CATERPILLAR 6030 RH120E Hydraulic Excavator Operation Instruction Manual – PDF DOWNLOAD
FILE DETAILS:
CATERPILLAR 6030 RH120E Hydraulic Excavator Operation Instruction Manual – PDF DOWNLOAD
Language : English
Pages : 314
Downloadable : Yes
File Type : PDF
DESCRIPTION:
CATERPILLAR 6030 RH120E Hydraulic Excavator Operation Instruction Manual – PDF DOWNLOAD
PREFACE:
About this Operating Instructions:
- These operating instructions are designed to famil- iarize the operator with the machine and its
desig- nated use. - The operating instructions contain important in- formation on how to operate the machine
safely, properly and with maximum efficiency. Observing these instructions helps to
prevent hazardous situations, to reduce repair costs and downtimes and to increase the
reliability and service life of the machine. - The operating instructions must be supplemented by the respective national rules and
regulations for accident prevention and environmental protection. - The operating instructions must always be avail- able in the driver’s cab of the machine.
The operating instructions must be read and put into practice by any person in charge
of carrying out work with or on the machine, such as
▪ operation, including setting-up, troubleshoot- ing in the course of work, care,
evacuation of production waste and disposal of fuels and consumables,
▪ maintenance (inspection, servicing, repair) and / or
▪ transport.
- In addition to the operating instructions and the mandatory rules and regulations for
accident pre- vention and environmental protection in the user’s country and at the place where the
machine is to be used, the generally recognized technical rules for safe and proper working
must be observed ¹ - The operating instructions are directed to the min- ing-machine specialist. They cannot provide
basic know-how. This can be acquired, for example, in several days’ instruction by a
qualified Bucyrus HEX mechanic or by attending an Bucyrus HEX training course for
operators or maintenance per- sonnel. - The Bucyrus HEX after-sales service will be pleased to deal with any queries you
may have after reading through the operating instructions. - All Bucyrus HEX operating manuals are issued in German and then translated. Even a good transla-
tion may give rise to questions which Bucyrus HEX will be pleased to answer. - The operating instructions are not work instruc- tions for carrying out major repairs.
Such work is willingly done for you by the Bucyrus HEX after-
sales service.
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
CATERPILLAR 6030 RH120E Hydraulic Excavator Operation Instruction Manual – PDF DOWNLOAD
1 INTRODUCTION 1-1
PREFACE 1-1
About this Operating Instructions 1-1
Further machine documentation 1-1
WARRANTY 1-2
FUNDAMENTAL SAFETY INSTRUCTIONS 1-3
Warnings and symbols 1-3
Contents of the Declaration of Conformity 1-3
DESIGNATED USE 1-4
Noise emissions 1-5
Vibration data 1-5
ORGANIZATIONAL MEASURES 1-6
Selection and qualification of personnel; basic responsibilities 1-7
Safety instructions governing specific operational phases 1-7
Special work in conjunction with utilization of the machine and maintenance and repairs as well as
troubleshooting during work; disposal of parts and consumables 1-8
Warning of special dangers 1-9
Gas, dust, steam and smoke 1-9
Hydraulic equipment 1-10
FIRE AND EXPLOSION HAZARD 1-11
NOTES 1-13
2 OPERATION 2-1
OPERATION – SAFETY INSTRUCTIONS 2-3
Operating Instructions, where to store it in the driver’s cab 2-4
FIRE AND EXPLOSION HAZARD 2-5
DESCRIPTION OF THE EXCAVATOR 2-6
Excavator layout 2-7
Undercarriage 2-8
Superstructure 2-8
Drive 2-8
Hydraulic system 2-8
Control and Monitoring Platform (CAMP) 2-8
Board-Control-System (BCS) 2-9
Demand control / Zero-flow regulation 2-9
Automatic reset to idling 2-9
Electrical system 2-9
Signs 2-10
Entering and leaving the machine Safety instructions 2-17
Access ladder lighting 2-17
Swinging ladder 2-18
Folding ladder (optional) 2-19
Escape ladder (optional) 2-20
Switching the cab interior lighting on and off 2-21
OPERATING INSTRUCTIONS 6030, RH120E
Table of contents
vi BA RH120E(3 725 074.00)-EN
Switching the maintenance lights on and off 2-22
Emergency shut-off function 2-23
Shutting off the supply voltage (battery main switch) 2-24
Driver’s seat 2-25
Reducing the operators exposure to vibrations 2-27
Trainer’s / instructor’s seat 2-27
Fire extinguisher 2-28
Fire extinguisher (option) 2-28
Automatic fire-extinguishing system (optional) 2-29
Windscreen washer 2-29
Harness (optional) 2-30
MONITORING, WARNING AND CONTROL ELEMENTS 2-34
Engine 1 (LH), control and monitoring 2-41
Engine 2 (RH), control and monitoring 2-43
PUTTING THE MACHINE INTO OPERATION 2-60
Reducing the operator’s exposure to noise 2-60
Refuelling 2-60
Back-up heating (option), filling in fuel 2-61
Service station (tanklift) 2-61
Switching the electrical system on and off 2-67
Engines, emergency shut-off 2-67
Preheating system for engine and hydraulic oil (optional) 2-68
Fuel preheating system (optional) 2-69
STARTING AND STOPPING THE ENGINES 2-70
Starting the engines 2-70
Starting the left-hand engine 2-70
Starting the right-hand engine 2-70
Engines – adjusting the speed 2-71
Starting the engines at low temperatures 2-71
Shutting off the engines 2-72
Shutting off the left-hand engine 2-72
Shutting off the right-hand engine 2-72
AIR CONDITIONER (OPTION) 2-73
Back-up heating driver’s cab (option) 2-73
Back-up heating (option) 2-74
TRAVELLING, SAFETY INSTRUCTIONS 2-75
TRAVELLING 2-76
Superstructure basic position 2-76
Travelling forwards/backwards 2-76
Superstructure holding brake 2-80
Track parking brake 2-80
TRANSPORTING THE MACHINE 2-81
Transport – Safety instructions 2-81
WORKING OPERATION – SAFETY INSTRUCTIONS 2-82
WORKING OPERATION 2-84
Before starting work 2-84
OPERATING INSTRUCTIONS 6030, RH120E
Table of contents
BA RH120E(3 725 074.00)-EN vii
Activating the electronic excavator control 2-84
Swinging the superstructure 2-85
Braking the superstructure 2-85
Working 2-86
After daily operation 2-87
OPTIONAL EQUIPMENT 2-88
Water spraying system 2-88
Additional silencers 2-88
ASSEMBLING WORKING EQUIPMENT – SAFETY INSTRUCTIONS 2-89
Securing the machine 2-90
CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS) 2-91
NOTES 2-93
3 INSPECTION AND SERVICING 3-1
INSPECTION AND SERVICING – SAFETY INSTRUCTIONS 3-3
INSPECTION AND SERVICING WORK, FIRE AND EXPLOSION HAZARD 3-9
INSPECTION AND SERVICING PLANS – INSTRUCTIONS 3-11
Intervals 3-11
Change of engine oil l 3-11
Air-intake system 3-11
Oils / Greases 3-11
Cleaning jobs 3-11
Components 3-11
Plan V 3-13
Plan N 3-15
Plan T and W 3-17
Plan A – E 3-19
LUBRICATING CHART – GREASE 3-26
Lubricating chart – Grease (legend) 3-27
Filling quantities – Grease 3-27
INSPECTION PLAN – OIL 3-28
Inspection plan – Oil (legend) 3-29
Filling quantities – oil 3-30
Filling quantities – other 3-30
LUBRICANTS 3-31
Notes on the selection of oils and greases 3-31
Avoid mixing of different hydraulic fluids 3-31
I. Oils for combustion engines 3-32
II. Oils for hydraulic system 3-33
III.a Oils for pump gearboxes 3-34
III.b Oils for swing gearboxes 3-35
III.c Oils for travel gearboxes 3-36
V. Greases for bearings and swing rings 3-37
SERVICING WORK 3-38
Hose line for oil and cooling liquid changes 3-38
OPERATING INSTRUCTIONS 6030, RH120E
Table of contents
viii BA RH120E(3 725 074.00)-EN
ENGINE 3-39
Engine – Safety instructions 3-39
Checking the engine oil level / Topping up 3-40
Changing the engine oil 3-41
Replacing the oil filters 3-43
Engine oil reservoir, filling in engine oil 3-43
Cold-starting fluid (ether) – Replacing the pressure vessel 3-44
COOLING SYSTEM 3-45
Radiators 3-45
Cooling liquid change 3-47
AIR-INTAKE SYSTEM 3-48
Dust trap, cleaning 3-48
Main filter elements 3-49
Safety filter element 3-51
Air-intake lines 3-51
FUEL SYSTEM 3-52
Fuel system – Safety instructions 3-52
Replacing the fuel filter 3-52
Primary fuel filter, drain water 3-53
Replacing the primary fuel filter 3-53
Venting the fuel system 3-54
Cleaning the fuel tanks 3-54
Water trap (option) 3-56
ELECTRICAL SYSTEM 3-58
Electrical system – Safety instructions 3-58
Alternator – Instructions 3-58
Battery 3-59
Switchgear cabinet 3-61
Equipotential bonding 3-63
Floodlight projector, replacing the lamp 3-65
HYDRAULIC SYSTEM 3-67
Hydraulic system – Safety instructions 3-67
Depressurizing the hydraulic system 3-67
Checking the hydraulic oil level 3-68
Hydraulic oil return-flow filters (hydraulic oil reservoir), replace 3-70
Bypass valves (hydraulic oil reservoir), replace 3-72
Replacing the hydraulic oil return-flow filters (filter housing) 3-73
Bypass valves (filter housing – cooling system), replace 3-74
Breather filter, replace 3-75
Filter (servo circuit), replace 3-76
High-pressure filter for working hydraulics, replace 3-77
High-pressure filters for swing circuit, replace 3-78
Filter pump control, clean 3-79
Changing the hydraulic oil 3-80
Avoid mixing of different hydraulic fluids 3-80
Venting the hydraulic system 3-84
Cleaning the hydraulic oil cooler 3-85
Electronic excavator control 3-86
Pressure accumulators – Emergency lowering and servo circuit 3-87
OPERATING INSTRUCTIONS 6030, RH120E
Table of contents
BA RH120E(3 725 074.00)-EN ix
PUMP TRANSFER GEARBOX 3-88
Checking the gearbox oil level / Topping up with oil 3-88
Gearbox venting 3-90
Pump transfer gearbox lube oil filters 3-91
SWING GEARBOX 3-92
Gearbox – Checking the oil level / Topping up with oil 3-92
Changing the gearbox oil 3-92
Gearbox venting 3-93
SWING GEARBOX 3-94
Gearbox – Checking the oil level / Topping up with oil 3-94
Changing the gearbox oil 3-95
Gearbox venting 3-96
TRAVEL GEARBOX 3-97
Gearbox – Checking the oil level / Topping up with oil 3-97
Travel gearbox – Changing oil 3-98
Pre-chamber – Changing the oil 3-98
Brake chamber – Changing oil 3-99
Breather filter 3-99
CRAWLER TRACKS 3-100
Track roller, Support roller 3-101
Track tensioner 3-102
Pressure-accumulator inspection regulations 3-103
Checking the gas charging pressure in the pressure accumulator 3-103
SWING RING 3-104
Swing ring – Instructions 3-104
Bearing races 3-104
CENTRAL LUBRICATING SYSTEM 3-106
Design 3-106
Function 3-107
Filling up the grease container 3-108
Breather filter grease container, check / replace 3-108
Checking the greasing pressure 3-109
Unblocking a grease line 3-109
Oilfilter replace (hydraulic circuit grease pump) 3-110
Grease filter replace (filling the grease container) 3-111
Grease filter replace (Grease lines) 3-111
OTHER MAINTENANCE 3-112
Engine 3-112
Heating and air conditioning 3-112
RAMP-TYPE LADDER (OPTIONAL) 3-113
Pressure-accumulator inspection regulations 3-114
Extract from the German regulations 3-114
Checking the gas charging pressure in the pressure accumulator 3-114
ON-BOARD CRANE (OPTIONAL) 3-115
Monitoring, warning and control elements 3-115
Checking the on-board crane 3-115
OPERATING INSTRUCTIONS 6030, RH120E
Table of contents
x BA RH120E(3 725 074.00)-EN
Drive unit 3-116
On-board crane 3-116
On-Board crane, checking tightness of fastening bolts 3-117
PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING 3-118
Putting the excavator out of operation 3-118
Battery storage 3-118
Recommissioning 3-118
NOTES 3-119
4 REPAIR WORK 4-1
REPAIR WORK – SAFETY INSTRUCTIONS 4-3
REPAIR WORK, FIRE AND EXPLOSION HAZARD 4-5
REPAIR WORK, ENGINE 4-6
ELECTRICAL SYSTEM 4-7
Assisted starting (with jumper cables) – Safety instructions 4-7
Assisted starting (with jumper cables) 4-7
Starting the engine with jumper cables (external batteries 4-7
HYDRAULIC SYSTEM 4-9
Repair instructions 4-9
Hydraulic hoses – Instructions 4-9
PRESSURE ACCUMULATORS – SAFETY INSTRUCTIONS 4-10
WELDING AND FLAME CUTTING WORKS – SAFETY INSTRUCTIONS 4-11
DISPOSAL AT THE END OF THE SERVICE LIFE 4-14
Appropriate disposal of batteries 4-15
NOTES 4-17
5 ANNEX 5-1
BOARD-CONTROL-SYSTEM 5-3
BCS III, what’s that? 5-3
The keys on the front side 5-4
Other elements on the front side 5-4
BCSIII, the start screen 5-5
Information given on the start screen, top section 5-6
Information given on the start screen, central section 5-7
Information given on the start screen, lower section 5-8
Information given on the “Service” screen 5-9
Engine data screen 5-10
Hydraulic data screen 5-11
Lubrication data screen 5-12
Controls adjustment data screen 5-13
View documents screen 5-14
Signal table screen 5-15
Signal table screen, location 5-16
Signal table screen, diagram 5-17
Signal table screen, diagram configuration 5-18
OPERATING INSTRUCTIONS 6030, RH120E
Table of contents
BA RH120E(3 725 074.00)-EN xi
Code table screen 5-19
BCS III, interfaces 5-20
USB interface, data storage 5-20
Saving data to a USB stick 5-21
Saving data to a USB stick, continued 5-22
Saving data to a USB stick, continued 5-23
BCSIII, cleaning 5-24
BCSIII, disposal 5-24
TROUBLESHOOTING 5-25
Instructions on troubleshooting 5-25
Layout of the fault table 5-25
Possible causes 5-25
Measures 5-25
Section 5-25
FAULT TABLES 5-26
Combustion engine – Fault table 5-26
Working hydraulics – Fault table 5-27
Track drive – Fault table 5-28
Swing mechnism – Fault table 5-29
Central lubricating system – Fault table 5-30
ENGINE MONITORING, CONTROL LAMPS 5-31
HYDRAULIC CIRCUIT DIAGRAM 5-32
ABBREVIATIONS 5-33
ABBREVIATIONS 5-34
ECHNICAL DATA 5-35
NOTES 5-37
6 INDEX 6-1
VIDEO PREVIEW OF THE MANUAL:
PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
S.V