CAT 6030AC 6030ACFS Hydraulic Shovel Operation & Maintenance Manual - PDF DOWNLOAD

OMM 6030AC, 6030ACFS(3 847 030.00)-EN 07 / 2014

Operation and Maintenance Manual 6030AC, 6030ACFS Hydraulic Shovel

No.

OMM 6030AC, 6030ACFS(3 847 030.00)-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 documentation-HEX@cat.com https://mining.cat.com www.bucyrus-hex.de

© Copyright Caterpillar Global Mining Hydraulic Mining Shovels GmbH 2014. 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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OMM 6030AC, 6030ACFS(3 847 030.00)-EN

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

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 Part 4 REPAIR WORK

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

Repair personnel 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 ________________________________________________________________________ 1-3 Further machine documentation ______________________________________________________ 1-3 WARRANTY ______________________________________________________________________ 1-4 FUNDAMENTAL SAFETY INSTRUCTIONS _____________________________________________ 1-5 Warnings and symbols _____________________________________________________________ 1-5 DESIGNATED USE _________________________________________________________________ 1-6 ORGANIZATIONAL MEASURES ______________________________________________________ 1-7 Selection and qualification of personnel; basic responsibilities ______________________________ 1-8 Safety instructions governing specific operational phases __________________________________ 1-8 Special work in conjunction with utilization of the machine and maintenance and repairs as well as troubleshooting during work; disposal of parts and consumables ____________________________ 1-9 Warning of special dangers ________________________________________________________ 1-10 Gas, dust, steam and smoke _______________________________________________________ 1-11 Hydraulic / pneumatc equipment ____________________________________________________ 1-11 Noise __________________________________________________________________________ 1-11 Oil, grease and other chemical substances ____________________________________________ 1-11 Transporting and recommissioning __________________________________________________ 1-11 ACCIDENT PREVENTION REGULATIONS FOR ELECTRICALLY POWERED SHOVELS________ 1-12 Safety instructions for shovels with electric motor _______________________________________ 1-13 FIRE AND EXPLOSION HAZARD ____________________________________________________ 1-14 NOTES _________________________________________________________________________ 1-15 2 OPERATION ______________________________________________________________________ 2-1 OPERATION - SAFETY INSTRUCTIONS _______________________________________________ 2-3 Operating Instructions, where to store it in the operator’s cab _______________________________ 2-4 FIRE AND EXPLOSION HAZARD _____________________________________________________ 2-5 DESCRIPTION OF THE SHOVEL _____________________________________________________ 2-6 Shovel layout ____________________________________________________________________ 2-7 Undercarriage ____________________________________________________________________ 2-8 Superstructure ___________________________________________________________________ 2-8 Drive ___________________________________________________________________________ 2-8 Hydraulic system _________________________________________________________________ 2-8 Pump Managing System (PMS) ______________________________________________________ 2-8 Stored Program Control (SPC) _______________________________________________________ 2-8 Control Management System (CMS) __________________________________________________ 2-8 Demand control / Zero-flow regulation _________________________________________________ 2-9 Board-Control-System (BCS) ________________________________________________________ 2-9 Electrical system __________________________________________________________________ 2-9 Signs __________________________________________________________________________ 2-11 Entering and leaving the machine, Safety instructions ____________________________________ 2-19 Access lighting __________________________________________________________________ 2-19 Swinging ladder _________________________________________________________________ 2-20

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OMM 6030AC, 6030ACFS(3 847 030.00)-EN

TABLE OF CONTENTS Folding ladder (optional) ___________________________________________________________ 2-21 Cab interior lamp ________________________________________________________________ 2-22 Servicing lighting _________________________________________________________________ 2-23 Illuminating the control column ______________________________________________________ 2-23 EMERGENCY STOP switch ________________________________________________________ 2-24 Servicing switch _________________________________________________________________ 2-25 Windscreen washer ______________________________________________________________ 2-25 Operator's seat __________________________________________________________________ 2-26 Fire extinguisher _________________________________________________________________ 2-28 Automatic fire-extinguishing system (optional) __________________________________________ 2-29 Trainer's / instructor's seat _________________________________________________________ 2-29 Emergency escape device (optional) _________________________________________________ 2-30 MONITORING, WARNING AND CONTROL ELEMENTS __________________________________ 2-34 PUTTING THE MACHINE INTO OPERATION ___________________________________________ 2-57 Service station (tanklift) ___________________________________________________________ 2-57 Battery main switch, switching on and off______________________________________________ 2-60 Electrical system (24V), switching on and off ___________________________________________ 2-60 Switching the electric motor on and off________________________________________________ 2-61 Time-out before restart ____________________________________________________________ 2-62 Electric motor can not be switched on ________________________________________________ 2-63 In case of failure _________________________________________________________________ 2-63 Circuit breaker, switching on and off _________________________________________________ 2-64 Motor protection relay, function _____________________________________________________ 2-66 Warm-up procedure for electric shovels _______________________________________________ 2-68 Air conditioner (option) ____________________________________________________________ 2-69 TRAVELLING THE MACHINE _______________________________________________________ 2-70 Travelling, Safety Instructions ______________________________________________________ 2-70 Travelling ______________________________________________________________________ 2-71 Emergency machine drive _________________________________________________________ 2-75 Locking the superstructure _________________________________________________________ 2-77 Track parking brake ______________________________________________________________ 2-77 TRANSPORTING THE MACHINE ____________________________________________________ 2-78 Transport - Safety instructions ______________________________________________________ 2-78 WORKING OPERATION - SAFETY INSTRUCTIONS _____________________________________ 2-79 Working equipment, avoid extreme positions ___________________________________________ 2-80 WORKING OPERATION ____________________________________________________________ 2-81 Before starting work ______________________________________________________________ 2-81 Swinging the superstructure ________________________________________________________ 2-81 Braking the superstructure _________________________________________________________ 2-81 Working ________________________________________________________________________ 2-82 Emergency lowering of the working equipment _________________________________________ 2-83 After daily operation ______________________________________________________________ 2-83 ASSEMBLING WORKING EQUIPMENT - SAFETY INSTRUCTIONS_________________________ 2-84 Securing the machine _____________________________________________________________ 2-85

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OMM 6030AC, 6030ACFS(3 847 030.00)-EN

TABLE OF CONTENTS CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS) ____________ 2-86 ON-BOARD CRANE (OPTIONAL) ____________________________________________________ 2-87 On-board crane, monitoring, warning and control elements _______________________________ 2-87 On-board crane, putting into operation ________________________________________________ 2-88 On-board crane, drive unit _________________________________________________________ 2-88 On-Board crane, – blocking the boom in position of rest __________________________________ 2-89 On-board crane, checking _________________________________________________________ 2-89 Monitoring cameras ______________________________________________________________ 2-90 NOTES _________________________________________________________________________ 2-91 3 INSPECTION AND SERVICING _______________________________________________________ 3-1 SAFETY INSTRUCTIONS FOR SHOVELS WITH ELECTRIC MOTOR ________________________ 3-3 INSPECTION AND SERVICING - SAFETY INSTRUCTIONS ________________________________ 3-5 FIRE AND EXPLOSION HAZARD ____________________________________________________ 3-11 INSPECTION AND SERVICING PLANS - INSTRUCTIONS ________________________________ 3-13 Intervals _______________________________________________________________________ 3-13 Oils / Greases ___________________________________________________________________ 3-13 Cleaning jobs ___________________________________________________________________ 3-13 Components ____________________________________________________________________ 3-13 Plan V _________________________________________________________________________ 3-15 Plan N _________________________________________________________________________ 3-17 Plan T and W ___________________________________________________________________ 3-19 Plan A – E ______________________________________________________________________ 3-21 LUBRICATING CHART – GREASE ___________________________________________________ 3-26 Lubricating chart – Grease (legend) __________________________________________________ 3-26 Filling quantities – Grease _________________________________________________________ 3-27 INSPECTION PLAN - OIL ___________________________________________________________ 3-28 Inspection plan – Oil (legend) _______________________________________________________ 3-29 Filling quantities - oil ______________________________________________________________ 3-30 Filling quantities - other____________________________________________________________ 3-30 LUBRICANTS ____________________________________________________________________ 3-31 Notes on the selection of oils and greases _____________________________________________ 3-31 Avoid mixing of different hydraulic fluids ______________________________________________ 3-31 II. Oil for hydraulic system ______________________________________________________ 3-32 III.a Oils for pump gearbox _______________________________________________________ 3-33 III.b Oils for swing gearboxes _____________________________________________________ 3-34 III.c Oils for travel gearboxes _____________________________ Fehler! Textmarke nicht definiert.

V. Greases for bearings and slewing rings _________________ Fehler! Textmarke nicht definiert.

SERVICING WORK ________________________________________________________________ 3-37 Hose line for oil change ___________________________________________________________ 3-37 ELECTRIC MOTOR _______________________________________________________________ 3-38 Electric motor - Safety instructions ___________________________________________________ 3-38 Cleaning the electric motor _________________________________________________________ 3-38 Electric motor, greasing ___________________________________________________________ 3-39

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OMM 6030AC, 6030ACFS(3 847 030.00)-EN

TABLE OF CONTENTS ELECTRICAL SYSTEM _____________________________________________________________ 3-40 Electrical system - Safety instructions ________________________________________________ 3-40 Battery_________________________________________________________________________ 3-41 Switchgear cabinet _______________________________________________________________ 3-43 Slip ring maintenance _____________________________________________________________ 3-46 Floodlight projector, replacing the lamp _______________________________________________ 3-47 HYDRAULIC SYSTEM _____________________________________________________________ 3-49 Hydraulic system - Safety instructions ________________________________________________ 3-49 Depressurizing the hydraulic system _________________________________________________ 3-49 Checking the hydraulic oil level _____________________________________________________ 3-50 Changing the hydraulic oil return-flow filter (hydraulic oil reservoir) __________________________ 3-52 Bypass valves (hydraulic oil reservoir) ________________________________________________ 3-54 Replacing the hydraulic oil return-flow filters (filter housing) _______________________________ 3-55 Bypass valves (filter housing - cooling system) _________________________________________ 3-56 Breather filter ___________________________________________________________________ 3-57 Filter (control circuit and auxiliary control circuit) ________________________________________ 3-58 High-pressure filter for working hydraulics _____________________________________________ 3-59 High-pressure filters for slewing circuit ________________________________________________ 3-60 High-pressure filters for feeding circuits and slewing pumps _______________________________ 3-61 Changing the hydraulic oil _________________________________________________________ 3-62 Venting the hydraulic system _______________________________________________________ 3-65 Cleaning the hydraulic oil cooler _____________________________________________________ 3-66 Electronic shovel control ___________________________________________________________ 3-67 Pressure accumulator - Emergency lowering ___________________________________________ 3-68 Pressure accumulator – Servo control- and feeding circuit ________________________________ 3-68 PUMP DRIVE GEARBOX ___________________________________________________________ 3-70 Checking the gearbox oil level / Topping up with oil _____________________________________ 3-70 Gearbox venting _________________________________________________________________ 3-72 Pump drive gearbox lube oil filters ___________________________________________________ 3-73 SLEWING GEARBOX ______________________________________________________________ 3-74 Gearbox - Checking the oil level / Topping up with oil ____________________________________ 3-74 Changing the gearbox oil __________________________________________________________ 3-74 Gearbox venting _________________________________________________________________ 3-75 SWING GEARBOX ________________________________________________________________ 3-76 Gearbox - Checking the oil level / Topping up with oil ____________________________________ 3-76 Changing the gearbox oil __________________________________________________________ 3-77 Gearbox venting _________________________________________________________________ 3-78 TRAVEL GAERBOX _______________________________________________________________ 3-79 Gearbox - Checking the oil level / Topping up with oil ____________________________________ 3-79 Travel gearbox - Changing oil ______________________________________________________ 3-80 Pre-chamber - Changing the oil ____________________________ Fehler! Textmarke nicht definiert.

Brake chamber - Changing oil ______________________________________________________ 3-81 Breather filter ___________________________________________________________________ 3-81 CRAWLER TRACKS _______________________________________________________________ 3-82 Track roller, Support roller _________________________________________________________ 3-83 Track tensioner __________________________________________________________________ 3-84 Pressure-accumulator inspection regulations___________________________________________ 3-85 Checking the gas charging pressure in the pressure accumulator __________________________ 3-85

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OMM 6030AC, 6030ACFS(3 847 030.00)-EN

TABLE OF CONTENTS SWING RING_____________________________________________________________________ 3-86 Swing ring - Instructions ___________________________________________________________ 3-86 Bearing races ___________________________________________________________________ 3-86 CENTRAL LUBRICATING___________________________________________________________ 3-88 Design _________________________________________________________________________ 3-88 Function _______________________________________________________________________ 3-89 Replacing the grease drum ________________________________________________________ 3-90 Checking the greasing pressure _____________________________________________________ 3-91 Unblocking a grease line. __________________________________________________________ 3-91 Oilfilter (hydraulic circuit grease pump) _______________________________________________ 3-92 Grease filter (grease lines) _________________________________________________________ 3-93 OTHER MAINTENANCE ____________________________________________________________ 3-94 Cleaning the cooling system ________________________________________________________ 3-94 Heating and air conditioning ________________________________________________________ 3-94 Air intake filters __________________________________________________________________ 3-94 HYDRAULIC LADDER _____________________________________________________________ 3-95 Pressure-accumulator inspection regulations___________________________________________ 3-96 Extract from the German regulations _________________________________________________ 3-96 Checking the gas charging pressure in the pressure accumulator __________________________ 3-96 PUTTING THE SHOVEL OUT OF OPERATION AND RECOMMISSIONING ___________________ 3-97 Putting the shovel out of operation ___________________________________________________ 3-97 Battery storage __________________________________________________________________ 3-97 Recommissioning ________________________________________________________________ 3-98 NOTES __________________________________________________________________________ 3-1 4 REPAIR WORK ____________________________________________________________________ 4-1 SAFETY INSTRUCTIONS FOR SHOVELS WITH ELECTRIC MOTOR ________________________ 4-3 REPAIR WORK - SAFETY INSTRUCTIONS _____________________________________________ 4-4 FIRE AND EXPLOSION HAZARD _____________________________________________________ 4-5 HYDRAULIC SYSTEM ______________________________________________________________ 4-6 Repair __________________________________________________________________________ 4-6 Hydraulic hoses – Instructions _______________________________________________________ 4-6 PRESSURE ACCUMULATORS - SAFETY INSTRUCTIONS ________________________________ 4-7 WELDING AND FLAME CUTTING WORKS - SAFETY INSTRUCTIONS _______________________ 4-8 DISPOSAL AT THE END OF THE SERVICE LIFE _______________________________________ 4-11 Appropriate disposal of batteries ____________________________________________________ 4-12 NOTES _________________________________________________________________________ 4-13 5 ANNEX __________________________________________________________________________ 5-1 TROUBLESHOOTING ______________________________________________________________ 5-3 Instructions on troubleshooting _______________________________________________________ 5-3 Layout of the fault table ____________________________________________________________ 5-3 Possible causes __________________________________________________________________ 5-3 Measures _______________________________________________________________________ 5-3 ix

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

TABLE OF CONTENTS Section _________________________________________________________________________ 5-3 FAULT TABLES ___________________________________________________________________ 5-4 Working hydraulics – Fault table _____________________________________________________ 5-4 Track drive – Fault table ____________________________________________________________ 5-5 Swing mechnism – Fault table _______________________________________________________ 5-6 Central lubricating system – Fault table ________________________________________________ 5-7 HYDRAULIC CIRCUIT DIAGRAM _____________________________________________________ 5-8 ABBREVIATIONS __________________________________________________________________ 5-9 NOISE AND VIBRATION INFORMATION ______________________________________________ 5-11 Noise emission information_________________________________________________________ 5-11 Vibration information ______________________________________________________________ 5-11 PRODUCT SPECIFICATION SHEET __________________________________________________ 5-12 NOTES _________________________________________________________________________ 5-13 6 INDEX ___________________________________________________________________________ 6-1

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OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INTRODUCTION 1 INTRODUCTION Operation and Maintenance 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 Part 4 REPAIR WORK

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

Repair personnel 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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OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INTRODUCTION

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OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INTRODUCTION PREFACE This Operation and Maintenance Manual is designed to familiarize the operator with the machine and its designated use.

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

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

The Operation and Maintenance Manual must be read and put into practice by any person in charge of carrying out work with or on the machine, such as operation, including setting-up, troubleshooting in the course of work, care, evacuation of production waste and disposal of fuels and consumables, maintenance (inspection, servicing, repair) and / or transport.

In addition to the Operation and Maintenance 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 Maintenance 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 (Caterpillar Global Mining Hydraulic Mining Shovels 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 Maintenance Manual.

All CGM HMS GmbH Operation and Maintenance 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 Maintenance 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 Maintenance 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 Maintenance Manual, Volume 2: spare-parts list of the machine, Volume 3: crossreference list of spare-parts, Volume 4: electrical circuit diagram and key, Volume 5: documentation of the engine and of other components, Volume 6: Service Manual Part 1 Volume 7: Service Manual Part 2 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 Maintenance 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.

1 Complies with VDMA recommendation "Operation and Maintenance Manual"

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OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INTRODUCTION WARRANTY The warranty of CGM HMS GmbH presupposes among other things that the servicing works as described in the Operation and Maintenance Manual have been performed: by the CGM HMS GmbH Service 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 Service checklists.

Do not operate the machine when components / assemblies are defective or missing, 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 the CGM HMS GmbH Service.

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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OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INTRODUCTION FUNDAMENTAL SAFETY INSTRUCTIONS Complies with VDMA recommendation "Operating Instructions"

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

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

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OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INTRODUCTION DESIGNATED 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) 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 Maintenance 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.

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

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, for fitting or reparing of other machines is contrary to its designated use and considered as "unauthorized use".

gravel, blasted rock, ore, 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 Maintenance Manual and complying with the inspection and maintenance directives.

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Lifting eyes on the lower carriage - are settled for transporting with a crane only.

- must not be used for towing a machine.

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.

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INTRODUCTION ORGANIZATIONAL MEASURES The Operation and Maintenance 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 Maintenance 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 Maintenance 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 Maintenance Manual and in particular the chapter on safety before beginning work. Reading the Operation and Maintenance 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 Maintenance 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 Maintenance 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.

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OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INTRODUCTION Selection and qualification of personnel; basic responsibilities

Safety instructions governing specific operational phases

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

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.

Standard operation

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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.

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

Start the machine from the operator's seat only.

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

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INTRODUCTION 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.

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 Maintenance 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 safety-oriented 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 Maintenance 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.

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 pre-

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OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INTRODUCTION servatives 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.

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.

Warning of special dangers Electric energy 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 require a high-voltage supply (ca. 25 kV).

The high voltage is generated by a ballast unit.

Switch off the electrical system of the 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

1-10

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INTRODUCTION Gas, dust, steam and smoke

Noise

Always start and operate the engine in a wellvented area; 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).

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).

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

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

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

Hydraulic- and pneumatic 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.

1-11

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INTRODUCTION ACCIDENT PREVENTION REGULATIONS FOR ELECTRICALLY POWERED SHOVELS The safety and accident-prevention regulations valid in the respective country must be observed.

The following requirements are based on extracts from the German accident prevention regulations "Electrical Systems (BGV A3)".

The installation, modification and repair of the electromechanical component of electrical systems and components must be delegated only to qualified electricians or firms employing such experts.

A "qualified electrician" in the context of this regulation is a person who, on the basis of specialized training, know-how and experience as well as knowledge of the relevant regulations, is in a position to judge the extent of the work assigned to him and to recognize any potential hazards.

The machine owner/contractor must inform all persons working on electrical installations and components or in the vicinity of components conducting electricity during operation, or who are responsible for the operation of electrical systems, of the potential danger of electricity and must instruct them on the accident prevention regulations relevant to their work. Instruction in safety measures is to be repeated at intervals appropriate to the operating conditions. If necessary, special working regulations must be displayed.

The shovel and its electrical systems must be adequately protected against other potential hazards of electricity, e.g. fire and explosion.

Electrical systems and components must be protected against electric shock in the case of a fault, e.g. short circuit to exposed conductive part.

1-12

Any parts of the electrical system conducting current when in operation must be housed in lock-up switchgear cabinets. Hazard warning signs are displayed on these lock-up cabinets.

VOLTAGE HAZARD The switchgear cabinets must be secured against unauthorized opening. The key must be kept by the electrician in charge.

Electrical systems and components must not be used unless they comply with the operational and local safety requirements. They must be in an orderly state and must be kept in such a state.

Any defects or malfunctions occurring in electrical systems or components must be reported to the electrician in charge.

Before switching on any systems, the shovel operator must check that no one is working on the machine or its electrical systems.

The heavy-duty power cable must never be driven over, buried or ripped away. The shovel equipment must never be set down on the power cable. When the shovel is being moved, the cable must never be pulled or dragged over the ground.

Whenever work is being carried out on electrically powered shovels, the general rules of engineering especially those concerning low and medium voltage - must be observed. Regulations such as those issued by the German VDE, e.g. specification VDE 0100, should be observed. Observe all the related laws and rules in your state or country.

Before commencing any work on electrical systems and components, the electrician in charge (or an electrician appointed by him) must switch the power off all circuits and lock them in the OFF state as follows: Switch voltage OFF all systems.

Check with voltage detectors that all systems are voltage-free.

Lock switches/systems to prevent them from being switched ON. The above procedures must be carried out in the given sequence.

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INTRODUCTION The machine contractor must provide all the necessary protective equipment and adopt the necessary safety procedures. He must ensure that the safety equipment is used and the safety procedures observed.

The shovel operator and all personnel working on the shovel must use the protective equipment and carry out the specified safety procedures.

It is absolutely forbidden to work on any systems or components while they are conducting current. Fatal injury can occur.

If work has to be done in special cases on systems or components conducting current, appropriate safety measures must be taken. Work must not be done on "live" systems and components except by the electrician in charge. The machine contractor must also be notified.

The shovel and its electrical systems must not be switched on again until the above safety procedures have been cancelled and all working areas are prepared for the resumption of operations. Start-up can be ordered only by the person in charge (qualified electrician). Time-based switch-on agreements are absolutely forbidden.

Safety instructions for shovels with electric motor Before carrying out any maintenance and repair work on the electrical system, the following precautions must be taken:

In the transformer station Switch off the supply voltage Lock the safety device preventing switch-on; apply a warning sign Check that the electrical system is off circuit and dead Connect to earth and short-circuit Protect adjacent and live parts against accidental contact

On the shovel Switch off the switch-disconnector Lock the safety device preventing switch-on; apply a warning sign Remove the cover Check that the electrical system is off circuit and dead Connect to earth and short-circuit Slide the partition into the disconnector housing

1-13

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INTRODUCTION FIRE AND EXPLOSION HAZARD Prior to commencing work, obtain informationon the national and corporate rules for the prevention of accidents.

Pay particular attention to hazards caused by combustible and easily flammable substances.on the safe handling of the fire extinguishers to be used.

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

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

Do not store or handle any flammable substances during operation.

Clean the shovel thoroughly, if possible, with a steam jet (rubber parts and electric components with compressed air - refer to information label), when, for example, oil, grease, fuel or cleaner was spilled.

Such substances may spontaneously ignite if they get into the vicinity of hot units or objects such as turbo superchargers.

Even battery gases can ignite in open flames or fire.

Avoid parking the shovel in places where combustible substances such as coal dust or tar are present. open or smouldering fire may occur.

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

1-14

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.

Ensure sufficient ventilation.

Clean the 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.

DANGER TO LIFE Call the fire brigade.

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

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INTRODUCTION NOTES ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... 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1-15

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INTRODUCTION

1-16

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

OPERATION 2 OPERATION Operating instructions

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 Part 4 REPAIR WORK

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

Repair personnel 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

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

OPERATION

2-2

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

OPERATION OPERATION - SAFETY INSTRUCTIONS Operating instructions Never operate the machine before having read and understood the operating instructions.

Safety belt For machines with a safety belt for operating personnel: Check the safety belt attached to the operator's seat. In the event of damage or after an accident, have it replaced immediately.

Apply the safety belt before starting work.

State of the machine 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 operating instructions 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 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.

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

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.

Entering and leaving the machine Always face the machine when entering or leaving it.

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

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.

2-3

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

OPERATION 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.

Persons within the hazard zone

Operating Instructions, where to store it in the operator’s cab One copy of the Operating Instructions for the machine must be available in the operator’s cab during operation.

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

Always use the horn to warn persons in the immediate vicinity of the machine before starting up the machine.

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

Marshallers The marshaller must keep outside the hazard zone.

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:

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

OPERATION FIRE AND EXPLOSION HAZARD Safety instructions Prior to commencing work, obtain information on the national and corporate rules for the prevention of accidents.

Pay particular attention to hazards caused by combustible and easily flammable substances.on the safe handling of the fire extinguishers to be used.

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

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

Do not store or handle any flammable substances during operation.

Clean the shovel thoroughly, if possible, with a steam jet (rubber parts and electric components with compressed air - refer to information label), when, for example, oil, grease, solvent or cleaner was spilled.

Such substances may spontaneously ignite if they get into the vicinity of hot units or objects.

Even battery gases can ignite in open flames or fire.

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

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.

Ensure sufficient ventilation.

Clean the 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 burning oil over a wide area. Water causes short-circuits in the electrical system thus possibly entailing new hazards.

DANGER TO LIFE Call the fire brigade.

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

open or smouldering fire may occur.

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

2-5

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

OPERATION DESCRIPTION OF THE SHOVEL

Fig. 2-2:

2-6

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

OPERATION Shovel layout

35 - Fire-extinguisher

see Fig. 2-2:

36 - Batteries

Undercarriage

37 - Control-cabinet with CMS

1 - Track drive

38 - Control-cabinet (24 V) with battery main

2 - Idler

switch

3 - Track roller

39 – Control-cabinet, pre-heating system

4 - support roller

40 – Control cabinet, reactive currant

5 - Crawler track

compensation (optional)

6 - Track tensioner

41 - Service station

7 - Slewing ring

42 – On-board crane (optional)

8 - Ladder

44 - Grease container of central lubricating sys-

9 - Slip ring assembly

tem

10 - Cable guide for drag cable

46 - Ladder

Superstructure

47 - Ladder

11 - Elektric motor

49 - Counterweight

12 - Switchgear cabinets (DER I and II, medium

Loading bucket

voltage, circuit breaker)

51 - Boom

13 - Switchgear cabinet

52 - TriPower linkage

15 - Switchgear cabinet and battery charger

53 - Stick

17 - Hydraulic oil reservoir

54 - Bottom-dump bucket

18 - Hydraulic oil cooler

55 - Boom cylinder

20 - Pump drive gearbox

56 - Stick cylinder

21 - Working pump

57 - Tipping cylinder

22 - Cooling oil pump

58 - Bottom-dump cylinder

23 - Servo system pump

64 - Control valves

24 - Gearbox circulating pump

65 - Quick-action valve

25 – Fan drive (hydraulic oil cooler) 27 - Slewing pump 28 – Filling pump (slewing circuit) 29 - Slewing gear 30 - Travel block and rotor 31 - Operator's cab 32 - Control stand with BCS 34 - Air conditioner

2-7

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

OPERATION Undercarriage

Stored Program Control (SPC)

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 superstructure are connected by means of a slewing ring.

The SPC controls the functions:

Superstructure The superstructure accommodates the drive and part of the hydraulic and electrical equipment.

Drive The drive unit comprises electric motor, 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 superstructure 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.

Pump Managing System (PMS) The Pump Managing System (PMS) with overlimit regulation ensures optimum utilization of the installed or preset engine power. The electronic pump demand control prevents the machine from demanding more hydraulic power than the electric motor can furnish. A microprocessor ensures that the hydraulic output power of the pump is optimally suited to the actual operation conditions.

The PMS box (load-limit regulator) is installed in a control cabinet in the operator's cab.

2-8

Switch on electric motor, Switch off electric motor Stop, Central lubricating system, Further auxiliary functions.

Further information is given in the Service Manual “Stored-program control”.

Control Management System (CMS) The CMS is an electrohydraulic servocontrol.

Together with the PMS, it provides for optimum interaction between drive hydraulic circuit and working movements.

The required working movements are recognized by microcontroller-assisted scanning of the operating elements (hand levers, pedals) and transmitted to electrohydraulic valves.

In the system sequence, the drive regulation is first activated to provide hydraulic working energy. Only then are working movements enabled.

Further information is given in the Service Manual.

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

OPERATION 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: minimum power losses, reduced temperature of the hydraulic oil and greater service life of hydraulic pumps and electric motor.

Board-Control-System (BCS) The BCS is a data-evaluating and dataprocessing system whose function is to collect, evaluate and store data about the shovel's operating status and to display these to the operator.

The BCS is based on a micro-processor. The measured values (actual values) supplied by sensors and transducers installed in the shovel are compared to preset nominal values. Out-oflimit conditions are displayed in the form of error messages in the cab.

Critical operating conditions are additionally indicated by optical and acoustic warning signals.

Further dedails are set out in the Board-ControlSystem operating instructions.

Electrical system Supply voltage (medium voltage)

6300 / 6600 V

Control voltage (low voltage)

400/230 V

Lighting voltage

24 V

Emergency voltage

24 V

Control voltage

24 V

2-9

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

OPERATION Power supply The electric power is supplied to the shovel through the drag cable (1, Fig. 2-3:) and connection box (3).

The drag cable is guided by a cable guide (2).

The power is then transmitted via the slip ring assembly (4) to the circuit breaker in the switchgear cabinet (Fig. 2-4:).

The drag cable can be wound on a cable reel (optional).

Fig. 2-3:

Fig. 2-4:

2-10

OMM 6030AC, 6030ACFS(3 847 030.00)-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 spare part numbers are set out in the spare-parts list of the machine.

Fig. 2-5: - Fig 2-10: show the location of warning and instruction signs on the machine.

The numbers in brackets, for example (23), tell the item number in the resp. spare parts group.

2-11

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

OPERATION

Fig. 2-5:

2-12

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

OPERATION

Fig. 2-6:

2-13

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

OPERATION

Fig. 2-7:

2-14

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

OPERATION

Fig. 2-8:

2-15

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

OPERATION

Fig. 2-9:

2-16

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

OPERATION

Fig. 2-10:

2-17

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

OPERATION

Machine number

Electric motor number

The identification plate (Fig. 2-13) with the machine number is attached to the front side of the A-frame (arrow, Fig. 2-14).

The serial number plate (1, Fig. 2-13:) for the electric motor is located on the electric motor.

Fig. 2-13:

Fig. 2-11:

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.

Fig. 2-12:

2-18

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

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

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

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

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

Access lighting The access can be illuminated in the dark. The access lighting is switched on: When you stand beside the shovel: By a pull switch (2, Fig. 2-15:) operated with a string from the ground. The lighting system switch is located under the counterweight.

When you are in the cab: With switch (5, Fig. 2-16:).

The access lighting is activated for three minutes and then switched off automatically.

Always face the machine when entering or leaving it.

Fig. 2-15:

Fig. 2-14:

Fig. 2-16:

2-19

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

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

Lowering the swinging ladder (from the upper carriage) Start electric motor.

Push lever (1, Fig. 2-18:) on control valve (2) downwards to position “ II “.

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

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

Fig. 2-17:

Raising the swinging ladder (from the upper carriage) Start electric motor.

Pull lever (1, , Fig. 2-18:) on control valve (2) upwards to position “ I “.

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

Fig. 2-19:

Lowering the swinging ladder (from the bottom) Pull down rope (3, Fig. 2-20:).

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

Fig. 2-18:

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

2-20

Fig. 2-20:

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

OPERATION Folding ladder (optional) Raising resp. lowering the folding ladder (Fig. 2-21:).

Lowering the folding ladder (from the upper carriage) Start electric motor.

Push lever (1, Fig. 2-22:) on control valve (2) downwards to position “ II “.

The folding ladder is lowered (Fig. 2-21:).

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

Fig. 2-21:

Raising the folding ladder (from the upper carriage) Start electric motor.

Pull lever (1, Fig. 2-22:) on control valve (2) upwards to position “ I “.

The folding ladder is raised (Fig. 2-23:).

Fig. 2-23:

Lowering the folding ladder (from the bottom) Pull down rope (3, Fig. 2-24:).

The folding ladder is lowered (Fig. 2-21:).

Fig. 2-22:

The upper carriage can only be swung when the folding ladder is raised completely (Fig. 2-23:).

Fig. 2-24:

2-21

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

OPERATION Cab interior lamp The interior lamp is switched on and off with switch (Fig. 2-25:).

Switch position 0 - lamp off, 1 - lamp on.

The interior lamp is also switched on and off with switches (arrow, Fig. 2-26:) and / or (96, Fig. 2-27:).

The interior lamp can be used even if the electrical system is switched off.

Therefore, switch off the interior lamp when leaving the machine. The batteries may be discharged if the interior lamp is left on for prolonged periods.

Fig. 2-25:

Fig. 2-26:

Fig. 2-27:

2-22

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

OPERATION Servicing lighting

Illuminating the control column

Switch on the lamps in the modules with switches (95, Fig. 2-28: and arrow, Fig. 2-29:).

Switch (95, Fig. 2-29:) is located in the control column in the operator's cab.

Switch (arrow, Fig. 2-29:) is located beside the cab door.

There are also switches build in the modules.

The control column front could be illuminated with a lamp (30, Fig. 2-30:).

Turn lamp head from "0" to "I" to switch the lamp on.

Fig. 2-30:

Fig. 2-28:

Fig. 2-29:

2-23

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

OPERATION EMERGENCY STOP switch The entire electrical system beginning at the output side of the circuit breaker switch is switched off by the EMERGENCY STOP switches. The electric motor wil be shut off.

Medium voltage 6.3 kV is still alive at the input side of the circuit breaker switch (in control column medium voltage 6.3 kV).

To switch off the whole machine from any electric power, electric power must be switched off at the power supply station where the supply cable is connected.

Fig. 2-31:

The battery voltage of 24V still remain, it can be switched off with the key operated switch in the control column or with the battery main switch (see "Electrical system (24V) switching on / off" and "Battery main switch").

In an emergency, actuate one of the EMERGENCY STOP switches.

The EMERGENCY STOP switches are located in the control column in the operator's cab (31, Fig. 2-31:), in the front of the 400V control cabinet in the counterweight (3, Fig. 2-32:), near the service lift (6, Fig. 2-33:). The pull switch is is operated by a string (5).

The electrical system can be switched on after the EMERGENCY STOP switches are activated, to do so, pull out switches (Pull switch Fig. 2-33: must be pushed in).

Fig. 2-32:

Fig. 2-33:

2-24

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

OPERATION Servicing switch

Windscreen washer

Before starting live-line servicing work e.g. measuring and testing with voltage applied, press switch (4, Fig. 2-34:) and secure it with a padlock.

Pressing the switch transmits a signal to the PLC. The electric motor can not be switched on.

The reservoir of the windscreen washing system (1, Fig. 2-35:) is installed in the cab module. For the reservoir capacity refer to the "Refilling quantities Other" table.

Fig. 2-35:

Fig. 2-34:

2-25

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

OPERATION Operator's seat The operator's seat (Fig. 2-36: and Fig. 2-37:) can be adjusted in several positions.

Fig. 2-36:

2-26

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"

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

OPERATION

Fig. 2-37:

2-27

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

OPERATION Fire extinguisher

Handling

The shovel is equipped with two four extinguishers.

The conventional one is located near the operators cab (Fig. 2-38:), the carbon dioxide fire extinguishers are located near the electric motor and switching cabinets.

Fig. 2-39:

Fig. 2-38:

The shovel operator and the maintenance personnel must informthemselves 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.

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

The carbon dioxide fire extinguishers are intended for fighting fires of electrical parts.

2-28

Pull out securing pin (2, Fig. 2-39:).

Strike knob (3) hard, then release again.

Operate the extinguishing gun.

After fire-fighting, the extinguisher must be refilled Immediately and prepared ready for use.

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.

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

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.

The 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.

Individual extinguishing circuits can be activated manually.

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 shovel operation the cab is equipped with a second seat.

This seat is installed behind the operator's seat (arrow, Fig. 2-40:).

Sit down on this seat and do not forget to fasten the seat-belt (if installed).

Do not leave this seat during the training / instruction session and /or as long as the machine is in operation.

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.

Fig. 2-40:

2-29

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

OPERATION Emergency escape device (optional) Elements of the harness (Fig. 2-41:- Fig. 2-43:) 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. 2-42:

Fig. 2-43:

See Description of the supplier.

Fig. 2-41:

Important hints 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.

2-30

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

OPERATION Pull loop (6) of the back support (1) between your legs to the front (Fig. 2-46:).

Pull loop (5, Fig. 2-47:) through loop (6).

Taking on harness Take harness out of handbag (15, Fig. 2-44:).

Fig. 2-44:

Take on shoulder belts (2 and 3, Fig. 2-45:).

3 Fig. 2-47:

Pull loop (4, Fig. 2-47:) through loop (5).

Press the hooking safety device (17, Fig. 2-47:) of the snap hook (16).

Fig. 2-45:

Pull back support (1, Fig. 2-45:) behind your body (Fig. 2-46:). The loops (4 and 5) are in front of your body.

Fig. 2-48:

Fig. 2-46:

2-31

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

OPERATION Hang up loop (4, Fig. Fig. 2-49:) into snap hook (16).

If you have the harness put on in such a way in case of danger you can escape from the shovel (Fig. Fig. 2-51:).

Fig. 2-49:

Release hooking safety device (17, Fig. 2-50:).

Fig. 2-51:

Fig. 2-50:

2-32

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

OPERATION

2-33

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

OPERATION MONITORING, WARNING AND CONTROL ELEMENTS

Fig. 2-52:

2-34

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

OPERATION (Fig. 2-52:) No.

Element

Function

1

BCS

Electronic measuring-data collection and processing system

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

2

Monitor

BCS

Displays the data collected.

Gives warnings and provides help, if desired.

3

UP button

Selects the BCS program; Positions the Cursor.

4

DOWN button

Selects the BCS program; Positions the Cursor.

5

ENTER button

Confirms a program; Activates a desired program.

6

BACK button

Recalls the Service Menu.

7

HOLD button

Freezes actual service data.

8

Print button

Recalls the Print Menu.

9

SERV. button

Recalls the Service Menu.

10

HELP button

Recalls the Help Menu.

11

BL + button

Adjusts BCS monitor background lighting brighter.

12

BL - button

Adjusts BCS monitor background lighting darker.

Symbol

2-35

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

OPERATION

Fig. 2-53

2-36

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

OPERATION (Fig. 2-53) No.

Element

Function

30

Lamp

Illuminates the front side of the control column.

31

Pushswitch

Emergency OFF

Symbol

The entire electrical system is interrupted in all poles by the on-board circuit breaker.

Even after actuation of the EMERGENCY STOP switch, medium voltage (6.3 KV / 6,6kV) is present (primarily) from the transformer station via drag cable and slip ring assembly to the circuit breaker.

32

Key-switch

Switches the low voltage system on and off.

33

Buzzer

Gives an acoustic warning signal if a fault is reported: Electric motor – winding temperature too high – bearing temperature too high bord transformer temperature too high Hydraulic oil level too low Distributor gearbox temperature too high Swing pump temperature (1 and / or 2; too high Swing gearbox temperature (1 and / or 2) too high Fault in lubricating system

Lower the equipment to the ground and switch off electric motor immediately if the buzzer (33) sounds and the BCS indicates a fault. The buzzer (33) continues to sound until the fault has been retified.

2-37

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

OPERATION

Fig. 2-54:

2-38

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

OPERATION (Fig. 2-54:) No.

Element

Function

33

Buzzer (continued)

Gives an acoustic warning signal if a fault is reported:

Symbol

Distributor gearbox contaminated Working pump (1, 2, 3, and / or 4; left and / or right) contaminated Swing motor (1 and / or 2) contaminated Swing circuit temperature (1 and / or 2) too high Lubricating system pressure too low Grease level in lubricating system too low On-board voltage 24 V too low The buzzer (33) continues to sound until the fault has been retified.

34

Buzzer

Gives an acoutic warning signal when the stick/boom angle to too small.

35

Terminals

For electronic machine diagnostics.

36

Antenna (Optional)

37

Radio (Optional)

2-39

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

OPERATION

Fig. 2-55:

2-40

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

OPERATION (Fig. 2-55:) No.

Element

Function

41

Indicator lamp

Medium voltage

Lamp is lit up when the circuit breaker is switched on. Medium voltage 6.3 kV applied.

42

Indicator lamp

Rotary field monitoring

Lamp is lit up when the rotary field (phasing) is correct.

51

Button

Electric motor ON

Switches on the electric motor.

52

Button

Electric motor OFF

Switches off the electric motor.

Symbol

2-41

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

OPERATION

Fig. 2-56:

2-42

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

OPERATION (Fig. 2-56:) No.

Element

Function

71

Switch

Travel motors

Switches on the fast gear (overdrive).

72

Switch

Undercarriage holding brake

CCW: brake permanently applied The shovel can not be driven CW:

Symbol

Every time the shovel stops, the undercarriage brake is automatically applied after approx. 8 sec.

The undercarriage brake is automatically released when the travel function is activated.

Actuate switch only when the shovel is stationary. Do not use as service brake.

73

Taster

Reset

Activate after a fault in the central lubricating system.

74

Switch

Electronic shovel control

Switches on the electronic servo control.

75

Switch

76

Cigarette lighter

77

Switch

Not connected.

Not connected.

2-43

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

OPERATION

Fig. 2-57:

2-44

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

OPERATION (Fig. 2-57:) No.

Element

Function

81

Switch

Not connected.

82

Switch

Superstructure holding brake

Symbol

Blocks the superstructure.

Actuate switch only when the shovel is stationary.

Do not use as service brake.

83

Switch

Windscreen wiper

Activates permanent / intermittent wiping.

84

Switch

Screen washer

Activates the wipe / wash function.

85

Switch

Floodlamps

Switches on the floodlamps on the operator´s cab.

86

Switch

Floodlamps

Switches on the floodlamps on the operator´s cab roof.

87

Switch

Floodlamps

Switches on the floodlamps on the hydraulic oil cooler.

88

Switch

Floodlamps

Switches on the floodlamps on the counterweight.

2-45

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

OPERATION

3 Fig. 2-58:

2-46

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

OPERATION (Fig. 2-58:) No.

Element

Function

Symbol

91

Switch

Emergency Operation Boom/Stick

Actuate and hold if boom and stick must be lowered in an emergency.

92

Button

Dumper count

RESET of counter.

93

Switch

Activates boom cylinder limit switch (optional)

94

Button

When switched it is possible to swing the uppercarriage and to drive the shovel even when the hydraulic ladder or the service station is in the lower position.

Risk of damaging the ladder or the service station!

Be careful and swing the uppercarriage and drive the shovel very slowly and only a short way.

95

Switch

Lighting

Switches on the lighting for servicing work.

96

Switch

Lighting

Switches the cab lighting on and off.

97

Switch

Windscreen wiper rear window (optional)

Activates permanent wiping.

98

Switch

Beacon (optional)

Switches the beacon on and off.

2-47

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

OPERATION

3 Fig. 2-59:

2-48

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

OPERATION (Fig. 2-59:) No.

Element

Function

101 Button 102 Button

Symbol

Free for options.

Boom floating position (shovel equipment only)

If actuated: stick cylinders are pressurized when retracted.

Actuate button (102) only when control lever (115) is in “0“ position.

103 Button

Boom floating position

If actuated: boom cylinders are pressurized when retracted.

Actuate button (103) only when control lever (116) is in “0“ position.

104 Button

Warning signal

Activates the horn.

105 Button

Electronic shovel control

Switches the electronic shovel control on and off (inside the operators seat).

ON – operator is sitting on the seat.

OFF – operator stands up.

111 Pedal

Bottom-dump buck- Opens / closes the bottom-dump bucket. et

112 Pedal

Travelling, left track

forwards / reverse

113 Pedal

Travelling, right track

forwards / reverse

115 Control lever

Lifts and lowers the bucket / backhoe bucket stick; Swings and brakes the superstructure.

116 Control lever

Raises and lowers the boom; Tipping and rearward tilting of bucket resp. backhoe bucket.

117 Button

Bottom-dump bucket

To the left - opens the bottom-dump bucket.

To the right – closes the bottom-dump bucket.

118 Button

By-pass for the automatically switch off for stick- and /or backhoe cylinders (Option)

To the left – automatically stopped stickand/or backhoe cylinders can be driven slowly to the limit stopps.

To the right – Not connected.

2-49

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

OPERATION

Fig. 2-60:

2-50

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

OPERATION (Fig. 2-60:) Optional equipment No.

Element

Function

121 Rotary switch

Fan

Selects the intensity level of the blower (3 levels).

122 Rotary switch

Mode

Selects the desired control function (heating, cooling, ventilation, defrosting).

123 Knob

Thermostat

Sets the desired temperature inside the cab.

125

Control

Additional heating (optional equipment)

Controlling the additional heating device via touch screen, see Back-up heating manufacturers manual.

126

Momentary switch

Switches additional heating control OFF.

127

Momentary switch

Switches additional heating control ON.

128

Momentary switch

Not used on this machine.

129

Momentary switch

Not used on this machine.

130

Momentary switch

Reset fault monitoring.

Symbol

2-51

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

OPERATION

Fig. 2-61:

2-52

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

OPERATION (Fig. 2-61:) Optional equipment No.

Element

Function

151 Warning lamp

Slewing pump 1 contaminated

Lights up when the slewing pump is contaminated with metal particles.

152 Warning lamp

Slewing pump 2 contaminated

Lights up when the slewing pump is contaminated with metal particles.

153 Warning lamp

Slewing pump 3 contaminated

Lights up when the slewing pump is contaminated with metal particles.

154 Warning lamp

Slewing pump 4 contaminated

Lights up when the slewing pump is contaminated with metal particles.

155 Warning lamp

Main pump 1 contaminated

Lights up when the main pump is contaminated with metal particles.

156 Warning lamp

Main pump 2 contaminated

Lights up when the main pump is contaminated with metal particles.

157 Warning lamp

Distributor gearbox contaminated

Lights up when the distributor gearbox is contaminated with metal particles.

158 Warning lamp

Slewing pump 1 temperature

Lights up when the temperature in the slewing pump is too high

159 Warning lamp

Slewing pump 2 temperature

Lights up when the temperature in the slewing pump is too high

160 Warning lamp

Slewing pump 3 temperature

Lights up when the temperature in the slewing pump is too high

161 Warning lamp

Slewing pump 4 temperature

Lights up when the temperature in the slewing pump is too high

162 Warning lamp

Main pump 3 contaminated

Lights up when the main pump is contaminated with metal particles.

163 Warning lamp

Main pump 4 contaminated

Lights up when the main pump is contaminated with metal particles.

164 Warning lamp

Distributor gearbox contaminated

Lights up when the distributor gearbox is contaminated with metal particles.

Symbol

2-53

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

OPERATION

Fig. 2-62:

2-54

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

OPERATION (Fig. 2-62:) Optional equipment No.

Element

Function

165 Warning lamp

Slewing motor 1 contaminated

Lights up when the slewing motor is contaminated with metal particles.

166 Warning lamp

Slewing motor 2 contaminated

Lights up when the slewing motor is contaminated with metal particles.

167 Warning lamp

Symbol

free for optional

168 Warning lamp

Hydraulic oil filter contaminated

Lights up when the flow resistance in the filter is too high. Replace filter elements if the warning lamp fails to go out when the oil is at operating temperature.

169 Warning lamp

Min. hydraulic oil level

Lights up when the hydraulic oil level in the hydraulic tank is too low.

170 Warning lamp

Electronic shovel control ON

Lights up when the electronic shovel control is switched on.

171 Indicator light

Hydraulic oil tank

Lights up when one of the shut-off valves of the hydraulic oil tank is closed When the valve is closed, the electric motor cannot be started.

When a shutoff valve is closed with the electric motor running, the motor is stopped.

172 Thermometer

Hydraulic oil

Indicates hydraulic oil temperature in hydraulic tank.

2-55

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

OPERATION

2-56

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

OPERATION PUTTING THE MACHINE INTO OPERATION Before daily start-up, carry out works in accordance with servicing plan T (cf. Part 3 "Inspection and servicing").

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

Otherwise, increased fire and explosion hazard will exist.

Service station (tanklift) The shovel is equipped with a central service station (Fig. 2-63:The service station is attached to the frame and accessible from the ground below the uppercarriage. Express couplings are provided for refilling the following consumables (fluids).

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

Pos. Fig. 2-63: 5

10 11

Fluid

Express coupling for

Gearbox oil for pump drive gearbox (optional) Hydraulic oil tank

Filling and/or draining

Grease for central greasing system

Filling and/or draining Filling

A service vehicle is needed for filling and/or draining of the fluids.

Lowering the service station Draw out control knob (21, Fig. 2-63:) of valve (22) with rope (25). The service station is brought down to the lower position. Turn knob (21) by 90° and engage.

Raising the service station Disengage control knob (21) of valve (22), turn by 90° and press in. The service station is raised to the top position.

Refilling and draining For filling in or for draining fluids, unscrew the cap of the corresponding express coupling (Fig. 2-63:).

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

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

Fig. 2-63:

2-57

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

OPERATION

Assemblies resp. Measuring device reservoirs

Remarks

Pump drive gearbox

Dipstick (Fig. 2-64:)

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

Hydraulic oil tank

Inspection glass (1, Fig. Checking the oil level: 2-65:), sign (2. Fig. 2-65: Extend the piston rods of stick and bucket cylinders halfway. Stand working equipment on the ground. and Fig. 2-66:)

Check oil level at an oil temperature of ca. 50 °C (122°F), with the electric motor stationary.

Fill in oil when the oil level in the inspection glass has dropped below the "min" mark. Stop filling if the oil reaches the "max" mark on the inspection glass or the acoustic warning signal "Travel alarm" sounds (cf. chapter "Hydraulic system - Checking the hydraulic oil level / Refilling hydraulic oil").

Fig. 2-64:

Fig. 2-66:

Fig. 2-65:

2-58

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

OPERATION

Assemblies resp. Measuring device reservoirs

Remarks

Grease container – BCS display (Fig. 2-67:) cental lubricating system

BCS display indicates a warning when the grease container is empty.

Fill in grease using express coupling (11, Fig. 2-68:).

Switch on the display system with the toggle switch (23, Fig. 2-68:). Monitoring lamp (22) lits up.

Stop filling when BCS indicates "Grease container filled". The indicator lamp (24) lights up.

On completion of filling, switch the display system off again with the toggle switch (23). Monitoring lamp (22) is off.

Fig. 2-67:

Fig. 2-68:

2-59

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

OPERATION Battery main switch, switching on and off

Electrical system (24V), switching on and off

When the shovel is disconnected from the medium voltage (6.3 kV) the electrical system (24V) is supplied with voltage by two batteries.

With the battery main switch, the electrical system (24V) is disconnected from the batteries.

The battery main switch is located at the right side wall of the control cabinet (24V). The control cabinet (24V) is mounted in the operator's cab module beneath the operator's cab.

The electrical system is switched on or off with key-switch (32, Fig. 2-70:).

Switching the battery main switch on Insert switching handle into battery main switch (position "0", Fig. 2-69:) and turn it to position "I".

Switching the battery main switch off Turn switching handle from position "I", Fig. Fig. 2-69: to position "0" and withdraw.

Switching the electrical system (24V) on Insert key into key-switch (32) and turn to the right.

Now all electronical assemblies of the shovel are supplied with voltage, computer systems are started. A selftest is carried out.

The Board Control System (BCS) displays current operating data as well as detected faults.

If there are no critical faults detected BCS enables starting the electric motor.

If there are critical faults or failings detected BCS disables starting the electric motor and displays corresponding explanatory text.

For more information see "Operating Instructions Board-Control-System".

Switching the electrical system (24V) off Turn key in key-switch (32) to the left and withdraw

Fig. 2-69:

Fig. 2-70:

2-60

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

OPERATION Switching the electric motor on and off Before switching on the electric motor Before switching on the electric motor, check that nobody is working on the electrical system or on the shovel itself.

Switch on the electric motor only when all these work on the shovel is finished and all persons leave the danger area.

Switch on battery main switch (see: "Battery main switch, switching on and off").

Switch on electrical system (24V) (see: "Electrical system (24V), switching on and off").

Check telltales (14 and 16, Fig. 2-71:), they must lit up in green colour.

If so, electric motor can be switched on (see: "Switching the electric motor on").

If telltales didn`t lit up in green colour, BCS has detected critical operating conditions or faults which prohibit starting the electric motor. BCS indicates this case with telltales (for instance 15, Fig. 2-71:) as well as by displaying corresponding text.

Fig. 2-71:

Switching the electric motor on Actuate switch-key (51, Fig. 2-72:), the electric motor is switched on.

During starting period the electric motor heavily warm up. Therefore it is not allowed to switch it on and off at will. By means of an electronical time-out circuit (PLC) the electric motor can be switched on only three times a hour (time-out period is 30 minutes).

Fig. 2-72:

2-61

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

OPERATION Switching the electric motor off

Time-out before restart

During breaks in operation and at the end of each shift, the working equipment must be lowered onto the ground.

The electric motor must NOT be switched off until the equipment is resting on the ground.

During starting period the electric motor heavily warms up. Therefore it is not allowed to switch it on and off at will. By means of an electronical time-out circuit (PLC) the electric motor can be switched on only three times a hour (time-out period is 30 minutes).

The 30 minutes period means the time from switching on the electric motor up to the next switching on, e. g.

Electric motor is switched on, runs 20 minutes and then is switched off. Now the time-out period is 10 minutes before restart.

After running more than 30 minutes without interruption the electric motor can be switched on without any time-out period.

PLC prohibits switching on the electric motors until they are cooled down.

Monitoring lamp (14, Fig. 2-74:) on the BCS display is flashing in yellow colour until the time-out period is over. The remaining time is displayed also.

Monitoring lamp lit up in green colour when the time-out period is over and PLC enables switching on the electric motor.

To avoid straining the vacuum contactor, the electric motor should be shut down only when load-free, i.e. without any of the hydraulic units being activated at the same time via the control valve.

Actuate switch-key (52, Fig. 2-73:). The electric motor starts running down.

Turn key in key-switch (32) counter-clockwise and withdraw.

The control voltage is switched off.

The electric motor only can be switched on again, after the time-out period (30 minutes after last switching on) is over (see: "Time-out before restart", "Before switching on the electric motor" and "Switching on the electric motor").

Fig. 2-73:

2-62

Fig. 2-74:

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

OPERATION Electric motor can not be switched on If BCS prohibits switching on the electric motor the operator should check the following: Time-out before restart period still running?

EMERGENCY STOP switch in control column unlocked?

EMERGENCY STOP switch in control cabinet (400V) unlocked?

EMERGENCY STOP pullswitch near the service station unlocked?

Servicing switch unlocked?

Monitoring lamps "6.3 kV OK" and "PHASE SEQUENCE OK" on the control cabinet (400V) and on the control column lighting?

If not, the circuit breaker is switched off or the 6.3 kV voltage supply is missing.

Shut-off flaps at the hydraulik oil reservoir closed?

Check BCS display: Faults or explanatory text displayed? If so, give information to the electric maintenance personnel.

In case of failure If failures in the electrical systems occur, BCS displayes warnings and corresponding explanatory text Failures in electrical systems may exclusively be removed by specialist personnel for maintenance and service on electrical systems.

The following faults may be responsible: fault in high-voltage transformer 6.3 kV/ 400V/ 230V transformer overloaded. earth fault.

If BCS display shows "Overcurrent", the operator does not know if an "Earth fault" happens. In worst case the shovel may be energized.

The operator must notify the electrician in charge from the shovel superstructure.

The electrician must then cut off the voltage supply from the transformer station and locate and rectify the fault.

If after all of these checks the electric motor cannot be switched on the operator has to inform the specialist personnel for maintenance and service on electric shovels. Only these have the skills to work in a safe way, for trouble shooting and removing the fault.

2-63

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

OPERATION Circuit breaker, switching on and off By means of the circuit breaker the supplied medium voltage 6.3kV can be connected to the shovels electrical system or can be disconnected from it.

The circuit breaker is installed in the control cabinet 6.3 kV (Fig. 2-75: and Fig. 2-76:).

Switching the circuit breaker on is possible only when PLC and motor protection relay enable thie function. In this case, monitoring lamp (Fig. 2-76:) lights up.

The circuit breaker is operated with an actuating lever which is stored in a fixture inside the control cabinet 6.3 kV.

Switching on the circuit breaker Slip actuating lever (Fig. 2-77:) onto the actuating shaft of the circuit breaker. Pull locking element outwards against spring pressure.

Turn actuating lever by ca. 180° upwards (Fig. 2-77:). This tensions the cut-out spring.

Turn actuating lever (Fig. 2-78:) by 180° downwards.

This tensions the cut-in spring and the circuit breaker is switched on.

Engage locking ring.

The indicator lamps "6.3 kV OK" (1, Fig. 2-79:) and "PHASE SEQUENCE OK" (2) comes on at the control cabinet 400V and at the control column in the operator's cab.

Withdraw the actuating lever and put it into its fixture.

Fig. 2-77:

Fig. 2-75:

Fig. 2-76:

Fig. 2-78:

2-64

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

OPERATION Switching off the circuit breaker Slip actuating lever (Fig. 2-80:) onto the actuating shaft of the circuit breaker.

Pull locking element outwards against spring pressure.

Using actuating lever (Fig. 2-80:), turn actuating shaft ca. 20° clockwise.

This releases the cut-out spring. The circuit breaker is switched off.

The indicator lamps "6.3 kV OK" (1, Fig. 2-79:) and "PHASE SEQUENCE OK" (2) goes out at the control cabinet 400V and at the control column in the operator's cab.

Withdraw the actuating lever and put it into its fixture.

Further detailed information is given in the attached leaflet on circuit breakers.

Fig. 2-79:

Fig. 2-80:

2-65

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

OPERATION Motor protection relay, function

The electric motor is equipped with a motor protection relay. The relay is located in the 400 V switch cabinet (Fig. 2-81:).

The relay monitors the operating conditions of the electric motor and protects the motor against faults in the electrical system of the motor Depending on the nature of the fault, the motor protection relay switches off the power supply of the motor via the vacuum contactor or the power supply of the machine via the switch-disconnector.

At the factory, the motor protection relay is programmed for the following functions: protection against overcurrents, protection against overloading, detection of ground faults,

Fig. 2-81:

temperature monitoring, restart inhibit, protection against undervoltage, protection against load unbalance (failure of a phase) phase sequence monitoring, change of frequency, run-up period monitoring.

In case a severe fault of the motor system is detected in operation, the motor protection relay is activated and the electric motor shut off automatically.

If the motor protection relay detects a severe fault before or during the starting sequence of the electric motor, it prevents the motor from being started.

Depending on the type of fault detected, one or more LEDs on the front panel light up (9, Fig. 2-82:).

After rectification of the fault press button (7). The LED is extinguished. The motor protection relay is again operational.

For more information please refer to the the manufacturer's description.

2-66

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

OPERATION Front panel control and monitoring elements See Fig. 2-82:

1 2 3 4 5 6

7 8 9

RUN indicator (LED) Display screen (provides information on states of operation) Display screen navigation keys Function key freely programmable (not used for this machine) Control of other equipment (not used for this machine) USB interface for communication with external devices (only for CGM HMS GmbH Service) Reset for LEDs of item 9.

Cover for keypad of item 4.Functional description of the LEDs of item 9.

LEDs G1 – G8, on after detection of a fault: G1 – Overcurrent G2 – Undervoltage/overvoltage G3 – Load unbalance G4 – Frequency change G5 – Overload G6 – Phase sequence fault, ground fault G7 – Run-up monitoring, restart inhibit G8 – Emergency STOP activated

Fig. 2-82:

For more information please refer to the the manufacturer's description.

2-67

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

OPERATION Warm-up procedure for electric shovels Operator procedure during start up in extreme cold weather After starting the electric motor check for any faults on the BCS display.

Make sure the “SERVO” switch (74, Fig. 2-85) is in the OFF position.

Use the “Boom up” (116, Fig. 2-84: backwards) or “Stick out” function (115, Fig. 2-84: forwards) to engage the hydraulic pumps.

This will engage the pumps without moving the attachment.

Do so until: - the hydraulic oil temperature reaches 10°C on the gauge and - the PTO temperature has reached 5°C. You can now turn ON the “SERVO” switch (74, Fig. 2-85Fig. 2-86:) and move the attachment in a slow function one at a time.

Do not extend the cylinders fully.

Fig. 2-83:

Swing circuit warm-up before you start digging Make sure the attachment or bucket is on the ground.

Turn “Swing brake” switch OFF (82, Fig. 2-86:).

Turn “SERVO” switch ON (74).

Use “Swing left” or “Swing right” function (115, Fig. 2-84:) slowly. This will heat the swing hydraulic circuit quickly.

Once the swing temperature is warm you can lift the attachment and swing the shovel in a slow 360° left then right.

Fig. 2-84:

Fig. 2-85:

2-68

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

OPERATION Air conditioner (option) Ventilation / Heating

Control panel (Sigma)

The air needed for ventilation and/or heating is sucked in from outside the cab by a blower and ducted to the air outlets.

If necessary, the air in the cab is sucked in through the and recirculated.

(see Fig. 2-86:)

The air conditioner control elements are located at the left side of the control column (Fig. 2-86:).

Do not switch the air conditioner to "cooling“ when the back-up heating (optional) is on.

1

Rotary switch

Selects the intensity level of the blower (3 levels).

2

Rotary switch

Selects the desired control function (heating, cooling, ventilation, defrosting).

3

Thermostat

Sets the desired temperature inside the cab.

Fig. 2-86:

2-69

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

OPERATION TRAVELLING THE MACHINE 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 superstructure is turned by more than 90° from the BASIC POSITION, the shovel travels in the opposite direction to that selected.

If the position of the superstructure 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.

Warn persons in the immediate vicinity by sounding the horn before setting off.

Never travel across slopes.

Take the utmost care on slippery, greasy ground.

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. 2-87:) Travel the shovel in reverse approx. 50 m (164ft).

Travel the shovel in forwards approx. 50 m (164ft).

Stop the 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 10x.

Check all idlers, track rollers and support rollers for leaks.

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

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

Trailing cable Never touch the trailing cable.

Risk of voltage transfer, if the trailing cable insulation is defective!

Change the position of the trailing cable only by means of a cable hook.

Fig. 2-87:

2-70

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

OPERATION Travelling Superstructure basic position Travel direction and sense of actuation of pedals (112 and 113, Fig. 2-89:) are identical only when the shovel is in its BASIC POSITION (Fig. 2-88:).

Travelling forwards/backwards Travelling forwards: depress pedals (112 and 113) forwards.

The shovel travels in the direction of the idler (2, Fig. 2-88:).

Travelling backwards: depress pedals (112 and 113, Fig. 2-89:) backwards.

The shovel travels in the direction of the drive sprocket (4,Fig. 2-88:).

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

Fig. 2-88:

If the superstructure is slewed out of its basic position by more than 90° (Fig. 2-90:), the shovel moves in a direction opposite to that expected when pedals (112 and 113, Fig. 2-89:) are depressed.

Fig. 2-90:

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

Reverse the 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 gears must always be at the rear. Travel only in the basic position of the shovel and only forwards.

Be extremely careful on slippery and greasy ground.

Fig. 2-89:

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

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.

2-71

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

OPERATION Regulating the travelling speed Travelling on level ground Regulate the travelling speed with pedals (112 and 113, Fig. 2-91:) and Switch (71, Fig. 2-92:) to the right (slow gear) All forward/reverse travel movements are possible with this gear.

Switch (71, Fig. 2-92:) to the left (fast gear) The shovel can be travelled 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 shovel is stationary.

Fig. 2-92:

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

Depress pedals (112 and 113, Fig. 2-91:) fully to the limit stop.

Fig. 2-91:

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

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

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

2-72

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

OPERATION Cornering To take a right-hand corner forwards depress only pedal (112, Fig. 2-93:) forwards.

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

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

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 shovel'sdesignated use.

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

Fig. 2-93: Fig. 2-94:

Note Change the position of the undercarriage - parallel or perpendicular to the working face - only by cornering forwards/backwards (Fig. 2-94:).

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 shovel is to be travelled out of depressions (Fig. 2-95:): Cornering to the left from pos. 1 to pos. 2 Cornering to the right from pos. 2 to pos. 3 Fig. 2-95:

2-73

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

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

Travelling backwards over longer distances could result in damaging parts of the undercarriage or the travel gear.

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

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

Keep the loading bucket close to the ground. For a more uniform loading of the tracks, the equipment must, however, be kept at a steep angle (Fig. 2-96:).

Fig. 2-96:

Loading bucket equipment (Fig. 2-96:): Fully extend boom cylinder (1).

Extend bucket cylinder 2.

Extend stick cylinder 3.

Retract bucket cylinder 2 and stick cylinder (3) to such an extent as to reach the position of the equipment (Fig. 2-96:).

2-74

Lower the equipment when travelling underneath obstacles.

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

After travelling for 15 minutes without interruption, stop the shovel and check the temperatureof 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).

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

OPERATION Emergency machine drive

Required equipment

Moving the shovel after failure of the hydraulics

a self-propelled machine with a dual-circuit hydraulic system

The weight of the shovel, the resistance of the crawler tracks and the high reduction in the travel gearboxes make towing or pushing of the shovel in the event of a failure or of defects in the hydraulic system impossible.

max. working pressure min. working pressure pump discharge rate

380 bars 220 bars 150 l/min

These are minimum values. The pump discharge rate indicated corresponds to an shovel travelling speed of ca. 3 m/min.

4 high-pressure hoses ca. 11 m long; DN 40 1 ½“ SAE Connection at one end; ready for connection to the auxiliary machine at the other.

4 plugs (high-pressure type) for 6000 PSI 1 ½“ SAE connections.

Fig. 2-97:

The shovel can therefore only be moved with the help of another machine (Fig. 2-97:) (wheel loader or grader). The machine used as auxiliary machine must be equipped with a dual-circuit hydraulic system.

2-75

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

OPERATION Positioning of the machines

Emergency travel

The auxiliary machine is driven close to the RH 120-E from behind (Fig. 2-97:).

Loosen the high-pressure lines (1, 2, 3 and 4, Fig. 2-98) and close the open ends of the hoses.

Connect the hoses from the auxiliary machine to the ports of the "travel hydraulics" of the shovel.

High-pressure hoses (1 and 2) - circuit 1 on auxiliary machine High-pressure hoses (3 and 4) - circuit 2 on auxiliary machine

Start up the engine of the auxiliary machine.

The brakes of the RH 120-E are released by travel pressure.

Initiate the travelling movements carefully with the control levers. Adjust the direction and travelling speed of both tracks accordingly.

Shift the control lever to the final position.

Make sure the auxiliary machine is able to "follow" The RH 120-E can be steered as usual by releasing the one or the other control lever briefly.

Drive the shovel out of the hazard zone only.

Fig. 2-98

2-76

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

OPERATION Locking the superstructure

Track parking brake

The shovel is equipped with two superstructure holding brakes. The superstructure holding brakes are used to block the superstructure and the undercarriage.

The superstructure holding brakes are parking brakes.

Do not actuate the switch unless the superstructure is stationary. Do not use this switch while the superstructure is still in motion. Risk of damage to the brakes and the slewing gears.

To activate the holding brakes, press switch (82, Fig. 2-99:) when the excavator is parked,

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

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.

when travelling over longer distances.

Fig. 2-100:

Fig. 2-99:

For Service and Maintenance purposes the travelling gear brakes can also be applied with switch (72, Fig. 2-99:).

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 (72): 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.

2-77

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

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 shovel's crawler tracks and from ramps and loading platforms of the transport vehicle to minimize slipping.

Secure the transport vehicle against rolling away.

Use only tying equipment of sufficient strength (the weights and dimensions of the shovel are set out in the "Technical specifications").

Transport The dimensions and the service weight of the fully assembled shovel do not allow the 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. 2-101:).

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

Fig. 2-101:

2-78

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

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.

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;

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: Switch on the electric motor.

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 excavator can operate at a higher engine speed.

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 GmbH as "abusive utilization".

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

2-79

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

OPERATION Working equipment, avoid extreme positions Parts of the attachment may damage the machine if they are moved into extreme positions (see illustrations Fig. 2-102: and Fig. 2-103:).

Work carefully, avoiding extreme positions of this kind.

Fig. 2-102:

Fig. 2-103:

2-80

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

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".

Switch on the electric motor and start to perform no-load working movements for abt. 10 minutes with the shovel.

Swinging the superstructure The superstructure can only be swung if the superstructure holding brake is released.

To swing the superstructure to the right: shift control lever (115) to the right.

To swing the superstructure to the left: shift control lever (115) to the left.

After releasing, the control lever returns automatically to position "0". But the superstructures motion will not be braked automatically then. To bring the superstructure to standstill, shift control lever (115) into the opposite direction of superstructures motion (countering).

Braking the superstructure After releasing, the control lever returns automatically to position "0". But the superstructures motion will not be braked automatically then.

The superstructure is braked only by setting control lever (115) into the opposite direction (countering).

In an emergency apply parking brake with switch (82, Fig. 2-105:)

Fig. 2-104:

Switching on the electronic shovel control You can only move the working equipment after the electronic shovel control is switched on via switch (74, Fig. 2-104:) and the switch inside the operator’s seat (105).

Electronic shovel control activated - operator is sitting on his seat.

Electronic shovel control deactivated - operator's seat is empty.

Fig. 2-105:

2-81

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

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.

Close bucket completely before beginning to dig. Do not level off a surface with the front shell of the bucket open.

Raising and lowering the boom To raise the boom: pull control lever (116, Fig. 2-106:) 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.

Extending and retracting the bucket stick To extend the stick: push control lever (115) forwards.

To retract the stick: pull control lever (115) backwards.

To retract the stick with pressure: (only on bottom-dump bucket equipment) depress button (102) and push control lever (115) backwards.

2-82

Fig. 2-106:

Filling and emptying the bucket To fill/tip back the bucket: shift control lever (116) to the left.

To empty the bucket by dumping/tipping: shift control lever (116) to the right.

Opening and closing the bottom-dump bucket To open the bucket: press pedal (111) forwards / resp. press button (117) to the left.

To close the bucket: press pedal (111) backwards resp. press button (117) to the right.

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

OPERATION Emergency lowering of the working equipment With the electric-motor not functional, the working equipment can be lowered to the ground as follows: Switch on electrical system (24V) with keyoperated switch (32, Fig. 2-107:).

Actuate switch (91) and hold.

Push control lever (116, Fig. 2-108:) forwards.

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.

Switch off the electric motor.

Shift both control levers into all directions todepressurize the hydraulic cylinders.

Withdraw the key from the electrical systemkey-switch.

Set the battery main switch to OFF. Close the cab windows.

Lock the cab doors 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.

Inspect the hydraulic system, the track rollers, support rollers, idlers and gearboxes visually for leaks.

Escaping oil pollutes the environment.

Fig. 2-107:

Repair leaks immediately (or have them repaired).

Report oil accidents to the user of the machine.

Check the superstructure, undercarriage and the working equipment for damage and all steel components for cracks or fractures.

Report detected damage immediately to the user.

Clean off gross dirt, ice and snow from the fins and the fan wheel of the hydraulic oil cooler .

Fig. 2-108:

2-83

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

OPERATION ASSEMBLING WORKING EQUIPMENT - SAFETY INSTRUCTIONS Personel 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 gear 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. 2-109), use a fall arrester. Falling down from great hight may cause severe injuries. Connect the fall arrester to the safety line on the boom (arrow, Fig. 2-109).

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

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.

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

Fig. 2-109:

2-84

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

OPERATION Securing the machine Risk of injury The machine must not be started by unauthorized persons.

Therefore, secure the machine.

Observe the accident prevention regulations.

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 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.

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

Park the machine on level and stable ground.

Lock the superstructure.

Stand the working equipment on the ground.

Switch off the electric motor.

Depressurize the hydraulic system.

Withdraw the key from the key-switch.

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

Close all open bores, pipe and hose connections with pressure-resistant 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.

2-85

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

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 GLEITMO 815 anti-corrosive agent before fitting.

GLEITMO 815: 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 number of GLEITMO 815 is 2764305. Available from CGM HMS GmbH Spare-Parts Service.

2-86

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.

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

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

Do not lift persons.

Observe all national directives as well as specific regulations relevant to crane operation.

On-board crane, monitoring, warning and control elements (Fig. 2-110:)

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. Incorrect operation of the crane may give rise to life-threatening situations.

Fig. 2-110:

Pos. Element 1 Monitoring lamp 2 Warning lamp 3 Warning lamp 4 Monitoring lamp 5 Key-switch 6 7

10 11 12

Button Monitoring lamp Knob Monitoring lamp Warning lamp Button Button

21

Control lever

22 23 24

Control lever Control lever Control lever

8 9

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

2-87

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

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. 2-111:) 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. 2-111:).

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. 2-110:) 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”).

Fig. 2-111:

2-88

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

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 swing 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.

Swing the boom in the direction of the blocking device (Fig. 2-112:) 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. 2-112:).

Reinsert and lock the the cotter pin.

On-board crane, checking 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. 2-112:

2-89

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

OPERATION Monitoring cameras 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. 2-113:).

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

2-90

Fig. 2-113:

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

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2-91

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

OPERATION

2-92

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INSPECTION AND SERVICING 3 INSPECTION AND SERVICING Operating instructions

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 Part 4 REPAIR WORK

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

Repair personnel 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

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INSPECTION AND SERVICING

3-2

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INSPECTION AND SERVICING SAFETY INSTRUCTIONS FOR SHOVELS WITH ELECTRIC MOTOR

Connect the earthing kit (8) to the earthing points (2, 3 and 4) only by means of extension (5).

The earthing points may still carry residual voltages.

Maintenance and inspection work on electrical systems may only be performed by qualified electricians or by workshops employing such personnel.

A qualified electrician for the purpose of this regulation is a person who has the corresponding technical training, know-how and experience as well as knowledge of the pertinent prescriptions and who is therefore in a position to judge the work entrusted to him and the potential dangers in connection therewith.

Before carrying out any maintenance and inspection work on the electrical system, the following precautions must be taken:

In the transformer station Cut out the supply voltage.

Secure against switching on; apply a warning sign.

Fig. 3-1:

Check that the electrical system is off circuit.

Connect to earth and short-circuit.

Protect adjacent and live parts against accidental contact.

On the shovel Cut out the switch-disconnector (see the " Switching off the circuit breaker " chapter in part 2 of the present operating instructions) Secure the circuit breaker against switching on, e.g. seal in the actuating lever in a cabinet.

Apply a warning sign.

Fig. 3-2:

Remove the cover (1, Fig. 3-1:).

Check that the electrical system is off circuit and dead.

Connect to earth and short-circuit: (connect the earthing and short-circuiting line (8, Fig. 3-2:) in the following order to points (1 – 4): first to the fixed point (1), then one after another to the earthing points (2, 3 and 4).

Slide partition (6, Fig. 3-3:) into guide (7).

Fig. 3-3:

3-3

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INSPECTION AND SERVICING After inspection and maintenance at the electrical system, the following works must be performed:

On the hydraulic shovel Disconnect the earthing and short-circuiting line (8, Fig. 3-4:): first from the earthing points (2, 3 and 4) by means of extension (5), then from the fixed point (1).

Withdraw the partition (6, Fig. 3-5:).

Refit the cover (1, Fig. 3-6:).

Fig. 3-6:

In the transformer station

Fig. 3-4:

Disconnect the earthing and short-circuiting line.

Unlock the safety device preventing switch-on; remove the warning sign.

Remove the partitions.

Switch on the supply voltage.

On the hydraulic shovel Remove the warning sign.

Cut out the switch-disconnector (see the " Switching off the circuit breaker " chapter in part 2 of the present operating instructions).

Fig. 3-5:

3-4

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

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 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.

3-5

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INSPECTION AND SERVICING Cleaning jobs

Fastening and securing elements

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).

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

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.

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

Replace any damaged parts.

Handling flammable liquids When handling flammable liquids: never smoke, keep away from unshielded light sources and naked flames, 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.

3-6

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.

Used oil may be harmful to the skin.

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

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

Visisble oil losses Have any visible leakage repaired immediately.

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.

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INSPECTION AND SERVICING Relieving residual pressure in the hydraulic system

Screwed connections, piping, hydraulic hoses

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 electric motor 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 Switch off the electric motor Move all control levers and pedals repeatedly into all ndirections.

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.

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

Never repair damaged piping; always replace them.

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.

3-7

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INSPECTION AND SERVICING Non-polluting disposal

Seals

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.

Individual spares may contain asbestos. Such

Do not dispose of these substances together with household wastes.

Fill these substances into the containers provided for such purposes.

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

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

3-8

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.

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INSPECTION AND SERVICING Handling batteries

Before working on the electrical system

Battery Posts, terminals and related accessories contain lead and lead compounds, chemicals known to cause cancer and reproductive harm.

Wash hands after handling

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.

Batteries give off explosive gases.

Disconnect first the negative and then the positive terminal.

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.

After the work: Reconnect first the positive and then the negative terminal.

Wear gloves, firm protective clothing and goggles 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.

3-9

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INSPECTION AND SERVICING Selecting oils and greases

After servicing

Use the recommended qualities only, matching viscosities with the temperature level.

To prevent corrosion, coat all bright metal parts with a grease film.

Filters

On completing work, re-install all protective devices.

Replace / clean all filter elements or filter cartridges within the specified periods.

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 electric motor 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.

Lubricating Clean the lubricating nipple, then lubricate as scheduled.

3-10

Never switch on the electric motor while work is being done on the machine.

Carry out performance tests with the machine.

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INSPECTION AND SERVICING FIRE AND EXPLOSION HAZARD Safety instructions Prior to commencing work, obtain information on the national and corporate rules for the prevention of accidents.

Pay particular attention to hazards caused by combustible and easily flammable substances.on the safe handling of the fire extinguishers to be used.

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

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

Do not store or handle any flammable substances during operation.

Clean the shovel thoroughly, if possible, with a steam jet (rubber parts and electric components with compressed air - refer to information label), when, for example, oil, grease, solvent or cleaner was spilled.

Such substances may spontaneously ignite if they get into the vicinity of hot units or objects.

Even battery gases can ignite in open flames or fire.

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

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.

Ensure sufficient ventilation.

Clean the 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 burning oil over a wide area. Water causes short-circuits in the electrical system thus possibly entailing new hazards.

DANGER TO LIFE Call the fire brigade.

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

open or smouldering fire may occur.

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

3-11

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INSPECTION AND SERVICING

3-12

OMM 6030AC, 6030ACFS(3 847 030.00)-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 Do all jobs ....

V ...once prior to initial commissioning.

N ...after initial commissioning and during the running-in period (after 100OH).

T ...every 10 OH or every working shift 1) W ...every 60 OH or weekly .2 B ...after every 500 OH. C ...after every 1000 OH. D ...after every 5000 OH. E ...after every 10000 OH. OH = Bh = Operating hours

2

Oils / Greases For the specification of oils and greases to be used refer to the "Lubricants" section.

The numerals mentioned in the "Oil / Grease" column in the inspection and Servicing plans have the following meaning: I Oils for combustion engines and compressors II Oils for hydraulic systems IIIa, b, c Oils for gearboxes V Greases for bearings and slewing rings

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 The maintenance intervals for components, e.g. electric motor and gearboxes, 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.

Whichever comes first.

3-13

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INSPECTION AND SERVICING

3-14

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INSPECTION AND SERVICING Plan V Plan V - Once prior to initial commissioning Location

Servicing work

Electric motor

Lubricate Direction of rotation (cf. electric motor manufacturer´s servicing instructions)

Electrical system Battery Lighting Terminals Slip ring assembly Switch gear cabinets Monitoring, warning and control elements Button - EMERGENCY OFF Button (servicing works) BCS 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 - Pre-chambers - Brake-chambers Slewing ring Internal gearing Undercarriage Track roller Support roller Track Idler

3

Check liquid level Check operation Check for tightness Visual inspection Check for condensate, drain condensate Check function of monitoring, warning and control elements Check function Check function Check function Check function of working and travelling movement Check pressure (cf. Service Manual) Check oil level Vent (cf. chapter “venting hydraulic system“) Check oil level Check oil level Check oil level Check oil levels Check oil level Check oil level Check oil level Check grease filling Check for leaks and free movement 3 Check grease filling, fill with grease Check for leaks and free movement Check pressure (see Service Manual) Check for leaks and free movement

Page 1 of 2 Quantity/ No. 2

2

1

3 1 1

1 1 2 2 4 2 2x1 2x2 1 2x7 2x2 2 2

Valid for machines without automatic greasing system for the undercarriage

3-15

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INSPECTION AND SERVICING Plan V - Once prior to initial commissioning Location Central lubricating system - Grease container - Greasing and pause cycles Service – Station (tanklift) Air conditioner (optional) - Compressor Hydraulic ladder - central lubricating point All lines, fittings and connections All articutated joints and hinges Emergency escape device / seat - Harness (optional) - Harness holding device on cab roof

3-16

Servicing work

Check filling level Check setting Check operation Check oil level Grease Inspect visually for leaks, wearing marks Grease Check completeness and condition Check for tightness

Page 2 of 2 Quantity/ No.

1

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INSPECTION AND SERVICING Plan N Plan N – After initial commissioning and during the running-in period (After 100 OH) Page 1 of 1 Location

Electrical system Medium-voltage cells - mechanical connections - lines - terminals and plug connections Hydraulic system Oil cooler - Bearing - Fastening screws Return-flow filter Magnetic rod Pressure accumulator – emergency lowering Pump drive gearbox - Pre-chambers Swing gearbox (Gearbox P/N 3692960) - Fastening screws Swing gearbox (Gearbox P/N 3676892) - Brake chambers - Fastening screws Travel gearbox - Pre-chambers - Brake-chambers Fastening screws Swing ring Fastening screws (slewing ring, undercarriage and superstructure) Superstructure Fastening screws, especially at superstructure / pedestal / operator´s cab Undercarriage Fastening screws - carbody - trackframe - bottom rollers - trackframe - top rollers - trackframe Cable guide for power supply cable - Fastening screws cable guide / machine All lines, fittings and connections

4

Servicing work

Quantity/ No.

Check for tightness Check for tightness Check for tightness

Check for tightness Replace Clean Check function Change oil Change oil Change oil Check for tightness Change oil Change oil Check for tightness Change oil Change oil Change oil Check for tightness

7 1 1 4 1 4 2x3 4 2 4

2 4 2 24 2x14 2x24

Check for tightness (see Service Manual for tightening torques) Check for tightness

Check for tightness (see Service Manual for tightening torques)

Check for tightness (cf. Service Manual) Inspect visually for leaks, wearing marks

cf. “Refilling quantities – Oil“ table

3-17

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INSPECTION AND SERVICING

3-18

OMM 6030AC, 6030ACFS(3 847 030.00)-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

Electric motor

Listen for unusual machine noise Pay attention to running smoothness Clean

- Cooling fins

Quantity/ No.

Plan T

Plan W

Electrical system Lighting

Check operation

Switchgear cabinets

Check for condensate, drain condensate

- Electrical components

Visual check

- Breather filter - Dust trap

Remove dust

3

Buttons - EMERGENCY OFF

Check function

3

Button (servicing works)

Check function

1

Monitoring, warning and control elements

Check function of monitoring, warning and control elements Check function

1

BCS

Hydraulic system

Check function of working and travelling movement Inspect visually for leaks

Hydraulic oil reservoir Oil cooler

Check oil level Check / clean

1 2

Fan wheel

Check condition

2

High-pressure filter (tell-tale)

Check

2

Pump drive gearbox

Check oil level

1

- Expansion reservoir

Check oil level

1

Oil filter (tell-tale)

Check

1

Swing gearbox (P/N 3692960) Swing gearbox (P/N 3676892) - Expansion reservoirs Travel gearbox

Check oil level

2

Check oil level

4

Check for leaks

2

- Pre-chamber

Emergency escape device / seat - Holding device - Harness

Visual condition check Check tightness and fixation on cab Connect to the holding device

3-19

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INSPECTION AND SERVICING Plan T - Every 10 OH or every working shift (whichever comes first) Plan W - Every 60 OH or every week (whichever comes first) Location

Servicing work

Quantity/ No.

Undercarriage Tracks

Inspect track tension visually

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

Central lubricating system - Grease container

Check filling level

- Lubricating points

Check visually

Air conditioner (option)

(Carry out all service work described in the “Air Conditioning manual“ of the supplier) Check condition Check control module

Fire extinguisher Automatic fire-extinguishing system (optional) All lines, fittings and connections Inspect visually for leaks, wearing marks Shovel Overall cleaning

3-20

2

1

2 1

Page 2 of 2 Plan Plan T W

OMM 6030AC, 6030ACFS(3 847 030.00)-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)

Location Servicing in acc. with W or T Monitoring, warning and control elements - Joystick - Control spool - Pedal - Control spool (machine with loading shovel) Electric motor (c.f. Electric motor manufacturer´s servicing instructions)

Rotor (inside and outside of machine) Terminals

Screw connections Stator windings

Coupling

5

Servicing work

Menge / No.

Grease lightly

2x4

Grease lightly

3x25

Check for vibration Visual inspect interior of machine for degree of dirt deposits Lubricate Visual inspect all accessible places for rust Check tightness Check for degree of dirt deposits

Page 1 of 5 Plan Plan Plan Plan Plan A B C D E

5

2 1

Check condition and tightness Check insulating resistance Information about annual and five-annual work cf. Electric motor manufacturer´s servicing instructions For regrease intervals see the power rating plate / motor type plate attached to the electric motor.

Check for alignment and record measurements after every 2000 OH (refer to electric motors manufacturer’s servicing instructions)

apply a thin layer of low temperature grease

3-21

OMM 6030AC, 6030ACFS(3 847 030.00)-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)

Location

Servicing work

Electrical system Battery cable connections

Check for tightness

Battery

Check fluid level

Slip ring assembly

Visual inspection, if necessary clean inside from wear debris and grease.

(C.f. Slip ring manufacturer´s servicing instructions) Check for wear Replace Check for tightness

- Brushes Mechanical components Switchgear cabinets - Filter mat

Visual inspection

- Medium-voltage cells

Clean/dry

- Electrical components

Check for tightness

- Breather filter - filter element

Clean Replace

3-22

Menge / No.

2

Page 2 of 5 Plan Plan Plan Plan Plan A B C D E

OMM 6030AC, 6030ACFS(3 847 030.00)-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)

Location

Servicing work

Hydraulic system

Check pressure (cf. Service Manual)

Menge / No.

Page 3 of 5 Plan Plan Plan Plan Plan A B C D E

Oil cooler - Bearing - Fastening screw

Check for tightness

- Rubber bearing

Check condition

Return-flow filter Return-flow filter (cooling circuit) Bypass valve

Replace

7

Replace

2

Check / clean filter sieve

4

Bypass valve (cooling circuit)

Check / clean filter sieve

1

Magnetic rod

Check / clean

1

High-pressure filter

Check / clean

4

Replace

4

Check / clean

1

Replace

1

Check / clean

1

Replace

1

Check / clean

2

Replace

2

Check / clean

2

Replace

2

Replace Carry out oil analysis Change oil Check pressure (cf. Service Manual) Replace

4 1

High-pressure filter (control circuit) High-pressure filter (auxiliary control circuit) High-pressure filter (slewing circuit) High-pressure filter (feeding circuit) Breather filter Hydraulic oil reservoir Pressure accumulator Cylinder (seals and guide rings)

1

6 7

1

6

cf. “Refilling quantities – Oil“ table Unless it is regulary analyzed, the hydraulic oil must be changed every 5000 OH or after 3 years at the latest

7

3-23

OMM 6030AC, 6030ACFS(3 847 030.00)-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)

Location

Servicing work

Pump drive gearbox

Carry out oil analysis Change oil Clean Change oil

- Breather filter - Pre-chamber - Expansion reservoir - Breather filter Oil filter

Swing gearbox - Breather filter - Brake chamber (Gearbox P/N 3676892 only) Travel gearbox

- Magnetic rod - Pre-chambers - Magnetic rod - Brake-chambers - Breather filter

8

Clean Check for contamination and damage Replace Carry out oil analysis Change oil Replace Change oil

1 2 28 2x1 28

Carry out oil analysis Check oil level Change oil Clean Check oil level Change oil Clean Check oil level Change oil Clean / replace

2 2 28 2x6 2x1 2x18 2x1 2x2 2x28 2x1

cf. “Refilling quantities – Oil“ table

3-24

Menge / No. 1 8 1 1 68 1 1

Page 4 of 5 Plan Plan Plan Plan Plan A B C D E

OMM 6030AC, 6030ACFS(3 847 030.00)-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 5

Location

Servicing work

Swing ring

Check grease filling

Gearing / pinion

Check condition

Fastening screws (swing ring, undercarriage and superstructure) Undercarriage Diaphragm accumulator

Check for tightness (cf. Service Manual)

- Diaphragm

Check wear (cf. Service Manual) Check pressure (cf. Service Manual) Replace

Central lubricating system

Check function

Oilfilter (hydraulic circuit grease pump)

Check for contamination and damage Replace Check for contamination and damage Replace

Grease filter (grease lines)

Menge / No. 1

Plan E

1 1 1

1

Check / replace

1

Air conditioner (optional)

Carry out all service work described in the “Air Conditioning manual.

Clean / Replace

All articulated joints and hinges

Plan D

1

Breather filter

Modules, fastening screws

Plan C

2x1

Check for contamination and damage Replace

Steel components

Plan B

2

Grease filter (filling grease container)

- Filter mats

Plan A

1

Visual inspection acc. to “Structural Inspection Report every 500 9 OH” 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

9

„Structural Inspection Reports“ for inspections every 500 OH and every 5000 OH can be downloaded from the CGM HMS GmbH website, section „Support, Warranty“.

3-25

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INSPECTION AND SERVICING LUBRICATING CHART – GREASE

Fig. 3-7:

Lubricating chart – Grease (legend)

3-26

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INSPECTION AND SERVICING No. Greasing point

Number

1

Central lubricating system – grease container

1

3

Electric motor

2

6

Monitoring, warning and control elements

Lubricant properties

Grease every .... operating hours 10

V 10

1000 (refer also to the electric motors type plate)

V 10

1000

11

- Joystick

2x4

- Pedal

3 x 2 11

1000

All other greasing points are supplied with grease by the central lubricating system.

Filling quantities – Grease Greasing point Central lubricating system – grease container (depends on the type of container built in) Internal gearing – Roller-bearing slewing ring

Lubricant properties

V 10

Idler (permanent grease filling) Track rollers (permanent grease filling only when not connected to the central lubrication system) Support rollers (permanent grease filling)

10

cf. "LUBRICANTS" section

11

apply a thin layer of low temperature grease

Tribol CGM HMS GmbH part no. 2764564

Filling quant. in kg lb appr. 180 – 500 appr. 150

appr. 397 – 1102 appr. 331

2 x appr. 4.5

2 x appr. 10

14 x appr. 14

14 x appr. 31

4 x appr. 1.3

4 x appr. 2.9

3-27

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INSPECTION AND SERVICING INSPECTION PLAN - OIL

Fig. 3-8:

3-28

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INSPECTION AND SERVICING Inspection plan – Oil (legend) No. Location

Lubricant 12 properties

II III.a

1

Hydraulic system

1

2

Pump drive gearbox

1

- Pre-chambers

6

Swing gearbox (Gearbox P/N 3692960) Swing gearbox (Gearbox P/N 3676892) - Expansion reservoir - Expansion reservoir brake chamber Travel gearbox

2

3 4

5

12

Number

2 2 2

III.b III.b III.c

Check oil level every ... OH 10

Change oil every ... OH 13 10000

60

1000

10

1000

10

1000

10 10

1000 1000

500

5000

- Pre-chambers

2x1

500

5000

- Brake-chambers

2x2

500

5000

cf. "LUBRICANTS" section

13

Change hydraulic oil every 5000 OH unless the oil is analyzed at regular intervals, but not later than every 3 years.

3-29

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INSPECTION AND SERVICING Filling quantities - oil Location

Filling quantity

Oil

litres

gal

Hydraulic oil reservoir

appr. 3000

appr. 792.5

Pump drive gearbox

appr. 98

appr. 25.9

- Pre-chambers

6 x appr. 1

6 x appr. 0.26

Swing gearbox (Gearbox P/N 3692960)

2 x appr. 38

2 x appr. 10

Swing gearbox (Gearbox P/N 3676892) - Brake chambers Travel gearbox (Gearbox P/N 2712182) - Pre-chambers

2 x appr. 26 2 x appr. 6 2 x appr. 60 2 x appr. 7

2 x appr. 6.9 2 x appr. 1.6 2 x appr. 17.4 2 x appr. 1.9

- Brake-chambers Travel gearbox (Gearbox P/N 3683493 / 3737455) - Pre-chambers

4 x appr. 0.5 2 x appr. 94 4 x appr. 1

4 x appr. 0.13 2 x appr. 24.8 4 x appr. 0.26

II III.a III.b III.b III.c III.c

Filling quantities - other Location

Screen washer

3-30

Filling quantity litres

gal

appr. 13

appr. 3.4

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INSPECTION AND SERVICING LUBRICANTS 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 Operating Instructions 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 Operating Instructions.

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.

The oils and greases filled into the machine must meet at least the specifications mentioned in the

3-31

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INSPECTION AND SERVICING

II.

Fig. 3-9:

3-32

Oil for hydraulic system

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INSPECTION AND SERVICING

III.a Oils for pump drive gearbox and travel gearboxes

Fig. 3-10:

3-33

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INSPECTION AND SERVICING

III.b Oils for swing gearboxes

Fig. 3-11:

3-34

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INSPECTION AND SERVICING

V. Grease for bearings, slew rings and track system (Central lubrication system)

Fig. 3-12:

3-35

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INSPECTION AND SERVICING

Grease for idlers, track rollers and support rollers (Lifetime lubrication)

Fig. 3-13:

3-36

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INSPECTION AND SERVICING SERVICING WORK Hose line for oil change Collect escaping oil and cooling liquid and discard without polluting the environment.

The swing gearboxes are moreover equipped with automatic drain valves (1, Fig. 3-15:) These automatic drain valves permit oil 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 is can be done by means of a hose through the service station (tanklift) (Fig. 3-14:).

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. 3-15:

Change oil as follows: Place a collecting recipient for used oil under the corresponding automatic drain valve. For the recipient capacity refer to the "Re-filling 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 has drained away, unscrew hose line to allow the valve to close automatically.

Screw protective cap back in place.

Fig. 3-14:

3-37

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INSPECTION AND SERVICING ELECTRIC MOTOR Electric motor - Safety instructions Read and observe: "Inspection and Servicing – Safety Instructions" and the electric motor operating instructions.

Secure the machine as described in the "Securing the machine" section.

Wear protective gloves and firm working clothing.

Switch off electric motor, to do so actuate switch (52, Fig. 3-16:).

Set servicing switch (4, Fig. 3-17:) to locked position and secure in this position with a padlock.

Cleaning the electric motor Clean the electric motor, the cooling fins, bearing shields and ventilators from dust with compressed air, brushes and clothes only.

Remove the fan guard before cleaning the ventilator fan. Install it after cleaning.

Don't damage the protective coating while cleaning the electric-motor.

For more information see the manufacturers manual for the electric motor.

Fig. 3-16:

It is not permissible to clean the electric motor or any live shovel components with a steam cleaner and steam jet.

After finishing work on the electric motor remove the padlock from servicing switch (4, Fig. 3-17:) and unlock.

Fig. 3-17:

3-38

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INSPECTION AND SERVICING Electric motor, greasing Read and observe: "Inspection and Servicing – Safety Instructions" and the electric motor operating instructions.

Secure the machine as described in the "Securing the machine" section.

Wear protective gloves and firm working clothing.

During greasing the electric motor must be switched on. Be extremely careful to rotating parts.

Grease the bearings of the electric motor in regular intervals (see plate on the electric motor (Fig. 3-18:)).

Additional information on servicing the electrical motor is given in the electric motor operating instructions from the motor manufacturer.

Up to 30 minutes after greasing the temperature of the bearings might heavily increase. Thereafter the temperature decrease to normal. This is normal, the procedure is monitored on the BCS display.

Fig. 3-18:

Additional servicing work All servicing and maintenance work not described here are carried out by the CGM HMS GmbH after sales service resp. by the Service Dept. of the manufacturer of the electric motor. (see electric motor operating instructions).

3-39

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INSPECTION AND SERVICING ELECTRICAL SYSTEM Electrical system - Safety instructions

Interrupt electrical circuits with the circuit breaker before start working on the electrical system. All electric lines upwards from the circuit breaker are then without voltage (refer to the "Safety instructions for shovels with electric motor" at the beginning of this chapter).

Before starting live-line servicing work e.g. measuring and testing with voltage applied, press switch (4, Fig. 3-19:) and secure it with a padlock.

Now voltage is supplied to the whole system but the electric motor can not be switched on.

This prevents accidents, inadvertent starting of the electric motor, and short circuits.

The 24V circuits are energized by the two batteries when the circuit breaker is switched off. These lines can also be de-energized with the battery main switch. Shut off the electrical system with the battery main switch when carrying out repair work or during prolonged downtimes of the shovel.

Read and observe the "Inspection and servicing – Safety instructions" chapter.

Risk of injury caused by battery acid and gases.

Wear goggles, working gloves and firm working clothing.

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. The electrical circuit diagrams are annexed to the spare-parts list. Further information can be found in the CGM HMS GmbH Service Manual "Working with circuit diagrams".

Cables and cable lugs must not get in contact with other metal parts. Replace broken or damaged cables and the respective cable lugs.

If a bulb does not work after replacement, the pertaining fuses, connection cables and contacts must be checked.

Gas-discharge lamps in Xenon working lights are operated with high voltage.

Fig. 3-19:

3-40

OMM 6030AC, 6030ACFS(3 847 030.00)-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. 3-20:).

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“).

If the fluid level is too low, top up with distilled water only

Checking the charge condition of the battery The acid temperature must be 20 ° C (68°F).

Unscrew caps of the battery (Fig. 3-20:).

Measure the acid density of the battery using a commercial acid tester (Fig. 3-20:).

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

Fig. 3-20:

3-41

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

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.

Switch off the electric motor before removing the batteries to avoid damaging the alternator and the regulator.

Turn key in key-switch to position "0" and withdraw.

Set battery main switch (Fig. 3-21:) to “OFF“ position.

Disconnect and reconnect the terminal clamping lugs in the prescribed order.

Disconnecting and connecting in the wrong order may cause short-circuits.

Fig. 3-21:

3-42

The batteries (1, Fig. 3-22:) are located in the cab module underneath the operators cab.

The 12-volt batteries are connected in series and in parallel, so that the system voltage is 24 volts.

Fig. 3-22:

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.

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INSPECTION AND SERVICING Charging the batteries

Switchgear cabinet

The batteries are charged by the battery charger ( Fig. 3-23:) only if the electrical system with the circuit breaker is switched on.

The battery main switch (Fig. 3-24:) must be in position I "ON".

Breather filter In the switchgear cabinet For the 6.3 kV power supply (2, Fig. 3-25:), For the 400 V system (1, Fig. 3-25:), For the 24 V system (3, Fig. 3-26:).

The air is drawn in and cleaned by a ventilator with filter.

Fig. 3-23:

Fig. 3-25:

Fig. 3-24:

Fig. 3-26:

3-43

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INSPECTION AND SERVICING Emptying dust trap Press dust trap (14, Fig. 3-27:) and hold until the dust trap is empty.

Emptying the dust collector Loosen clips (11, Fig. 3-27:).

Remove dust collector (12) and empty.

Filter element, replace Remove dust collector (12, Fig. 3-27:).

Withdraw filter element (13, Fig. 3-28:).

Replace or clean filter element (13).

Refit dust collector (12, Fig. 3-27:).

Fig. 3-27:

Fig. 3-28:

3-44

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INSPECTION AND SERVICING Checking and cleaning the filter element Check the filter paper of the element by inserting a lamp into the element (Fig. 3-29:). 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. 3-30:) dry with compressed air by moving the compressed-air piston up and down inside it.

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.

Fig. 3-29:

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. 3-30:

3-45

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INSPECTION AND SERVICING Replacing filter mats

Slip ring maintenance

A filter mat is installed in the switchgear cabinet (Fig. 3-31:) behind the cover (4).

Check filter mats visually and replace if necessary.

See (Fig. 3-32:)

Fig. 3-31:

Drain condensate from the switch gear cabinets Check all cabinets for condensate.

Screw out draining plugs and drain condensate.

Keep the inner of the cabinets dry and clean.

High voltage, Danger to Life.

Switch off power supply at the transformer station.

Check that the slip ring assembly is without tension before opening it.

Read and observe the "Inspection and servicing – Safety instructions" chapter as well as the chapter “Electrical system, safety instructions”.

Observe the Servicing Instructions of the slip ring manufacturer.

Remove all tracks of dirt.

There is a transparent sideplate at the housing. Check the housing inside for wear debris coming from the brushes and for grease. Remove if necessary.

Clean insulators and check for damage.

Check condition of slip ring contact surfaces; remove any sign of oxydation, "splatter" or burn spots.

Check carbon brushes for signs of wear.

(See Servicing Instructions of the slip ring manufacturer).

Fig. 3-32:

3-46

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INSPECTION AND SERVICING 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.

3-47

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INSPECTION AND SERVICING Replacing a defective Xenon-lamp Read and observe the: „Floodlight projector, replacing the lamp, Safety instructions“.

Fig. 3-33

Fig. 3-34

Fig. 3-35

3-48

Switch off the projector, shut off the electric motor 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.

Remove four screws (1, Fig. 3-33) and withdraw the reflector (2) from the projector housing.

Withdraw connector (Fig. 3-34) from Xenon lamp socket.

Unscrew Xenon lamp holding clamp (Fig. 3-35).

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.

OMM 6030AC, 6030ACFS(3 847 030.00)-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.

Switch off the electric motor.

Risk of burning caused by hot hydraulic components (e.g. hydraulic oil reservoir, cylinder, valves).

Secure the machine as described in the "Securing the mmachine section.

Avoid skin contact with hydraulic oil.

Contact with hydraulic oil can cause skin injury.

Wear protective gloves and firm working clothing.

Depressurizing the hydraulic system Hydraulic systems may only be opened if they are completely depressurized. Even when an shovel is parked on a horizontal surface with the working equipment resting on the ground (Fig. 3-36:) and with its drive motor switched off, 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:

Fig. 3-36:

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.

3-49

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INSPECTION AND SERVICING Examples of system sections: 1) working hydraulics, 2) servo control circuit, 3) precharged return-flow line.

Depressurizing: Park the shovel on a horizontal surface.

Set the working equipment on the ground.

Switch off the electric motor.

Do not switch off the electrical system For sections 1 and 2, servo control and working hydraulics: Shift both control levers repeatedly into all dIrections (Fig. 3-37:).

For section 3, return-flow line: After switching off the electric motor, the precharging pressure decreases rapidly through the precharging valve. No measures are required before opening the return-flow line.

Checking the hydraulic oil level Bring hydraulic oil to operating temperature (abt. 50 °C / 122°F).

Park the machine on a horizontal surface.

Move all hydraulic cylinders to their central positions.

The oil level must lie between the “min” and the “max” marks of sign (2) near the inspection glass (1, Fig. 3-38:).

Fig. 3-38:

The hydraulic oil level is monitored by the BCS. The BCS displays a warning on the screen (Fig. 3-39:) if the hydraulic oil level is too low or too high.

Switch off the electric motor, locate cause and rectify.

Fig. 3-37:

Fig. 3-39:

3-50

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INSPECTION AND SERVICING

Fig. 3-42:

Fig. 3-40:

Stand working equipment on the ground as shown on the sign (Fig. 3-40:).

Sign (2, Fig. 3-41:) is attached beside the level inspection glass (1).

Hydraulic oil can also be filled inby means of the service station (Fig. 3-43:).

Unscrew cap of express coupling (10).

Connect filling hose express coupling of the service vehicle.

The use of the hose line is described in the "Hose line for oil change" section.

Fill in hydraulic oil until the oil level lies between the “min” and the “max” marks of the sign near the inspection glass (1, Fig. 3-41:) (oil grade cf. "LUBRICANTS").

Unscrew the hose line; the express coupling closes automatically.

Screw protective cap back in place

Fig. 3-41:

Fill in hydraulic oil through the return-flow filters.

Remove cover (19, Fig. 3-42:). abnehmen.

Fill in hydraulic oil through the opening until the oil level lies between the “min” and the “max” marks of sign (2) near the inspection glass (oil grade cf. "LUBRICANTS").

Fig. 3-43:

Before fitting the cover (19), check the sealing ring and replace, if damaged.

Fit cover together with sealing ring.

3-51

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INSPECTION AND SERVICING Changing the hydraulic oil returnflow filter (hydraulic oil reservoir)

Remove cover (3, Fig. 3-45:) together with sealing ring (5) and retaining disk (7).

Read and observe the "Inspection and servicing – Safety instructions" chapter.

Switch off the electric motor.

Risk of scalding caused by hot hydraulic oil.

The hydraulic oil reservoir itself may also be hot.

Avoid skin contact.

Skin contact with hydraulic oil may cause skin injury.

Wear protective gloves and firm working clothing.

Fig. 3-45:

Collect escaping hydraulic oil and discard without polluting the environment.

Remove cap (8, Fig. 3-46:) and sealing ring (10).

Withdraw filter element (9) and sealing ring (11) from basket (12).

Insert a new filter element.

If a filter element (9) is damaged, remove basket (12) and check/clean.

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. 3-44:). In this case, the filter elements (9, Fig. 3-46:) are heavily contaminated; after repairs on the hydraulic system; in case of damage.

Fig. 3-46:

Fig. 3-44:

3-52

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INSPECTION AND SERVICING Loosen screws (13, Fig. 3-47:) and take off spring clip (14) and disk (15).

Remove basket (12) and clean in paraffin oil.

Install basket (12).

Insert filter element (9) together with sealing ring (11) and cap (8) with sealing ring (10).

Refit cover (3).

Clean the magnetic rod The magnetic rod is located under cap (19).

If metal filings are detected, locate cause and rectify.

Contact the CGM HMS GmbH Service, if required.

Fig. 3-47:

3-53

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INSPECTION AND SERVICING Bypass valves (hydraulic oil reservoir)

Cleaning the filter screens

Read and observe the "Inspection and servicing – Safety instructions" chapter.

Switch off the electric motor.

Risk of scalding caused by hot hydraulic oil.

The hydraulic oil reservoir itself may also be hot.

Avoid skin contact.

Skin contact with hydraulic oil may cause skin injury.

Wear protective gloves and firm working clothing.

Collect escaping hydraulic oil and discard without polluting the environment.

Fig. 3-48:

Fig. 3-49:

Remove cover (3, Fig. 3-49:) together with sealing ring. Unscrew screws (25). Withdraw bypass valve. Take off screen (21) together with sealing ring and clean in white spirit or paraffin oil. Replace, if required.

Check sealing ring for damage and replace, if required.

Re-assemble the bypass valve.

Check sealing ring (28) for damage and replace, if required.

Insert bypass valve and fasten with screws (25).

Replacing the bypass valves and sealing rings Remove bypass valve as described under "Cleaning the screens".

Re-assemble the bypass valve with a new screen (21, Fig. 3-49:) and a new sealing ring.

Insert bypass valve with new sealing ring (243) and fasten with screws (25).

3-54

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INSPECTION AND SERVICING Replacing the hydraulic oil return-flow filters (filter housing)

Replace the return-flow filters (15, Fig. 3-50:) together with the return-flow filters in the hydraulic oil reservoir.

Read and observe the "Inspection and servicing – Safety instructions" chapter.

Switch off the electric motor.

Risk of scalding caused by hot hydraulic oil.

The hydraulic oil reservoir itself may also be hot.

Avoid skin contact.

Skin contact with hydraulic oil may cause skin injury.

Wear protective gloves and firm working clothing.

Collect escaping hydraulic oil and discard without polluting the environment.

Fig. 3-51:

Detach cover (10, Fig. 3-51: resp. Fig. 3-50:) together with sealing ring (12).

Withdraw filter element (15).

Insert a new filter element.

If metal filings are detected, locate cause and rectify.

Contact the CGM HMS GmbH Service, if required.

Refit cover (10) with new sealing ring (12).

Fig. 3-50:

3-55

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INSPECTION AND SERVICING Bypass valves (filter housing cooling system) Read and observe the "Inspection and servicing - Safety instructions" chapter.

Cleaning the screens Clean/replace the bypass valves (Fig. 3-52:) together with the bypass valves in the hydraulic oil reservoir.

Switch off the electric motor.

Risk of scalding caused by hot hydraulic oil.

The hydraulic oil reservoir itself may also be hot.

Avoid skin contact.

Skin contact with hydraulic oil may cause skin injury.

Wear protective gloves and firm working clothing.

Collect escaping hydraulic oil and discard without polluting the environment.

Fig. 3-53:

Detach cover (10, Fig. 3-53: resp. Fig. 3-52:) 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.

Re-assemble the bypass valve.

Insert bypass valve and fasten with screws (22).

Refit cover (10) with a new sealing ring (5).

Fig. 3-52:

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 (24).

Insert bypass valve with new sealing ring (24) and fasten with screws (22).

Refit cover (10) with a new sealing ring (5).

3-56

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INSPECTION AND SERVICING Breather filter Read and observe the "Inspection and servicing - Safety instructions" chapter.

Replacing the filter elements The breather filters (20, Fig. 3-54:) ensure venting of the hydraulic oil reservoir at varying hydraulic oil levels.

Switch off the electric motor.

Risk of scalding caused by hot hydraulic oil.

The hydraulic oil reservoir itself may also be hot.

Avoid skin contact.

Skin contact with hydraulic oil may cause skin injury.

Wear protective gloves and firm working clothing.

Fig. 3-54:

Unscrew screws (21). Remove holder (22) and withdraw filter element (20).

Check filter element and replace, if required.

3-57

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INSPECTION AND SERVICING Filter (control circuit and auxiliary control circuit) One filter each in the control circuit and auxiliary control circuit are installed (Fig. 3-55:).

Replacing the filter elements To filter the hydraulic oil in the control circuit, the machine is equipped with a high-pressure filter (8, Fig. 3-56:).

Change filter element regulary and when the BCS indicates a contamination.

Fig. 3-55:

Read and observe the "Inspection and servicing - Safety instructions" chapter.

Switch off the electric motor.

Risk of scalding caused by hot hydraulic oil.

The hydraulic oil reservoir itself may also be hot.

Avoid skin contact.

Skin contact with hydraulic oil may cause skin injury.

Wear protective gloves and firm working clothing.

3-58

Fig. 3-56:

Unscrew filter housing (5, Fig. 3-56:).

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.

Check seals (10 and 14) and replace, if required.

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.

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INSPECTION AND SERVICING High-pressure filter for working hydraulics To filter the hydraulic oil on the high-pressure side of the working hydraulic system, the machine is equipped with four high-pressure filters (8, Fig. 3-57:).

Checking/cleaning the filter elements Unscrew drain plug (11, Fig. 3-58:) and drain the hydraulic oil from the filter housing (9).

(Place a suitable resipient under the filter housing).

Unscrew filter housing (9).

Disengage filter element (15) with a slight turn from ist retaining catch and withdraw from filter housing (9).

Clean filter element (15) in white spirit or paraffin oil.

Replace filter element (15) if it is damaged.

Check seals (10 and 14) and replace, if required.

Re-assemble the filter element in reverse order.

Check for leaks after putting the filter into operation.

Fig. 3-57:

Read and observe the "Inspection and servicing – Safety instructions" chapter.

Switch off the electric motor.

Risk of scalding caused by hot hydraulic oil.

The filter housings themselves may also be hot.

Avoid skin contact.

Skin contact with hydraulic oil may cause skin injury.

Wear protective gloves and firm working clothing.

Collect escaping hydraulic oil and discard without polluting the environment.

Fig. 3-58:

Replacing the filter elements Detach the filter element as described under "Checking the filter elements".

Clean filter housing (9, Fig. 3-58:) and the sealing faces at the filter head with white spirit or paraffin oil.

Insert new filter element into filter housing (9) and refit to the filter head with new, lightly oiled sealing rings (10 and 14) and a new retaining ring (13).

Check high-pressure filter for leaks after putting it into operation.

3-59

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INSPECTION AND SERVICING High-pressure filters for slewing circuit Each of the two slewing circuits is equipped with a high-pressure filter (Fig. 22).

The filter elements (2, Fig. 23) are only to be cleaned/changed if necessary.

Read and observe: "Inspection and servicing - Safety instructions".

Checking/cleaning the filter elements Loosen flange (6, Fig. 3-59:).

Unscrew cover (5, Fig. 3-60).

Withdraw filter element (2) together with sealing ring (3) and retaining ring (4) from housing (1).

Clean filter element (2) with white spirit or paraffin oil.

Insert filter element into filter housing (1) and refit with new, lightly oiled sealing ring (10) and a new retaining ring (4).

Screw cover (5) into housing (1).

Refit flanche (6, Fig. 3-59:) to housing (1). heck high-pressure filter for leaks after putting it into operation.

Fig. 3-59:

Shut off the electric motor.

Risk of scalding from hot hydraulic oil.

The filter housings may also be hot.

Avoid skin contact.

Skin contact with hydraulic oil may cause skin injury.

Wear protective gloves and firm protective clothing.

Collect escaping hydraulic oil and discard without polluting the environment.

3-60

Fig. 3-60

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INSPECTION AND SERVICING High-pressure filters for feeding circuits and slewing pumps The shovel has two high-pressure filters (Fig. 3-61:) for the feeding circuits of the slewing pumps.

Two high-pressure filters each are installed beside the pump drive gearbox.

Read and observe: "Inspection and servicing - Safety instructions".

Checking/cleaning the filter element Detach flange (4, Fig. 3-62:).

Remove filter housings and pour out used oil.

Withdraw filter element (6) from filter housing (5).

Clean filter housings and sealing faces at filter head with white spirit or paraffin oil.

Insert new filter element into filter housing (5) and refit to filter head with a new, lightly oiled sealing ring (8).

Check the high-pressure filter for leaks after putting it into operation.

Fig. 3-61:

Shut off the electric motor.

Risk of scalding from hot hydraulic oil.

The filter housings may also be hot.

Avoid skin contact.

Skin contact with hydraulic oil may cause skin injury.

Wear protective gloves and firm protective clothing.

Collect escaping hydraulic oil and discard without polluting the environment.

Fig. 3-62:

Replacing the filter elements Detach the filter elements as described under "Checking the filter elements".

Install new filter element (6, Fig. 3-62:) and reassemble with a new, lightly oiled sealing ring (7).

Check the high-pressure filter for leaks after putting it into operation.

3-61

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INSPECTION AND SERVICING Changing the hydraulic oil

Drain the hydraulic oil at express couplings (1, Fig. 3-63:).

Read and observe the "Inspection and servicing - Safety instructions" chapter.

Switch off the electric motor.

Risk of scalding caused by hot hydraulic oil.

The hydraulic oil reservoir itself may also be hot.

Avoid skin contact.

Skin contact with hydraulic oil may cause skin injury.

Wear protective gloves and firm working clothing.

Collect escaping oil and discard without polluting the environment.

Do not switch on the electric motor when the hydraulic oil reservoir is empty. The hydraulic pumps may be destroyed if they are allowed to run dry.

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.

Switch off the electric motor.

3-62

Fig. 3-63:

Place suitable recipients under the drain valve (1) of the hydraulic oil reservoir. For the required capacity refer to the "Refilling quantities - Oil" table.

The use of the hose line is described in the "Hose line for oil change" section.

Unscrew the hose line; the oil drain valve closes automatically.

Screw protective cap back in place.

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INSPECTION AND SERVICING Drawing off hydaulic oil The hydraulic oil can also be drawn off through the service station (Fig. 3-64:).

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.

Switch off the electric motor.

Unscrew cap of express coupling (10).

Connect hose line of the service vehicle.

The hose line and its use are described in the "Hose line for oil change" section.

Remove hose line. The coupling closes automatically.

Screw on protective cap.

Cleaning the hydraulic oil reservoir Explosion hazard.

Do not use white spirit, paraffin oil or other solvents for cleaning.

Use diesel fuel or a special flushing oil.

Read and observe the "Inspection and servicing - Safety instructions" chapter.

Switch off the electric motor.

Skin contact with hydraulic oil may cause skin injury.

Avoid skin contact.

Wear protective gloves and firm working clothing.

Dispose of contaminated hydraulic oil without polluting the environment and separately from other waste.

Drain off hydraulic oil as described under "Draining off the hydraulic oil".

Remove cap (3, Fig. 3-65:).

Detach the return-flow filter.

Fig. 3-64:

Fig. 3-65:

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).

3-63

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INSPECTION AND SERVICING Filling in hydraulic oil Fill in hydraulic oil through the return-flow filters.

Remove cap (19, Fig. 3-66:).

Fill in hydraulic oil through the opening until the oil level lies between the “min” and the “max” marks of the sign near the inspection glass (1, Fig. 3-67:).

(Oil grade cf. "LUBRICANTS").

Hydraulic oil can also be filled by means of the service station (Fig. 3-68:).

Unscrew cap of express coupling (10).

The use of the hose line is described under "Hose line for oil change". 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 sign near the inspection glass (1, Fig. 3-67:).

(Oil grade cf. "LUBRICANTS").

Fig. 3-66: Fig. 3-68:

The oil level is also displayed on the BCSscreen (Fig. 3-69:).

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. 3-67:

Vent the hydraulic system.

Check the oil level in the hydraulic oil reservoir.

Top up with oil, if required.

Refit cap (19, Fig. 3-66:).

Fig. 3-69:

3-64

OMM 6030AC, 6030ACFS(3 847 030.00)-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 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).

Open the highest leakage oil port and fill in clean hydraulic oil up to the lower edge of the opening.

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.

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. 3-70: and Fig. 3-71:) must be either completely retracted or completely extended.

Fig. 3-71:

Always admit oil first to that side of the cylinder where the piston (2) is. This is • the piston-side port (3) when the piston rod is retracted (1, Fig. 3-70:), • the rod-side port (4) when the piston rod is extended (1, Fig. 3-71:).

If, for assembly reasons, the piston rod is inmiddle position, admit oil first to the pistonside 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.

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. 3-70:

3-65

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INSPECTION AND SERVICING Cleaning the hydraulic oil cooler Risk of injury from rotating cooler fan blades.

Switch off the electric motor.

Never start cleaning work until the cooler fan blades have stopped turning.

The hydraulic oil coolers reach the same temperature as the hydraulic oil. Risk of burning.

Allow the hydraulic oil cooler to cool down.

Wear protective gloves and firm protective clothing.

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.

The speeds of the fan motors (1, Fig. 3-72:) are thermostat-controlled. The fan motors run at maximum speed when the hydraulic oil temperature reaches ca. 60°C.

Cleaning The hydraulic oil coolers are located in the oil cooler module.

Clean the hydraulic oil coolers at regular intervals.

Switch off the electric motor Remove any accumulated dirt.

Clean the fan blades (2, Fig. 3-72:).

Clean the radiators with a jet of water or compressed air from outside to inside.

Leave hydraulic oil coolers to dry.

Check the hydraulic motors (1) for free movement.

In winter-time, check that the fans (2) turn freely and that the cooling fins are free from ice and snow.

Fig. 3-72:

3-66

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INSPECTION AND SERVICING Electronic shovel control

Pedal

Joystick

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. 3-74:).

Apply a thin layer of low temperature grease on the control spools of the pedals to prevent jamming of the control spools.

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. 3-73:) to prevent jamming of the joysticks.

Refit gaiter using a cable strap.

Fig. 3-74: Fig. 3-73:

3-67

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INSPECTION AND SERVICING Pressure accumulator - Emergency lowering

Pressure accumulator – Servo control- and feeding circuit

To permit the working equipment to be lowered in an emergency, the machine is equipped with a pressure accumulator (2,Fig. 3-75:).

The pressure accumulator (2) is located in the superstructure and is accessible from the ground.

The machine is equipped with a pressure accumulator (1,Fig. 3-76:). For the servo control- and feeding circut.

The pressure accumulator (1) is located above the pump drive gearbox.

Fig. 3-75:

Fig. 3-76:

3-68

OMM 6030AC, 6030ACFS(3 847 030.00)-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 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 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.

For measuring the precharge pressure in the pressure accumulator, observe the instructions set out in the booklet "Filling and testing device for pressure accumulators" annexed to this documentation

Group II p ≥ l bar and p·x l ≤ 200

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.

3-69

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INSPECTION AND SERVICING PUMP DRIVE GEARBOX Read and observe: "Inspection and servicing - Safety instructions.

Shut off the electric motor.

The gearbox housing 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.

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. 3-78) 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.

Pump drive gearbox, checking the gearbox oil level Park the machine as described in the "Securing the machine" section.

Check oil level only when gearbox is cold. Heated oil may result in inaccurate measurements.

Observe the information decals attached to the gearbox housings near the dipsticks.

Unscrew dipstick (1, Fig. 3-77:) and wipe.

Insert dipstick (1) again until the thread lies on top of the dipsticks tube, do not screw in Withdraw dipstick again and check oil level.

Oil level should lie between the two “min” and “max” markers on the dipstick. Top up with gearbox oil if required.

Screw in dipstick (1) again.

In case of significant oil losses check for leaks at the gearbox and on all components of the gearbox oil cooling system.

Too much oil in the gearbox may be a signal of defective seals at hydraulic components. Contact your Caterpillar dealer service.

Fig. 3-77:

3-70

Fig. 3-78

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INSPECTION AND SERVICING Pump drive gearbox, changing oil Carry out oil change when gearoil is nearly at operating temperature. All suspended particles and contaminations will be rinsed out with the old oil.

Recommendation: If the gearbox oil is heavily soiled, the gearbox should be flushed with fresh gearbox oil. In this case contact your Caterpillar dealer.

Drawing off gearbox oil The gearbox oil is drained with the service station (Fig. 3-79:) through express coupling (5).

Unscrew protective cap of express coupling and connect hose line of the service vehicle.

Drain gearbox oil.

Remove hose after the oil has been drained.

The coupling closes automatically.

Screw on protective cap.

Fig. 3-79:

Filling in gearbox oil (Oil grade see: „“LUBRICANTS / CONSUMABLES”).

Fill in gearbox oil with the service (Fig. 3-79:).

Unscrew cap of express coupling (5).

Connect hose line of service vehicle.

Fill in gear oil until the oil level reaches the „max“ mark on dipstick (1, Fig. 3-80:).

Remove filling hose after the oil has been filled in. The express coupling closes automatically.

Screw on protective cap.

Start electric motor and run for maximum two minutes, then shut off motor.

The pump drive cooling circuit has now been filled with oil.

Check gearbox oil level and top up to the correct filling level.

Check for leaks and for correct filling level after putting the machine back into operation (approx. after one hour).

Top up with oil if necessary through the plug of filler tube (arrows, Fig. 3-80:).

Note: The oil level is to be checked after about 30, 60 and 240 minutes running time as oil collects in the mounting flanges or is accumulated there to lubricate the slined hollow shafts. The gearbox oil cooling system is also to be filled with oil. Therefore it is absolutely necessary to check the oil level and top up with oil up to the correct level.

Fig. 3-80:

3-71

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INSPECTION AND SERVICING Pre-chamber

Gearbox venting

Draining off oil Prepare a collecting recipient for used oil.

Choose the required capacity in accordance with the "Refilling quantities - Oil" table.

Unscrew plug (7, Fig. 3-81) and drain off oil.

Screw plug (7) back in place.

Filling in oil Filling in oil cf. “Check oil level”.

The gearbox is vented through breather valve (2, Fig. 3-82:).

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.

Pre-chamber The gearbox is vented through breather valve (2, Fig. 3-82:).

Clean breather valve in accordance with the servicing plan.

Unscrew breather filter, clean with white spirit or paraffin oil and blow dry with compressed air.

Screw breather filter back in place.

Fig. 3-81

Fig. 3-82:

3-72

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INSPECTION AND SERVICING Pump drive gearbox lube oil filters

Filter element (5) must be changed after having been cleaned 8 - 10 times; at the latest however, after 1000 operating hours.

Check filter tell-tales (1, Fig. 3-83:) 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.

Fig. 3-84:

Fig. 3-83:

Remove flange (3, Fig. 3-84:).

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. 3-83:) and filter pot (4). Check o-ring (7, Fig. 3-84:) for damage; change if necessary.

Oil the o-ring lightly. Place filter element into filter pot and re-assemly.

Check filters for leakages after recommencing operation.

3-73

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INSPECTION AND SERVICING SLEWING GEARBOX (For swing gearboxes P/N 3692960) Read and observe: "Inspection and servicing - Safety instructions.

Shut off the electric motor.

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.

Wear protective gloves and firm working clothing.

The oil level must reach up at least to the lower mark on dipstick (1). Top up with gearbox oil, if required.

Screw dipstick (1) back in place.

Changing the gearbox oil Prepare a collecting recipient for used oil.

Choose the required capacity in accordance with the "Refilling quantities - Oil" table.

Fig. 3-86:

Draining off oil

Fig. 3-85:

Gearbox - Checking the oil level / Topping up with oil Park the machine as described under "Securing the machine".

Screw out dipstick (1, Fig. 3-85:) and wipe clean.

Insert dipstick (1) fully again (do not screw in) and withdraw a second time.

3-74

Attach hose (8, Fig. 3-86:) to drain valve (7) and drain off oil completely.

The use of the oil draining hose is described in the "Hose line for oil change" chapter.

The drain valve (7, Fig. 3-86:) is accessible from the undercarriage.

Remove hose. The oil drain valve closes automatically.

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INSPECTION AND SERVICING Filling in new oil / Topping up Unscrew plug (4, Fig. 3-87:) and fill in new oil.

Check oil level with dipstick (1, Fig. 3-87:).

Screw in plug (4) again.

Gearbox venting The gearbox is vented through breather filter (2, Fig. 3-87:).

Clean breather filter 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.

Fig. 3-87:

3-75

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INSPECTION AND SERVICING SWING GEARBOX (For swing gearbox P/N 3676892) Read and observe: "Inspection and servicing - Safety instructions.

Shut off the electric motor.

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.

The gearbox housings may be hot.

Wear protective gloves and firm working clothing.

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).

Gearbox - Checking the oil level / Topping up with oil Check the oil level visually at expansion tanks (5 and 6, Fig. 3-88:). The expansion tanks must be filled with gearbox oil up to abt. 1/3.

The oil level is visible from outside (light/dark area).

If necessary, unscrew cap (7) and fill in oil.

The hoses (4, Fig. 3-88:and Fig. 3-89:) connect the gearboxes (1) with the expansion reservoirs (5 and 6).

Check all threaded joints for leaks.

Expansion reservoir for oil in the brake chamber (6).

Fig. 3-89:

Fig. 3-88:

3-76

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INSPECTION AND SERVICING Changing the gearbox oil 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. 3-92:) from expansion reservoirs (5). Oil will escaping faster then.

Attach hose (3, Fig. 3-90:) to drain valve (2) and drain off oil completely.

The use of the oil draining hose is described in the "Hose line for oil change" chapter.

The drain valve (2, Fig. 3-91:) is accessible from the undercarriage.

Remove oil draining hose. The oil drain valve closes automatically.

Screw on protection cap to the drain valve.

Fig. 3-90:

Gearbox housing, filling in new oil / topping up Unscrew caps (7, Fig. 3-92:) from expansion reservoirs (5) and fill in new gearbox oil.

The expansion tanks must be filled with oil up to abt. 1/3.

The oil level is visible from outside (light/dark area).

Screw caps (7) back in place.

Fig. 3-91:

Fig. 3-92:

3-77

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INSPECTION AND SERVICING Brake chamber, 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. 3-94:) from expansion reservoirs (6). Oil will escaping faster then.

Unscrew plug at the upper edge of the gearbox housing (arrow, Fig. 3-93:).

Oil escapes.

Screw plug (arrow, Fig. 3-93:) back in place.

Gearbox venting The gearbox is vented through the caps of the expansion reservoirs (7, Fig. 3-94:).

Brake chamber, filling in new oil / topping up Fill in new gearbox oil into expansion reservoirs (6, Fig. 3-94:).

The expansion tanks must be filled with oil up to abt. 1/3.

The oil level is visible from outside (light/dark area).

Screw caps (7) back in place.

Fig. 3-94:

Fig. 3-93:

3-78

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INSPECTION AND SERVICING TRAVEL GEARBOX P/N 3683493 / 3737455

Brake chamber - Checking the oil level / Topping up with oil

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.

Unscrew checking screw (6, Fig. 3-96:).

The oil level should reach up to the lower edge of the opening. Top up with oil, if required.

Screw checking plug (6) 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 shovel into such a position that the screw plugs (1, 2 and 3, Fig. 3-95:) are in the displayed position.

Unscrew checking screw (3).

The oil level should reach up to the lower edge of the opening. Top up with oil, if required.

Screw checking plug (3) back in place.

Fig. 3-96:

Fig. 3-95:

3-79

OMM 6030AC, 6030ACFS(3 847 030.00)-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 shovel into such a position that the screw plugs (1, 2 and 3, Fig. 3-97:) 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 (1) allows the oil to run out more readily.

Clean screw plugs (1 and 2).

Screw plug (2) back in place.

Fig. 3-97:

Filling in oil Unscrew plug (1, Fig. 3-97:).

Fill in oil through opening in plug (1) until it flows out of opening in plug (1).

(Oil grade see “LUBRICANTS / CONSUMABLES” section).

Screw plug (1) back in place.

Fig. 3-98:

3-80

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INSPECTION AND SERVICING Brake chamber - 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.

Breather filter Unscrew breather filter (1 and 5, Fig. 3-99:) 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. 3-99:) and drain off the oil completely.

Slackening breather filter (5) allows the oil to run out more readily.

Clean screw plug (7).

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 in plug (6).

(Oil grade see “LUBRICANTS / CONSUMABLES” section).

Screw plug (6) and breather filter (5) back in place.

Fig. 3-99:

3-81

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INSPECTION AND SERVICING CRAWLER TRACKS 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

To clean the tracks: raise one side of the 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. 3-100:) thoroughly; clean the sliding planes on the idler guides.

excessive wear the track from breaking.

Fig. 3-100:

3-82

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INSPECTION AND SERVICING Track roller, Support roller Inspect all track and support rollers visually for leaks and free movement at regular intervals.

Track roller fastening Check fastening screws (4 Fig. 3-101:) regularly for tightness.

Tighten screws with a torque wrench to the prescribed tightening torque (see Service Manual).

Support roller fastening Check fastening screws (3, Fig. 3-101:) regularly for tightness.

Tighten screws with a torque wrench to the prescribed tightening torque (see Service Manual).

Fig. 3-101:

3-83

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INSPECTION AND SERVICING Track tensioner Design The tracks are tensioned with the help of the hydraulic pressure created during travelling. Fig. 3-102: and Fig. 3-103: show parts of the tracks and the tensioner:

Techncal data Track tensioning pressure Pressure limiting valve Gas pressure in pressure accumulator (nitrogen filling pressure)

ca. 70 bars / 1015 psi 330 bars / 4786 psi 50 bars / 725 psi

Function

Fig. 3-102:

1 2 3 4 5 6 7 8 9

Crawler track Idler Drive sprocket Support roller Pressure accumulator Pressure cylinder Pressure limiting valve Track roller Mini- measuring port

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 electric motor has been started. Retensioning is not required.

For cleaning and servicing work, the tracks can be slackened.

To do so: Switch off the electric motor.

Open both pressure limiting valves (7, Fig. 3-103:) to slacken the tracks.

After the work, screw down the pressure limiting valves (7) to the limit stop.

Fig. 3-103:

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.

3-84

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INSPECTION AND SERVICING Pressure-accumulator inspection regulations

Checking the gas charging pressure in the pressure accumulator

The following regulations are applicable only in Germany. Please observe the relevant regulations in force in your own country.

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. Cf. under "Function".

For measuring the precharge pressure in the pressure accumulator, observe the instructions set out in the booklet "Filling and testing device for pressure accumulators" annexed to this documentation.

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:

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

3-85

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INSPECTION AND SERVICING SWING RING Read and observe: "Inspection and servicing - Safety instructions.

Internal gearing The internal gearing (1, Fig. 3-105:) and the pinion (2) are enclosed in a housing (3, Fig. 3-106:). The housing forms a grease-filled trough in which the pinion of the swing mechanism moves.

Switch off the electric motor.

Wear protective gloves and firm protective clothing.

Swing ring - Instructions The grease filling must be replaced: when repairs have been carried out on the slewing ring, the slewing ring seals or the slewing ring housing.

Remove old grease completely before filling in new grease.

If greater losses are detected, locate cause immediately to prevent damage to the slewing 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 .

The grease is pumped to the greasing points of the bearing races by a distributor (Fig. 3-104:).

Fig. 3-105:

The grease is pumped to the greasing port of the grease trough by the distributor (Fig. 3-104:). 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. 3-106:). For checking, the cover must be removed.

Fig. 3-106:

Fig. 3-104:

3-86

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INSPECTION AND SERVICING Swing ring - Checking the grease filling Read and observe: "Inspection and servicing - Safety instructions.

Switch off the electric motor.

Wear protective gloves and firm protective clothing.

At regular intervals check internal gearing and teeth of swing mechanism pinion for condition, 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. 3-107:).

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 - 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, old grease has been removed in the course of other work.

Always fill in fresh grease by hand.

Risk of accidents. Never slew the superstructure when refilling grease.

Swing ring - Checking the screws for tightness The fastening screws of the swing ring in the superstructure and the undercarriage are tightened with their respective check torque (see Service Manual).

When these values are reached, the fastening screws are perfectly tight.

Loosen slack screws before tightening them with a torque wrench to the prescribed torque (see Service Manual).

Fig. 3-107:

3-87

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INSPECTION AND SERVICING CENTRAL LUBRICATING Design The shovel 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 the electric motor is running. All greasing points connected to the system are greased at regular intervals.

The central lubricating system is controlled electrohydraulically by the programmable SPC contoller.

The SPC is located in a switch box underneath the cab.

Fig. 3-109:

If a fault occurs, BCS gives a warning on the screen (Fig. 3-109:).

Actuate the "Reset" key (73, Fig. 3-108:) to eleminate the fault. If this is not possible, call in servicing personal.

For further information on the function and setting refer to the SERVICE MANUAL – SPC (storageprogrammable control).

Fig. 3-108:

3-88

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INSPECTION AND SERVICING Function The grease is pumped by the pump (2, Fig. 3-110:) via greasing lines from the grease container to the main distributors on the superstructure.

As soon as the grease container is empty, the BCS (Fig. 3-112) gives a warning signal. In the event of a fault, the "dumping" function is switched off automatically after 15 min.

Work can be continued when the grease container is filled with grease.

Fig. 3-110:

The control elements of the lubricating system are installed on the panel (3, Fig. 3-111:).

Fig. 3-112

Fig. 3-111:

The control elements of the lubricating system are installed on the panel (3, Fig. 3-111:).

3-89

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INSPECTION AND SERVICING Replacing the grease drum Detach lines (11, 12, 13 and 14 Fig. 3-113:).

Unscrew wing nuts (6).

Detach plate (5).

Remove cover (4) together with grease pump (2) from grease drum (1).

Fig. 3-113:

Replace the empty grease drum by a full one.

Place cover (4) with grease pump (2) back onto the grease drum.

Fasten plate (5) with wing nuts (6) on grease drum (1).

Refit lines (11, 12, 13 and 14).

3-90

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INSPECTION AND SERVICING Checking the greasing pressure Check every week, whether the oil pressure indicated by pressure gauge (4, Fig. 3-114:) is 60 bars / 870psi (the pressure is dependind on temperature and viscosity of the oil and may vary).

The necessary greasing pressure is generated by means of a pressure translator.

The greasing pressure is indicated by pressure gauge (9).

In the event of deviating pressure values, switch off the electric motor and check the central greasing system.

Lower oil pressure means that not all of the greasing points are supplied with grease.

Higher oil pressure may cause bursting of a greasing line.

Always refill the grease container in time to avoid air from penetrating into the greasing system. Air in the greasing may cause malfunctions.

Unblocking a grease line.

Fig. 3-114:

This oil pressure is reduced so that the pressure indicated by pressure gauge (3, Fig. 3-115:) is 35 – 40 bars (507psi – 580psi).

Put the shovel back into operation only after the lubricating 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.

Check the grease sieve regularly for contamination and clean, if required. The grease sieve must also be cleaned after an obstruction in one of the grease lines.

Cleaning Loosen nut (6, Fig. 3-114:).

Withdraw sieve and clean with white spirit or paraffin oil.

Re-insert sieve and fasten with nut (6).

Fig. 3-115:

3-91

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INSPECTION AND SERVICING Oilfilter (hydraulic circuit grease pump)

Replacing the filter element Change filter element regulary and when the BCS indicates a contamination.

Read and observe the "Inspection and servicing - Safety instructions" chapter.

Shut off the electric motor.

Risk of scalding caused by hot hydraulic oil.

The filter housings may also be hot.

Avoid skin contact.

Skin contact with hydraulic oil may cause skin injury.

Wear protective gloves and firm working clothing.

Fig. 3-117:

Fig. 3-116:

For filtering of the hydraulic oil, high pressure filter (11, Fig. 3-116:).is installed in the pumping line.

3-92

Unscrew filter housing (5, Fig. 3-117:).

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.

Check seals (10 and 14) and replace, if required.

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.

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INSPECTION AND SERVICING Grease filter (grease lines) Read and observe the "Inspection and servicing –Safety instructions" chapter.

Shut off the electric motor.

Grease filter (12, Fig. 3-118:) is installed in the greasing line to the grease container.

Checking the filter element Unscrew filter housing (42, Fig. 3-119:).

Withdraw filter element (43) from housing (42).

Remove the grease.

Clean filter housing and contact faces at the filter head with white spirit or paraffin oil.

Insert filter element into housing (42) and attach to the filter head with a new, slightly oiled sealing ring (46).

Check the high-pressure filter for leaks after the system has been put into operation.

Fig. 3-118:

Fig. 3-119:

Replacing the filter element Remove filter element as described under "Checking the filter element".

Insert new filter element and reassemble.

Check high-pressure filter for leaks after the system has been put into operation.

3-93

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INSPECTION AND SERVICING OTHER MAINTENANCE Cleaning the cooling system Check the radiators regularly.

Shut off the electric motor.

Remove any accumulated dirt.

Clean the fan blades.

Clean the radiators with a jet of water or compressed-air from the outside.

Dry up coolers.

Do not clean radiators with a wire brush or similar hard objects.

In case of firmly adhering dirt, remove radiator and clean.

Air intake filters Empty dust trap of the intake filter (1, Fig. 3-121:) and clean filter element respectively replace.

For servicing works cf. Section „Switchgear cabinet“ in the chapter „Electrical system“.

Heating and air conditioning Change the filter mats in the air intake regulary.

The filter mats are located inside the air conditioner housing at the operator’s cab roof (Fig. 3-120:).

Fig. 3-120:

Open cover of the air conditioner housing (Fig. 3-120:).

Clean or replace filter mats.

Close cover again.

3-94

Fig. 3-121:

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INSPECTION AND SERVICING HYDRAULIC LADDER To allow the hydraulic ladder (Fig. 3-122: and Fig. 3-123:) to be lowered in an emergency, the ladder mechanism is equipped with a pressure accumulator (1, Fig. 3-124:).

The pressure accumulator (1) is located in the superstructure and is accessible from the ground.

Check nitrogen pressure inside the pressure accumulator regularly (see Service Manual).

Fig. 3-124:

Fig. 3-122:

Fig. 3-123:

3-95

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INSPECTION AND SERVICING Pressure-accumulator inspection regulations

Checking the gas charging pressure in the pressure accumulator

The following regulations are applicable only in Germany. Please observe the relevant regulations in force in your own country.

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.

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: Group III p ≥ l bar and p·x l ≥ 200 bars p·x l ≤ 1000 bars

3-96

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 Inspection schedule to be drawn up by end user, based on experience with type of operation and operating fluids.

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INSPECTION AND SERVICING PUTTING THE SHOVEL OUT OF OPERATION AND RECOMMISSIONING Putting the shovel out of operation Park the shovel on firm and level ground.

Set the working equipment down on the ground, retracting the piston rods of the hydraulic cylinders as far as possible.

Set all control element to "0".

Clean the machine.

Carry out a visual inspection of the shovel.

Remove coarse dirt, snow and ice from the fins and fan wheel of the hydraulic oil cooler.

Protect all bright metal parts (e.g. piston rods) from rust and dirt.

Remove the batteries; cf. "Battery storage".

Secure the machine against unauthorized starting by: withdrawing the key from the key-switch, setting the battery main switch to OFF, setting the main circuit breaker to OFF, locking the cab door, securing all lockable hatches.

Cover up all openings.

Battery storage 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.

Check the acid density and the electrolyte level of the battery every two weeks.

Recharge the batteries at the latest, when the acid density has dropped to 1.23 kg/dm³.

Keep the batteries clean and dry on the outside.

3-97

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INSPECTION AND SERVICING Recommissioning Remove the covers.

Degrease / clean all protected components.

Check track tension (visual inspection) Check grease filling in grease container.

Oil level - slewing gearboxes, - pump drive gearboxes, - travel gearboxes.

Check oil level in hydraulic oil reservoir.

Check battery acid density and level.

Install batteries and reconnect.

Set battery main switch to ON. Set the main circuit breaker to ON. Function checks: - superstructure holding brake, - track brake, - lighting system, - signalling equipment.

Vent the hydraulic system.

3-98

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

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3-1

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INSPECTION AND SERVICING

3-2

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

REPAIR WORK 4 REPAIR WORK Operation and Maintenance 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 Part 4 REPAIR WORK

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

Repair personnel 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

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

REPAIR WORK

4-2

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

REPAIR WORK SAFETY INSTRUCTIONS FOR SHOVELS WITH ELECTRIC MOTOR Maintenance and inspection work on electrical systems may only be performed by qualified electricians or by workshops employing such personnel.

A qualified electrician for the purpose of this regulation is a person who has the corresponding technical training, know-how and experience as well as knowledge of the pertinent prescriptions and who is therefore in a position to judge the work entrusted to him and the potential dangers in connection therewith.

Before carrying out any maintenance and inspection work on the electrical system, the following precautions must be taken:

In the transformer station

After finishing repair work:

In the transformer station Disconnect the earthing and short-circuiting line.

Unlock the safety device preventing switch-on; remove the warning sign.

Remove the partitions.

Switch on the supply voltage.

On the hydraulic shovel Unlock the safety device preventing switch-on; remove the warning sign.

Switch on the circuit breaker, (see the " Switching on the circuit breaker " chapter in part 2 of the present Operation and Maintenance Manual).

Cut out the supply voltage.

Secure against switching on; apply a warning sign.

Check that the electrical system is off circuit.

Connect to earth and short-circuit.

Protect adjacent and live parts against accidental contact.

On the shovel Cut out the circuit breaker (see the " Switching off the circuit breaker " chapter in part 2 of the present Operation and Maintenance Manual) Secure circuit breaker against switching on, apply a warning sign.

Switch off the earthing switch (see manufacturers Operating Instructions).

4-3

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

REPAIR WORK REPAIR WORK - SAFETY INSTRUCTIONS Operation and Maintenance Manual Never carry out repair work without having read and understood the Operation and Maintenance Manual.

Pay special attention to: "Fundamental Safety Instructions", "Inspection and servicing - safety instructions" and all warnings and safety instructions attached to the machine.

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 Never open defective prestressed units but replace them as an entirety.

In exceptional cases, open only when the system and the operating sequence are precisely known and any special tools required are available.

The operating manual contains no information on this point.

4-4

Dismantling components Never do dismantling while the machine is at operating temperature.

Oils, greases, or coolants may have a high temperature and result in burning or scalding.

Leave time for the machine to cool down.

Before starting work, depressurize piping and hoses, cylinders, radiator, hydraulic tank and other systems or units.

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.

On completing the work, re-assemble all protective devices, covers and noise- and vibrationinsulation material.

Never start up the electric motor while work is being done on the machine.

Check the repaired components and all machine functions in a trial run.

Never release the machine for recommissioning until it is fully functioning.

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

REPAIR WORK FIRE AND EXPLOSION HAZARD Safety Instructions Prior to commencing work, inform on the national and corporate rules for prevention of accidents. Pay particular attention to hazards caused by combustible and easily flammable substances. on the safe handling of the fire extinguishers to be used.

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

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

Do not store or handle any flammable substances during operation.

Clean the shovel thoroughly, if possible, with a steam jet (rubber parts and electric components with compressed air - refer to information label), when, for example, oil, grease, fuel or cleaner was spilled.

Such substances may spontaneously ignite if they get into the vicinity of hot units.

Even battery gases can ignite in open flames or fire.

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

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

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.

Ensure sufficient ventilation.

Clean the 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.

open or smouldering fire may occur.

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

4-5

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

REPAIR WORK HYDRAULIC SYSTEM Repair Always depressurize the hydraulic system before disconnecting any hydraulic hoses or pipes.

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 – Instructions Even hoses that have been properly stored or used are subject to natural ageing. Their useful life is therefore limited.

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.

4-6

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

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 mechanically, never weld or solder.

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

4-7

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

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.

Welding work by qualified personnel only Carry out welding work only if you have received special training and if you have been ordered to perform such work.

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.

4-8

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 firefighting equipment must be present on site as fireguards.

Observe the instructions of the machine owner and of the mine.

Health hazards 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.

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

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.

Protect the vessels against damage and high temperatures.

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.

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.

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).

Lay the welding cables as far away from electric lines as possible.

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.

Protect withdrawn terminals and connectors from short circuits and soiling. Cover up terminals and connectors with foils or adhesive tape.

Never touch the enclosures of electrical and electronic modules with the welding electrode.

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.

4-9

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

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.

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.

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.

Welding and other mechanical work is forbidden as there is a risk of reducing the structural stability of the cab.

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.

4-10

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".

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

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 drive 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.

4-11

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

REPAIR WORK Further hazardous substances Batteries contain lead and acid.

Electronic modules are located in switch cabinets of the cab module, the engine module, the control column.

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.

Appropriate disposal of batteries The machine is equipped with batteries containing lead and other harmful and polluting substances.

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. 4-1:).

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. 4-1:

The symbols in Fig. 4-1: have the following meaning: 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.

4-12

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

REPAIR WORK NOTES .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. 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4-13

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

REPAIR WORK

4-14

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

ANNEX 5 ANNEX Operation and Maintenance 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 Part 4 REPAIR WORK

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

Repair personnel 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

5-1

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

ANNEX

5-2

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

ANNEX TROUBLESHOOTING Instructions on troubleshooting

Layout of the fault table

Faults are often due to the machine not being correctly operated or serviced.

For this reason, it is vital to read through the relevant section of the Operation and Maintenance 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.

Fault 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 Maintenance Manual. If there is no entry, the CGM HMS GmbH after-sales service should be consulted

5-3

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

ANNEX FAULT TABLES Working hydraulics – Fault table Fault

Remedial action

Working and swing functions not operational No boom function No bucket function No backhoe function No stick function Working movements too slow Power loss in working hydraulics

Uncontrolled working movements Cause Electronic shovel control not activated/defective

•

Check Adjust Replace Top up Reduce Clean

P E W A S R

1) Contact the CGM HMS GmbH Service Abschnitt P Working

•••••

•

Malfunction of pressure-relief valve

1)

•

•

Servo system pump defective

1)

••••• • •

•

5-4

• Malfunction of primary / sencondary pressure-relief valves ECO-power switch in 80%-position

1) P

Hydraulic oil temperatur too high (warning lamp lit, PMS fault indicator Hydraulic oil P/R lamp lit) oil cooler contaminated cooler cleaning 1) • Malfunction of solenoid valves 1) Malfunction of control spool •

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

ANNEX Track drive – Fault table Fault

Remedial action

No forward travel and no reversing travel Maximum travel speed cannot be reached Insufficient traction power

Check Adjust Replace Top up Reduce Clean

P E W A S R

1) Contact the CGM HMS GmbH Service Chapter ref.

1)

•

•

•

Cause Malfunction of pressure-relief valves

•

•

•

Servo system pump defective

•

•

•

Malfunction of travel valve (pedal)

1)

•

•

Malfunction of control spool

1)

1)

•

ECO-power switch in 80%-position

•

Hydraulic oil temperatur too high (warning lamp lit, PMS fault indi- Hydraulic cator lamp lit) oil cooler contaminated cooler cleaning

Travelling

P oil P/R

5-5

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

ANNEX Swing mechnism – Fault table Fault

Remedial action

No swing possible No righthand or lefthand swing Swing performance insufficient Uncontrolled swing movement

Check Adjust Replace Top up Reduce Clean 1) Contact the CGM HMS GmbH Service Chapter ref.

Working

P E W A S R

•

Cause Electronic shovel control not activated / defective

•

Superstructure holding brake applied

P

Pressure-relief valve adjusted too low level / defective

1)

Servo system pump defective

1)

•

•

• • •

•

Malfunction in feed-pressure circuit of swing pump

1)

•

Malfunction in high-pressure circuit of swing system

1)

•

Malfuction of moment-regulating valve

1)

Malfunction in swing pump displacement cylinder

1)

Excessive leakage in swing motor

1)

•

• •

5-6

P

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

ANNEX Central lubricating system – Fault table Fault

Remedial action

Grease pump not working, the BCS does not indicate a warning Automatic circuit breaker on Grease pump not working, pilot lamp lit Grease pump working, no grease delivered Greasing pressure too high or too low

•

Cause Timer defective

•

• •

•

•

•

Check Adjust Replace Top up Reduce Clean Vent 1) Contact the CGM GmbH Service Chapter ref.

P E W A S R L HMS

P/W

Lines between timer and hydraulic motor defective

P/W

Hydraulikmotor defektive

P/W

•

Grease pump defective

P/W

•

Grease sieve clogged

P/R

•

Distributor defective

P/W

•

Grease container empty

P/A

•

Grease pump does not suck grease

P/L

•

Leaky lines

P/L

•

Non-return valve defective Pressure switch defective

P/W E

•

•

5-7

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

ANNEX HYDRAULIC CIRCUIT DIAGRAM Detailled information can be found in the „Service Manual“ chapter 8 or contact CGM HMS GmbH service.

5-8

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

ANNEX ABBREVIATIONS A abt. acc.

Ah 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

= OMM = Operation and Maintenance

bar Bh

unit of pressure, 1 bar = 14.5 psi = OH = Operating hour

CE

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

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

Manual

CECE

CEN cm 3 cm /rev CCW CW dB(A)

kW

dia.

DIN

Decibel (sound intensity according measuring method A) Diameter German Industrial Standard

to

EDS eff. e.g. etc.

Electronic diagnostic system effective for example etcetera

Fig. FOPS FS ft

Figure, serial number of illustration Falling objects protective structures Rock shovel (working equipment) foot (unit of distance), 1 ft = 0.30 meter

gal GLR

gallon (unit of volume), 1 gal = 3.78 liters Full-load controller (electronic module for PMS)

HD Hydr.

Heavy duty Hydraulic, Hydraulics

i

Transmission ratio

i.e.

IFN

id est = that is ISO service rating, blocked

l lb Lb/in² LC LDA LED l/min LpA LS 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 Charge pressure-dependent full-load limiter Light-emitting diode Liters per minute Sound pressure at workplace Limited slip 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 Operating instructions Superstructure

oz

ounce (unit of volume) 1 oz = 0.03 liter

5-9

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

ANNEX ABBREVIATIONS PMS P/No. PS psi PLC

Pump Managing System Part number (CGM HMS GmbH ) Metric horsepower (1 PS = 0.74 kW) pund per sqare inch (unit of pressure), 1 psi = 0.069 bar Programmable logic controller

Qty.

Quantity

R, r resp.

RH ROPS rpm

Radius Respectively Crawler hydraulics (shovel) Roll-over protective structures -1 Revolutions per minute (= min )

SAE sec./s.

SN SW

Society of Aotomotive Engineers (USA) Second CGM HMS GmbH partnumber Width across flats

t TBG

typ.

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

U/min UW

Revolutions per minute Undercarriage

V VDMA

Volt (unit of electric voltage) Association of German Machinery and Systems Manufacturers

THB TL tm

W

Watt (unit of electric power)

°C °F > <

Degrees Celsius (temperature) Degrees Fahrenheit (temperature) greater than less than

5-10

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

ANNEX NOISE AND VIBRATION INFORMATION Noise emission information

Vibration information

Noise emission data are specified in acc. with ISO 6394.

Time-averaged A-weighted emission sound pressure level at operator’s position with the machine running at high idle: LAeq = XX dB.

On the condition that the hydraulic shovel 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. The vibrations operatored 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).

5-11

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

ANNEX PRODUCT SPECIFICATION SHEET

5-12

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

ANNEX NOTES .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. 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OMM 6030AC, 6030ACFS(3 847 030.00)-EN

ANNEX

5-14

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INDEX 6 INDEX Operating instructions

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 Part 4 REPAIR WORK

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

Repair personnel 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

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INDEX

6-2

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INDEX

A ABBREVIATIONS ............................................. 5-9 Access lighting ................................................ 2-19 ACCIDENT PREVENTION REGULATIONS FOR ELECTRICALLY POWERED SHOVELS .... 1-12 After daily operation ........................................ 2-83 Air conditioner (option).................................... 2-69 Air intake filters ............................................... 3-94 Appropriate disposal of batteries .................... 4-12 ASSEMBLING WORKING EQUIPMENT SAFETY INSTRUCTIONS .......................... 2-84 Automatic fire-extinguishing system (optional 2-29 Avoid mixing of different hydraulic fluids ........ 3-31

B Battery............................................................. 3-41 Battery main switch, switching and off............ 2-60 Battery storage ............................................... 3-97 Bearing races .................................................. 3-86 Before starting work ........................................ 2-81 Board-Control-System (BCS) ........................... 2-9 Brake chamber - Changing oil ........................ 3-81 Braking the superstructure.............................. 2-81 Breather filter ......................................... 3-57, 3-81 Bypass valves (filter housing - cooling system) .. 356 Bypass valves (hydraulic oil reservoir) ........... 3-54

C Cab interior lamp ............................................ 2-22 CENTRAL LUBRICATING .............................. 3-88 Central lubricating system – Fault table ........... 5-7 Changing the gearbox oil ....................... 3-74, 3-77 Changing the hydraulic oil .............................. 3-62 Changing the hydraulic oil return-flow filter (hydraulic oil reservoir ................................. 3-52 Checking the gas charging pressure in the pressure accumulator......................... 3-85, 3-96 Checking the greasing pressure ..................... 3-91 Checking the hydraulic oil level ...................... 3-50 Circuit breaker, switching on and off .............. 2-64 Cleaning jobs .................................................. 3-13 Cleaning the cooling system ........................... 3-94 Cleaning the electric motor ............................. 3-38 Cleaning the hydraulic oil cooler ..................... 3-66 Components ................................................... 3-13 Control Management System (CMS)................ 2-8 Corrosion protection for pins and bearings (bushings and hubs).................................... 2-86 CRAWLER TRACKS ...................................... 3-82

D Demand control / Zero-flow regulation ............. 2-9 Depressurizing the hydraulic system .............. 3-49 DESCRIPTION OF THE SHOVEL ................... 2-6

Design ............................................................. 3-88 DESIGNATED USE .......................................... 1-6 Disposal at the end of the service life ............. 4-11 Drive .................................................................. 2-8

E Electric motor - Safety instructions ................. 3-38 Electric motor can not be switched on ............ 2-63 Electric motor, greasing .................................. 3-39 Electrical system ............................................... 2-9 ELECTRICAL SYSTEM .................................. 3-40 Electrical system - Safety instructions ............ 3-40 Electrical system (24V), switching and off ...... 2-60 Electronic shovel control ................................. 3-67 ELEKTRIC MOTOR ........................................ 3-38 Emergency escape device (optional ............... 2-30 Emergency lowering of the working equipmen2-83 Emergency machine drive .............................. 2-75 EMERGENCY STOP switch ........................... 2-24 Entering and leaving the machine, Safety instructions .................................................. 2-19 Extract from the German regulations .............. 3-96

F FAULT TABLES ................................................ 5-4 Filling quantities - Grease ............................... 3-27 Filling quantities - oil ....................................... 3-30 Filling quantities - other ................................... 3-30 Filter (control circuit and auxiliary control circuit) 358 Fire and Explosion Hazard ............................... 4-5 FIRE AND EXPLOSION HAZARD . 1-14, 2-5, 3-11 Fire extinguisher ............................................. 2-28 Floodlight projector, replacing the lamp .......... 3-47 Folding ladder (optional) ................................. 2-21 Function .......................................................... 3-89 Further machine documentation ....................... 1-3

G Gas, dust, steam and smoke .......................... 1-11 Gearbox - Checking the oil level / Topping up with oil ........................................................ 3-74, 3-76 Gearbox venting............................ 3-72, 3-75, 3-78 Grease filter (grease lines) ............................. 3-93 Grease for bearings, slew rings and track system (Central lubrication system) ........................ 3-35 Grease for idlers, track rollers and support rollers (Lifetime lubrication) .................................... 3-36

H Heating and air conditioning ........................... 3-94 High-pressure filter for working hydraulics...... 3-59 High-pressure filters for feeding circuits and slewing pumps............................................. 3-61 High-pressure filters for slewing circuit ........... 3-60

6-3

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INDEX Hose line for oil change .................................. 3-37 Hydraulic / pneumatic equipment ................... 1-11 HYDRAULIC CIRCUIT DIAGRAM ................... 5-8 Hydraulic hoses – Instructions .......................... 4-6 HYDRAULIC LADDER ................................... 3-95 Hydraulic system .............................................. 2-8 HYDRAULIC SYSTEM ................................... 3-49 HYDRAULIC SYSTEM ..................................... 4-6 Hydraulic system - Safety instructions ............ 3-49

I Illuminating the control column ....................... 2-23 In case of failure ............................................. 2-63 INSPECTION AND SERVICING - SAFETY INSTRUCTIONS ........................................... 3-5 INSPECTION AND SERVICING PLANS INSTRUCTIONS ......................................... 3-13 INSPECTION PLAN - OIL .............................. 3-28 Inspection plan – Oil (Legend) ........................ 3-29 Instructions on troubleshooting ......................... 5-3 Intervals .......................................................... 3-13

L Layout of the fault table .................................... 5-3 Locking the superstructure ............................. 2-77 LUBRICANTS ................................................. 3-31 LUBRICATING CHART – GREASE ............... 3-26 Lubricating chart – Grease (legend) ............... 3-27

M Measures .......................................................... 5-3 Monitoring cameras ........................................ 2-90 MONITORING, WARNING AND CONTROL ELEMENTS ................................................. 2-34 Motor protection relay, function ...................... 2-66

N Noise ............................................................... 1-11 Noise and vibration information ...................... 5-11 Noise emission information............................. 5-11 NOTES.............................................. 3-1, 4-13, 5-1 NOTES................................................... 1-15, 2-91 Notes on the selection of oils and greases ..... 3-31

O Oil for hydraulic system .................................. 3-32 Oil, grease and other chemical substances.... 1-11 Oilfilter (hydraulic circuit grease pump) .......... 3-92 Oils / Greases ................................................. 3-13 Oils for pump drive gearbox and travel gearboxes .................................................................... 3-33 Oils for swing gearboxes ................................ 3-34 ON-BOARD CRANE (OPTIONAL) ................. 2-87 On-Board crane, – blocking the boom in position of rest .......................................................... 2-89 On-board crane, checking .............................. 2-89 6-4

On-board crane, drive unit .............................. 2-88 On-board crane, monitoring, warning and control elements ...................................................... 2-87 On-board crane, putting into operation ........... 2-88 Operating Instructions, where to store it in the operator’s cab ................................................ 2-4 OPERATION - SAFETY INSTRUCTIONS ....... 2-3 Operator's seat................................................ 2-26 ORGANIZATIONAL MEASURES ..................... 1-7 OTHER MAINTENANCE ................................ 3-94

P Plan A - E ........................................................ 3-21 Plan N ............................................................. 3-17 Plan T and W .................................................. 3-19 Plan V ............................................................. 3-15 Possible causes ................................................ 5-3 PREFACE ......................................................... 1-3 Pressure accumulator - Emergency lowering . 3-68 PRESSURE ACCUMULATORS - SAFETY INSTRUCTIONS ........................................... 4-7 Pressure-accumulator inspection regulations . 3-85 Pressure-accumulator inspection regulations . 3-96 Product specification sheet ............................. 5-12 PUMP DRIVE GEARBOX ............................... 3-70 Pump drive gearbox lube oil filters .................. 3-73 Pump drive gearbox, changing oil .................. 3-71 Pump drive gearbox, checking the gearbox oil level ............................................................. 3-70 Pump Managing System (PMS) ....................... 2-8 PUTTING THE MACHINE INTO OPERATION .. 257 Putting the shovel out of operation ................. 3-97 PUTTING THE SHOVEL OUT OF OPERATION AND RECOMMISSIONING ......................... 3-97

R Recommissioning............................................ 3-98 Repair ............................................................... 4-6 Repair work - Safety instructions ...................... 4-4 Replacing the grease drum ............................. 3-90 Replacing the hydraulic oil return-flow filters (filter housing) ....................................................... 3-55

S Safety instructions for shovels with electric motor .............................................................. 1-13, 4-3 SAFETY INSTRUCTIONS FOR SHOVELS WITH ELECTRIC MOTOR ...................................... 3-3 Safety instructions governing specific operational phases ........................................................... 1-8 Section .............................................................. 5-3 Securing the machine ..................................... 2-85 Selection and qualification of personnel; basic responsibilities ............................................... 1-8 Service station (tanklift)................................... 2-57 Servicing lighting ............................................. 2-23 Servicing switch .............................................. 2-25

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

INDEX SERVICING WORK ........................................ 3-37 Servo control- and feeding circuit ................... 3-68 Shovel layout .................................................... 2-7 Signs ............................................................... 2-11 SLEWING GEARBOX .................................... 3-74 Slewing mechnism – Fault table ....................... 5-6 Slip ring maintenance ..................................... 3-46 Special work in conjunction with utilization of the machine and maintenance and repairs as well as troubleshooting during work; disposal of parts and consumables ................................. 1-9 Stored Program Control (SPC) ......................... 2-8 Superstructure .................................................. 2-8 SWING GEARBOX ......................................... 3-76 SWING RING .................................................. 3-86 Swing ring - Instructions ................................. 3-86 Swinging ladder .............................................. 2-20 Swinging the superstructure ........................... 2-81 Switchgear cabinet ......................................... 3-43 Switching the electric motor on and off........... 2-61

Travel gearbox - Checking the oil level / Topping up with oil .................................................... 3-79 TRAVEL GEARBOX TRAVEL GEARBOX P/N 3683493 / 3737455 ..................................... 3-79 Travelling ........................................................ 2-71 TRAVELLING THE MACHINE ........................ 2-70 Travelling, Safety Instructions ......................... 2-70 TROUBLESHOOTING ...................................... 5-3

T

Warm-up procedure for electric shovels ......... 2-68 Warning of special dangers ............................ 1-10 Warnings and symbols...................................... 1-5 WARRANTY ..................................................... 1-4 Welding and flame cutting works - Safety instructions .................................................... 4-8 Windscreen washer ........................................ 2-25 Working ........................................................... 2-82 Working equipment, avoid extreme positions . 2-80 Working hydraulics – Fault table ....................... 5-4 WORKING OPERATION ................................ 2-81 Working operation - Safety instructions .......... 2-79

Time-out before restart ................................... 2-62 Track drive – Fault table ................................... 5-5 Track parking brake ........................................ 2-77 Track roller, Support roller .............................. 3-83 Track tensioner ............................................... 3-84 Trainer's / instructor's seat .............................. 2-29 Transport - Safety instructions ........................ 2-78 Transporting and recommissioning ................ 1-11 TRANSPORTING THE MACHINE ................. 2-78 Travel gearbox - Changing oil ........................ 3-80

U Unblocking a grease line. ............................... 3-91 Undercarriage ................................................... 2-8

V Venting the hydraulic system .......................... 3-65 Vibration information ....................................... 5-11

W

6-5

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