Caterpillar Bucyrus 6018 RH90C Hydraulic Excavator OPERATING INSTRUCTIONS Manual – PDF DOWNLOAD
FILE DETAILS:
Caterpillar Bucyrus 6018 RH90C Hydraulic Excavator OPERATING INSTRUCTIONS Manual – PDF DOWNLOAD
Language : English
Pages : 318
Downloadable : Yes
File Type : PDF
DESCRIPTION:
OPERATING INSTRUCTIONS 6018 / RH90C
Introduction
PREFACE
- 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 construction- machine specialist.
- They cannot provide basic know-how. This can be acquired, for example, in several days’ instruction by a qualified Bucyrus HEX mechanic or by attending an Bucyrus HEX training course for operators or maintenance personnel. The Bucyrus HEX after-sales service will be pleased to deal with any queries you may have after reading through the operating instructions. 1 Complies with VDMA recommendation “Operating instructions” All Bucyrus HEX operating manuals are issued in German and then translated.
- Even a good translation may give rise to questions which Bucyrus HEX will be pleased to answer. The operating instructions are not work instructions for carrying out major repairs. Such work is willingly done for you by the Bucyrus HEX aftersales service. The documentation relating to the machine is listed according to scope, quantity and language in the shipping note of the machine or in the covering letter if supplied separately. The operating instructions and spare-parts list are marked with the serial number of the machine. On taking receipt of the consignment, please check that the documentation is complete and in the language requested by you.
TABLE OF CONTENTS:
Caterpillar Bucyrus 6018 RH90C Hydraulic Excavator OPERATING INSTRUCTIONS Manual – PDF DOWNLOAD
TITLEPAGE.................................................................................................................................................................... 1 1 INTRODUCTION............................................................................................................................................................... 11 PREFACE ................................................................................................................................................................. 13 WARRANTY ................................................................................................................................................................ 14 FUNDAMENTAL SAFETY INSTRUCTIONS.......................................................................................................................................... 15 Warnings and symbols ................................................................................................................................................ 15 DESIGNATED USE .......................................................................................................................................................... 16 ORGANIZATIONAL MEASURES.................................................................................................................................................. 17 Selection and qualification of personnel; basic responsibilities..................................................................................................... 18 Safety instructions governing specific operational phases............................................................................................................ 18 Special work in conjunction with utilization of the machine and maintenance and repairs as well as troubleshooting during work; disposal of parts and consumables.... 19 Warning of special dangers........................................................................................................................................... 20 Gas, dust, steam and smoke........................................................................................................................................... 21 Hydraulic equipment.................................................................................................................................................. 21 INTRODUCTION, FIRE AND EXPLOSION HAZARD.................................................................................................................................. 22 NOTES ................................................................................................................................................................... 23 2 OPERATION.................................................................................................................................................................. 25 OPERATION - SAFETY INSTRUCTIONS ......................................................................................................................................... 27 Operating Instructions, where to store it in the driver’s cab ....................................................................................................... 28 OPERATION, FIRE AND EXPLOSION HAZARD .................................................................................................................................... 29 DESCRIPTION OF THE EXCAVATOR ............................................................................................................................................ 30 Excavator layout .................................................................................................................................................... 31 Undercarriage ....................................................................................................................................................... 32 Superstructure ...................................................................................................................................................... 32 Drive ............................................................................................................................................................... 32 Hydraulic system .................................................................................................................................................... 32 Pump Managing System (PMS) .......................................................................................................................................... 32 Stored Program Control (SPC) ........................................................................................................................................ 32 Central Management System (CMS) ..................................................................................................................................... 32 Demand control / Zero-flow regulation ............................................................................................................................... 33 Automatic engine speed reduction .................................................................................................................................... 33 Board-Control-System (BCS) .......................................................................................................................................... 33 Electrical system ................................................................................................................................................... 33 Signs and labels .................................................................................................................................................... 34 Entering and leaving the machine, Safety instructions ............................................................................................................... 41 Access ladder lighting .............................................................................................................................................. 41 Swinging ladder ..................................................................................................................................................... 42 Switching the cab interior lighting on and off ...................................................................................................................... 43 Switching the servicing lighting on and off ......................................................................................................................... 44 EMERGENCY STOP switch ............................................................................................................................................... 45 Driver’s seat ...................................................................................................................................................... 46 Trainer's / instructor's seat ....................................................................................................................................... 48 Windscreen washer ................................................................................................................................................... 48 Fire extinguisher ................................................................................................................................................... 49 Automatic fire-extinguishing system (optional) ...................................................................................................................... 50 Harness (optional) .................................................................................................................................................. 51 MONITORING, WARNING AND CONTROL ELEMENTS ................................................................................................................................ 54 PUTTING THE MACHINE INTO OPERATION ...................................................................................................................................... 86 Refuelling .......................................................................................................................................................... 86 Service station (tanklift) .......................................................................................................................................... 87 Switching the electrical system on and off .......................................................................................................................... 93 STARTING AND STOPPING THE ENGINES ....................................................................................................................................... 94 Starting the engines ................................................................................................................................................ 94 Starting the engines at low temperatures ............................................................................................................................ 95 AIR CONDITIONER (OPTION)................................................................................................................................................. 97 Back-up heating (option) ............................................................................................................................................ 98 DRIVING, SAFETY INSTRUCTIONS ............................................................................................................................................100 TRAVELLING ..............................................................................................................................................................101 Superstructure basic position .......................................................................................................................................101 Travelling forwards/backwards .......................................................................................................................................101 Locking the superstructure ..........................................................................................................................................105 Track parking brake .................................................................................................................................................105 TRANSPORTING THE MACHINE ................................................................................................................................................106 Transport - Safety instructions .....................................................................................................................................106 WORKING OPERATION - SAFETY INSTRUCTIONS .................................................................................................................................107 Running-in instructions for hydraulic cylinders .....................................................................................................................107 Warming-up phase for the hydraulic system ...........................................................................................................................107 Avoid extreme positions of the working equipment ....................................................................................................................108 WORKING OPERATION .......................................................................................................................................................109 Before starting work ................................................................................................................................................109 Switching on the electronic excavator control .......................................................................................................................109 Swinging the superstructure .........................................................................................................................................110 Braking the superstructure ..........................................................................................................................................110 Working movements ...................................................................................................................................................111 After daily operation ...............................................................................................................................................112 ASSEMBLING WORKING EQUIPMENT - SAFETY INSTRUCTIONS ......................................................................................................................113 Securing the machine ................................................................................................................................................115 CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS) ..........................................................................................................116 NOTES ...................................................................................................................................................................117 3 INSPECTION AND SERVICING...................................................................................................................................................119 INSPECTION AND SERVICING - SAFETY INSTRUCTIONS ..........................................................................................................................121 INSPECTION AND SERVICING WORK, FIRE AND EXPLOSION HAZARD ................................................................................................................127 INSPECTION AND SERVICING PLANS - INSTRUCTIONS ...........................................................................................................................129 Intervals............................................................................................................................................................129 Change of engine oil l...............................................................................................................................................129 Air-intake system ...................................................................................................................................................129 Oils / Greases ......................................................................................................................................................129 Cleaning jobs .......................................................................................................................................................129 Components ..........................................................................................................................................................129 Plan V ..............................................................................................................................................................131 Plan N ..............................................................................................................................................................133 Plan T and W ........................................................................................................................................................135 Plan A – E ..........................................................................................................................................................137 LUBRICATING CHART – GREASE ..............................................................................................................................................144 Lubricating chart – Grease (legend) .................................................................................................................................145 Filling quantities - Grease..........................................................................................................................................145 INSPECTION PLAN - OIL ...................................................................................................................................................146 Inspection plan – Oil (legend) ......................................................................................................................................147 Filling quantities - oil ............................................................................................................................................148 Filling quantities - other...........................................................................................................................................148 LUBRICANTS ..............................................................................................................................................................149 Notes on the selection of oils and greases ..........................................................................................................................149 Avoid mixing of different hydraulic fluids ..........................................................................................................................149 I. Oils for combustion engines ......................................................................................................................................150 II. Oils for hydraulic system .......................................................................................................................................151 III.a Oils for pump gearboxes .......................................................................................................................................152 III.b Oils for swing gearboxes ......................................................................................................................................153 III.c Oils for travel gearboxes .....................................................................................................................................154 V. Greases for bearings and swing rings .............................................................................................................................155 SERVICING WORK ..........................................................................................................................................................156 Hose line for oil and cooling liquid changes ........................................................................................................................156 ENGINE ..................................................................................................................................................................157 Engine - Safety instructions ........................................................................................................................................157 Checking the engine oil level / Topping up .........................................................................................................................158 Changing the engine oil .............................................................................................................................................159 Replacing the oil filters ...........................................................................................................................................161 Cold-starting fluid (ether) - Replacing the pressure vessel .........................................................................................................162 COOLING SYSTEM ..........................................................................................................................................................163 Radiators ...........................................................................................................................................................163 Cooling liquid change ...............................................................................................................................................165 AIR-INTAKE SYSTEM .......................................................................................................................................................166 Dust trap, cleaning ................................................................................................................................................166 Main filter elements ................................................................................................................................................167 Safety filter element ...............................................................................................................................................169 Air-intake lines ....................................................................................................................................................169 FUEL SYSTEM .............................................................................................................................................................170 Fuel system - Safety instructions ...................................................................................................................................170 Replacing the fuel filter ...........................................................................................................................................170 Venting the fuel system .............................................................................................................................................171 Cleaning the fuel tanks .............................................................................................................................................171 Water trap (option)..................................................................................................................................................173 ELECTRICAL SYSTEM ......................................................................................................................................................175 Electrical system - Safety instructions .............................................................................................................................175 Alternator - Instructions ...........................................................................................................................................175 Battery .............................................................................................................................................................176 Switchgear cabinet, filter element ..................................................................................................................................178 Floodlight projector, replacing the lamp ............................................................................................................................180 Lighting systems in LED technonogy, instructions ....................................................................................................................182 HYDRAULIC SYSTEM ........................................................................................................................................................183 Hydraulic system - Safety instructions ..............................................................................................................................183 Depressurizing the hydraulic system .................................................................................................................................183 Checking the hydraulic oil level ....................................................................................................................................184 Changing the hydraulic oil return-flow (hydraulic oil reservoir) ....................................................................................................186 Bypass valves (hydraulic oil reservoir) .............................................................................................................................188 Breather filter .....................................................................................................................................................189 High-pressure filter for working hydraulics .........................................................................................................................190 High-pressure filters for the servo circuit .........................................................................................................................191 Filter (control circuit) ............................................................................................................................................192 Changing the hydraulic oil ..........................................................................................................................................193 Venting the hydraulic system.........................................................................................................................................196 Cleaning the hydraulic oil cooler....................................................................................................................................197 Electronic excavator control.........................................................................................................................................198 Pressure accumulator - Emergency lowering............................................................................................................................199 PUMP GEARBOX ............................................................................................................................................................200 Checking the gearbox oil level / Topping up with oil ................................................................................................................200 Changing the gearbox oil ............................................................................................................................................200 Gearbox venting .....................................................................................................................................................202 SWING GEARBOX ...........................................................................................................................................................203 Gearbox - Checking the oil level / Topping up with oil ..............................................................................................................203 Changing the gearbox oil ............................................................................................................................................203 Gearbox venting .....................................................................................................................................................204 TRAVEL GAERBOX ..........................................................................................................................................................205 Gearbox - Checking the oil level / Topping up with oil ..............................................................................................................205 Gearbox - Checking the oil level / Topping up with oil ..............................................................................................................205 Breather filter .....................................................................................................................................................205 CRAWLER TRACKS ..........................................................................................................................................................206 Track roller, Support roller ........................................................................................................................................207 Track tensioner .....................................................................................................................................................208 Pressure-accumulator inspection regulations .........................................................................................................................209 Checking the gas charging pressure in the pressure accumulator.......................................................................................................209 SWING RING ..............................................................................................................................................................210 Swing ring - Instructions............................................................................................................................................210 Bearing races .......................................................................................................................................................210 CENTRAL LUBRICATING SYSTEM, STANDARD ....................................................................................................................................212 Design ..............................................................................................................................................................212 Function ............................................................................................................................................................213 Replacing the grease container ......................................................................................................................................214 Filling up the grease container .....................................................................................................................................214 Checking the greasing pressure ......................................................................................................................................215 Unblocking a grease line.............................................................................................................................................215 Oilfilter (hydraulic circuit grease pump) )..........................................................................................................................216 Grease filter (Filling the grease container) .......................................................................................................................217 Grease filter (Grease lines) ........................................................................................................................................218 OTHER MAINTENANCE .......................................................................................................................................................219 Engine ..............................................................................................................................................................219 Heating and air conditioning ........................................................................................................................................219 HYDRAULIC LADDER ........................................................................................................................................................220 Pressure-accumulator inspection regulations ........................................................................................................................221 PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING ..............................................................................................................222 Putting the excavator out of operation ..............................................................................................................................222 Battery storage .....................................................................................................................................................222 Recommissioning .....................................................................................................................................................222 NOTES ...................................................................................................................................................................223 4 REPAIR WORK................................................................................................................................................................225 REPAIR WORK - SAFETY INSTRUCTIONS........................................................................................................................................227 REPAIR WORK, FIRE AND EXPLOSION HAZARD ..................................................................................................................................229 ENGINE, REPAIR WORK .....................................................................................................................................................230 ELECTRICAL SYSTEM .......................................................................................................................................................231 Assisted starting (with jumper cables) – Safety instructions ........................................................................................................231 Assisted starting (with jumper cables)...............................................................................................................................231 Starting the engine with jumper cables (external batteries ..........................................................................................................231 HYDRAULIC SYSTEM ........................................................................................................................................................233 Repair instructions .................................................................................................................................................233 Hydraulic hoses – Instructions .....................................................................................................................................233 PRESSURE ACCUMULATORS - SAFETY INSTRUCTIONS .............................................................................................................................234 WELDING AND FLAME CUTTING WORKS - SAFETY INSTRUCTIONS ...................................................................................................................235 DISPOSAL AT THE END OF THE SERVICE LIFE .................................................................................................................................238 Appropriate disposal of batteries ...................................................................................................................................239 NOTES ...................................................................................................................................................................241 5 ANNEX......................................................................................................................................................................243 TROUBLESHOOTING .........................................................................................................................................................245 Instructions on troubleshooting .....................................................................................................................................245 Layout of the fault table ...........................................................................................................................................245 Possible causes .....................................................................................................................................................245 Measures ............................................................................................................................................................245 Section .............................................................................................................................................................245 FAULT TABLES ............................................................................................................................................................246 Combustion engine - Fault table .....................................................................................................................................246 Working hydraulics – Fault table ....................................................................................................................................247 Track drive – Fault table ...........................................................................................................................................248 Swing mechnism – Fault table ........................................................................................................................................249 Central lubricating system – Fault table ............................................................................................................................250 HYDRAULIC CIRCUIT DIAGRAM ...............................................................................................................................................251 ABBREVIATIONS ...........................................................................................................................................................253 ABBREVIATIONS........................................................................................................................................................254 TECHNICAL DATA ..........................................................................................................................................................255 Product Specification Sheet..........................................................................................................................................257 Page 2...............................................................................................................................................................258 Page 3...............................................................................................................................................................259 Page 4...............................................................................................................................................................260 Page 5...............................................................................................................................................................261 Page 6...............................................................................................................................................................262 Page 7...............................................................................................................................................................263 Page 8...............................................................................................................................................................264 Page 9...............................................................................................................................................................265 NOTES ...................................................................................................................................................................266 6 INDEX......................................................................................................................................................................268 TITLEPAGE....................................................................................................................................................................273 DESCRIPTION .............................................................................................................................................................277 Functions ...........................................................................................................................................................277 Components ..........................................................................................................................................................277 DISPLAYS : USING BCS.....................................................................................................................................................278 Display and keyboard ................................................................................................................................................280 Indicator lights ................................................................................................................................................281 Buttons .........................................................................................................................................................281 Instruments .........................................................................................................................................................282 Service menu ........................................................................................................................................................282 Program 1: Oil change ...........................................................................................................................................283 Program 2 to 6 ..................................................................................................................................................283 The programs (Fig. 15)...........................................................................................................................................283 Program 2: Service ..............................................................................................................................................283 Program 3: Engine ...............................................................................................................................................284 Program 4: Hydraulics (Fig. 19)..................................................................................................................................284 Program 5: Excavator ...........................................................................................................................................285 Program 6: Operating hours ......................................................................................................................................285 HOLD function ...................................................................................................................................................286 Program 7: Setting date and time ................................................................................................................................287 Program 8: Complete fault list ..................................................................................................................................288 Program 9: Service Bucyrus HEX ..................................................................................................................................288 Fault reports .......................................................................................................................................................289 Service data & fault storage: print-out or transfer into Buffer .....................................................................................................290 APPENDIX ................................................................................................................................................................291 Print-out ...........................................................................................................................................................291
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