Caterpillar Bucyrus 6018 RH90C Hydraulic Excavator OPERATING INSTRUCTIONS Manual – PDF DOWNLOAD

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Caterpillar Bucyrus 6018 RH90C Hydraulic Excavator OPERATING INSTRUCTIONS Manual – PDF DOWNLOAD

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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

• 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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