Caterpillar Bucyrus 6040 RH170B Hydraulic Excavator Operating Instructions Manual BI651399 – PDF DOWNLOAD
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Caterpillar Bucyrus 6040 RH170B Hydraulic Excavator Operating Instructions Manual BI651399 – PDF DOWNLOAD
Language : English
Pages : 329
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Caterpillar Bucyrus 6040 RH170B Hydraulic Excavator Operating Instructions Manual BI651399 – 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 6040 RH170B Hydraulic Excavator Operating Instructions Manual BI651399 – PDF DOWNLOAD
TITLEPAGE..................................................................................................................................................................... 1 1 INTRODUCTION................................................................................................................................................................ 13 PREFACE .................................................................................................................................................................. 15 Further machine documentation ........................................................................................................................................ 15 WARRANTY ................................................................................................................................................................. 16 FUNDAMENTAL SAFETY INSTRUCTIONS........................................................................................................................................... 17 Warnings and symbols ................................................................................................................................................. 17 DESIGNATED USE, UNAUTHORIZED USE ......................................................................................................................................... 18 Noise emission information ........................................................................................................................................... 19 Vibration information ................................................................................................................................................ 19 ORGANIZATIONAL MEASURES .................................................................................................................................................. 20 Selection and qualification of personnel; basic responsibilities ..................................................................................................... 21 Safety instructions governing specific operational phases ............................................................................................................ 21 Special work in conjunction with utilization of the machine and maintenance and repairs as well as troubleshooting during work; disposal of parts and consumables .... 22 Warning of special dangers ........................................................................................................................................... 23 Gas, dust, steam and smoke ........................................................................................................................................... 23 Hydraulic equipment .................................................................................................................................................. 24 FIRE AND EXPLOSION HAZARD ................................................................................................................................................ 25 NOTES .................................................................................................................................................................... 27 2 OPERATION................................................................................................................................................................... 29 OPERATION - SAFETY INSTRUCTIONS .......................................................................................................................................... 31 Operating Instructions, where to store it in the driver’s cab ........................................................................................................ 32 FIRE AND EXPLOSION HAZARD ................................................................................................................................................ 33 DESCRIPTION OF THE HYDRAULIC SHOVEL....................................................................................................................................... 34 Hydraulic shovel layout .............................................................................................................................................. 35 Undercarriage ........................................................................................................................................................ 36 Superstructure ....................................................................................................................................................... 36 Drive ................................................................................................................................................................ 36 Hydraulic system ..................................................................................................................................................... 36 Control and Monitoring Platform (CAMP) ............................................................................................................................... 36 Board-Control-System (BCS) ........................................................................................................................................... 37 Demand control / Zero-flow regulation ................................................................................................................................ 37 Automatic reset to idling ............................................................................................................................................ 37 Electrical system .................................................................................................................................................... 37 Signs ................................................................................................................................................................ 38 Entering and leaving the machine Safety instructions ................................................................................................................. 46 Access ladder lighting ............................................................................................................................................... 46 Swinging ladder (optional) ........................................................................................................................................... 47 Folding ladder ....................................................................................................................................................... 48 Emergency exit in driver’s cab and escape ladder ..................................................................................................................... 49 Escape ladder near engine compartment (optional) ..................................................................................................................... 50 Switching the cab interior lighting on and off ....................................................................................................................... 51 Switching the maintenance lights on and off .......................................................................................................................... 52 Emergency shut-off function .......................................................................................................................................... 53 Battery isolator switch, shutting off supply voltage ................................................................................................................. 55 Starter isolator switch, shutting off starter voltage ................................................................................................................ 55 Reducing the operators exposure to vibrations ........................................................................................................................ 58 Trainer's / instructor's seat ........................................................................................................................................ 58 Fire extinguisher .................................................................................................................................................... 59 Automatic fire-extinguishing system (optional) ....................................................................................................................... 60 Windscreen washer .................................................................................................................................................... 60 Operating hours meter ................................................................................................................................................ 60 Emergency escape device / seat (optional) ............................................................................................................................ 61 MONITORING, WARNING AND CONTROL ELEMENTS ................................................................................................................................. 64 Engine 1 (LH), control and monitoring ................................................................................................................................ 71 Engine 2 (RH), control and monitoring ................................................................................................................................ 73 PUTTING THE MACHINE INTO OPERATION ....................................................................................................................................... 92 Reducing the operator's exposure to noise ............................................................................................................................ 92 Refuelling ........................................................................................................................................................... 93 Back-up heating (option), filling in fuel ............................................................................................................................ 93 Service station (tanklift) ........................................................................................................................................... 94 Emergency off switch ................................................................................................................................................. 95 Switching the electrical system on and off ...........................................................................................................................100 Engines, emergency shut-off ..........................................................................................................................................100 Preheating system for engine and hydraulic oil (optional) ............................................................................................................101 Fuel preheating system (optional) ....................................................................................................................................102 STARTING AND STOPPING THE ENGINES ........................................................................................................................................104 Starting the engines .................................................................................................................................................104 Starting the left-hand engine.........................................................................................................................................104 Starting the right-hand engine........................................................................................................................................104 Engines – adjusting the speed ........................................................................................................................................105 Starting the engines at low temperatures .............................................................................................................................105 Shutting off the engines .............................................................................................................................................106 Shutting off the left-hand engine.....................................................................................................................................106 Shutting off the right-hand engine....................................................................................................................................106 AIR CONDITIONER (OPTIONAL) ...............................................................................................................................................107 Back-up heating driver’s cab (optional) ..............................................................................................................................108 Back-up heating (optional) ...........................................................................................................................................109 MAXIMUM MACHINE INCLINATIONS, INFORMATION ................................................................................................................................110 TRAVELLING, SAFETY INSTRUCTIONS ..........................................................................................................................................112 TRAVELLING ...............................................................................................................................................................113 Superstructure basic position ........................................................................................................................................113 Travelling forwards/backwards ........................................................................................................................................113 Superstructure holding brake .........................................................................................................................................117 Track parking brake ..................................................................................................................................................117 TRANSPORTING THE MACHINE .................................................................................................................................................118 Transport - Safety instructions ......................................................................................................................................118 WORKING OPERATION - SAFETY INSTRUCTIONS ..................................................................................................................................119 WORKING OPERATION ........................................................................................................................................................121 Before starting work .................................................................................................................................................121 Activating the electronic hydraulic shovel control ...................................................................................................................121 Swinging the superstructure ..........................................................................................................................................122 Braking the superstructure ...........................................................................................................................................122 Working ..............................................................................................................................................................123 After daily operation ................................................................................................................................................124 ASSEMBLING WORKING EQUIPMENT - SAFETY INSTRUCTIONS .......................................................................................................................125 Securing the machine .................................................................................................................................................126 CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS) ...........................................................................................................127 ON-BOARD CRANE (OPTIONAL) ................................................................................................................................................128 Monitoring, warning and control elements .............................................................................................................................128 On-board crane, putting into operation ...............................................................................................................................129 On-board crane, drive unit ...........................................................................................................................................129 On-Board crane, – blocking the boom in position of rest ..............................................................................................................130 Checking the on-board crane ..........................................................................................................................................130 NOTES ....................................................................................................................................................................131 3 INSPECTION AND SERVICING....................................................................................................................................................133 INSPECTION AND SERVICING - SAFETY INSTRUCTIONS ...........................................................................................................................135 INSPECTION AND SERVICING WORK, FIRE AND EXPLOSION HAZARD .................................................................................................................139 INSPECTION AND SERVICING PLANS - INSTRUCTIONS ............................................................................................................................141 Plan V ...............................................................................................................................................................143 Plan N ...............................................................................................................................................................145 Plan T and W..........................................................................................................................................................147 Plan A – E ...........................................................................................................................................................149 LUBRICATING CHART – GREASE ...............................................................................................................................................156 Lubricating chart – Grease (legend) ..................................................................................................................................157 Filling quantities - Grease...........................................................................................................................................157 INSPECTION PLAN - OIL ....................................................................................................................................................158 Inspection plan – Oil (legend) .......................................................................................................................................159 Filling quantities - oil .............................................................................................................................................160 Filling quantities - other............................................................................................................................................160 LUBRICANTS / CONSUMABLES .................................................................................................................................................161 Notes on the selection of oils and greases ...........................................................................................................................161 Avoid mixing of different hydraulic fluids ...........................................................................................................................161 I. Oils for combustion engines .......................................................................................................................................162 II. Oils for hydraulic system ........................................................................................................................................163 III.a Oils for pump gearboxes ........................................................................................................................................164 III.b Oils for swing gearboxes .......................................................................................................................................165 III.c Oils for travel gearboxes ......................................................................................................................................166 V. Greases for bearings and swing rings ..............................................................................................................................167 Fluid grease for idlers, track rollers and support rollers ...........................................................................................................168 SERVICING WORK ...........................................................................................................................................................169 Hose line for oil and cooling liquid changes .........................................................................................................................169 ENGINE ...................................................................................................................................................................170 Engine - Safety instructions .........................................................................................................................................170 Engine oil, checking the level / topping up ..........................................................................................................................171 Engine oil reservoir (optional), checking the oil level / topping up .................................................................................................172 Engine oil, change ...................................................................................................................................................173 Engine oil reservoir (optional), draining the oil off ................................................................................................................175 Engine oil filter, replace ...........................................................................................................................................177 Engine oil reservoir (optional), replacing the oil filters ...........................................................................................................178 Cold-starting fluid (ether) - Replacing the pressure vessel ..........................................................................................................179 COOLING SYSTEM ...........................................................................................................................................................180 Temperature ..........................................................................................................................................................180 Radiators ............................................................................................................................................................181 Cooling-liquid level check ...........................................................................................................................................181 Cooling liquid, change ...............................................................................................................................................184 Testing the cooling liquid composition ...............................................................................................................................186 AIR-INTAKE SYSTEM ........................................................................................................................................................187 Dust trap, cleaning .................................................................................................................................................187 Main filter elements .................................................................................................................................................188 Main filter elements, checking and cleaning ..........................................................................................................................189 Safety filter element ................................................................................................................................................190 Air-intake lines .....................................................................................................................................................190 FUEL SYSTEM ..............................................................................................................................................................191 Fuel system - Safety instructions ....................................................................................................................................191 Fuel filter, replace .................................................................................................................................................191 Primary fuel filter, drain water .....................................................................................................................................192 Primary fuel filter, replace .........................................................................................................................................192 Venting the fuel system ..............................................................................................................................................193 Cleaning the fuel tanks ..............................................................................................................................................193 Water trap (optional) ................................................................................................................................................195 ELECTRICAL SYSTEM .......................................................................................................................................................197 Electrical system - Safety instructions ..............................................................................................................................197 Alternator - Instructions ............................................................................................................................................197 Electrical circuit diagrams ..........................................................................................................................................197 Electrical system switch-cabinets ....................................................................................................................................197 Replacing lamps and bulbs ............................................................................................................................................197 Battery ..............................................................................................................................................................198 Charging batteries inside the machine, safety instructions ...........................................................................................................199 Removing and installing the battery ..................................................................................................................................200 Switchgear cabinet, aeration .........................................................................................................................................201 Xenon floodlight projector, replacing the lamp .......................................................................................................................203 Lighting systems in LED technonogy, instructions .....................................................................................................................205 HYDRAULIC SYSTEM .........................................................................................................................................................206 Hydraulic system - Safety instructions ...............................................................................................................................206 Depressurizing the hydraulic system ..................................................................................................................................206 Checking the hydraulic oil level .....................................................................................................................................207 Replacing the hydraulic oil return-flow filter (hydraulic oil reservoir) .............................................................................................209 Bypass valves (hydraulic oil reservoir) ..............................................................................................................................212 Replacing the bypass valves and sealing rings ........................................................................................................................212 Replacing the hydraulic oil return-flow filters (filter housing cooling system) ......................................................................................213 Bypass valves (filter housing - cooling system) ......................................................................................................................214 Breather filter ......................................................................................................................................................215 Filter (control circuit and auxiliary control circuit)................................................................................................................216 High-pressure filter for working hydraulics ..........................................................................................................................217 High-pressure filters for the servo circuit ..........................................................................................................................218 High-pressure filters for feeding circuits and slewing pumps .........................................................................................................219 Changing the hydraulic oil ...........................................................................................................................................220 Avoid mixing of different hydraulic fluids ...........................................................................................................................220 Venting the hydraulic system..........................................................................................................................................224 Cleaning the hydraulic oil cooler.....................................................................................................................................225 Electronic hydraulic shovel control...................................................................................................................................226 Pressure accumulator - Emergency lowering ............................................................................................................................227 PUMP TRANSFER GEARBOX ....................................................................................................................................................228 Checking the pump gearbox oil level / Topping up with oil ............................................................................................................228 Changing the pump gearbox oil ........................................................................................................................................229 Pump gearbox venting .................................................................................................................................................231 Pump transfer gearbox lube oil filters ...............................................................................................................................232 SWING GEARBOX ............................................................................................................................................................233 Swing gearbox - Checking the oil level / Topping up with oil .........................................................................................................233 Gearbox venting ......................................................................................................................................................233 Changing the swing gearbox oil .......................................................................................................................................234 TRAVEL GEARBOX (PN 2763213) ..............................................................................................................................................236 Travel gearbox - Checking the oil level / Topping up with oil ........................................................................................................236 Pre-chamber / spur wheel section, Check the oil level / Top up with oil ..............................................................................................236 Hydraulic motor chamber - Check the oil level / Top up with oil ......................................................................................................236 Travel gearbox, Changing oil .........................................................................................................................................237 Pre-chamber / spur wheel section, Changing oil .......................................................................................................................237 Hydraulic motor chamber, Changing oil ................................................................................................................................238 Travel gearbox breather filter, Clean / Replace ......................................................................................................................238 TRAVEL GEARBOX (PN 3719869) ..............................................................................................................................................239 Travel gearbox - Checking the oil level / Topping up with oil ........................................................................................................239 Hydraulic motor chambers, Check the oil level / Top up with oil ......................................................................................................239 Travel gearbox, Changing oil .........................................................................................................................................240 Hydraulic motor chambers, Changing oil ...............................................................................................................................240 CRAWLER TRACKS ...........................................................................................................................................................241 Track roller, Support roller .........................................................................................................................................242 Track tensioner ......................................................................................................................................................243 Pressure-accumulator inspection regulations ..........................................................................................................................244 Checking the gas charging pressure in the pressure accumulator........................................................................................................244 SWING RING ...............................................................................................................................................................245 Swing ring – Instructions ............................................................................................................................................245 Bearing races ........................................................................................................................................................245 CENTRAL LUBRICATING SYSTEM ...............................................................................................................................................247 Design ...............................................................................................................................................................247 Function .............................................................................................................................................................248 Filling up the grease container ......................................................................................................................................249 Breather filter grease container, check / replace ....................................................................................................................249 Checking the greasing pressure .......................................................................................................................................250 Unblocking a grease line .............................................................................................................................................250 Oilfilter replace (hydraulic circuit grease pump) ....................................................................................................................251 Grease filter replace (filling the grease container) .................................................................................................................252 Grease filter replace (Grease lines) .................................................................................................................................252 OTHER MAINTENANCE ........................................................................................................................................................253 Engine ...............................................................................................................................................................253 Heating and air conditioning .........................................................................................................................................253 Reservoirs for used grease at the A-frame, emptying ..................................................................................................................254 Hydraulic ladder, pressure accumulator ...............................................................................................................................254 Pressure-accumulator inspection regulations .........................................................................................................................255 Extract from the German regulations...................................................................................................................................255 Checking the gas charging pressure in the pressure accumulator .......................................................................................................255 ON-BOARD CRANE, DRIVE UNIT ...............................................................................................................................................256 On-board crane, greasing..............................................................................................................................................256 On-Board crane, checking tightness of fastening bolts ................................................................................................................257 PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING ...............................................................................................................258 Putting the hydraulic shovel out of operation.........................................................................................................................258 Battery storage ......................................................................................................................................................258 Recommissioning.......................................................................................................................................................258 NOTES ...................................................................................................................................................................259 4 REPAIR WORK.................................................................................................................................................................261 REPAIR WORK - SAFETY INSTRUCTIONS.........................................................................................................................................263 CONFINED SPACES - SAFETY INSTRUCTIONS ....................................................................................................................................264 REPAIR WORK, FIRE AND EXPLOSION HAZARD ...................................................................................................................................265 REPAIR WORK, ENGINE.......................................................................................................................................................266 HYDRAULIC SYSTEM .........................................................................................................................................................267 Repair instructions ..................................................................................................................................................267 Hydraulic hoses – Instructions ......................................................................................................................................267 PRESSURE ACCUMULATORS - SAFETY INSTRUCTIONS...............................................................................................................................268 WELDING AND FLAME CUTTING WORKS - SAFETY INSTRUCTIONS ....................................................................................................................269 DISPOSAL AT THE END OF THE SERVICE LIFE ..................................................................................................................................272 Appropriate disposal of batteries ....................................................................................................................................273 NOTES ....................................................................................................................................................................275 5 ANNEX.......................................................................................................................................................................277 BOARD-CONTROL-SYSTEM .....................................................................................................................................................279 BCS III, what’s that? ................................................................................................................................................279 The keys on the front side ...........................................................................................................................................280 Other elements on the front side .....................................................................................................................................280 BCSIII, the start screen .............................................................................................................................................281 Information given on the start screen, top section ...................................................................................................................282 Information given on the start screen, central section ...............................................................................................................283 Information given on the start screen, lower section .................................................................................................................284 Information given on the “Service” screen ............................................................................................................................285 Engine data screen ...................................................................................................................................................286 Hydraulic data screen ................................................................................................................................................287 Lubrication data screen ..............................................................................................................................................288 Controls adjustment data screen ......................................................................................................................................289 View documents screen ................................................................................................................................................290 Signal table screen ..................................................................................................................................................291 Signal table screen, location ........................................................................................................................................292 Signal table screen, diagram .........................................................................................................................................293 Signal table screen, diagram configuration ...........................................................................................................................294 Code table screen ....................................................................................................................................................295 BCS III, interfaces ..................................................................................................................................................296 USB interface, data storage ..........................................................................................................................................296 Saving data to a USB stick ...........................................................................................................................................297 Saving data to a USB stick, continued ................................................................................................................................298 Saving data to a USB stick, continued ................................................................................................................................299 BCSIII, cleaning .....................................................................................................................................................300 BCSIII, disposal .....................................................................................................................................................300 TROUBLESHOOTING ..........................................................................................................................................................301 Instructions on troubleshooting ......................................................................................................................................301 Layout of the fault table ............................................................................................................................................301 Possible causes ......................................................................................................................................................301 Measures .............................................................................................................................................................301 Section ..............................................................................................................................................................301 FAULT TABLES .............................................................................................................................................................302 Combustion engine - Fault table ......................................................................................................................................302 Working hydraulics – Fault table .....................................................................................................................................303 Track drive – Fault table ............................................................................................................................................304 Swing mechnism – Fault table .........................................................................................................................................305 Central lubricating system – Fault table .............................................................................................................................306 ENGINE MONITORING, CONTROL LAMPS .........................................................................................................................................307 HYDRAULIC CIRCUIT DIAGRAM ................................................................................................................................................308 ABBREVIATIONS ............................................................................................................................................................309 ABBREVIATIONS.........................................................................................................................................................310 TECHNICAL DATA ...........................................................................................................................................................311 Product Specification Sheet...........................................................................................................................................313 Page 2............................................................................................................................................................314 Page 3............................................................................................................................................................315 Page 4............................................................................................................................................................316 Page 5............................................................................................................................................................317 Page 6............................................................................................................................................................318 Page 7............................................................................................................................................................319 Page 8............................................................................................................................................................320 Page 9............................................................................................................................................................321 NOTES ....................................................................................................................................................................322 6 INDEX.......................................................................................................................................................................324
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