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Cat Bucyrus 6015 RH40E Hydraulic Excavator Operation Instruction Manual BI651402 – PDF DOWNLOAD
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Cat Bucyrus 6015 RH40E Hydraulic Excavator Operation Instruction Manual BI651402 – PDF DOWNLOAD
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Description
Cat Bucyrus 6015 RH40E Hydraulic Excavator Operation Instruction Manual BI651402 – PDF DOWNLOAD
FILE DETAILS:
Cat Bucyrus 6015 RH40E Hydraulic Excavator Operation Instruction Manual BI651402 – PDF DOWNLOAD
Language : English
Pages :244
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Cat Bucyrus 6015 RH40E Hydraulic Excavator Operation Instruction Manual BI651402 – PDF DOWNLOAD
PREFACE
About this Operating Instructions
- These operating instructions are designed to familiarize the operator with the machine and its designated use. The operating instructions contain important information on how to operate the machine safely, properly and with maximum efficiency.
- Observing these instructions helps to prevent hazardous situations, to reduce repair costs and downtimes and to increase the reliability and service life of the machine. The operating instructions must be supplemented by the respective national rules and regulations for accident prevention and environmental protection.
- The operating instructions must always be available in the driver’s cab of the machine. The operating instructions must be read and put into practice by any person in charge of carrying out work with or on the machine, such as
operation, including setting-up, troubleshooting in the course of work, care, evacuation of production waste and disposal of fuels and consumables,
maintenance (inspection, servicing, repair) and / or
transport.
In addition to the operating instructions and the mandatory rules and regulations for accident prevention and environmental protection in the user’s country and at the place where the machine is to be used, the generally recognized technical rules for safe and proper working must be observed 1. The operating instructions are directed to the mining- machine specialist. They cannot provide basic know-how. This can be acquired, for example, in several days’ instruction by a qualified Bucyrus HEX mechanic or by attending an Bucyrus HEX training course for operators or maintenance personnel
- The Bucyrus HEX after-sales service will be pleased to deal with any queries you may have after reading through the operating instructions.
- All Bucyrus HEX operating manuals are issued in German and then translated. Even a good translation may give rise to questions which Bucyrus HEX will be pleased to answer.
- The operating instructions are not work instructions for carrying out major repairs. Such work is willingly done for you by the Bucyrus HEX aftersales service
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Cat Bucyrus 6015 RH40E Hydraulic Excavator Operation and Maintenance Manual BI651402 – PDF DOWNLOAD
1 INTRODUCTION............................................................................................................................................................... 11 PREFACE ................................................................................................................................................................. 13 Further machine documentation ....................................................................................................................................... 13 WARRANTY ................................................................................................................................................................ 14 FUNDAMENTAL SAFETY INSTRUCTIONS ......................................................................................................................................... 15 Warnings and symbols ................................................................................................................................................ 15 Contents of the Declaration of Conformity ........................................................................................................................... 15 DESIGNATED USE, UNAUTHORIZED USE ........................................................................................................................................ 16 Noise emission information .......................................................................................................................................... 17 Vibration information ............................................................................................................................................... 17 ORGANIZATIONAL MEASURES ................................................................................................................................................. 18 Personal protective equipment and the working clothing .............................................................................................................. 18 Selection and qualification of personnel; basic responsibilities .................................................................................................... 19 Safety instructions governing specific operational phases ........................................................................................................... 19 Special work in conjunction with utilization of the machine and maintenance and repairs as well as troubleshooting during work; disposal of parts and consumables.... 20 Warning of special dangers........................................................................................................................................... 21 Transporting and recommissioning .................................................................................................................................... 22 FIRE AND EXPLOSION HAZARD ............................................................................................................................................... 23 NOTES ................................................................................................................................................................... 25 2 OPERATION.................................................................................................................................................................. 27 OPERATION - SAFETY INSTRUCTIONS ......................................................................................................................................... 29 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 ....................................................................................................................................................... 34 Superstructure ...................................................................................................................................................... 34 Drive ............................................................................................................................................................... 34 Hydraulic system .................................................................................................................................................... 34 Pump Managing System (PMS) .......................................................................................................................................... 34 Programmable Logic Controller (PLC) ................................................................................................................................. 34 Demand control / Zero-flow regulation ............................................................................................................................... 35 Automatic engine speed reduction ................................................................................................................................... 35 Electrical system ................................................................................................................................................... 35 Signs ............................................................................................................................................................... 37 DRIVER'S CAB ........................................................................................................................................................ 38 Entering and leaving the machine - Safety instructions .............................................................................................................. 38 Windscreen washer ................................................................................................................................................... 39 Driver's seat ....................................................................................................................................................... 40 Adjusting the control consoles ...................................................................................................................................... 41 Trainer's / instructor's seat ....................................................................................................................................... 42 Fire-extinguisher ................................................................................................................................................... 43 MONITORING, WARNING AND CONTROL ELEMENTS ................................................................................................................................ 44 PUTTING THE MACHINE INTO OPERATION ...................................................................................................................................... 63 Reducing the operator's exposure to noise ........................................................................................................................... 63 Refuelling .......................................................................................................................................................... 63 Switching the electrical system on and off .......................................................................................................................... 66 Battery main switch ................................................................................................................................................. 67 Preheating system for engine and hydraulic oil (optional) ........................................................................................................... 68 Fuel preheating system (optional) ................................................................................................................................... 69 STARTING AND STOPPING THE ENGINE ........................................................................................................................................ 70 VENTILATION AND HEATING ................................................................................................................................................. 72 Air conditioner (optional) .......................................................................................................................................... 72 Auxiliary heating (optional) ........................................................................................................................................ 72 MAXIMUM MACHINE INCLINATIONS, INFORMATION ............................................................................................................................... 73 TRAVELLING, SAFETY INSTRUCTIONS ......................................................................................................................................... 74 Running-in specifications for components of the crawler tracks....................................................................................................... 74 TRAVELLING .......................................................................................................................................................... 75 Locking the superstructure .......................................................................................................................................... 79 Track parking brake ................................................................................................................................................. 79 TRANSPORTING THE MACHINE ................................................................................................................................................ 80 Transport - Safety instructions ..................................................................................................................................... 80 WORKING OPERATION ....................................................................................................................................................... 82 SAFETY INSTRUCTIONS ................................................................................................................................................. 82 Before starting work ................................................................................................................................................ 84 Slewing and braking the superstructure .............................................................................................................................. 85 Working ............................................................................................................................................................. 86 After daily operation ............................................................................................................................................... 87 ASSEMBLING WORKING EQUIPMENT - SAFETY INSTRUCTIONS ...................................................................................................................... 88 Securing the machine ................................................................................................................................................ 89 CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS) .......................................................................................................... 90 LIFTING OPERATIONS ...................................................................................................................................................... 91 Safety instructions ................................................................................................................................................. 91 Load-hooks on backhoe buckets. ...................................................................................................................................... 92 NOTES ................................................................................................................................................................... 97 3 INSPECTION AND SERVICING................................................................................................................................................... 99 INSPECTION AND SERVICING - SAFETY INSTRUCTIONS ..........................................................................................................................101 INSPECTION AND SERVICING WORK, FIRE AND EXPLOSION HAZARD ................................................................................................................105 ENVIRONMENTALLY COMPATIBLE HYDRAULIC FLUID ..............................................................................................................................106 Environmentally compatible hydraulic fluid - operating instructions .................................................................................................106 Environmentally compatible hydraulic fluid, conversion ..............................................................................................................106 Environmentally compatible hydraulic fluid - Sampling ...............................................................................................................107 ENVIRONMENT-FRIENDLY LUBRICANTS AND GEARBOX OILS ........................................................................................................................108 Lubricants for bearings .............................................................................................................................................108 Gearbox oils ........................................................................................................................................................108 INSPECTION AND SERVICING PLANS - INSTRUCTIONS ...........................................................................................................................109 Plan V ..............................................................................................................................................................111 Plan N ..............................................................................................................................................................113 Plan T and W ........................................................................................................................................................115 Plan A – E ..........................................................................................................................................................117 LUBRICATING CHART – GREASE ..............................................................................................................................................122 Lubricating chart – Grease (legend) .................................................................................................................................123 Filling quantities - Grease..........................................................................................................................................123 INSPECTION PLAN - OIL ...................................................................................................................................................124 Inspection plan – Oil (legend) ).....................................................................................................................................125 Filling quantities - oil ............................................................................................................................................126 Filling quantities - other...........................................................................................................................................126 LUBRICANTS ..............................................................................................................................................................127 Notes on the selection of oils and greases ..........................................................................................................................127 Avoid mixing of different hydraulic fluids ..........................................................................................................................127 I. Oils for combustion engine .......................................................................................................................................128 II. Oils for hydraulic system .......................................................................................................................................129 III.a Oils for pump gearbox .........................................................................................................................................130 III.b Oils for swing gearbox ........................................................................................................................................131 III.c Oils for travel gearbox .......................................................................................................................................132 V. Greases for bearings and slewing rings ...........................................................................................................................133 Fluid grease for idlers, track rollers and support rollers ..........................................................................................................134 SERVICING WORK ..........................................................................................................................................................135 Hose line for oil and cooling liquid changes ........................................................................................................................135 ENGINE ..................................................................................................................................................................136 Engine - Safety instructions ........................................................................................................................................136 Checking the engine oil level / Topping up .........................................................................................................................136 Changing the engine oil .............................................................................................................................................137 Replacing the engine oil filters ....................................................................................................................................138 Cold-starting fluid (ether) - Replacing the pressure vessel .........................................................................................................139 COOLING SYSTEM ..........................................................................................................................................................140 Temperature .........................................................................................................................................................140 Cooler and cooling liquid............................................................................................................................................140 Topping up with coolant .............................................................................................................................................141 Changing the coolant ................................................................................................................................................141 AIR-INTAKE SYSTEM .......................................................................................................................................................143 Dust trap, cleaning .................................................................................................................................................143 Main filter elements ................................................................................................................................................144 Safety filter element ...............................................................................................................................................146 Air-intake lines ....................................................................................................................................................146 FUEL SYSTEM .............................................................................................................................................................147 Fuel system - Safety instructions ...................................................................................................................................147 Fuel pre-filter, Draining off water .................................................................................................................................147 Fuel pre-filter, replace ............................................................................................................................................148 Secondary fuel filter, replace ......................................................................................................................................149 Fuel tank - Venting .................................................................................................................................................150 Cleaning the fuel tank ..............................................................................................................................................150 Refuelling station (optional) .......................................................................................................................................151 Water trap (option)..................................................................................................................................................152 ELECTRICAL SYSTEM ......................................................................................................................................................154 Electrical system - Safety instructions .............................................................................................................................154 Alternator - Instructions ...........................................................................................................................................154 Electrical circuit diagrams .........................................................................................................................................154 Electrical system switch-cabinets ...................................................................................................................................154 Replacing lamps and bulbs ...........................................................................................................................................154 Floodlight projector, safety instructions ...........................................................................................................................155 Lighting systems in LED technonogy, instructions ....................................................................................................................157 Battery .............................................................................................................................................................158 Charging batteries inside the machine, safety instructions ..........................................................................................................159 Removing and installing the battery .................................................................................................................................160 HYDRAULIC SYSTEM ........................................................................................................................................................161 Hydraulic system - Safety instructions ..............................................................................................................................161 Depressurizing the hydraulic system .................................................................................................................................161 Checking the hydraulic oil level ....................................................................................................................................162 Topping up with hydraulic oil .......................................................................................................................................162 Changing the hydraulic oil return-flow (hydraulic oil reservoir) ....................................................................................................163 Bypass valves (working circuit) .....................................................................................................................................164 Bypass valves (cooling circuit) .....................................................................................................................................165 Breather filter .....................................................................................................................................................166 High-pressure filter for working hydraulics .........................................................................................................................167 High-pressure filters for the servo circuit and the feeding circuit of the slewing pump .............................................................................168 Changing the hydraulic oil ..........................................................................................................................................169 Avoid mixing of different hydraulic fluids ..........................................................................................................................169 Venting the hydraulic system.........................................................................................................................................172 Cleaning the hydraulic oil cooler....................................................................................................................................173 Pressure accumulator ................................................................................................................................................174 PUMP TRANSFER GEARBOX ...................................................................................................................................................175 Checking the gearbox oil level / Topping up with oil ................................................................................................................175 Changing the gearbox oil ............................................................................................................................................176 SLEWING GEARBOX .........................................................................................................................................................178 Gearbox - Checking the oil level / Topping up with oil ..............................................................................................................178 Changing the gearbox oil ............................................................................................................................................178 Gearbox venting .....................................................................................................................................................179 Output pinion .......................................................................................................................................................179 TRAVEL GEARBOX ..........................................................................................................................................................180 Gearbox - Checking the oil level / Topping up with oil ..............................................................................................................180 Travel gearbox - Changing the oil ...................................................................................................................................180 Gearbox venting .....................................................................................................................................................180 CRAWLER TRACKS ..........................................................................................................................................................181 Track rollers, support rollers, track pads ..........................................................................................................................181 Track tensioner .....................................................................................................................................................183 Pressure-accumulator inspection regulations .........................................................................................................................184 Checking the gas charging pressure in the pressure accumulator.......................................................................................................184 SWING RING ..............................................................................................................................................................185 Swing ring - Instructions............................................................................................................................................185 Bearing races........................................................................................................................................................185 CENTRAL LUBRICATING .....................................................................................................................................................187 Design and function .................................................................................................................................................187 Greasing cycle .....................................................................................................................................................189 Venting the grease pump .............................................................................................................................................191 Venting the grease lines ............................................................................................................................................191 Unblocking a grease line ............................................................................................................................................191 Cleaning the grease sieves ..........................................................................................................................................192 Lubricating the grease distributor of the working equipment .........................................................................................................192 OTHER MAINTENANCE .......................................................................................................................................................193 Heating and air conditioning ........................................................................................................................................193 PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING ..............................................................................................................194 Putting the excavator out of operation ..............................................................................................................................194 Battery storage .....................................................................................................................................................194 Recommissioning .....................................................................................................................................................194 NOTES ...................................................................................................................................................................195 4 REPAIR WORK................................................................................................................................................................197 REPAIR WORK - SAFETY INSTRUCTIONS........................................................................................................................................199 REPAIR WORK, FIRE AND EXPLOSION HAZARD ..................................................................................................................................200 REPAIR WORK, ENGINE .....................................................................................................................................................201 HYDRAULIC SYSTEM ........................................................................................................................................................202 Repair instructions .................................................................................................................................................202 Hydraulic hoses – Instructions .....................................................................................................................................202 ELECTRICAL SYSTEM .......................................................................................................................................................203 Assisted starting (with jumper cables) – Safety instructions ........................................................................................................203 Assisted starting (with jumper cables)...............................................................................................................................203 Starting the engine with jumper cables (external batteries ..........................................................................................................203 PRESSURE ACCUMULATORS - SAFETY INSTRUCTIONS..............................................................................................................................205 WELDING AND FLAME CUTTING WORKS - SAFETY INSTRUCTIONS ...................................................................................................................206 DISPOSAL AT THE END OF THE SERVICE LIFE .................................................................................................................................209 Dismantling and removal instructions ................................................................................................................................209 Risk of deflagrations ...............................................................................................................................................209 Risk of fire ........................................................................................................................................................209 Disposing of the machine without polluting the environment ..........................................................................................................209 Further hazardous substances ........................................................................................................................................210 Appropriate disposal of batteries ...................................................................................................................................211 NOTES ...................................................................................................................................................................213 5 ANNEX......................................................................................................................................................................215 TROUBLESHOOTING .........................................................................................................................................................217 Instructions on troubleshooting .....................................................................................................................................217 Layout of the fault table ...........................................................................................................................................217 Possible causes .....................................................................................................................................................217 Measures ............................................................................................................................................................217 Section .............................................................................................................................................................217 FAULT TABLES ............................................................................................................................................................218 Combustion engine - Fault table .....................................................................................................................................218 ,Working hydraulics – Fault table ...................................................................................................................................218 Track drive – Fault table ...........................................................................................................................................220 Slewing mechnism – Fault table ......................................................................................................................................221 Central lubricating system – Fault table ............................................................................................................................222 HYDRAULIC CIRCUIT DIAGRAM ...............................................................................................................................................223 ABBREVIATIONS ...........................................................................................................................................................225 TECHNICAL DATA ..........................................................................................................................................................227 Product Specification Sheet .........................................................................................................................................229 NOTES ...................................................................................................................................................................237 6 INDEX......................................................................................................................................................................239
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