Celect defective (software error)

Op. E P

Engine Instr.

Op. P/W 1) 1) 1) 1)

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Annex Working hydraulics – Fault table Fault

Remedial action

Working and swing functions not operational Check No boom function No bucket function No backhoe function No stick function Working movements too slow Power loss in working hydraulics

Adjust Replace Top up Reduce Clean

P E W A S R

1) Contact the CGM HMS GmbH Uncontrolled working movements Service Cause Abschnitt Electronic hydraulic shovel control not activated/defective Working P  Malfunction of pressure-relief valve 1)   1)   Servo system pump defective 1)       Malfunction of primary / sencondary pressure-relief valves Engine speed too low P  ECO-power switch in 80%-position P  Fuel filter contaminated Fuel filter P/W  Insufficient engine power Engine mal- 1)  function Hydraulic oil temperatur too high (warning lamp lit, PMS fault indicator Hydraulic oil P/R  lamp lit) oil cooler contaminated cooler cleaning Engine coolant temperature too high (warning lamp lit and PMS fault 1)  indicator lamp flashing) 1)  Malfunction of solenoid valves Malfunction of control spool 1)   Engine coupling defective 

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Annex Track drive – Fault table Fault

Remedial action

No forward travel and no reversing travel Check Maximum travel speed cannot be reached Insufficient traction power

Adjust Replace Top up Reduce Clean

  

        

   

P E W A S R

1) Contact the CGM HMS GmbH Service Cause Chapter ref.

Malfunction of pressure-relief valves 1) Servo system pump defective 1) Malfunction of travel valve (pedal) 1) Engine nominal speed too low 1) Malfunction of control spool 1) ECO-power switch in 80%-position Travelling P Insufficient engine power Engine mal- 1) fuction Hydraulic oil temperatur too high (warning lamp lit, PMS fault indi- Hydraulic oil P/R cator lamp lit) oil cooler contaminated cooler cleaning Engine coolant temperature too high (warning lamp lit and PMS 1) fault indicator lamp flashing)

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Annex Swing mechnism – Fault table Fault

Remedial action

No swing possible Check No righthand or lefthand swinging Slewing performance insufficient Uncontrolled swinging movement

     



 

    

5-32

Cause Electronic hydraulic shovel control not activated / defective Limiting switch optional, hydraulic ladder not complete retracted Upperstructure holding brake applied Pressure-relief valve adjusted too low level / defective Servo system pump defective Malfunction in feed-pressure circuit of swing pump Malfunction in high-pressure circuit of swing system Malfuction of moment-regulating valve Malfunction in swing pump displacement cylinder Excessive leakage in swing motor

Adjust Replace Top up Reduce

P E W A S R

Clean 1) Contact the CGM HMS GmbH Service Chapter ref.

Working P Operation P P 1) 1) 1) 1) 1) 1) 1)

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Annex Central lubricating system – Fault table Fault

Remedial action

Grease pump not working, the BCS does not indicate a warning Automatic circuit breaker on Check Grease pump not working, pilot lamp lit Grease pump working, no grease delivered Greasing pressure too high or too low

   

  



  

    

Cause Timer defective Lines between timer and hydraulic motor defective Hydraulikmotor defektive Grease pump defective Grease sieve clogged Distributor defective Grease container empty Grease pump does not suck grease Leaky lines Non-return valve defective Pressure switch defective

Adjust Replace Top up Reduce

P E W A S R L

Clean Vent 1) Contact the CGM HMS GmbH Service Chapter ref.

P/W P/W P/W P/W P/R P/W P/A P/L P/L P/W E

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Annex ENGINE MONITORING, CONTROL LAMPS

Warning lamp, red (50 and 60): Ignoring the signal lamp may lead to a potential engine breakdown.

The control lamps 

(49 and 50, Fig. 5-25:) for the left engine,



(59 and 60, Fig. 5-25:) for the right engine,

indicate malfunctions and signal when certain limit values have been exceeded.

An automatic check is performed after switching on the electrical system of the machine; both lamps will light up for approx. 5 seconds and turn off afterwards.

The warning lamp lights up as soon as certain limit values for the following operating parameters of the engine have been exceeded: (An "Event“ occurred): 

Charge air temperature at engine intake,



Temperature of coolant,



Engine oil pressure,



Engine speed (protection against overspeed),



Fuel pressure,



Fuel temperature.

In case of an event (e.g. temperature of coolant is too high), the lamp will light up. The diagnosis lamp provides the event code at the same time (flashing).

In case of a previously specified threshold value, the engine will reduce the output (so-called "engine derate“). This is not indicated by the lamps, e. g.: 

Engine oil pressure approx. 1bar (14.5psi) (rotation speed dependent),



Temperature of coolant above 111°C (231.8°F),

The diagnosis lamp indicates malfunctions of the electronic control of the engine.



Temperature of intake air above 86°C (186.8°F),

For example: faulty sensors, cable breaks etc.



Temperature of fuel above 91°C (195.8°F).

Fig. 5-25:

Diagnosis lamp, yellow (49 and 59):

The indication uses so-called flash codes.

In case of a malfunction, the diagnosis lamp represents two digits, the "diagnosis code" or an "event code“.

This takes place by the flashing of the diagnosis lamp in quick succession.

The first and second digits of the flash code are derived by counting the flash signals.

There is a time interval of approx. 2 seconds between the flashing sequence of the first and second digit.

In case of several diagnosis codes, the time interval between two different diagnosis codes is approx. four seconds.

Refer to the engine's operating and maintenance manual for matching the diagnosis and event codes with the cause of malfunction.

Diagnosis codes are intended to isolate an error and are not suitable for detailed fault diagnostics.

5-34

In case of a reduced output, for example by exceeding the maximum working height, none of the lamps will light up or flash.

The limit values and the engine's response when those values are exceeded can be adjusted in the so-called monitoring system within certain limits (service provided by the engine manufacturer).

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Annex HYDRAULIC CIRCUIT DIAGRAM Detailled information can be found in the „Service Manual“ chapter 8 or contact your Caterpillar dealer.

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Annex ABBREVIATIONS

API approx.

Ampere (SI base unit of electric current) about according to Ampere hours (SI base unit of quantity of electricity) American Petroleum Institute approximately

BA bar Bh

= OI = Operation and Maintenence Manual unit of pressure, 1 bar = 14.5 psi = OH = Operating hour

CAMP CE

Control and Monitoring Platform Communauté Européenne = European community Committee for european Construction Equipment (Defines a measure for bucket, grab or scoop filling) European Standardization Committee 1 centimeter (= /100 m) Cubic centimeters per revolution counterclockwise clockwise

A abt. acc.

Ah

CECE CEN cm 3 cm /rev CCW CW

dia.

DIN

Decibel (sound intensity according to measuring method A) Diameter German Industrial Standard

ECM eff. e.g. etc.

Electronic Control Module on engines effective for example etcetera

Fig. FMI

Figure, serial number of illustration Failure Mode Identifier, description malfunctions according to SAE J1939 Falling objects protective structures Rock shovel (working equipment) foot (unit of distance), 1 ft = 0.30 meter

dB(A)

FOPS FS ft gal GLR

of

gallon (unit of volume), 1 gal = 3.78 liters Full-load controller (electronic module for PMS)

Incl.

ISO

Including, inclusive of International Standardization Organization

kg 3 kg/dm

Kilogram (unit of weight), 1 kg = 2.2 lb Kilograms per cubic decimeter (= unit of specific density) Kilometers per hour KiloNewtons per meter (1 kNm = 1000 Nm) = unit of torque Kilowatt (1 kW = 1.36 hp)

km/h kNm kW l lb Lb/in² LC LED l/min LpA LwA

Liter (unit of volume), 1 liter = 0.26 gal pound (unit of mass), 1 lb = 0.45 kg Pounds per square inch (= psi) Long crawler Light-emitting diode Liters per minute Sound pressure at workplace Sound power level of the machine in stationary operation

m MA mA max. min.

-1 min mm

Meter (unit of distance), 1 m = 3.28 ft Tightening torque 1 Milliampere (= /1000 A) maximal, maximum minimal, minimum Revolutions per minute Millimeter (=1/1000 m)

N N, kN NLGI NLGI– Klasse Nm No.

Normal, standard version Newton, kiloNewton (unit of force) National Lubricating Grease Institute (USA) Consistency – lubricant classification acc.

To DIN 51 818 Newtonmeter (unit of torque) Number

OH op.inst.

OW

Operating hour Operation and Maintenence Manual Upperstructure

oz

ounce (unit of volume) 1 oz = 0.03 liter

HD Hydr.

Heavy duty Hydraulic, Hydraulics

PMS P/No. PS psi

i i.e.

IFN

Transmission ratio

PLC

Pump Managing System Part number Metric horsepower (1 PS = 0.74 kW) pund per sqare inch (unit of pressure), 1 psi = 0.069 bar Programmable logic controller

id est = that is ISO service rating, blocked

Qty.

Quantity

5-36

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Annex ABBREVIATIONS R, r resp.

RH RTF ROPS rpm

Radius Respectively Crawler hydraulics (hydraulic shovel) Rich Text Format, textbased file format Roll-over protective structures -1 Revolutions per minute (= min )

SAE sec./s.

SN SPN

Society of Aotomotive Engineers (USA) Second CGM HMS GmbH partnumber Suspect Parameter Number, description of malfunctions according to SAE J1939 Width across flats

SW t TBG THB TL tm typ.

U/min USB UW V VDMA

Metric ton (= 1000 kg) Civil Engineering Employer’s Liability Insurance Association Service Manual Backhoe dipper (attachment) Tons by meters (obsolescent unit of swing torque) Typical Revolutions per minute Universal Serial Bus, interface for fast data exchange Undercarriage Volt (unit of electric voltage) Association of German Machinery and Systems Manufacturers

W

Watt (unit of electric power)

°C °F > <

Degrees Celsius (temperature) Degrees Fahrenheit (temperature) greater than less than

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Annex PRODUCT SPECIFICATION SHEET

5-2

6030/6030 FS Hydraulic Shovel

Engine* Engine Model Gross Power – SAE J1995 Net Power – SAE J1349

2 × Cat® C27 ACERT™ 1140 kW 1,530 hp 1140 kW 1,530 hp

*Electric drive option available (1000 kW) on 6030 AC/6030 AC FS

Bucket Bucket Capacity – Front Shovel (heaped 2:1) 16.5 m3 Bucket Capacity – Backhoe (heaped 1:1) 17.0 m3 Operating Specifications Bucket Payload 30 tonnes Operating Weight – Front Shovel 294 tonnes Operating Weight – Backhoe 296 tonnes

21.6 yd3 22.0 yd3 34 tons 324 tons 326 tons

6030/6030 FS Hydraulic Shovel Specifications General Data Operating weight Face Shovel Backhoe Engine output SAE J1995 2 × Cat C27 ACERT Standard bucket capacity Face Shovel (heaped 2:1) Backhoe (heaped 1:1)

Diesel Engines Make and model 294 tonnes 296 tonnes

324 tons 326 tons

1140 kW

1,530 hp

16.5 m3 17.0 m3

21.6 yd3 22.2 yd3

Features • TriPower shovel attachment • Independent oil cooling system • Spacious walk-through machine house • 5-circuit hydraulic system • On-board electronics system: Control and Monitoring Platform (CAMP) • Board Control System (BCS III) • Torque control in closed-loop swing circuit • Automatic central lubrication system • Xenon working lights

Operating Weight Face Shovel Standard track pads 1000 mm Operating weight 293 800 kg Ground pressure 22.0 N/cm2 • Additional track pads available on request Backhoe Standard track pads 1000 mm Operating weight 296 000 kg Ground pressure 22.1 N/cm2 • Additional track pads available on request

3 ft 3 in 647,710 lb 31.9 psi

Total rated net power – ISO 3046/1 Total rated net power – SAE J1349 Total rated gross power – SAE J1995 Number of cylinders (each engine) Bore Stroke Displacement Aspiration Maximum altitude without deration at 15° C (59° F) – above sea-level Alternators Emission Fuel tank capacity

2 × 150A U.S. E.P.A. Flex 5360 L 1,416 gal

• Hydraulically driven radiator fan with electronically controlled fan speed • Micro processed engine management • Heavy-duty air filters • Two-stage fuel filter, including water separator • Additional high-capacity water separator

Electric Motor – 6030 AC/6030 AC FS Type

3 ft 3 in 652,560 lb 32.1 psi

2 × Cat C27 (U.S. EPA Tier 2) 1,530 hp 1140 kW 1,800 min-1 1,800 min-1 1140 kW 1,530 hp 1,800 min-1 1,800 min-1 1140 kW 1,530 hp 1,800 min-1 1,800 min-1 12 137.7 mm 5.42 in 152.4 mm 6.0 in 27.0 L 1,648 in3 Turbocharged and charge air-cooled 1750 m 5,750 ft

Output Voltage Rated current IN Frequency Speed Starting current

Squirrel cage induction motor 1000 kW 6.3 kV ± 10% (other on request) 109A (at 6.3 kV) 50 Hz (60 Hz on request) 1,500 min-1 (1,800 min-1 at 60 Hz) 450% of IN (253% of IN optional)

• Custom-made electric motor with increased gap between rotor and stator to withstand severe mining conditions • Power limit control by Pump Managing System

24

Electrical System (diesel drive)

Hydraulic Oil Cooling

System voltage Batteries (12V each) in series/ parallel installation Working spotlights

Oil flow of cooling pumps Diesel version

24V 4 × 210 Ah 420 Ah – 24V 8 × high brightness Xenon lights

• Battery isolation relays • Emergency stop switches accessible from ground level and in engine module

Hydraulic System with Pump Managing System Main pumps Maximum oil flow Diesel version AC version Maximum pressure, attachment Maximum pressure, travel Swing pumps Maximum oil flow Diesel version AC version Maximum pressure, swing pumps Total volume of hydraulic oil – approximately Hydraulic tank capacity – approximately

4 × variable swash plate pumps 4 × 552 4 × 146 L/min gal/min 4 × 543 4 × 143 L/min gal/min 310 bar 4,495 psi 360 bar 5,220 psi 2 × reversible swash plate double pumps 2 × 394 L/min 2 × 426 L/min 350 bar 3500 L

2 × 104 gal/min 2 × 113 gal/min 5,080 psi 925 gal

2500 L

660 gal

• Pump Managing System contains: – Electronic load limit control – Flow on demand from main pumps depending on joystick position – Automatic regulation of main pumps to zero flow without demand – Automatic RPM reduction of engine speed during working breaks – Reduced oil flow of main pumps at high hydraulic oil temperature or at high engine temperature • Pressure cut-off for main pumps • Cooling of pump transmission gear oil • Filters: – Full-flow high-pressure filters (100 μm) for the main pumps, installed directly behind each pump – High pressure filters (100 μm) for the closed swing circuit – Full-flow filters (10 μm) for the complete return circuit – Full-flow filters (10 μm) for the cooling return circuit – Pressure filters (40 μm and 6 μm) for servo circuit – Transmission oil filters (40 μm)

AC version Diameter of fans

2 × 467 2 × 123 L/min gal/min 2 × 459 2 × 121 L/min gal/min 2 × 1220 mm 2 × 48 in

• Cooling system is fully independent of all main circuits, i.e. controlled cooling capacity is available whenever engine is running • Gear-type cooling pumps supplying high-volume, low-pressure oil to fans and aluminum coolers • Variable axial piston pumps supplying low-volume, high-pressure oil to fans • Fan speed is thermostatically controlled • Extremely high cooling efficiency to ensure optimum oil temperature

Swing System Swing drives

Parking brakes

Maximum swing speed Diesel version AC version Swing ring

2 compact planetary transmissions with axial piston motors Wet multiple-disc brake, spring-loaded/hydraulically released 4.6 rpm 5.0 rpm Triple-race roller bearing with sealed internal gearing

• Closed-loop swing circuit with torque control • Hydraulic braking of the swing motion by counteracting control • All raceways of swing ring as well as grease bath for internal gearing supplied by automatic, central lubrication system

Retractable Service Station Retractable service station installed underneath the engine module and easily accessible from ground.

Equipped with: • Quick couplings for: – Diesel fuel – Engine coolant – left/right – Pump transmission gear oil – left/right – Engine oil – left/right – Hydraulic oil tank – Grease container • Cat jump-start socket • Indicator lights for fuel tanks left/right full and grease container full

25

6030/6030 FS Hydraulic Shovel Specifications Operator’s Cab Operator’s eye level – approximately Internal dimensions of cab Length Width Height

Undercarriage 6.5 m

21 ft 4 in

2200 mm 1600 mm 2150 mm

7 ft 3 in 5 ft 3 in 7 ft 1 in

• Pneumatically cushioned and multi-adjustable comfort seat with lumbar support, seat heating, safety belt, head- and armrests • Switch in seat cushion to automatically neutralize the hydraulic controls when operator leaves the seat • Joystick controls integrated in independently adjustable seat consoles • Fold-away auxiliary seat with safety belt • FOPS (rock guard; approved according to DIN ISO 3449) integrated into cab structure • All-round safety glass, armored windshield and sliding side window • Windshield with parallel intermittent wiper/washer • Roller blind at windshield • Board Control System (BCS III): Electronic monitoring, data logging and diagnostic system for vital signs and service data of engines, hydraulic and lubrication system, featuring: – Robust instrument panel including large (12 in) colored touch screen for intuitive handling – On-screen PDF documentation (e.g. operating instructions, technical handbook, spare parts catalog, electric circuit diagram) – On-screen trouble shooting assistance – Graphic charts of logged data – Fault memory with storage of related conditions – USB, Lan (TCP/IP) and CAN BUS interfaces for data export • Machine access via retractable boarding ladder, hydraulically operated • Emergency exit harness kit

Travel speed (2 stages) 1st stage – maximum 2nd stage – maximum Maximum tractive force Gradeability of travel drives – approximate Track pads (each side) Bottom rollers (each side) Support rollers (each side) Travel drives (each side)

Parking brakes

1.4 km/h 2.7 km/h 1637 kN 64%

0.87 mph 1.68 mph 367,880 lbf

47 7 2 plus a skid plate in between 1 planetary transmission with 2 two-stage axial piston motors Wet multiple disc brake, spring loaded/hydraulically released

• Cast double-grouser combined pad-links with bushings connected by hardened full floating pins • All running surfaces of sprockets, idlers, rollers and pad links, as well as teeth contact areas of sprocket and pad links, are hardened • Fully hydraulic self-adjusting track tensioning system with membrane accumulator • Automatic hydraulic retarder valve to prevent over-speed on downhill travel • Acoustic travel alarm

Automatic Lubrication System Capacity of grease container

450 L

120 gal

• Dual-circuit system with hydraulically driven heavy-duty pump and electronic time relay control to adjust the pause/lube times • Connected to the lubrication system are the swing roller bearing with internal gearing and all pivot points of attachment, bucket and cylinders • System failures displayed by Board Control System • Grease filters (200 μm) between service station and container as well as directly behind grease pump

26

Attachments • Booms and sticks are torsion-resistant, welded box design of high-tensile steel with solid steel castings at pivot areas • Welding procedures allow for internal counter-welding (double prep weld) wherever possible • Booms and sticks are stress-relieved after welding • Catwalks with rails at boom (FS and BH) • Pressure-free lowering of boom (FS and BH) and stick (FS) by means of a float valve • Shovel attachment with unique TriPower kinematics ensuring the following main features: – Horizontal automatic constant-angle bucket guidance – Vertical automatic constant-angle bucket guidance – Automatic roll-back limiter to prevent material spillage – Kinematic assistance to hydraulic forces – Constant boom momentum throughout the whole lift arc – Crowd force assistance • All buckets (FS and BH) are equipped with a wear package consisting of: – Special liner material covering main wear areas inside and outside of bucket – Lip shrouds between teeth – Wing shrouds on side walls – Heel shrouds at bottom edges • Special wear packages for highly abrasive materials on request

Component Accessibility on Superstructure

4

4

2

1 3

8

7

5

6

2

9

1

3

11

10

12 Anti-slip walking areas Anti-slip catwalks

1 Diesel engines 2 Gearboxes with hydraulic pumps

7 Rotary distributor 8 Travel valves

3 Engine radiators with hydraulically driven fan 4 Oil coolers

9 Batteries 10 Operator’s seat

5 Hydraulic tank 6 Swing drives

11 BCS tower 12 Auxiliary seat

27

6030/6030 FS Hydraulic Shovel Specifications Dimensions All dimensions are approximate. Dimensions and weights of AC machine differs slightly. Separate drawings, dimensions and weights can be provided upon request.

10

8 11

9

14 1 3 2

4 5 12

6 7

13

1

6500 mm

21 ft 4 in

8

6450 mm

21 ft 2 in

2

2150 mm

7 ft 1 in

9

6310 mm

20 ft 8 in

3

4950 mm

16 ft 3 in

10

7110 mm

25 ft 4 in

4

1940 mm

6 ft 4 in

11

5300 mm

17 ft 5 in

5

880 mm

2 ft 11 in

12

1000 mm

3 ft 3 in

6

5980 mm

19 ft 8 in

13

5800 mm

19 ft 0 in

7

7630 mm

25 ft 0 in

14

7600 mm

24 ft 11 in

28

Working Range – TriPower Face Shovel Attachment (FS) All dimensions are approximate. ft 45

m 14 13

40 35

12 11 10

30 25

9 8 7

20 15 10 5 0 –5 –10

6 5 4 3 2 1 0 –1 –2 –3 15 14 13 12 11 10

9

8

50

30

25

45

40

35

7

6 20

5

4 15

3 10

2

1 5

0 m 0 ft

Boom

6.2 m

20 ft 4 in

Boom

6.2 m

20 ft 4 in

Stick

4.4 m

14 ft 5 in

Stick

4.4 m

14 ft 5 in

1320 kN 1210 kN 960 kN

296,640 lbf 271,920 lbf 215,740 lbf

Working Range Maximum digging height Maximum digging reach Maximum digging depth Maximum dumping height Crowd distance on level

13.9 m 13.7 m 2.5 m 10.7 m 4.9 m

45 ft 7 in 44 ft 11 in 8 ft 2 in 35 ft 1 in 16 ft 1 in

Digging Forces Maximum crowd force Maximum crowd force at ground level Maximum breakout force

Face Shovels Type Capacity heaped 1:1 Capacity heaped 2:1 Total width Inner width Opening width Number of teeth Weight including wear kit Maximum material density (loose)

Iron Ore Shovel 11.6 m3 (15.2 yd3) 10.0 m3 (13.1 yd3) 3620 mm (11 ft 11 in) 3220 mm (10 ft 7 in) 1680 mm (5 ft 6 in) 5 23 400 kg (51,590 lb) 3.2 t/m3 (5,390 lb/yd3)

Iron Ore Shovel 13.9 m3 (18.2 yd3) 12.0 m3 (15.7 yd3) 3900 mm (12 ft 10 in) 3500 mm (11 ft 6 in) 1790 mm (5 ft 10 in) 6 26 700 kg (58,860 lb) 2.6 t/m3 (4,210 lb/yd3)

Heavy Rock Shovel 15.4 m3 (20.1 yd3) 13.5 m3 (17.7 yd3) 3900 mm (12 ft 10 in) 3500 mm (11 ft 6 in) 1790 mm (5 ft 10 in) 6 27 300 kg (60,190 lb) 2.2 t/m3 (3,710 lb/yd3)

Heavy Rock Shovel 17.0 m3 (22.2 yd3) 15.0 m3 (19.6 yd3) 3900 mm (12 ft 10 in) 3500 mm (11 ft 6 in) 1790 mm (5 ft 10 in) 6 27 500 kg (60,630 lb) 2.0 t/m3 (3,370 lb/yd3)

Standard Rock Shovel 19.0 m3 (24.9 yd3) 16.5 m3 (21.6 yd3) 3900 mm (12 ft 10 in) 3500 mm (11 ft 6 in) 1790 mm (5 ft 10 in) 6 27 900 kg (61,510 lb) 1.8 t/m3 (3,030 lb/yd3) 29

6030/6030 FS Hydraulic Shovel Specifications Working Range – Backhoe Attachment (BH) All dimensions are approximate. ft 50 45 40 35 30 25 20 15 10 5 0 –5 –10 –15 –20 –25

m 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 –1 –2 –3 –4 –5 –6 –7 –8 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 m 60 55 50 45 40 35 30 25 20 15 10

5

0 ft

Boom

8.5 m

27 ft 11 in

Boom

8.5 m

27 ft 11 in

Stick

4.0 m

13 ft 9 in

Stick

4.0 m

13 ft 9 in

Digging Forces Maximum crowd force Maximum breakout force

880 kN 870 kN

197,760 lbf 195,520 lbf

Working Range Maximum digging depth Maximum digging reach Maximum digging height

6.2 m 15.1 m 13.8 m

20 ft 4 in 49 ft 6 in 45 ft 3 in

Backhoes Type Capacity heaped 1:1 Capacity heaped 2:1 Capacity struck Total width Inner width Number of teeth Weight including universal wear kit Maximum material density (loose)

30

Iron Ore Bucket 12.0 m3 (15.7 yd3) 10.9 m3 (14.3 yd3)

Heavy Rock Bucket 15.0 m3 (19.6 yd3) 13.4 m3 (17.5 yd3)

Standard Rock Bucket 17.0 m3 (22.2 yd3) 15.1 m3 (19.8 yd3)

9.6 m3 (12.6 yd3) 3450 mm (12 ft 2 in) 3000 mm (9 ft 10 in) 5 15 900 kg (35,050 lb) 2.6 t/m3 (4,380 lb/yd3)

11.8 m3 (15.4 yd3) 3880 mm (12 ft 9 in) 3430 mm (11 ft 3 in) 5 16 900 kg (37,260 lb) 2.0 t/m3 (3,370 lb/yd3)

13.2 m3 (17.3 yd3) 4360 mm (14 ft 4 in) 3930 mm (12 ft 11 in) 6 18 800 kg (41,450 lb) 1.8 t/m3 (3,030 lb/yd3)

General Packing List Crawler side frame with track pads (2 units, each) Gross weight

38 000 kg (83,770 lb)

1 Length

7700 mm (25 ft 3 in)

Width

1850 mm (6 ft 1 in)

2 Height

1950 mm (6 ft 5 in)

2 1

Undercarriage center frame with swing roller bearing Gross weight

25 000 kg (55,120 lb)

1 Length

5550 mm (18 ft 3 in)

Width

3400 mm (11 ft 2 in)

2 Height

1850 mm (6 ft 1 in)

2 1

Superstructure center frame Gross weight

34 750 kg (76,610 lb)

1 Length

8520 mm (27 ft 11 in)

Width

3120 mm (10 ft 3 in)

2 Height

2660 mm (8 ft 9 in)

2

1 Engine module with diesel engines Gross weight C27

25 800 kg (56,880 lb)

1 Length

3700 mm (12 ft 2 in)

Width

5300 mm (17 ft 5 in)

2 Height

3100 mm (10 ft 2 in)

2

1 Oil cooler module Gross weight

4900 kg (10,800 lb)

1 Length

3900 mm (12 ft 10 in)

Width

1550 mm (5 ft 1 in)

2 Height

2900 mm (9 ft 6 in)

2

1 Above values are approximate. Details may vary depending on scope of supply and destination. Exact data subject to selected machine configuration and final packing list.

31

6030/6030 FS Hydraulic Shovel Specifications General Packing List Cab pedestal module Gross weight

4830 kg (10,650 lb)

1 Length

3640 mm (11 ft 11 in)

Width

2000 mm (6 ft 7 in)

2 Height

3150 mm (10 ft 4 in)

2

1 Crate with cabin and FOPS Gross weight

3960 kg (8,730 lb)

1 Length

3500 mm (11 ft 6 in)

Width

2610 mm (8 ft 7 in)

2 Height

2870 mm (9 ft 5 in)

2

1 Counterweight including radiators Gross weight

33 500 kg (73,850 lb)

1 Length

1200 mm (3 ft 11 in)

Width

5300 mm (17 ft 5 in)

2 Height

3000 mm (9 ft 10 in)

2

1 Crates 1 Length

Width

2 Height

Gross Weight

2 Swing gears

1800 mm (4 ft 2 in)

1100 mm (5 ft 11 in)

2000 mm (6 ft 7 in)

2780 kg (6,130 lb)

Grease container with pump

1380 mm (4 ft 6 in)

1070 mm (3 ft 6 in)

2060 mm (6 ft 9 in)

840 kg (1,850 lb)

Barrels (hydraulic oil; grease; antifreeze)

2500 mm (8 ft 2 in)

1300 mm (4 ft 3 in)

1270 mm (4 ft 8 in)

1640 kg (3,620 lb)

Swing ring cover

2140 mm (7 ft 0 in)

2030 mm (6 ft 8 in)

1280 mm (4 ft 2 in)

600 kg (820 lb)

Retractable ladder

4400 mm (14 ft 5 in)

1100 mm (3 ft 7 in)

2000 mm (6 ft 7 in)

620 kg (1,370 lb)

Bolts

3400 mm (11 ft 2 in)

1250 mm (4 ft 1 in)

1370 mm (4 ft 6 in)

1920 kg (4,230 lb)

Content

2 1

Above values are approximate. Details may vary depending on scope of supply and destination. Exact data subject to selected machine configuration and final packing list.

32

TriPower Shovel Attachment Boom with main valve block, TriPower linkages and rods Gross weight

26 400 kg (58,200 lb) 2

1 Length

6700 mm (22 ft)

Width

2600 mm (8 ft 6 in)

2 Height

2850 mm (9 ft 4 in)

1

Stick Gross weight 1 Length Width 2 Height

8840 kg (19,490 lb)

2

4950 mm (16 ft 3 in) 1840 mm (6 ft)

1

1900 mm (6 ft 3 in)

Face shovel including pin for stick Capacity (2:1)

15.0 m3 (19.6 yd3)

16.5 m3 (21.6 yd3)

Gross weight

28 200 kg (62,170 lb)

28 600 kg (63,050 lb)

3650 mm (12 ft)

3900 mm (12 ft 10 in)

Width

3900 mm (12 ft 10 in)

3900 mm (12 ft 10 in)

2 Height

3600 mm (11 ft 10 in)

3600 mm (11 ft 10 in)

1 Length

2

1

Bundle with two stick cylinders Gross weight

2 3800 kg (8,380 lb)

1

1 Length

3950 mm (13 ft)

Width

1100 mm (3 ft 7 in)

2 Height

600 mm (2 ft)

Bundle with two bucket cylinders Gross weight

2 3800 kg (8,380 lb)

1

1 Length

3950 mm (13 ft)

Width

1100 mm (3 ft 7 in)

2 Height

600 mm (2 ft)

Crates with catwalks, railings and other parts Gross weight

1400 kg (3,090 lb)

4760 kg (10,490 lb)

1 Length

3250 mm (10 ft 8 in)

5000 mm (16 ft 5 in)

Width

1850 mm (6 ft 1 in)

1900 mm (6 ft 3 in)

2 Height

920 mm (3 ft)

1740 mm (5 ft 9 in)

2 1

Above values are approximate. Details may vary depending on scope of supply and destination. Exact data subject to selected machine configuration and final packing list.

33

6030/6030 FS Hydraulic Shovel Specifications Backhoe Attachment Monoboom with main valve block Gross weight

32 700 kg (72,090 lb)

1 Length

9400 mm (30 ft 10 in)

Width

2700 mm (8 ft 10 in)

2 Height

3800 mm (12 ft 6 in)

2

1 Stick with linkage and bucket cylinders Gross weight

16 200 kg (35,710 lb)

1 Length

6000 mm (19 ft 8 in)

Width

2100 mm (6 ft 11 in)

2 Height

2300 mm (7 ft 7 in)

2 1

Backhoe bucket including pin for stick Capacity (1:1)

15.0 m3 (19.6 yd3)

17.0 m3 (22.2 yd3)

Gross weight

17 600 kg (38,800 lb)

19 500 kg (42,990 lb)

1 Length

3800 mm (12 ft 6 in)

3850 mm (12 ft 8 in)

Width

3700 mm (12 ft 2 in)

4150 mm (13 ft 7 in)

2 Height

2900 mm (9 ft 6 in)

2900 mm (9 ft 6 in)

2

1

Bundle with two stick cylinders Gross weight

2 6350 kg (14,000 lb)

1 Length

4250 mm (13 ft 11 in)

Width

1200 mm (3 ft 11 in)

2 Height

1

610 mm (2 ft)

Crates with catwalks, railings and other parts Gross weight

3200 kg (7,050 lb)

1010 kg (2,230 lb)

1 Length

4950 mm (16 ft 3 in)

3250 mm (10 ft 8 in)

Width

1900 mm (6 ft 3 in)

1850 mm (6 ft 1 in)

2 Height

1900 mm (6 ft 3 in)

920 mm (3 ft)

2 1

Above values are approximate. Details may vary depending on scope of supply and destination. Exact data subject to selected machine configuration and final packing list.

34

6030/6030 FS Optional Equipment Optional Equipment Optional equipment may vary. Consult your Cat dealer for details.

GENERAL • Export crating • Finishing as per end user’s corporate colors SUPERSTRUCTURE • Mechanical service crane on superstructure • Hydraulic service crane on superstructure with auxiliary engine • Folding access stairway, stairway angle approximately 45°

• Round container with a standard 200 L (53 gal) grease barrel (instead of 450 L (119 gal) grease container) • Lubricated pinion for greasing of internal gearing of swing ring • Various cold-weather packages

UNDERCARRIAGE • Track pad width 800 mm (2 ft 7 in) or 1200 mm (3 ft 11 in) • Automatic lubrication of rollers by central lube system • Cover plate under carbody (belly plate)

CAB • Various heating and air-conditioning systems • Roller blinds at all windows • Outside-mounted sun shields

ATTACHMENT • Guards for shovel cylinders of FS attachment • Xenon lighting on boom • Special wear packages

Additional optional equipment available on request.

35

For more complete information on Cat products, dealer services, and industry solutions, visit us on the web at www.cat.com © 2013 Caterpillar Inc. All rights reserved Materials and specifications are subject to change without notice.

Featured machines in photos may include additional equipment.

See your Cat dealer for available options.

CAT, CATERPILLAR, SAFETY.CAT.COM, their respective logos, “Caterpillar Yellow” and the “Power Edge” trade dress, as well as corporate and product identity used herein, are trademarks of Caterpillar and may not be used without permission.

AEHQ6967 (05-2013)

BA 6030(3 847 020.00)-EN

Annex NOTES .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. 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.............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. ..............................................................................................................................................................................

5-3

BA 6030(3 847 020.00)-EN

Annex

5-4

BA 6030(3 847 020.00)-EN

Index 6 INDEX Operation and Maintenence Manual

Target group

Part 1 INTRODUCTION FUNDAMENTAL SAFETY INSTRUCTIONS

Operating personnel + Inspection and servicing personnel + Repair personnel

Part 2 OPERATION

Operating personnel The operating personnel must have knowhow relevant to the operation and the application of this or comparable machines.

Part 3 INSPECTION AND SERVICING

Inspection and servicing personnel

Part 4 REPAIR WORK

Repair personnel

The inspection and servicing personnel must have know-how relevant to the inspection and servicing of this or comparable machines.

The repair personnel must have know-how and experience relevant to the repair of this or comparable machines.

Part 5 ANNEX

Operating personnel + Inspection and servicing personnel + Repair personnel

Part 6 INDEX

Operating personnel + Inspection and servicing personnel + Repair personnel

6-1

BA 6030(3 847 020.00)-EN

Index

6-2

BA 6030(3 847 020.00)-EN

Index

A ABBREVIATIONS...................................... 5-33 Access ladder lighting................................ 2-20 Activating the electronic hydraulic shovel control .......................................................... 2-95 After daily operation ................................... 2-99 Air conditioner (optional) ............................ 2-81 Air-intake lines ........................................... 3-60 AIR-INTAKE SYSTEM............................... 3-57 Alternator - Instructions.............................. 3-67 Appropriate disposal of batteries ................. 4-6 ASSEMBLING WORKING EQUIPMENT SAFETY INSTRUCTIONS ................... 2-100 Automatic fire-extinguishing system .......... 2-32 Automatic fire-extinguishing system (optional 233 Automatic reset to idling ............................ 2-11 Avoid mixing of different hydraulic fluids... 3-32, 3-90

B Back-up heating (option), filling in fuel....... 2-67 Back-up heating (optional)......................... 2-83 Back-up heating operator’s cab (optional) . 2-82 Battery........................................................ 3-68 Battery isolator switch, shutting off supply voltage ......................................................... 2-28 Battery storage............................................. 3-4 BCS III, interfaces...................................... 5-20 BCS III, what’s that? .................................... 5-3 BCSIII, cleaning ......................................... 5-24 BCSIII, disposal ......................................... 5-24 BCSIII, the start screen................................ 5-5 Bearing races........................................... 3-117 Before starting work................................... 2-95 Board-control-system................................... 5-3 Board-Control-System (BCS) .................... 2-11 Brake chamber - Changing oil ................. 3-112 Brake chamber, Changing oil .................. 3-109 Braking the upperstructure ........................ 2-96 Breather filter ................................ 3-109, 3-112 Breather filter fuel tank, replace................. 3-63 Breather filter grease container, check / replace..................................................... 3-121 Breather filter, replace ............................... 3-85 Bypass valves (filter housing - cooling system), checking / replacing ............................... 3-84 Bypass valves (hydraulic oil reservoir), checking / cleaning .......................................... 3-82

C CENTRAL LUBRICATING system .......... 3-119 Central lubricating system – Fault table..... 5-30 Changing the hydraulic oil.......................... 3-90

Charging batteries inside the machine, safety instructions ............................................. 3-69 Checking the gas charging pressure in the pressure accumulator................ 3-116, 3-127 Checking the greasing pressure .............. 3-122 Checking the hydraulic oil level.................. 3-77 Checking the on-board crane................... 2-105 Cleaning the hydraulic oil cooler ................ 3-95 Code table screen ...................................... 5-19 Cold-starting fluid (ether) – Replacing the pressure vessel ............................................. 3-50 Combustion engine - Fault table ................ 5-26 confined spaces - Safety instructions .......... 4-4 Control and Monitoring Platform (CAMP) .. 2-10 Controls adjustment data screen ............... 5-13 Coolant for use on all combustion engines 3-39 Cooling liquid, change................................ 3-55 COOLING SYSTEM................................... 3-51 Cooling-liquid level check........................... 3-52 Corrosion protection for pins and bearings (bushings and hubs) ............................. 2-102 CRAWLER TRACKS ............................... 3-113

D Demand control / Zero-flow regulation....... 2-11 Depressurizing the hydraulic system ......... 3-76 DESCRIPTION OF THE hydraulic shovel ... 2-6 Design ...................................................... 3-119 Designated use, unauthorized use............... 1-4 Disposal at the end of the service life .......... 4-5 Drive........................................................... 2-10 Dust trap, cleaning ..................................... 3-57

E Electrical circuit diagrams .......................... 3-67 Electrical system ........................................ 2-11 ELECTRICAL SYSTEM ............................. 3-67 Electrical system - Safety instructions........ 3-67 Electrical system switch-cabinets .............. 3-67 Electronic hydraulic shovel control, clean / lubricate..................................................... 3-96 Emergency escape device / seat (optional 2-34 Emergency exit in operator’s cab and escape ladder...................................................... 2-23 Emergency lowering of the working equipment ................................................................ 2-98 Emergency off switch................................. 2-69 Emergency shut-off function ...................... 2-26 Engine ...................................................... 3-125 ENGINE ..................................................... 3-41 Engine - Safety instructions ....................... 3-41 Engine 1 (LH), control and monitoring ....... 2-45 Engine 2 (RH), control and monitoring....... 2-47 Engine data screen .................................... 5-10 Engine monitoring, Control lamps.............. 5-31 Engine oil filter, replace.............................. 3-48 Engine oil reservoir (optional), checking the oil level / topping up .................................... 3-43 3

BA 6030(3 847 020.00)-EN

Index Engine oil reservoir (optional), draining the oil off ........................................................... 3-46 Engine oil reservoir (optional), replacing the oil filters....................................................... 3-49 Engine oil, change ..................................... 3-44 Engine oil, checking the level / topping up. 3-42 Engines – adjusting the speed................... 2-79 Engines, emergency shut-off ..................... 2-74 Entering and leaving the machine Safety instructions................................................ 2-20 Extract from the German regulations....... 3-127

F FAULT TABLES......................................... 5-26 Filling........................................................ 3-121 Filling quantities - Grease .......................... 3-28 Filling quantities - oil .................................. 3-31 Filling quantities - other.............................. 3-31 Filter (servo control circuit) ........................ 3-86 Filter pump control, clean .......................... 3-89 Fire and explosion hazard .................. 1-11, 2-5 Fluid for hydraulic system .......................... 3-34 Folding ladder ............................................ 2-22 Fuel filter, replace ...................................... 3-61 Fuel preheating system (optional) ............. 2-76 FUEL SYSTEM.......................................... 3-61 Fuel system - Safety instructions............... 3-61 Fuel system, venting.................................. 3-63 Fuel tanks, cleaning................................... 3-63 Function ................................................... 3-120 Further machine documentation.................. 1-1

HYDRAULIC SYSTEM............................... 3-76 HYDRAULIC SYSTEM................................. 4-7 Hydraulic system - Safety instructions ....... 3-76

I Information given on the .............................. 5-9 Information given on the start screen, central section ...................................................... 5-7 Information given on the start screen, lower section ...................................................... 5-8 Information given on the start screen, top section............................................................ 5-6 Inspection and servicing - Safety instructions 33 Inspection and Servicing plans - Instructions. 39 inspection and servicing work, Fire and Explosion Hazard .............................................. 3-7 INSPECTION PLAN - OIL.......................... 3-29 Inspection plan – Oil (legend) .................... 3-30 Instructions on troubleshooting .................. 5-25

L Layout of the fault table.............................. 5-25 Lighting systems in LED technonogy, instructions ........................................................ 3-75 LUBRICANTS / consumables .................... 3-32 LUBRICATING CHART – GREASE .......... 3-27 Lubricating chart – Grease (legend) .......... 3-28 Lubrication data screen.............................. 5-12

G

M

Gas, dust, steam and smoke....................... 1-9 Grease filter replace (filling the grease container) ................................................... 3-124 Grease filter replace (Grease lines)......... 3-124 Grease for bearings, slew rings and track system (Central lubrication system) ............ 3-37 Grease for idlers, track rollers and support rollers (Lifetime lubrication) .................... 3-38

Main filter elements .................................... 3-58 Main filter elements, checking and cleaning .. 359 Maximum machine inclinations, information .. 284 Measures ................................................... 5-25 Monitoring cameras – function................. 2-106 Monitoring cameras (optional)) ................ 2-106 Monitoring, warning and control elements 2-103 MONITORING, WARNING AND CONTROL ELEMENTS ............................................ 2-38

H Heating and air conditioning .................... 3-125 High-pressure filter for working hydraulics, replace ................................................... 3-87 High-pressure filters for swing circuit, replace388 Hose line for oil and cooling liquid changes3-40 HYDRAULIC CIRCUIT DIAGRAM............. 5-32 Hydraulic data screen ................................ 5-11 Hydraulic equipment .................................. 1-10 Hydraulic hoses – Instructions..................... 4-7 Hydraulic ladder, pressure accumulator .. 3-126 Hydraulic shovel layout – undercarriage and working equipment ................................... 2-9 Hydraulic shovel layout - upperstructure...... 2-7 Hydraulic system........................................ 2-10 4

N Noise emission information.......................... 1-5 Notes................................ 1-13, 2-107, 3-6, 5-4 NOTES......................................................... 4-8 Notes on the selection of oils and greases 3-32

O Oil for swing gearboxes ............................. 3-36 Oilfilter replace (hydraulic circuit grease pump) .............................................................. 3-123 Oils for combustion engines....................... 3-33

BA 6030(3 847 020.00)-EN

Index Oils for pump drive gearboxes and travel gearboxes...................................................... 3-35 ON-BOARD CRANE (OPTIONAL) .......... 2-103 On-Board crane, – blocking the boom in position of rest ............................................ 2-105 On-Board crane, checking tightness of fastening bolts .................................................... 3-3 On-board crane, drive unit ........................... 3-2 On-board crane, drive unit ....................... 2-104 On-board crane, greasing............................ 3-2 On-board crane, putting into operation .... 2-104 Operating hours meter............................... 2-33 Operation - Safety instructions .................... 2-3 Operation and Maintenence Manual, where to store it in the operator’s cab..................... 2-4 Operator’s seat ....................................... 2-29 Organizational measures............................. 1-6 Other elements on the front side ................. 5-4 OTHER MAINTENANCE ......................... 3-125

P Plan A – E .................................................. 3-18 Plan N ........................................................ 3-13 Plan T and W ............................................. 3-16 Plan V ........................................................ 3-11 Possible causes......................................... 5-25 Pre-chamber / spur gear section, Changing the oil.......................................................... 3-108 Preface ........................................................ 1-1 Preheating system for engine and hydraulic oil (optional) ................................................ 2-75 Pressure accumulator - Emergency lowering 397 PRESSURE ACCUMULATORS - SAFETY INSTRUCTIONS ...................................... 4-8 Pressure-accumulator inspection regulations 3116 Pressure-accumulator inspection regulations 3127 Primary fuel filter, drain water .................... 3-62 Primary fuel filter, replace .......................... 3-62 Pump gearbox, change oil ......................... 3-99 Pump gearbox, checking the oil level / Topping up with oil ............................................... 3-98 Pump gearbox, venting............................ 3-100 PUMP TRANSFER GEARBOX ................. 3-98 Pump transfer gearbox lube oil filters ...... 3-101 PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING .... 3-4 Putting the hydraulic shovel out of operation3-4 Putting the machine back into operation, reset of emergency shut off function............... 2-27 PUTTING THE MACHINE INTO OPERATION ............................................................... 2-66

R Radiators ................................................... 3-52 Recommissioning ........................................ 3-4

Reducing the operator's exposure to noise 2-66 Reducing the operators exposure to vibrations ................................................................ 2-31 Refuelling ................................................... 2-67 Removing and installing the battery ........... 3-70 Repair instructions ....................................... 4-7 Repair work - Safety instructions ................. 4-3 repair work, ENGINE ................................... 4-6 repair work, Fire and Explosion Hazard ....... 4-5 Replacing lamps and bulbs ........................ 3-67 Replacing the bypass valves and sealing rings ................................................................ 3-82 Replacing the hydraulic oil return-flow filter (hydraulic oil reservoir) ........................... 3-79 Replacing the hydraulic oil return-flow filters (filter housing cooling system) ................ 3-83 Reservoirs for used grease at the A-frame, emptying ............................................... 3-126

S Safety filter element ................................... 3-60 Safety instructions governing specific operational phases ............................................ 1-7 Saving data to a USB stick......................... 5-21 Saving data to a USB stick, continued .. 5-22, 523 Section ....................................................... 5-25 Securing the machine .............................. 2-101 Selection and qualification of personnel; basic responsibilities .......................................... 1-7 Service station (tanklift).............................. 2-68 SERVICING WORK ................................... 3-40 Shutting off the engines ............................. 2-80 Signal table screen..................................... 5-15 Signal table screen, diagram ..................... 5-17 Signal table screen, diagram configuration 5-18 Signal table screen, location ...................... 5-16 Signs .......................................................... 2-12 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 Starter isolator switch, shutting off starter voltage.......................................................... 2-28 Starting and stopping the engines.............. 2-78 Starting the engines ................................... 2-78 Starting the engines at low temperatures .. 2-79 SWING GEARBOX ....................... 3-102, 3-104 Swing gearbox venting............................. 3-103 Swing gearbox, changing oil .................... 3-103 Swing gearbox, checking the oil level / Topping up with oil................................... 3-102, 3-104 Swing gearbox, hanging oil ...................... 3-105 Swing gearbox, venting............................ 3-106 Swing mechnism – Fault table ................... 5-29 SWING RING........................................... 3-117 Swing ring - Instructions........................... 3-117 Swinging ladder (optional).......................... 2-21 Swinging the upperstructure ...................... 2-96 Switchgear cabinet, aeration...................... 3-71 5

BA 6030(3 847 020.00)-EN

Index Switching the cab interior lighting on and off . 224 Switching the electrical system on and off. 2-74 Switching the maintenance lights on and off . 225

T TECHNICAL DATA...................................... 5-2 Temperature .............................................. 3-51 Testing the cooling liquid composition ....... 3-56 The keys on the front side ........................... 5-4 Track drive – Fault table ............................ 5-28 Track parking brake................................... 2-91 Track roller, Support roller ....................... 3-114 Track tensioner ........................................ 3-115 Trainer's / instructor's seat......................... 2-31 Transport - Safety instructions................... 2-92 Transporting the machine.......................... 2-92 Travel gearbox - Changing oil.................. 3-111 Travel gearbox - Checking the oil level / Topping up with oil...................................... 3-110 TRAVEL GEARBOX P/N 2712182 .......... 3-107 TRAVEL GEARBOX P/N 3683493 .......... 3-110 Travel gearbox, changing oil.................... 3-108 Travel gearbox, checking the oil level / Topping up with oil ............................................. 3-107 TRAVELLING ............................................ 2-87 Travelling forwards/backwards .................. 2-87 TRAVELLING, SAFETY INSTRUCTIONS 2-86 TROUBLESHOOTING .............................. 5-25

U

6

Unblocking a grease line.......................... 3-122 Undercarriage ............................................ 2-10 Upperstructure ........................................... 2-10 Upperstructure basic position .................... 2-87 Upperstructure holding brake..................... 2-91 USB interface, data storage....................... 5-20

V Venting the hydraulic system ..................... 3-94 Vibration information .................................... 1-5 View documents screen............................. 5-14

W Warning of special dangers ......................... 1-9 Warnings and symbols................................. 1-3 Warranty ...................................................... 1-2 Water trap (optional) .................................. 3-65 Welding and flame cutting works - Safety instructions .................................................. 4-2 Windscreen washer ................................... 2-33 Working...................................................... 2-97 Working hydraulics – Fault table................ 5-27 WORKING OPERATION ........................... 2-95 Working operation - Safety instructions ..... 2-93

X Xenon floodlight projector, replacing the lamp373

BA 6030(3 847 020.00)-EN

Index

6-2

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