CATERPILLAR 6040 RH 170B Hydraulic Excavator Operating Instruction Manual – PDF DOWNLOAD

Description

CATERPILLAR 6040 RH 170B Hydraulic Excavator Operating Instruction Manual – PDF DOWNLOAD

FILE DETAILS:

CATERPILLAR 6040 RH 170B Hydraulic Excavator Operating Instruction Manual – PDF DOWNLOAD

Language : English
Pages : 329
Downloadable : Yes
File Type : PDF

DESCRIPTION:

CATERPILLAR 6040 RH 170B Hydraulic Excavator Operating Instruction Manual – PDF DOWNLOAD

PREFACE:

• These operating instructions are designed to famil- iarize the operator with the machine and its
  desig- nated use.
• The operating instructions contain important in- formation on how to operate the machine
  safely, properly and with maximum efficiency. Observing these instructions helps to
  prevent hazardous situations, to reduce repair costs and downtimes and to increase the
  reliability and service life of the machine.
  The operating instructions must be supplemented by the respective national rules and
  regulations for accident prevention and environmental protection.
• The operating instructions must always be avail- able in the driver’s cab of the machine.

The operating instructions must be read and put into practice by any person in charge
of carrying out work with or on the machine, such as
▪ operation, including setting-up, troubleshoot- ing in the course of work, care,
evacuation of production waste and disposal of fuels and consumables,
▪ maintenance (inspection, servicing, repair) and / or
▪ transport.

• In addition to the operating instructions and the mandatory rules and regulations for
  accident pre- vention and environmental protection in the user’s country and at the place where the
  machine is to be used, the generally recognized technical rules for safe and proper working
  must be observed ¹.
• The operating instructions are directed to the min- ing-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 per- sonnel.
• 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 transla-
  tion may give rise to questions which Bucyrus HEX will be pleased to answer.
• The operating instructions are not work instruc- tions for carrying out major repairs.
  Such work is willingly done for you by the Bucyrus HEX after-
  sales service.

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

CATERPILLAR 6040 RH 170B Hydraulic Excavator Operating Instruction Manual – PDF DOWNLOAD

1 INTRODUCTION 1-1
PREFACE 1-3
Further machine documentation 1-3
WARRANTY 1-4
FUNDAMENTAL SAFETY INSTRUCTIONS 1-5
Warnings and symbols 1-5
DESIGNATED USE, UNAUTHORIZED USE 1-6
Noise emission information 1-7
Vibration information 1-7
ORGANIZATIONAL MEASURES 1-8
Selection and qualification of personnel; basic responsibilities 1-9
Safety instructions governing specific operational phases 1-9
Special work in conjunction with utilization of the machine and maintenance and repairs as well as
troubleshooting during work; disposal of parts and consumables 1-10
Warning of special dangers 1-11
Gas, dust, steam and smoke 1-11
Hydraulic equipment 1-12
FIRE AND EXPLOSION HAZARD 1-13
NOTES 1-15
2 OPERATION 2-1
OPERATION – SAFETY INSTRUCTIONS 2-3
Operating Instructions, where to store it in the driver’s cab 2-4
FIRE AND EXPLOSION HAZARD 2-5
DESCRIPTION OF THE HYDRAULIC SHOVEL 2-6
Hydraulic shovel layout 2-7
Undercarriage 2-8
Superstructure 2-8
Drive 2-8
Hydraulic system 2-8
Control and Monitoring Platform (CAMP) 2-8
Board-Control-System (BCS) 2-9
Demand control / Zero-flow regulation 2-9
Automatic reset to idling 2-9
Electrical system 2-9
Signs 2-10
Entering and leaving the machine Safety instructions 2-18
Access ladder lighting 2-18
Swinging ladder (optional) 2-19
Folding ladder 2-20
Emergency exit in driver’s cab and escape ladder 2-21
Escape ladder near engine compartment (optional) 2-22
Switching the cab interior lighting on and off 2-23
Switching the maintenance lights on and off 2-24
OPERATING INSTRUCTIONS 6040 / RH170B
Table of contents
vi BA RH170B(3 725 081.00)-EN
Emergency shut-off function 2-25
Battery isolator switch, shutting off supply voltage 2-27
Starter isolator switch, shutting off starter voltage 2-27
Driver’s seat 2-28
Reducing the operators exposure to vibrations 2-30
Trainer’s / instructor’s seat 2-30
Fire extinguisher 2-31
Automatic fire-extinguishing system (optional) 2-32
Windscreen washer 2-32
Operating hours meter 2-32
Emergency escape device / seat (optional) 2-33
MONITORING, WARNING AND CONTROL ELEMENTS 2-36
Engine 1 (LH), control and monitoring 2-43
Engine 2 (RH), control and monitoring 2-45
PUTTING THE MACHINE INTO OPERATION 2-64
Reducing the operator’s exposure to noise 2-64
Refuelling 2-65
Back-up heating (option), filling in fuel 2-65
Service station (tanklift) 2-66
Emergency off switch 2-67
Switching the electrical system on and off 2-72
Engines, emergency shut-off 2-72
Preheating system for engine and hydraulic oil (optional) 2-73
Fuel preheating system (optional) 2-74
STARTING AND STOPPING THE ENGINES 2-76
Starting the engines 2-76
Starting the left-hand engine 2-76
Starting the right-hand engine 2-76
Engines – adjusting the speed 2-77
Starting the engines at low temperatures 2-77
Shutting off the engines 2-78
Shutting off the left-hand engine 2-78
Shutting off the right-hand engine 2-78
AIR CONDITIONER (OPTIONAL) 2-79
Back-up heating driver’s cab (optional) 2-80
Back-up heating (optional) 2-81
MAXIMUM MACHINE INCLINATIONS, INFORMATION 2-82
TRAVELLING, SAFETY INSTRUCTIONS 2-84
TRAVELLING 2-85
Superstructure basic position 2-85
Travelling forwards/backwards 2-85
Superstructure holding brake 2-89
Track parking brake 2-89
TRANSPORTING THE MACHINE 2-90
Transport – Safety instructions 2-90
OPERATING INSTRUCTIONS 6040 / RH170B
Table of contents
BA RH170B(3 725 081.00)-EN vii
WORKING OPERATION – SAFETY INSTRUCTIONS 2-91
WORKING OPERATION 2-93
Before starting work 2-93
Activating the electronic hydraulic shovel control 2-93
Swinging the superstructure 2-94
Braking the superstructure 2-94
Working 2-95
After daily operation 2-96
ASSEMBLING WORKING EQUIPMENT – SAFETY INSTRUCTIONS 2-97
Securing the machine 2-98
CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS) 2-99
ON-BOARD CRANE (OPTIONAL) 2-100
Monitoring, warning and control elements 2-100
On-board crane, putting into operation 2-101
On-board crane, drive unit 2-101
On-Board crane, – blocking the boom in position of rest 2-102
Checking the on-board crane 2-102
NOTES 2-103
3 INSPECTION AND SERVICING 3-1
INSPECTION AND SERVICING – SAFETY INSTRUCTIONS 3-3
INSPECTION AND SERVICING WORK, FIRE AND EXPLOSION HAZARD 3-7
INSPECTION AND SERVICING PLANS – INSTRUCTIONS 3-9
Plan V 3-11
Plan N 3-13
Plan T and W 3-15
Plan A – E 3-17
LUBRICATING CHART – GREASE 3-24
Lubricating chart – Grease (legend) 3-25
Filling quantities – Grease 3-25
INSPECTION PLAN – OIL 3-26
Inspection plan – Oil (legend) 3-27
Filling quantities – oil 3-28
Filling quantities – other 3-28
LUBRICANTS / CONSUMABLES 3-29
Notes on the selection of oils and greases 3-29
Avoid mixing of different hydraulic fluids 3-29
I. Oils for combustion engines 3-30
II. Oils for hydraulic system 3-31
III.a Oils for pump gearboxes 3-32
III.b Oils for swing gearboxes 3-33
III.c Oils for travel gearboxes 3-34
V. Greases for bearings and swing rings 3-35
Fluid grease for idlers, track rollers and support rollers 3-36
OPERATING INSTRUCTIONS 6040 / RH170B
Table of contents
viii BA RH170B(3 725 081.00)-EN
SERVICING WORK 3-37
Hose line for oil and cooling liquid changes 3-37
ENGINE 3-38
Engine – Safety instructions 3-38
Engine oil, checking the level / topping up 3-39
Engine oil reservoir (optional), checking the oil level / topping up 3-40
Engine oil, change 3-41
Engine oil reservoir (optional), draining the oil off 3-43
Engine oil filter, replace 3-45
Engine oil reservoir (optional), replacing the oil filters 3-46
Cold-starting fluid (ether) – Replacing the pressure vessel 3-47
COOLING SYSTEM 3-48
Temperature 3-48
Radiators 3-49
Cooling-liquid level check 3-49
Cooling liquid, change 3-52
Testing the cooling liquid composition 3-54
AIR-INTAKE SYSTEM 3-55
Dust trap, cleaning 3-55
Main filter elements 3-56
Main filter elements, checking and cleaning 3-57
Safety filter element 3-58
Air-intake lines 3-58
FUEL SYSTEM 3-59
Fuel system – Safety instructions 3-59
Fuel filter, replace 3-59
Primary fuel filter, drain water 3-60
Primary fuel filter, replace 3-60
Venting the fuel system 3-61
Cleaning the fuel tanks 3-61
Water trap (optional) 3-63
ELECTRICAL SYSTEM 3-65
Electrical system – Safety instructions 3-65
Alternator – Instructions 3-65
Electrical circuit diagrams 3-65
Electrical system switch-cabinets 3-65
Replacing lamps and bulbs 3-65
Battery 3-66
Charging batteries inside the machine, safety instructions 3-67
Removing and installing the battery 3-68
Switchgear cabinet, aeration 3-69
Xenon floodlight projector, replacing the lamp 3-71
Lighting systems in LED technonogy, instructions 3-73
HYDRAULIC SYSTEM 3-74
Hydraulic system – Safety instructions 3-74
Depressurizing the hydraulic system 3-74
Checking the hydraulic oil level 3-75
Replacing the hydraulic oil return-flow filter (hydraulic oil reservoir) 3-77
OPERATING INSTRUCTIONS 6040 / RH170B
Table of contents
BA RH170B(3 725 081.00)-EN ix
Bypass valves (hydraulic oil reservoir) 3-80
Replacing the bypass valves and sealing rings 3-80
Replacing the hydraulic oil return-flow filters (filter housing cooling system) 3-81
Bypass valves (filter housing – cooling system) 3-82
Breather filter 3-83
Filter (control circuit and auxiliary control circuit) 3-84
High-pressure filter for working hydraulics 3-85
High-pressure filters for the servo circuit 3-86
High-pressure filters for feeding circuits and slewing pumps 3-87
Changing the hydraulic oil 3-88
Avoid mixing of different hydraulic fluids 3-88
Venting the hydraulic system 3-92
Cleaning the hydraulic oil cooler 3-93
Electronic hydraulic shovel control 3-94
Pressure accumulator – Emergency lowering 3-95
PUMP TRANSFER GEARBOX 3-96
Checking the pump gearbox oil level / Topping up with oil 3-96
Changing the pump gearbox oil 3-97
Pump gearbox venting 3-99
Pump transfer gearbox lube oil filters 3-100
SWING GEARBOX 3-101
Swing gearbox – Checking the oil level / Topping up with oil 3-101
Gearbox venting 3-101
Changing the swing gearbox oil 3-102
TRAVEL GEARBOX (PN 2763213) 3-104
Travel gearbox – Checking the oil level / Topping up with oil 3-104
Pre-chamber / spur wheel section, Check the oil level / Top up with oil 3-104
Hydraulic motor chamber – Check the oil level / Top up with oil 3-104
Travel gearbox, Changing oil 3-105
Pre-chamber / spur wheel section, Changing oil 3-105
Hydraulic motor chamber, Changing oil 3-106
Travel gearbox breather filter, Clean / Replace 3-106
TRAVEL GEARBOX (PN 3719869) 3-107
Travel gearbox – Checking the oil level / Topping up with oil 3-107
Hydraulic motor chambers, Check the oil level / Top up with oil 3-107
Travel gearbox, Changing oil 3-108
Hydraulic motor chambers, Changing oil 3-108
CRAWLER TRACKS 3-109
Track roller, Support roller 3-110
Track tensioner 3-111
Pressure-accumulator inspection regulations 3-112
Checking the gas charging pressure in the pressure accumulator 3-112
SWING RING 3-113
Swing ring – Instructions 3-113
Bearing races 3-113
CENTRAL LUBRICATING SYSTEM 3-115
Design 3-115
OPERATING INSTRUCTIONS 6040 / RH170B
Table of contents
x BA RH170B(3 725 081.00)-EN
Function 3-116
Filling up the grease container 3-117
Breather filter grease container, check / replace 3-117
Checking the greasing pressure 3-118
Unblocking a grease line 3-118
Oilfilter replace (hydraulic circuit grease pump) 3-119
Grease filter replace (filling the grease container) 3-120
Grease filter replace (Grease lines) 3-120
OTHER MAINTENANCE 3-121
Engine 3-121
Heating and air conditioning 3-121
Reservoirs for used grease at the A-frame, emptying 3-122
Hydraulic ladder, pressure accumulator 3-122
Pressure-accumulator inspection regulations 3-123
Extract from the German regulations 3-123
Checking the gas charging pressure in the pressure accumulator 3-123
ON-BOARD CRANE, DRIVE UNIT 3-124
On-board crane, greasing 3-124
On-Board crane, checking tightness of fastening bolts 3-125
PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING 3-126
Putting the hydraulic shovel out of operation 3-126
Battery storage 3-126
Recommissioning 3-126
NOTES 3-127
4 REPAIR WORK 4-1
REPAIR WORK – SAFETY INSTRUCTIONS 4-3
CONFINED SPACES – SAFETY INSTRUCTIONS 4-4
REPAIR WORK, FIRE AND EXPLOSION HAZARD 4-5
REPAIR WORK, ENGINE 4-6
HYDRAULIC SYSTEM 4-7
Repair instructions 4-7
Hydraulic hoses – Instructions 4-7
PRESSURE ACCUMULATORS – SAFETY INSTRUCTIONS 4-8
WELDING AND FLAME CUTTING WORKS – SAFETY INSTRUCTIONS 4-9
DISPOSAL AT THE END OF THE SERVICE LIFE 4-12
Appropriate disposal of batteries 4-13
NOTES 4-15
5 ANNEX 5-1
BOARD-CONTROL-SYSTEM 5-3
BCS III, what’s that? 5-3
The keys on the front side 5-4
Other elements on the front side 5-4
OPERATING INSTRUCTIONS 6040 / RH170B
Table of contents
BA RH170B(3 725 081.00)-EN xi
BCSIII, the start screen 5-5
Information given on the start screen, top section 5-6
Information given on the start screen, central section 5-7
Information given on the start screen, lower section 5-8
Information given on the “Service” screen 5-9
Engine data screen 5-10
Hydraulic data screen 5-11
Lubrication data screen 5-12
Controls adjustment data screen 5-13
View documents screen 5-14
Signal table screen 5-15
Signal table screen, location 5-16
Signal table screen, diagram 5-17
Signal table screen, diagram configuration 5-18
Code table screen 5-19
BCS III, interfaces 5-20
USB interface, data storage 5-20
Saving data to a USB stick 5-21
Saving data to a USB stick, continued 5-22
Saving data to a USB stick, continued 5-23
BCSIII, cleaning 5-24
BCSIII, disposal 5-24
TROUBLESHOOTING 5-25
Instructions on troubleshooting 5-25
Layout of the fault table 5-25
Possible causes 5-25
Measures 5-25
Section 5-25
FAULT TABLES 5-26
Combustion engine – Fault table 5-26
Working hydraulics – Fault table 5-27
Track drive – Fault table 5-28
Swing mechnism – Fault table 5-29
Central lubricating system – Fault table 5-30
ENGINE MONITORING, CONTROL LAMPS 5-31
HYDRAULIC CIRCUIT DIAGRAM 5-32
ABBREVIATIONS 5-33
ABBREVIATIONS 5-34
TECHNICAL DATA 5-35
NOTES 5-37
6 INDEX 6-1

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