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Cat 6050 6050FS Hydraulic Excavator Operation and Maintenance Manual BI651385 – PDF DOWNLOAD
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Cat 6050 6050FS Hydraulic Excavator Operation and Maintenance Manual BI651385 – PDF DOWNLOAD
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Description
Cat 6050 6050FS Hydraulic Excavator Operation and Maintenance Manual BI651385 – PDF DOWNLOAD
FILE DETAILS:
Cat 6050 6050FS Hydraulic Excavator Operation and Maintenance Manual BI651385 – PDF DOWNLOAD
Language : English
Pages : 304
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Cat 6050 6050FS Hydraulic Excavator Operation and Maintenance Manual BI651385 – PDF DOWNLOAD
PREFACE
About this Operating Instructions
- These operating instructions are designed to familiarize the operator with the machine and its designated use. The operating instructions contain important information on how to operate the machine safely, properly and with maximum efficiency.
- Observing these instructions helps to prevent hazardous situations, to reduce repair costs and downtimes and to increase the reliability and service life of the machine. The operating instructions must be supplemented by the respective national rules and regulations for accident prevention and environmental protection.
- The operating instructions must always be available in the driver’s cab of the machine. The operating instructions must be read and put into practice by any person in charge of carrying out work with or on the machine, such as
operation, including setting-up, troubleshooting in the course of work, care, evacuation of production waste and disposal of fuels and consumables,
maintenance (inspection, servicing, repair) and / or
transport.
In addition to the operating instructions and the mandatory rules and regulations for accident prevention and environmental protection in the user’s country and at the place where the machine is to be used, the generally recognized technical rules for safe and proper working must be observed 1. The operating instructions are directed to the mining- machine specialist. They cannot provide basic know-how. This can be acquired, for example, in several days’ instruction by a qualified Bucyrus HEX mechanic or by attending an Bucyrus HEX training course for operators or maintenance personnel
- The Bucyrus HEX after-sales service will be pleased to deal with any queries you may have after reading through the operating instructions.
- All Bucyrus HEX operating manuals are issued in German and then translated. Even a good translation may give rise to questions which Bucyrus HEX will be pleased to answer.
- The operating instructions are not work instructions for carrying out major repairs. Such work is willingly done for you by the Bucyrus HEX aftersales service
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Cat 6050 6050FS Hydraulic Excavator Operation and Maintenance Manual BI651385 – PDF DOWNLOAD
TITLEPAGE.................................................................................................................................................................... 1 1 INTRODUCTION............................................................................................................................................................... 13 PREFACE ................................................................................................................................................................. 15 About this Operating Instructions ................................................................................................................................... 15 Further machine documentation ....................................................................................................................................... 15 WARRANTY ................................................................................................................................................................ 16 FUNDAMENTAL SAFETY INSTRUCTIONS ......................................................................................................................................... 17 Warnings and symbols ................................................................................................................................................ 17 DESIGNATED USE, UNAUTHORIZED USE ........................................................................................................................................ 18 ORGANIZATIONAL MEASURES ................................................................................................................................................. 19 Selection and qualification of personnel; basic responsibilities .................................................................................................... 20 Safety instructions governing specific operational phases ........................................................................................................... 20 Special work in conjunction with utilization of the machine and maintenance and repairs as well as troubleshooting during work; disposal of parts and consumables.... 21 Warning of special dangers........................................................................................................................................... 22 FIRE AND EXPLOSION HAZARD ............................................................................................................................................... 24 NOTES ................................................................................................................................................................... 25 2 OPERATION.................................................................................................................................................................. 27 OPERATION - SAFETY INSTRUCTIONS.......................................................................................................................................... 29 Operating Instructions, where to store it in the driver’s cab ....................................................................................................... 30 OPERATION, FIRE AND EXPLOSION HAZARD .................................................................................................................................... 31 DESCRIPTION OF THE EXCAVATOR............................................................................................................................................. 32 Excavator layout .................................................................................................................................................... 33 Undercarriage........................................................................................................................................................ 34 Superstructure....................................................................................................................................................... 34 Drive................................................................................................................................................................ 34 Hydraulic system..................................................................................................................................................... 34 Pump Managing System (PMS)........................................................................................................................................... 34 Stored Program Control (SPC) ........................................................................................................................................ 34 Central Management System (CMS) ..................................................................................................................................... 34 Demand control / Zero-flow regulation................................................................................................................................ 35 Automatic engine speed reduction .................................................................................................................................... 35 Board-Control-System (BCS) .......................................................................................................................................... 35 Electrical system ................................................................................................................................................... 35 Signs ............................................................................................................................................................... 36 Entering and leaving the machine, Safety instructions................................................................................................................ 44 Access lighting ..................................................................................................................................................... 44 Folding ladder (optional) ........................................................................................................................................... 45 Swinging ladder (optional) .......................................................................................................................................... 46 Cab interior lamp ................................................................................................................................................... 47 Servicing lighting .................................................................................................................................................. 48 Illuminating the control column ..................................................................................................................................... 48 EMERGENCY STOP switch ............................................................................................................................................... 49 Escape ladder ....................................................................................................................................................... 50 Trainer's / instructor's seat ....................................................................................................................................... 51 Windscreen washer ................................................................................................................................................... 51 Driver's seat ....................................................................................................................................................... 52 Fire extinguisher ................................................................................................................................................... 54 Automatic fire-extinguishing system (optional) ...................................................................................................................... 55 Harness (optional) .................................................................................................................................................. 56 MONITORING, WARNING AND CONTROL ELEMENTS ................................................................................................................................ 60 PUTTING THE MACHINE INTO OPERATION ...................................................................................................................................... 90 Refuelling .......................................................................................................................................................... 90 Service station (tanklift) .......................................................................................................................................... 90 Switching the electrical system on and off .......................................................................................................................... 96 STARTING AND STOPPING THE ENGINES ....................................................................................................................................... 97 Starting the engines ................................................................................................................................................ 97 Starting the engines at low temperatures ............................................................................................................................ 98 Shutting off the engines ............................................................................................................................................ 99 Emergency - stop .................................................................................................................................................... 99 AIR CONDITIONER (OPTION) ................................................................................................................................................100 Back-up heating (option) ............................................................................................................................................101 MAXIMUM MACHINE INCLINATIONS, INFORMATION ...............................................................................................................................103 TRAVELLING, SAFETY INSTRUCTIONS .........................................................................................................................................104 Superstructure basic position .......................................................................................................................................105 Travel forwards/backwards ...........................................................................................................................................105 Emergency machine drive .............................................................................................................................................109 Superstructure holding brakes .......................................................................................................................................111 Track parking brake .................................................................................................................................................111 TRANSPORTING THE MACHINE ................................................................................................................................................112 Transport - Safety instructions .....................................................................................................................................112 WORKING OPERATION - SAFETY INSTRUCTIONS .................................................................................................................................113 WORKING OPERATION .......................................................................................................................................................115 Before starting work ................................................................................................................................................115 Swing the superstructure ............................................................................................................................................115 Braking the superstructure ..........................................................................................................................................115 Working movements ...................................................................................................................................................116 After daily operation ...............................................................................................................................................117 ASSEMBLING WORKING EQUIPMENT - SAFETY INSTRUCTIONS ......................................................................................................................118 Securing the machine ................................................................................................................................................119 CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS) ..........................................................................................................120 ON-BOARD CRANE (OPTIONAL) ...............................................................................................................................................121 On-board crane, monitoring, warning and control elements ............................................................................................................121 On-board crane, putting into operation ..............................................................................................................................122 On-board crane, drive unit ..........................................................................................................................................122 On-Board crane, – blocking the boom in position of rest .............................................................................................................123 On-board crane, checking ............................................................................................................................................123 OPTIONAL EQUIPMENT ......................................................................................................................................................124 Monitoring cameras...................................................................................................................................................124 NOTES ...................................................................................................................................................................125 3 INSPECTION AND SERVICING...................................................................................................................................................127 INSPECTION AND SERVICING - SAFETY INSTRUCTIONS ..........................................................................................................................129 INSPECTION AND SERVICING WORK, FIRE AND EXPLOSION HAZARD ................................................................................................................134 INSPECTION AND SERVICING PLANS - INSTRUCTIONS ...........................................................................................................................135 Intervals............................................................................................................................................................135 Change of engine oil ................................................................................................................................................135 Air-intake system ...................................................................................................................................................135 Oils / Greases ......................................................................................................................................................135 Cleaning jobs .......................................................................................................................................................135 Components ..........................................................................................................................................................135 Plan V ..............................................................................................................................................................137 Plan N ..............................................................................................................................................................139 Plan T and W ........................................................................................................................................................141 Plan A – E ..........................................................................................................................................................143 LUBRICATING CHART – GREASE ..............................................................................................................................................152 Lubricating chart – Grease (legend) .................................................................................................................................153 Filling quantities – Grease .........................................................................................................................................153 INSPECTION PLAN - OIL ...................................................................................................................................................154 Inspection plan – Oil (legend) ......................................................................................................................................155 Filling quantities - oil ............................................................................................................................................156 Filling quantities – other ..........................................................................................................................................156 LUBRICANTS ..............................................................................................................................................................157 Notes on the selection of oils and greases ..........................................................................................................................157 Avoid mixing of different hydraulic fluids ..........................................................................................................................157 I. Oils for combustion engines ......................................................................................................................................158 II. Oils for hydraulic system .......................................................................................................................................159 III.a Oils for pump gearboxes and travel gearboxes ..................................................................................................................160 III.b Oils for swing gearboxes ......................................................................................................................................161 V. Greases for bearings, swing rings and track system (Central lubrication system) ..................................................................................162 Grease for idlers, track rollers and support rollers (Lifetime lubrication) .........................................................................................163 Coolant for use on all combustion engines ...........................................................................................................................164 SERVICING WORK ..........................................................................................................................................................165 Hose line for oil and cooling liquid changes ........................................................................................................................165 ENGINE ..................................................................................................................................................................166 Engine - Safety instructions ........................................................................................................................................166 Engine oil, checking the level / topping up .........................................................................................................................167 Engine oil reservoir, checking the oil level / topping up ...........................................................................................................168 Engine oil, change ..................................................................................................................................................169 Engine oil reservoir (optional), draining the oil off ...............................................................................................................171 Oil change prolongation system, replacing the oil filter ............................................................................................................173 Eliminator filter and centrifuge (optional) .........................................................................................................................174 Cold-starting fluid (ether) - Replacing the pressure vessel .........................................................................................................176 COOLING SYSTEM ..........................................................................................................................................................177 Cooling liquid, change ..............................................................................................................................................180 Water filter, change ................................................................................................................................................182 AIR-INTAKE SYSTEM .......................................................................................................................................................183 Main filter elements, removal and installation ......................................................................................................................184 Main filter elements, checking and cleaning .........................................................................................................................185 Safety filter element, replace ......................................................................................................................................186 Air-intake lines ....................................................................................................................................................187 Dust collection .....................................................................................................................................................187 FUEL SYSTEM .............................................................................................................................................................188 Fuel system, Safety instructions ....................................................................................................................................188 Fuel filter, replace ................................................................................................................................................188 Fuel system, venting ................................................................................................................................................189 Cleaning the fuel tanks .............................................................................................................................................189 Water trap (option) .................................................................................................................................................191 ELECTRICAL SYSTEM ......................................................................................................................................................193 Electrical system - Safety instructions .............................................................................................................................193 Alternator - Instructions ...........................................................................................................................................193 Battery .............................................................................................................................................................194 Switchgear cabinet ..................................................................................................................................................196 Floodlight projector, replacing the lamp ............................................................................................................................198 HYDRAULIC SYSTEM ........................................................................................................................................................200 Hydraulic system - Safety instructions ..............................................................................................................................200 Depressurizing the hydraulic system .................................................................................................................................200 Checking the hydraulic oil level ....................................................................................................................................201 Changing the hydraulic oil return-flow filters (hydraulic oil reservoir) ............................................................................................203 Bypass valves (hydraulic oil reservoir) .............................................................................................................................205 Replacing the bypass valves and sealing rings .......................................................................................................................205 Breather filter .....................................................................................................................................................206 Filter (control circuit).............................................................................................................................................207 High-pressure filter for working hydraulics .........................................................................................................................208 High-pressure filters for the servo circuit .........................................................................................................................209 High-pressure filters for feeding circuits and slewing pumps ........................................................................................................210 High-pressure filters for slewing circuit ...........................................................................................................................211 Changing the hydraulic oil ..........................................................................................................................................212 Avoid mixing of different hydraulic fluids ..........................................................................................................................212 Venting the hydraulic system.........................................................................................................................................216 Cleaning the hydraulic oil cooler....................................................................................................................................217 Electronic excavator control.........................................................................................................................................218 Pressure accumulator - Emergency lowering............................................................................................................................219 PUMP TRANSFER GEARBOX ...................................................................................................................................................220 Checking the gearbox oil level / Topping up with oil ................................................................................................................220 Changing the gearbox oil ............................................................................................................................................221 Gearbox, breather valve .............................................................................................................................................222 Pre-chamber, breather valve .........................................................................................................................................223 Pump transfer gearbox lube oil filters ..............................................................................................................................224 SWING GEARBOX ...........................................................................................................................................................225 Gearbox - Checking the oil level / Topping up with oil ..............................................................................................................225 Changing the gearbox oil ............................................................................................................................................225 Gearbox venting .....................................................................................................................................................226 TRAVEL GEARBOX (VALID FOR GEARBOX PN 3673978) ...........................................................................................................................227 Travel gearbox - Checking the oil level / Topping up with oil .......................................................................................................227 Travel gearbox - Changing oil .......................................................................................................................................228 Breather filters, clean / replace ...................................................................................................................................229 TRAVEL GEARBOX (VALID FOR GEARBOX PN 2763214) ...........................................................................................................................230 Travel gearbox - Checking the oil level / Topping up with oil .......................................................................................................230 Travel gearbox - Changing oil .......................................................................................................................................231 Pre-stage - Changing the oil .......................................................................................................................................231 Brake chambers - Changing oil .......................................................................................................................................232 Breather filters, clean / replace ...................................................................................................................................232 CRAWLER TRACKS ..........................................................................................................................................................233 Track roller, Support roller ........................................................................................................................................234 Track tensioner .....................................................................................................................................................235 Pressure-accumulator inspection regulations .........................................................................................................................236 Checking the gas charging pressure in the pressure accumulator.......................................................................................................236 SWING RING ..............................................................................................................................................................237 Swing ring – Instructions ...........................................................................................................................................237 Bearing races .......................................................................................................................................................237 CENTRAL LUBRICATING .....................................................................................................................................................239 Design ..............................................................................................................................................................239 Function ............................................................................................................................................................240 Filling up the grease container .....................................................................................................................................241 Breather filter .....................................................................................................................................................241 Checking the greasing pressure ......................................................................................................................................242 Unblocking a grease line.............................................................................................................................................243 Oilfilter (hydraulic circuit grease pump) ...........................................................................................................................244 Grease filter (Filling the grease container) ........................................................................................................................245 Grease filter (Grease lines) ........................................................................................................................................246 OTHER MAINTENANCE .......................................................................................................................................................247 Engine ..............................................................................................................................................................247 Equipment, checking .................................................................................................................................................248 Hydraulic ladder (optional) .........................................................................................................................................248 Pressure-accumulator inspection regulations .........................................................................................................................249 Extract from the German regulations..................................................................................................................................249 Checking the gas charging pressure in the pressure accumulator.......................................................................................................249 ON-BOARD CRANE, DRIVE UNIT ..............................................................................................................................................250 On-board crane, lubricating .........................................................................................................................................251 On-Board crane, checking tightness of fastening bolts ...............................................................................................................251 PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING ..............................................................................................................252 Putting the excavator out of operation...............................................................................................................................252 Battery storage......................................................................................................................................................252 Recommissioning......................................................................................................................................................252 NOTES ..................................................................................................................................................................253 4 REPAIR WORK................................................................................................................................................................255 REPAIR WORK - SAFETY INSTRUCTIONS........................................................................................................................................257 REPAIR WORK, FIRE AND EXPLOSION HAZARD ..................................................................................................................................259 REPAIR WORK, ENGINE......................................................................................................................................................260 ELECTRICAL SYSTEM .......................................................................................................................................................261 Assisted starting (with jumper cables) – Safety instructions ........................................................................................................261 Assisted starting (with jumper cables)...............................................................................................................................261 Starting the engine with jumper cables (external batteries ..........................................................................................................261 HYDRAULIC SYSTEM.........................................................................................................................................................263 Repair instructions .................................................................................................................................................263 Hydraulic hoses – Instructions ......................................................................................................................................263 PRESSURE ACCUMULATORS - SAFETY INSTRUCTIONS..............................................................................................................................264 WELDING AND FLAME CUTTING WORKS - SAFETY INSTRUCTIONS ...................................................................................................................265 DISPOSAL AT THE END OF THE SERVICE LIFE ................................................................................................................................268 Dismantling and removal instructions ................................................................................................................................268 Risk of deflagrations ...............................................................................................................................................268 Risk of fire ........................................................................................................................................................268 Disposing of the machine without polluting the environment ..........................................................................................................269 Further hazardous substances ........................................................................................................................................269 Appropriate disposal of batteries ...................................................................................................................................270 NOTES ...................................................................................................................................................................271 5 ANNEX......................................................................................................................................................................273 TROUBLESHOOTING .........................................................................................................................................................275 Instructions on troubleshooting .....................................................................................................................................275 Layout of the fault table ...........................................................................................................................................275 Possible causes .....................................................................................................................................................275 Measures ............................................................................................................................................................275 Section .............................................................................................................................................................275 FAULT TABLES ............................................................................................................................................................276 Combustion engine - Fault table .....................................................................................................................................276 Working hydraulics – Fault table ....................................................................................................................................277 Track drive – Fault table ...........................................................................................................................................278 Swing mechnism – Fault table ........................................................................................................................................279 Central lubricating system – Fault table ............................................................................................................................280 Engine electronic unit, displaying stored fault codes ...............................................................................................................281 HYDRAULIC CIRCUIT DIAGRAM ...............................................................................................................................................282 ABBREVIATIONS ...........................................................................................................................................................283 ABBREVIATIONS........................................................................................................................................................284 TECHNICAL DATA ..........................................................................................................................................................285 Product Specification Sheet .........................................................................................................................................287 NOTES ...................................................................................................................................................................297 6 INDEX......................................................................................................................................................................299
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