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CAT 6060 RH 340B Hydraulic Excavator Operating Instruction Manual – PDF DOWNLOAD
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Description
CAT 6060 RH 340B Hydraulic Excavator Operating Instruction Manual – PDF DOWNLOAD
FILE DETAILS:
CAT 6060 RH 340B Hydraulic Excavator Operating Instruction Manual – PDF DOWNLOAD
Language : English
Pages : 304
Downloadable : Yes
File Type : PDF
DESCRIPTION:
CAT 6060 RH 340B Hydraulic Excavator Operating Instruction Manual – PDF DOWNLOAD
PREFACE:
- These operating instructions are designed to fa- miliarize the operator with the machine
and its designated use. - The operating instructions contain important in- formation 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 avail- able 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, troubleshoot- ing 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 pre- vention 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 .
- 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. 1 Complies with VDMA recommendation “Operating instructions”.
- All Bucyrus HEX operating manuals are issued in German and then translated. Even a good translation may give rise to questions which Bucyrus HEX will be pleased to answer.
- The operating instructions are not work instructions for carrying out major repairs. Such work is willingly done for you by the Bucyrus HEX aftersales service.
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
CAT 6060 RH 340B Hydraulic Excavator Operating Instruction Manual – PDF DOWNLOAD
TABLE OF CONTENTS............................................................................................................................................................. 5 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 ........................................................................................................................................................... 18 ORGANIZATIONAL MEASURES .................................................................................................................................................. 19 Personal protective equipment and the working clothing................................................................................................................ 19 Selection and qualification of personnel; basic responsibilities ..................................................................................................... 20 Safety instructions governing specific operational phases ............................................................................................................ 20 Standard operation................................................................................................................................................ 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 Electric energy................................................................................................................................................... 22 High-voltage system............................................................................................................................................... 22 Battery .......................................................................................................................................................... 22 Gas, dust, steam and smoke ........................................................................................................................................... 22 Hydraulic equipment .................................................................................................................................................. 23 Noise............................................................................................................................................................. 23 Oil, grease and other chemical substances......................................................................................................................... 23 Ether............................................................................................................................................................. 23 Transporting and recommissioning.................................................................................................................................. 23 FIRE AND EXPLOSION HAZARD ................................................................................................................................................ 24 NOTES .................................................................................................................................................................... 25 2 OPERATION................................................................................................................................................................... 27 OPERATION - SAFETY INSTRUCTIONS .......................................................................................................................................... 29 Operating instructions................................................................................................................................................ 29 Operating personnel................................................................................................................................................... 29 Personal protective gear and working clothing......................................................................................................................... 29 Safety belt........................................................................................................................................................... 29 State of the machine.................................................................................................................................................. 29 Entering and leaving the machine...................................................................................................................................... 29 Hazard range.......................................................................................................................................................... 29 Persons within the hazard zone........................................................................................................................................ 30 Marshallers........................................................................................................................................................... 30 Securing the machine.................................................................................................................................................. 30 Operating Instructions, where to store it in the driver’s cab ........................................................................................................ 30 FIRE AND EXPLOSION HAZARD................................................................................................................................................. 31 DESCRIPTION OF THE EXCAVATOR ............................................................................................................................................. 32 Excavator layout ..................................................................................................................................................... 33 Undercarriage..................................................................................................................................................... 33 Superstructure.................................................................................................................................................... 33 Loading bucket.................................................................................................................................................... 33 Backhoe bucket.................................................................................................................................................... 33 Undercarriage ........................................................................................................................................................ 34 Superstructure ....................................................................................................................................................... 34 Drive ................................................................................................................................................................ 34 Hydraulic system ..................................................................................................................................................... 34 Control and Monitoring Platform (CAMP) ............................................................................................................................... 34 Board-Control-System (BCS) ........................................................................................................................................... 35 Demand control / Zero-flow regulation................................................................................................................................. 35 Automatic reset to idling............................................................................................................................................. 35 Electrical system .................................................................................................................................................... 35 Signs ................................................................................................................................................................ 36 Warning and instruction signs..................................................................................................................................... 36 Machine number.................................................................................................................................................... 43 Engine number..................................................................................................................................................... 43 Component numbers................................................................................................................................................. 43 Entering and leaving the machine, Safety instructions ................................................................................................................ 44 Access ladder lighting ............................................................................................................................................... 44 Swinging ladder ...................................................................................................................................................... 45 Folding ladder (optional) ............................................................................................................................................ 46 Escape ladder (optional) ............................................................................................................................................. 47 Switching the cab interior lighting on and off ....................................................................................................................... 48 Switching the maintenance lights on and off .......................................................................................................................... 49 Emergency shut-off function .......................................................................................................................................... 50 Putting the machine back into operation........................................................................................................................... 50 Shutting off the supply voltage (battery main switch) ................................................................................................................ 51 Driver’s seat ....................................................................................................................................................... 52 Reducing operators exposure to vibrations ............................................................................................................................ 54 Trainer's / instructor's seat ........................................................................................................................................ 54 Windscreen washer .................................................................................................................................................... 54 Fire extinguisher..................................................................................................................................................... 55 Extinguishing agent .............................................................................................................................................. 55 Handling.......................................................................................................................................................... 55 Inspection........................................................................................................................................................ 55 Automatic fire-extinguishing system (optional) ....................................................................................................................... 56 Inspection........................................................................................................................................................ 56 Manual activation................................................................................................................................................. 56 Harness (optional) ................................................................................................................................................... 57 Elements of the harness........................................................................................................................................... 57 Important hints................................................................................................................................................... 57 Taking on harness................................................................................................................................................. 58 MONITORING, WARNING AND CONTROL ELEMENTS ................................................................................................................................. 60 Engine 1 (LH), control and monitoring ................................................................................................................................ 67 Engine 2 (RH), control and monitoring ................................................................................................................................ 69 Symbol............................................................................................................................................................ 71 121............................................................................................................................................................... 79 Monitoring device................................................................................................................................................. 79 Engine monitoring (engine 1 left)................................................................................................................................. 79 122............................................................................................................................................................... 79 Thermometer....................................................................................................................................................... 79 Engine temperature(engine 1 left)................................................................................................................................. 79 123............................................................................................................................................................... 79 Pressure gauge.................................................................................................................................................... 79 Engine oil pressure (engine 1 left)............................................................................................................................... 79 124............................................................................................................................................................... 79 Warning device.................................................................................................................................................... 79 Engine monitoring(engine 1 left).................................................................................................................................. 79 125............................................................................................................................................................... 79 Indicator lamp.................................................................................................................................................... 79 Idle(engine 1 left)............................................................................................................................................... 79 126............................................................................................................................................................... 79 Warning lamp...................................................................................................................................................... 79 Cooling water level (engine 1 left)............................................................................................................................... 79 127............................................................................................................................................................... 79 Warning lamp...................................................................................................................................................... 79 Alternator (engine 1 left)........................................................................................................................................ 79 131............................................................................................................................................................... 81 Monitoring device................................................................................................................................................. 81 Engine monitoring (engine 2 right)................................................................................................................................ 81 132............................................................................................................................................................... 81 Thermometer....................................................................................................................................................... 81 Engine temperature(engine 2 right)................................................................................................................................ 81 133............................................................................................................................................................... 81 Pressure gauge.................................................................................................................................................... 81 Engine oil pressure (engine 2 right).............................................................................................................................. 81 134............................................................................................................................................................... 81 Warning device.................................................................................................................................................... 81 Engine monitoring(engine 2 right)................................................................................................................................. 81 135............................................................................................................................................................... 81 Indicator lamp.................................................................................................................................................... 81 Idle(engine 2 right).............................................................................................................................................. 81 136............................................................................................................................................................... 81 Warning lamp...................................................................................................................................................... 81 Cooling water level (engine 2 right).............................................................................................................................. 81 137............................................................................................................................................................... 81 Warning lamp...................................................................................................................................................... 81 Alternator (engine 2 right)....................................................................................................................................... 81 Element........................................................................................................................................................... 83 Element........................................................................................................................................................... 85 PUTTING THE MACHINE INTO OPERATION ....................................................................................................................................... 86 Reducing the operator's exposure to noise ............................................................................................................................ 86 Refuelling ........................................................................................................................................................... 86 Refuelling - Safety instructions ................................................................................................................................. 86 Filling in fuel .................................................................................................................................................. 87 Back-up heating (option), filling in fuel ............................................................................................................................ 87 Service station (tanklift) ........................................................................................................................................... 87 Lowering the service station ..................................................................................................................................... 88 Raising the service station ...................................................................................................................................... 88 Refilling and draining ........................................................................................................................................... 88 Switching the electrical system on and off ........................................................................................................................... 93 Engines, emergency shut-off .......................................................................................................................................... 93 Preheating system for engine and hydraulic oil (optional) ............................................................................................................ 94 Preheating system for engine and hydraulic oil, function ......................................................................................................... 94 Switching the preheating system for engine and hydraulic oil on and off .......................................................................................... 94 Fuel preheating system (optional) .................................................................................................................................... 95 Fuel preheating system, function.................................................................................................................................. 95 Switching the fuel preheating system on and off................................................................................................................... 95 STARTING AND STOPPING THE ENGINES ........................................................................................................................................ 96 Starting the engines ................................................................................................................................................. 96 Starting the left-hand engine......................................................................................................................................... 96 Starting the right-hand engine........................................................................................................................................ 96 Engines – adjusting the speed ........................................................................................................................................ 97 Starting the engines at low temperatures ............................................................................................................................. 97 Shutting off the engines ............................................................................................................................................. 98 Shutting off the left-hand engine..................................................................................................................................... 98 Shutting off the right-hand engine.................................................................................................................................... 98 AIR CONDITIONER (OPTIONAL) ............................................................................................................................................... 99 Control unit (SIGMA) ................................................................................................................................................. 99 Back-up heating driver’s cab (optional) .............................................................................................................................. 99 Back-up heating (optional) ...........................................................................................................................................100 TRAVELLING, SAFETY INSTRUCTIONS ..........................................................................................................................................101 TRAVELLING ...............................................................................................................................................................102 Superstructure basic position ........................................................................................................................................102 Travelling forwards/backwards ........................................................................................................................................102 Regulating the travelling speed ..................................................................................................................................103 Travelling uphill and downhill ...................................................................................................................................103 Cornering ........................................................................................................................................................104 Turning ..........................................................................................................................................................104 Note..............................................................................................................................................................104 Travelling over long distances ...................................................................................................................................105 Superstructure holding brake .........................................................................................................................................106 Track parking brake ..................................................................................................................................................106 TRANSPORTING THE MACHINE .................................................................................................................................................107 Transport - Safety instructions ......................................................................................................................................107 Transport ........................................................................................................................................................107 WORKING OPERATION - SAFETY INSTRUCTIONS ..................................................................................................................................108 Running-in instructions for hydraulic cylinders.......................................................................................................................108 Warming up the hydraulic system.......................................................................................................................................108 Avoid extreme positions of the attachment.............................................................................................................................109 WORKING OPERATION ........................................................................................................................................................110 Before starting work .................................................................................................................................................110 Activating the electronic excavator control ..........................................................................................................................110 Swinging the superstructure ..........................................................................................................................................111 Braking the superstructure ...........................................................................................................................................111 Working ..............................................................................................................................................................112 Extending and retracting the bucket or backhoe bucket stick ......................................................................................................112 Opening and closing the bottom-dump bucket .......................................................................................................................112 Raising and lowering the boom ....................................................................................................................................112 Filling and emptying the bucket or the backhoe ...................................................................................................................112 After daily operation ................................................................................................................................................113 Parking the machine ..............................................................................................................................................113 ASSEMBLING WORKING EQUIPMENT - SAFETY INSTRUCTIONS .......................................................................................................................114 Personel..............................................................................................................................................................114 Personal protective gear and working clothes..........................................................................................................................114 Tools and auxiliaries.................................................................................................................................................114 Securing the working equipment........................................................................................................................................114 Securing the machine..................................................................................................................................................114 Selecting the attachments.............................................................................................................................................114 Protective roof against falling objects...............................................................................................................................114 Securing the machine .................................................................................................................................................115 Risk of injury....................................................................................................................................................115 CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS) ...........................................................................................................116 Application of GLEITMO 815............................................................................................................................................116 NOTES ....................................................................................................................................................................117 3 INSPECTION AND SERVICING....................................................................................................................................................119 INSPECTION AND SERVICING - SAFETY INSTRUCTIONS ...........................................................................................................................121 Operating manual......................................................................................................................................................121 Inspection and servicing personnel....................................................................................................................................121 Personal protective equipment and working clothing....................................................................................................................121 Securing the working equipment........................................................................................................................................121 Securing the machine..................................................................................................................................................121 Climbing onto and off the machine.....................................................................................................................................121 Checking the state of tools...........................................................................................................................................121 Cleaning jobs.........................................................................................................................................................122 Handling flammable liquids............................................................................................................................................122 Fastening and securing elements.......................................................................................................................................122 Spare parts...........................................................................................................................................................122 Handling oils and greases.............................................................................................................................................122 Visisble oil losses...................................................................................................................................................122 Relieving residual pressure in the hydraulic system...................................................................................................................123 Screwed connections, piping, hydraulic hoses..........................................................................................................................123 Handling batteries....................................................................................................................................................125 Handling of cold-starting fluid (ether)...............................................................................................................................125 INSPECTION AND SERVICING WORK, FIRE AND EXPLOSION HAZARD .................................................................................................................127 INSPECTION AND SERVICING PLANS - INSTRUCTIONS ............................................................................................................................129 Intervals ............................................................................................................................................................129 Change of engine oil .................................................................................................................................................129 Air-intake system ....................................................................................................................................................129 Oils / Greases .......................................................................................................................................................129 Cleaning jobs ........................................................................................................................................................129 Components ...........................................................................................................................................................129 Plan V ...............................................................................................................................................................131 Plan N ...............................................................................................................................................................133 Plan T ...............................................................................................................................................................135 Plan A – E ...........................................................................................................................................................137 LUBRICATING CHART ........................................................................................................................................................144 Lubricating chart – Grease (legend) ..................................................................................................................................145 Filling quantities - Grease...........................................................................................................................................145 INSPECTION PLAN - OIL ....................................................................................................................................................146 Inspection plan – Oil (legend) .......................................................................................................................................147 Filling quantities - oil .............................................................................................................................................148 Filling quantities - other............................................................................................................................................148 LUBRICANTS ...............................................................................................................................................................149 Notes on the selection of oils and greases ...........................................................................................................................149 Original Bucyrus HEX oils and greases.............................................................................................................................149 Alternative oils and greases......................................................................................................................................149 Avoid mixing of different hydraulic fluids ...........................................................................................................................149 I. Oils for combustion engines and compressors .......................................................................................................................150 II. Oils for hydraulic system (selection) ............................................................................................................................151 III.a Oils for pump distribution gearboxes ...........................................................................................................................152 III.b Oils for swing gearboxes .......................................................................................................................................153 III.c Oils for travel gearboxes ......................................................................................................................................154 V. Greases for bearings and swing rings ..............................................................................................................................155 SERVICING WORK ...........................................................................................................................................................156 Hose line for oil and cooling liquid changes .........................................................................................................................156 ENGINE ...................................................................................................................................................................157 Engine - Safety instructions .........................................................................................................................................157 Checking the engine oil level / Topping up ..........................................................................................................................158 Changing the engine oil ..............................................................................................................................................159 Drawing off engine oil with the service station...................................................................................................................159 Filling in engine oil ............................................................................................................................................160 Filling in engine oil through the service station.................................................................................................................160 Replacing the oil filter .............................................................................................................................................161 Oil filters.......................................................................................................................................................161 Cold-starting fluid (ether) - Replacing the pressure vessel ..........................................................................................................162 COOLING SYSTEM ...........................................................................................................................................................163 Temperature ..........................................................................................................................................................163 Radiators ............................................................................................................................................................164 Cooling-liquid level .............................................................................................................................................164 Topping up cooling liquid ........................................................................................................................................165 Checking the SCA concentration (if filled in).....................................................................................................................165 Cooling liquid, change ...............................................................................................................................................166 Draining off cooling liquid ......................................................................................................................................166 Filling in cooling liquid using the service station...............................................................................................................166 Testing the cooling liquid composition ...........................................................................................................................166 AIR-INTAKE SYSTEM ........................................................................................................................................................167 Dust trap, cleaning .................................................................................................................................................167 Main filter elements .................................................................................................................................................168 Removal and installation .........................................................................................................................................168 Checking and cleaning the main filter element ....................................................................................................................169 Safety filter element ................................................................................................................................................170 Removal and installation .........................................................................................................................................170 Air-intake lines .....................................................................................................................................................170 FUEL SYSTEM ..............................................................................................................................................................171 Fuel system - Safety instructions ....................................................................................................................................171 Replacing the fuel filter ............................................................................................................................................171 Venting the fuel system ..............................................................................................................................................172 Cleaning the fuel tanks ..............................................................................................................................................172 Water trap (option) ..................................................................................................................................................174 Servicing ........................................................................................................................................................174 ELECTRICAL SYSTEM .......................................................................................................................................................176 Electrical system - Safety instructions ..............................................................................................................................176 Alternator - Instructions ............................................................................................................................................176 Battery ..............................................................................................................................................................177 Checking the battery fluid level .................................................................................................................................177 Checking charge of batteries .....................................................................................................................................177 Removing and installing the battery ..............................................................................................................................178 Switchgear cabinet ...................................................................................................................................................179 Breather filter ..................................................................................................................................................179 Emptying dust trap ...............................................................................................................................................179 Emptying the dust collector ......................................................................................................................................179 Filter element ...................................................................................................................................................179 Checking and cleaning the filter element .........................................................................................................................180 Floodlight projector, replacing the lamp .............................................................................................................................181 Safety instructions...............................................................................................................................................181 Further instructions..............................................................................................................................................181 Replacing a defective Xenon-lamp..................................................................................................................................182 HYDRAULIC SYSTEM .........................................................................................................................................................183 Hydraulic system - Safety instructions ...............................................................................................................................183 Depressurizing the hydraulic system ..................................................................................................................................183 Checking the hydraulic oil level .....................................................................................................................................184 Changing the hydraulic oil return-flow (hydraulic oil reservoir) .....................................................................................................186 Bypass valves (hydraulic oil reservoir) ..............................................................................................................................188 Cleaning the filter screens ......................................................................................................................................188 Replacing the bypass valves and sealing rings ....................................................................................................................188 Breather filter ......................................................................................................................................................189 Replacing the filter elements ....................................................................................................................................189 Filter (control circuit)..............................................................................................................................................190 Replacing the filter element......................................................................................................................................190 High-pressure filter for working hydraulics ..........................................................................................................................191 Checking/cleaning the filter elements ............................................................................................................................191 Replacing the filter elements ....................................................................................................................................191 High-pressure filters for the servo circuit ..........................................................................................................................192 Checking/cleaning the filter elements.............................................................................................................................192 Replacing the filter elements.....................................................................................................................................192 High-pressure filters for feeding circuits and swing pumps ...........................................................................................................193 Checking/cleaning the filter element..............................................................................................................................193 Replacing the filter elements.....................................................................................................................................193 High-pressure filters for swing circuit ..............................................................................................................................194 Checking/cleaning the filter elements ............................................................................................................................194 Replacing the filter elements ....................................................................................................................................194 Bearing flushing for main pumps, replace filter ......................................................................................................................195 Bearing flushing, function........................................................................................................................................195 Replacing the filter element......................................................................................................................................195 Changing the hydraulic oil ...........................................................................................................................................196 Drawing off hydaulic oil .........................................................................................................................................196 Drawing off hydaulic oil .........................................................................................................................................197 Cleaning the hydraulic oil reservoir .............................................................................................................................197 Filling in hydraulic oil .........................................................................................................................................198 Venting the hydraulic system..........................................................................................................................................199 Venting the hydraulic components..................................................................................................................................199 Cleaning the hydraulic oil cooler.....................................................................................................................................200 Cleaning..........................................................................................................................................................200 Electronic excavator controls.........................................................................................................................................201 Joystick .........................................................................................................................................................201 Pedal.............................................................................................................................................................201 Pressure accumulator - Emergency lowering.............................................................................................................................202 Fig. 389:.........................................................................................................................................................202 Pressure-accumulator inspection regulations ......................................................................................................................202 Extract from the German regulations...............................................................................................................................202 Extract from the German acceptance regulations....................................................................................................................202 PUMP TRANSFER GEARBOX ....................................................................................................................................................203 Checking the gearbox oil level / Topping up with oil .................................................................................................................203 Pre-chambers, checking oil level, topping up with oil ................................................................................................................203 Changing the gearbox oil .............................................................................................................................................204 Draining off oil..................................................................................................................................................204 Filling in oil ...................................................................................................................................................204 Pre-chambers, changing the gearbox oil ...............................................................................................................................205 Draining off oil..................................................................................................................................................205 Filling in oil ...................................................................................................................................................205 Gearbox venting ......................................................................................................................................................205 Pre-chamber venting ..................................................................................................................................................206 Pump transfer gearbox lube oil filters ...............................................................................................................................207 SWING GEARBOX ............................................................................................................................................................208 Swing Gearbox - Checking the oil level / Topping up with oil .........................................................................................................208 Changing the gearbox oil .............................................................................................................................................209 Draining off oil .................................................................................................................................................209 Filling in new oil / Topping up ..................................................................................................................................209 Swing Gearbox venting ................................................................................................................................................209 TRAVEL GEARBOX (GEARBOX P/N 3683483) .....................................................................................................................................210 Travel gearbox - Checking the oil level / Topping up with oil ........................................................................................................210 Spur gear section - Checking the oil level / Topping up with oil .................................................................................................210 Brake chamber - Checking the oil level / Topping up with oil .....................................................................................................210 Travel gearbox - Changing oil ........................................................................................................................................211 Draining off oil..................................................................................................................................................211 Filling in oil ...................................................................................................................................................211 Spur gear section - Changing the oil / Draining off oil...........................................................................................................211 Filling in oil ...................................................................................................................................................211 Brake chamber - Changing oil .....................................................................................................................................212 Draining off oil..................................................................................................................................................212 Filling in oil ...................................................................................................................................................212 Travel gearbox - Breather filter .....................................................................................................................................212 TRAVEL GEARBOX(GEARBOX P/N 3683496) ......................................................................................................................................213 Travel gearbox - Checking the oil level / Topping up with oil ........................................................................................................213 Hydraulic motor chamber - Checking the oil level / Topping up with oil ...........................................................................................214 Travel gearbox - Changing oil ........................................................................................................................................215 Draining off oil .................................................................................................................................................215 Filling in oil ...................................................................................................................................................215 Hydraulic motor chamber - Changing oil ...........................................................................................................................216 Draining off oil..................................................................................................................................................216 Filling in oil ...................................................................................................................................................216 Travel gearbox -Breather filter ......................................................................................................................................216 CRAWLER TRACKS ...........................................................................................................................................................217 Cleaning .............................................................................................................................................................217 Track rollers ........................................................................................................................................................218 Track roller fastening ...........................................................................................................................................218 Support roller fastening .........................................................................................................................................218 Track tensioner ......................................................................................................................................................219 Design ...........................................................................................................................................................219 Technical data ...................................................................................................................................................219 Function .........................................................................................................................................................219 Pressure-accumulator inspection regulations ..........................................................................................................................220 Extract from the German regulations...............................................................................................................................220 Extract from the German acceptance regulations....................................................................................................................220 Checking the gas charging pressure in the pressure accumulator........................................................................................................220 SWING RING ...............................................................................................................................................................221 Swing ring - Instructions.............................................................................................................................................221 Bearing races.........................................................................................................................................................221 Internal gearing..................................................................................................................................................221 Swing ring - Checking the grease filling..........................................................................................................................222 Swing ring - Filling in grease....................................................................................................................................222 Swing ring - Checking the screws for tightness....................................................................................................................222 CENTRAL LUBRICATING ......................................................................................................................................................223 Design ...............................................................................................................................................................223 Function .............................................................................................................................................................224 Filling up the grease container ......................................................................................................................................225 Breather filter ......................................................................................................................................................225 Checking the greasing pressure .......................................................................................................................................226 Unblocking a grease line..............................................................................................................................................227 Cleaning .........................................................................................................................................................227 Oilfilter (hydraulic circuit grease pump) ............................................................................................................................228 Replacing the filter element......................................................................................................................................228 Grease filter (Filling the grease container) .........................................................................................................................229 Checking the filter element.......................................................................................................................................229 Replacing the filter element......................................................................................................................................229 Grease filter (Grease lines) .........................................................................................................................................230 Checking the filter element.......................................................................................................................................230 Replacing the filter element......................................................................................................................................230 OTHER MAINTENANCE ........................................................................................................................................................231 Engine ...............................................................................................................................................................231 Cleaning .........................................................................................................................................................231 Means of fastening ...............................................................................................................................................231 Cooling system ...................................................................................................................................................231 Exhaust system ...................................................................................................................................................231 Heating and air conditioning .........................................................................................................................................231 Hydraulic ladder, pressure accumulator ...............................................................................................................................232 Pressure-accumulator inspection regulations ..........................................................................................................................233 Extract from the German regulations...................................................................................................................................233 Extract from the German acceptance regulations....................................................................................................................233 Checking the gas charging pressure in the pressure accumulator........................................................................................................233 ON-BOARD CRANE (OPTIONAL) ................................................................................................................................................234 Monitoring, warning and control elements .............................................................................................................................234 Checking the on-board crane...........................................................................................................................................234 Extract from the inspection and testing regulations...............................................................................................................234 Drive unit ...........................................................................................................................................................235 Crane engine......................................................................................................................................................235 Air-intake system.................................................................................................................................................235 Hydraulic system..................................................................................................................................................235 On-board crane........................................................................................................................................................235 Servicing.........................................................................................................................................................235 On-Board crane, checking tightness of fastening bolts ................................................................................................................236 PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING ...............................................................................................................237 Putting the excavator out of operation ...............................................................................................................................237 Battery storage ......................................................................................................................................................237 Recommissioning ......................................................................................................................................................237 NOTES ...................................................................................................................................................................238 4 REPAIR WORK.................................................................................................................................................................239 REPAIR WORK - SAFETY INSTRUCTIONS.........................................................................................................................................241 Operating instructions................................................................................................................................................241 Repair personnel......................................................................................................................................................241 Working in greater heights............................................................................................................................................241 Prestressed units.....................................................................................................................................................241 Dismantling components................................................................................................................................................241 Never remove lead seals...............................................................................................................................................241 After the repair work.................................................................................................................................................241 REPAIR WORK, FIRE AND EXPLOSION HAZARD ...................................................................................................................................242 REPAIR WORK, ENGINE ......................................................................................................................................................243 ELECTRICAL SYSTEM ........................................................................................................................................................244 Assisted starting (with jumper cables) – Safety instructions .........................................................................................................244 Assisted starting (with jumper cables)................................................................................................................................244 Prior to assisted starting .......................................................................................................................................244 Starting the engine with jumper cables (external batteries ...........................................................................................................244 Connecting the jumper cables .....................................................................................................................................245 Starting up the engine ...........................................................................................................................................245 Disconnecting the jumper cables ..................................................................................................................................245 HYDRAULIC SYSTEM .........................................................................................................................................................246 Repair instructions ..................................................................................................................................................246 Hydraulic hoses – Instructions ......................................................................................................................................246 PRESSURE ACCUMULATORS - SAFETY INSTRUCTIONS...............................................................................................................................247 WELDING OPERATIONS - SAFETY INSTRUCTIONS .................................................................................................................................248 Welding operations only by trained personnel..........................................................................................................................248 Pressurized vessels and pressure accumulators.........................................................................................................................248 Swing joints and hinges...............................................................................................................................................248 Notes on the electric system..........................................................................................................................................248 Additional information................................................................................................................................................248 NOTES ....................................................................................................................................................................249 5 ANNEX.......................................................................................................................................................................251 BOARD-CONTROL-SYSTEM .....................................................................................................................................................253 BCS III, what’s that? ................................................................................................................................................253 What it is........................................................................................................................................................253 What it does......................................................................................................................................................253 Benefits for the operator.........................................................................................................................................253 Want more information?............................................................................................................................................253 The keys on the front side ...........................................................................................................................................254 Other elements on the front side .....................................................................................................................................254 BCSIII, the start screen .............................................................................................................................................255 Information given on the start screen, top section ...................................................................................................................256 Information given on the start screen, central section ...............................................................................................................257 Information given on the start screen, lower section .................................................................................................................258 Information given on the “Service” screen ............................................................................................................................259 Engine data screen ...................................................................................................................................................260 Hydraulic data screen ................................................................................................................................................261 Lubrication data screen ..............................................................................................................................................262 Controls adjustment data screen ......................................................................................................................................263 View documents screen ................................................................................................................................................264 Signal table screen ..................................................................................................................................................265 Signal table screen, location ........................................................................................................................................266 Signal table screen, diagram .........................................................................................................................................267 Signal table screen, diagram configuration ...........................................................................................................................268 Code table screen ....................................................................................................................................................269 BCS III, interfaces ..................................................................................................................................................270 USB interface, data storage ..........................................................................................................................................270 Saving data to a USB stick ...........................................................................................................................................271 Saving data to a USB stick, continued ................................................................................................................................272 Saving data to a USB stick, continued ................................................................................................................................273 BCSIII, cleaning .....................................................................................................................................................274 BCSIII, disposal .....................................................................................................................................................274 TROUBLESHOOTING ..........................................................................................................................................................275 Instructions on troubleshooting ......................................................................................................................................275 Layout of the fault table ............................................................................................................................................275 Fault.............................................................................................................................................................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 HYDRAULIC CIRCUIT DIAGRAM ................................................................................................................................................281 Vibration data .......................................................................................................................................................281 ABBREVIATIONS ............................................................................................................................................................282 ABBREVIATIONS.........................................................................................................................................................283 TECHNICAL DATA ...........................................................................................................................................................285 NOTES ....................................................................................................................................................................297 6 INDEX.......................................................................................................................................................................299
Questions? Email us: [email protected]
PLEASE NOTE:
- This is the SAME MANUAL used by the dealerships to diagnose your vehicle
- No waiting for couriers / posts as this is a PDF manual and you can download it within 2 minutes time once you make the payment.
- Your payment is all safe and the delivery of the manual is INSTANT – You will be taken to the DOWNLOAD PAGE.
- So have no hesitations whatsoever and write to us about any queries you may have : heydownloadss @gmail.com
S.V
