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Caterpillar 6030 RH120E Hydraulic Excavator Operating Instructions Manual BI651401 – PDF DOWNLOAD
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Caterpillar 6030 RH120E Hydraulic Excavator Operating Instructions Manual BI651401 – PDF DOWNLOAD
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Description
Caterpillar 6030 RH120E Hydraulic Excavator Operating Instructions Manual BI651401 – PDF DOWNLOAD
FILE DETAILS:
Caterpillar 6030 RH120E Hydraulic Excavator Operating Instructions Manual BI651401 – PDF DOWNLOAD
Language : English
Pages : 314
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Caterpillar 6030 RH120E Hydraulic Excavator Operating Instructions Manual BI651401 – 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 6030 RH120E Hydraulic Excavator Operating Instructions Manual BI651401 – PDF DOWNLOAD
TITLEPAGE.................................................................................................................................................................... 1 1 INTRODUCTION............................................................................................................................................................... 13 PREFACE ................................................................................................................................................................. 15 About this Operating Instructions ................................................................................................................................... 15 Further machine documentation ....................................................................................................................................... 15 WARRANTY ................................................................................................................................................................ 16 FUNDAMENTAL SAFETY INSTRUCTIONS.......................................................................................................................................... 17 Warnings and symbols ................................................................................................................................................ 17 Contents of the Declaration of Conformity ........................................................................................................................... 17 DESIGNATED USE........................................................................................................................................................... 18 Noise emissions ..................................................................................................................................................... 19 Vibration data ...................................................................................................................................................... 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 EXCAVATOR............................................................................................................................................. 34 Excavator 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................................................................................................................. 45 Access ladder lighting .............................................................................................................................................. 45 Swinging ladder ..................................................................................................................................................... 46 Folding ladder (optional) ........................................................................................................................................... 47 Escape ladder (optional) ............................................................................................................................................ 48 Switching the cab interior lighting on and off ...................................................................................................................... 49 Switching the maintenance lights on and off ......................................................................................................................... 50 Emergency shut-off function ......................................................................................................................................... 51 Shutting off the supply voltage (battery main switch) ............................................................................................................... 52 Driver’s seat ...................................................................................................................................................... 53 Reducing the operators exposure to vibrations ....................................................................................................................... 55 Trainer's / instructor's seat ....................................................................................................................................... 55 Fire extinguisher.................................................................................................................................................... 56 Fire extinguisher (option) .......................................................................................................................................... 56 Automatic fire-extinguishing system (optional) ...................................................................................................................... 57 Windscreen washer ................................................................................................................................................... 57 Harness (optional) .................................................................................................................................................. 58 MONITORING, WARNING AND CONTROL ELEMENTS ................................................................................................................................ 62 Engine 1 (LH), control and monitoring ............................................................................................................................... 69 Engine 2 (RH), control and monitoring ............................................................................................................................... 71 PUTTING THE MACHINE INTO OPERATION ...................................................................................................................................... 88 Reducing the operator's exposure to noise ........................................................................................................................... 88 Refuelling .......................................................................................................................................................... 88 Back-up heating (option), filling in fuel ........................................................................................................................... 89 Service station (tanklift) .......................................................................................................................................... 89 Switching the electrical system on and off .......................................................................................................................... 95 Engines, emergency shut-off ......................................................................................................................................... 95 Preheating system for engine and hydraulic oil (optional) ........................................................................................................... 96 Fuel preheating system (optional) ................................................................................................................................... 97 STARTING AND STOPPING THE ENGINES ....................................................................................................................................... 98 Starting the engines ................................................................................................................................................ 98 Starting the left-hand engine........................................................................................................................................ 98 Starting the right-hand engine....................................................................................................................................... 98 Engines – adjusting the speed ....................................................................................................................................... 99 Starting the engines at low temperatures ............................................................................................................................ 99 Shutting off the engines ............................................................................................................................................100 Shutting off the left-hand engine....................................................................................................................................100 Shutting off the right-hand engine...................................................................................................................................100 AIR CONDITIONER (OPTION) ................................................................................................................................................101 Back-up heating driver’s cab (option) ...............................................................................................................................101 Back-up heating (option) ............................................................................................................................................102 TRAVELLING, SAFETY INSTRUCTIONS .........................................................................................................................................103 TRAVELLING ..............................................................................................................................................................104 Superstructure basic position .......................................................................................................................................104 Travelling forwards/backwards .......................................................................................................................................104 Superstructure holding brake ........................................................................................................................................108 Track parking brake .................................................................................................................................................108 TRANSPORTING THE MACHINE ................................................................................................................................................109 Transport - Safety instructions .....................................................................................................................................109 WORKING OPERATION - SAFETY INSTRUCTIONS .................................................................................................................................110 WORKING OPERATION .......................................................................................................................................................112 Before starting work ................................................................................................................................................112 Activating the electronic excavator control .........................................................................................................................112 Swinging the superstructure .........................................................................................................................................113 Braking the superstructure ..........................................................................................................................................113 Working .............................................................................................................................................................114 After daily operation ...............................................................................................................................................115 OPTIONAL EQUIPMENT ......................................................................................................................................................116 Water spraying system ...............................................................................................................................................116 Additional silencers ................................................................................................................................................116 ASSEMBLING WORKING EQUIPMENT - SAFETY INSTRUCTIONS ......................................................................................................................117 Securing the machine ................................................................................................................................................118 CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS) ..........................................................................................................119 NOTES ...................................................................................................................................................................121 3 INSPECTION AND SERVICING...................................................................................................................................................123 INSPECTION AND SERVICING - SAFETY INSTRUCTIONS ..........................................................................................................................125 INSPECTION AND SERVICING WORK, FIRE AND EXPLOSION HAZARD ................................................................................................................131 INSPECTION AND SERVICING PLANS - INSTRUCTIONS ...........................................................................................................................133 Intervals............................................................................................................................................................133 Change of engine oil l...............................................................................................................................................133 Air-intake system ...................................................................................................................................................133 Oils / Greases ......................................................................................................................................................133 Cleaning jobs .......................................................................................................................................................133 Components ..........................................................................................................................................................133 Plan V ..............................................................................................................................................................135 Plan N ..............................................................................................................................................................137 Plan T and W.........................................................................................................................................................139 Plan A – E ..........................................................................................................................................................141 LUBRICATING CHART – GREASE ..............................................................................................................................................148 Lubricating chart – Grease (legend) .................................................................................................................................149 Filling quantities – Grease .........................................................................................................................................149 INSPECTION PLAN - OIL ...................................................................................................................................................150 Inspection plan – Oil (legend) ......................................................................................................................................151 Filling quantities - oil ............................................................................................................................................152 Filling quantities - other...........................................................................................................................................152 LUBRICANTS ..............................................................................................................................................................153 Notes on the selection of oils and greases ..........................................................................................................................153 Avoid mixing of different hydraulic fluids ..........................................................................................................................153 I. Oils for combustion engines ......................................................................................................................................154 II. Oils for hydraulic system .......................................................................................................................................155 III.a Oils for pump gearboxes .......................................................................................................................................156 III.b Oils for swing gearboxes ......................................................................................................................................157 III.c Oils for travel gearboxes .....................................................................................................................................158 V. Greases for bearings and swing rings .............................................................................................................................159 SERVICING WORK ..........................................................................................................................................................160 Hose line for oil and cooling liquid changes ........................................................................................................................160 ENGINE ..................................................................................................................................................................161 Engine - Safety instructions ........................................................................................................................................161 Checking the engine oil level / Topping up .........................................................................................................................162 Changing the engine oil .............................................................................................................................................163 Replacing the oil filters ...........................................................................................................................................165 Engine oil reservoir, filling in engine oil .........................................................................................................................165 Cold-starting fluid (ether) - Replacing the pressure vessel .........................................................................................................166 COOLING SYSTEM ..........................................................................................................................................................167 Radiators ...........................................................................................................................................................167 Cooling liquid change ...............................................................................................................................................169 AIR-INTAKE SYSTEM .......................................................................................................................................................170 Dust trap, cleaning ................................................................................................................................................170 Main filter elements ................................................................................................................................................171 Safety filter element ...............................................................................................................................................173 Air-intake lines ....................................................................................................................................................173 FUEL SYSTEM .............................................................................................................................................................174 Fuel system - Safety instructions ...................................................................................................................................174 Replacing the fuel filter ...........................................................................................................................................174 Primary fuel filter, drain water ....................................................................................................................................175 Replacing the primary fuel filter ...................................................................................................................................175 Venting the fuel system .............................................................................................................................................176 Cleaning the fuel tanks .............................................................................................................................................176 Water trap (option)..................................................................................................................................................178 ELECTRICAL SYSTEM ......................................................................................................................................................180 Electrical system - Safety instructions .............................................................................................................................180 Alternator - Instructions ...........................................................................................................................................180 Battery .............................................................................................................................................................181 Switchgear cabinet ..................................................................................................................................................183 Equipotential bonding ...............................................................................................................................................185 Floodlight projector, replacing the lamp ............................................................................................................................187 HYDRAULIC SYSTEM ........................................................................................................................................................189 Hydraulic system - Safety instructions ..............................................................................................................................189 Depressurizing the hydraulic system .................................................................................................................................189 Checking the hydraulic oil level ....................................................................................................................................190 Hydraulic oil return-flow filters (hydraulic oil reservoir), replace ................................................................................................192 Bypass valves (hydraulic oil reservoir), replace ....................................................................................................................194 Replacing the hydraulic oil return-flow filters (filter housing) ....................................................................................................195 Bypass valves (filter housing - cooling system), replace ............................................................................................................196 Breather filter, replace ............................................................................................................................................197 Filter (servo circuit), replace .....................................................................................................................................198 High-pressure filter for working hydraulics, replace ................................................................................................................199 High-pressure filters for swing circuit, replace ....................................................................................................................200 Filter pump control, clean ..........................................................................................................................................201 Changing the hydraulic oil ..........................................................................................................................................202 Avoid mixing of different hydraulic fluids ..........................................................................................................................202 Venting the hydraulic system.........................................................................................................................................206 Cleaning the hydraulic oil cooler....................................................................................................................................207 Electronic excavator control.........................................................................................................................................208 Pressure accumulators - Emergency lowering and servo circuit ........................................................................................................209 PUMP TRANSFER GEARBOX ...................................................................................................................................................210 Checking the gearbox oil level / Topping up with oil ................................................................................................................210 Gearbox venting .....................................................................................................................................................212 Pump transfer gearbox lube oil filters ..............................................................................................................................213 SWING GEARBOX ...........................................................................................................................................................214 Gearbox - Checking the oil level / Topping up with oil ..............................................................................................................214 Changing the gearbox oil ............................................................................................................................................214 Gearbox venting .....................................................................................................................................................215 SWING GEARBOX ...........................................................................................................................................................216 Gearbox - Checking the oil level / Topping up with oil ..............................................................................................................216 Changing the gearbox oil ............................................................................................................................................217 Gearbox venting .....................................................................................................................................................218 TRAVEL GEARBOX ..........................................................................................................................................................219 Gearbox - Checking the oil level / Topping up with oil ..............................................................................................................219 Travel gearbox - Changing oil .......................................................................................................................................220 Pre-chamber - Changing the oil ......................................................................................................................................220 Brake chamber - Changing oil ........................................................................................................................................221 Breather filter .....................................................................................................................................................221 CRAWLER TRACKS ..........................................................................................................................................................222 Track roller, Support roller ........................................................................................................................................223 Track tensioner .....................................................................................................................................................224 Pressure-accumulator inspection regulations .........................................................................................................................225 Checking the gas charging pressure in the pressure accumulator.......................................................................................................225 SWING RING ..............................................................................................................................................................226 Swing ring - Instructions............................................................................................................................................226 Bearing races........................................................................................................................................................226 CENTRAL LUBRICATING SYSTEM ..............................................................................................................................................228 Design ..............................................................................................................................................................228 Function ............................................................................................................................................................229 Filling up the grease container .....................................................................................................................................230 Breather filter grease container, check / replace ...................................................................................................................230 Checking the greasing pressure ......................................................................................................................................231 Unblocking a grease line ............................................................................................................................................231 Oilfilter replace (hydraulic circuit grease pump) ...................................................................................................................232 Grease filter replace (filling the grease container) ................................................................................................................233 Grease filter replace (Grease lines) ................................................................................................................................233 OTHER MAINTENANCE .......................................................................................................................................................234 Engine ..............................................................................................................................................................234 Heating and air conditioning ........................................................................................................................................234 RAMP-TYPE LADDER (OPTIONAL) .............................................................................................................................................235 Pressure-accumulator inspection regulations .........................................................................................................................236 Extract from the German regulations..................................................................................................................................236 Checking the gas charging pressure in the pressure accumulator.......................................................................................................236 ON-BOARD CRANE (OPTIONAL) ...............................................................................................................................................237 Monitoring, warning and control elements ............................................................................................................................237 Checking the on-board crane..........................................................................................................................................237 Drive unit ..........................................................................................................................................................238 On-board crane.......................................................................................................................................................238 On-Board crane, checking tightness of fastening bolts ...............................................................................................................239 PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING ..............................................................................................................240 Putting the excavator out of operation...............................................................................................................................240 Battery storage......................................................................................................................................................240 Recommissioning......................................................................................................................................................240 NOTES ..................................................................................................................................................................241 4 REPAIR WORK................................................................................................................................................................243 REPAIR WORK - SAFETY INSTRUCTIONS........................................................................................................................................245 REPAIR WORK, FIRE AND EXPLOSION HAZARD ..................................................................................................................................247 REPAIR WORK, ENGINE......................................................................................................................................................248 ELECTRICAL SYSTEM .......................................................................................................................................................249 Assisted starting (with jumper cables) – Safety instructions ........................................................................................................249 Assisted starting (with jumper cables)...............................................................................................................................249 Starting the engine with jumper cables (external batteries ..........................................................................................................249 HYDRAULIC SYSTEM ........................................................................................................................................................251 Repair instructions .................................................................................................................................................251 Hydraulic hoses – Instructions .....................................................................................................................................251 PRESSURE ACCUMULATORS - SAFETY INSTRUCTIONS..............................................................................................................................252 WELDING AND FLAME CUTTING WORKS - SAFETY INSTRUCTIONS ...................................................................................................................253 DISPOSAL AT THE END OF THE SERVICE LIFE .................................................................................................................................256 Appropriate disposal of batteries ...................................................................................................................................257 NOTES ...................................................................................................................................................................259 5 ANNEX......................................................................................................................................................................261 BOARD-CONTROL-SYSTEM ....................................................................................................................................................263 BCS III, what’s that? ...............................................................................................................................................263 The keys on the front side ..........................................................................................................................................264 Other elements on the front side ....................................................................................................................................264 BCSIII, the start screen ............................................................................................................................................265 Information given on the start screen, top section ..................................................................................................................266 Information given on the start screen, central section ..............................................................................................................267 Information given on the start screen, lower section ................................................................................................................268 Information given on the “Service” screen ...........................................................................................................................269 Engine data screen ..................................................................................................................................................270 Hydraulic data screen ...............................................................................................................................................271 Lubrication data screen .............................................................................................................................................272 Controls adjustment data screen .....................................................................................................................................273 View documents screen ...............................................................................................................................................274 Signal table screen .................................................................................................................................................275 Signal table screen, location .......................................................................................................................................276 Signal table screen, diagram ........................................................................................................................................277 Signal table screen, diagram configuration ..........................................................................................................................278 Code table screen ...................................................................................................................................................279 BCS III, interfaces .................................................................................................................................................280 USB interface, data storage .........................................................................................................................................280 Saving data to a USB stick ..........................................................................................................................................281 Saving data to a USB stick, continued ...............................................................................................................................282 Saving data to a USB stick, continued ...............................................................................................................................283 BCSIII, cleaning ....................................................................................................................................................284 BCSIII, disposal ....................................................................................................................................................284 TROUBLESHOOTING .........................................................................................................................................................285 Instructions on troubleshooting .....................................................................................................................................285 Layout of the fault table ...........................................................................................................................................285 Possible causes .....................................................................................................................................................285 Measures ............................................................................................................................................................285 Section .............................................................................................................................................................285 FAULT TABLES ............................................................................................................................................................286 Combustion engine - Fault table .....................................................................................................................................286 Working hydraulics – Fault table ....................................................................................................................................287 Track drive – Fault table ...........................................................................................................................................288 Swing mechnism – Fault table ........................................................................................................................................289 Central lubricating system – Fault table ............................................................................................................................290 ENGINE MONITORING, CONTROL LAMPS ........................................................................................................................................291 HYDRAULIC CIRCUIT DIAGRAM ...............................................................................................................................................292 ABBREVIATIONS ...........................................................................................................................................................293 ABBREVIATIONS........................................................................................................................................................294 TECHNICAL DATA ..........................................................................................................................................................295 Product Specification Sheet..............................................................................................................................................297 NOTES ...................................................................................................................................................................307 6 INDEX......................................................................................................................................................................309
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