CAT 6050, 6050 FS Hydraulic Shovel Operation & Maintenance Manual EM027997-0 - PDF DOWNLOAD

EM027997-0 (en-us)

Operation and Maintenance Manual 6050, 6050 FS Hydraulic Shovel DH250157 –UP DHM50164 –UP

Language: Original Instructions

EM027997-0

EM027997-0

OPERATING INSTRUCTIONS 6050 / 6050FS

Hydraulic Excavator 6050, 6050FS No. Caterpillar Global Mining HMS GmbH

BA RH200(3 847 006.00)-EN

EM027997-0

OPERATING INSTRUCTIONS 6050 / 6050FS

Published by:

Caterpillar Global Mining HMS GmbH Dept. Technical Publications D-44149 Dortmund, Karl-Funke-Straße 36 Tel. 49 (0) 231 922-4340 Fax 49 (0) 231 922-5005 E-Mail documentation.HEX@cat.com https://mining.cat.com www.bucyrus-hex.com

© Copyright Caterpillar Global Mining Hydraulic Mining Shovels GmbH 2012. The reproduction, distribution and utilization of this manual / file as well as the communication of its content to others without express authorization is prohibited. Offenders will be held liable for the payment of damages. All rights reserved in the event of the grant of a patent, utility model or design.

Printed in Germany

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The Bucyrus HEX operating manual is in 6 sections; the sections are designed for different target groups: Operating instructions

Target group

Part 1 INTRODUCTION FUNDAMENTAL SAFETY INSTRUCTIONS

Operating personnel + Inspection and servicing personnel + Repair personnel

Part 2 OPERATION

Operating personnel The operating personnel must have knowhow relevant to the operation and the application of this or comparable machines.

Part 3 INSPECTION AND SERVICING Part 4 REPAIR WORK

Inspection and servicing personnel The inspection and servicing personnel must have know-how relevant to the inspection and servicing of this or comparable machines.

Repair personnel The repair personnel must have know-how and experience relevant to the repair of this or comparable machines.

Part 5 ANNEX

Part 6 INDEX

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Operating personnel + Inspection and servicing personnel + Repair personnel Operating personnel + Inspection and servicing personnel + Repair personnel

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OPERATING INSTRUCTIONS 6050 / 6050FS Table of contents TABLE OF CONTENTS 1 INTRODUCTION __________________________________________________________________ 1-1 PREFACE _______________________________________________________________________ 1-3 About this Operating Instructions ____________________________________________________ 1-3 Further machine documentation _____________________________________________________ 1-3 WARRANTY______________________________________________________________________ 1-4 FUNDAMENTAL SAFETY INSTRUCTIONS _____________________________________________ 1-5 Warnings and symbols ____________________________________________________________ 1-5 DESIGNATED USE, UNAUTHORIZED USE ____________________________________________ 1-6 ORGANIZATIONAL MEASURES _____________________________________________________ 1-7 Selection and qualification of personnel; basic responsibilities______________________________ 1-8 Safety instructions governing specific operational phases _________________________________ 1-8 Special work in conjunction with utilization of the machine and maintenance and repairs as well as troubleshooting during work; disposal of parts and consumables____________________________ 1-9 Warning of special dangers________________________________________________________ 1-10 FIRE AND EXPLOSION HAZARD____________________________________________________ 1-12 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 OPERATION, 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 Pump Managing System (PMS) _____________________________________________________ 2-8 Stored Program Control (SPC) ______________________________________________________ 2-8 Central Management System (CMS) _________________________________________________ 2-8 Demand control / Zero-flow regulation ________________________________________________ 2-9 Automatic engine speed reduction ___________________________________________________ 2-9 Board-Control-System (BCS) _______________________________________________________ 2-9 Electrical system _________________________________________________________________ 2-9 Signs _________________________________________________________________________ 2-10 Entering and leaving the machine, Safety instructions ___________________________________ 2-18 Access lighting _________________________________________________________________ 2-18 Folding ladder (optional) __________________________________________________________ 2-19 Swinging ladder (optional)_________________________________________________________ 2-20 Cab interior lamp ________________________________________________________________ 2-21 Servicing lighting ________________________________________________________________ 2-22 Illuminating the control column _____________________________________________________ 2-22 EMERGENCY STOP switch _______________________________________________________ 2-23 Escape ladder __________________________________________________________________ 2-24 BA RH200(3 847 006.00)-EN

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OPERATING INSTRUCTIONS 6050 / 6050FS Table of contents Trainer's / instructor's seat ________________________________________________________ 2-25 Windscreen washer______________________________________________________________ 2-25 Driver's seat ___________________________________________________________________ 2-26 Fire extinguisher ________________________________________________________________ 2-28 Automatic fire-extinguishing system (optional) _________________________________________ 2-29 Harness (optional) _______________________________________________________________ 2-30 MONITORING, WARNING AND CONTROL ELEMENTS __________________________________ 2-34 PUTTING THE MACHINE INTO OPERATION __________________________________________ 2-64 Refuelling _____________________________________________________________________ 2-64 Service station (tanklift) ___________________________________________________________ 2-64 Switching the electrical system on and off ____________________________________________ 2-70 STARTING AND STOPPING THE ENGINES ___________________________________________ 2-71 Starting the engines _____________________________________________________________ 2-71 Starting the engines at low temperatures _____________________________________________ 2-72 Shutting off the engines___________________________________________________________ 2-73 Emergency - stop _______________________________________________________________ 2-73 AIR CONDITIONER (OPTION) ______________________________________________________ 2-74 Back-up heating (option) __________________________________________________________ 2-75 MAXIMUM MACHINE INCLINATIONS, INFORMATION ___________________________________ 2-77 TRAVELLING, SAFETY INSTRUCTIONS ______________________________________________ 2-78 Superstructure basic position ______________________________________________________ 2-79 Travel forwards/backwards ________________________________________________________ 2-79 Emergency machine drive_________________________________________________________ 2-83 Superstructure holding brakes _____________________________________________________ 2-85 Track parking brake _____________________________________________________________ 2-85 TRANSPORTING THE MACHINE____________________________________________________ 2-86 Transport - Safety instructions _____________________________________________________ 2-86 WORKING OPERATION - SAFETY INSTRUCTIONS ____________________________________ 2-87 WORKING OPERATION ___________________________________________________________ 2-89 Before starting work _____________________________________________________________ 2-89 Swing the superstructure__________________________________________________________ 2-89 Braking the superstructure ________________________________________________________ 2-89 Working movements _____________________________________________________________ 2-90 After daily operation _____________________________________________________________ 2-91 ASSEMBLING WORKING EQUIPMENT - SAFETY INSTRUCTIONS ________________________ 2-92 Securing the machine ____________________________________________________________ 2-93 CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS)____________ 2-94 ON-BOARD CRANE (OPTIONAL)____________________________________________________ 2-95 On-board crane, monitoring, warning and control elements _______________________________ 2-95 On-board crane, putting into operation _______________________________________________ 2-96 On-board crane, drive unit_________________________________________________________ 2-96 On-Board crane, – blocking the boom in position of rest _________________________________ 2-97 On-board crane, checking _________________________________________________________ 2-97

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OPERATING INSTRUCTIONS 6050 / 6050FS Table of contents OPTIONAL EQUIPMENT___________________________________________________________ 2-98 Monitoring cameras______________________________________________________________ 2-98 NOTES_________________________________________________________________________ 2-99 3 INSPECTION AND SERVICING ____________________________________________________ 3-101 INSPECTION AND SERVICING - SAFETY INSTRUCTIONS______________________________ 3-103 INSPECTION AND SERVICING WORK, FIRE AND EXPLOSION HAZARD __________________ 3-108 INSPECTION AND SERVICING PLANS - INSTRUCTIONS _______________________________ 3-109 Intervals______________________________________________________________________ 3-109 Change of engine oil ____________________________________________________________ 3-109 Air-intake system_______________________________________________________________ 3-109 Oils / Greases _________________________________________________________________ 3-109 Cleaning jobs _________________________________________________________________ 3-109 Components __________________________________________________________________ 3-109 Plan V _______________________________________________________________________ 3-111 Plan N _______________________________________________________________________ 3-113 Plan T and W__________________________________________________________________ 3-115 Plan A – E ____________________________________________________________________ 3-117 LUBRICATING CHART – GREASE__________________________________________________ 3-126 Lubricating chart – Grease (legend) ________________________________________________ 3-127 Filling quantities – Grease________________________________________________________ 3-127 INSPECTION PLAN - OIL _________________________________________________________ 3-128 Inspection plan – Oil (legend) _____________________________________________________ 3-129 Filling quantities - oil ____________________________________________________________ 3-130 Filling quantities – other _________________________________________________________ 3-130 LUBRICANTS __________________________________________________________________ 3-131 Notes on the selection of oils and greases ___________________________________________ 3-131 Avoid mixing of different hydraulic fluids _____________________________________________ 3-131 I. Oils for combustion engines ___________________________________________________ 3-132 II. Oils for hydraulic system ____________________________________________________ 3-133 III.a Oils for pump gearboxes and travel gearboxes _________________________________ 3-134 III.b Oils for swing gearboxes __________________________________________________ 3-135 V. Greases for bearings, swing rings and track system (Central lubrication system) ________ 3-136 Grease for idlers, track rollers and support rollers (Lifetime lubrication) _____________________ 3-137 Coolant for use on all combustion engines ___________________________________________ 3-138 SERVICING WORK ______________________________________________________________ 3-139 Hose line for oil and cooling liquid changes __________________________________________ 3-139 ENGINE _______________________________________________________________________ 3-140 Engine - Safety instructions_______________________________________________________ 3-140 Engine oil, checking the level / topping up ___________________________________________ 3-141 Engine oil reservoir, checking the oil level / topping up__________________________________ 3-142 Engine oil, change______________________________________________________________ 3-143 Engine oil reservoir (optional), draining the oil off ______________________________________ 3-145 Oil change prolongation system, replacing the oil filter __________________________________ 3-147 Eliminator filter and centrifuge (optional)_____________________________________________ 3-148 Cold-starting fluid (ether) - Replacing the pressure vessel _______________________________ 3-150

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OPERATING INSTRUCTIONS 6050 / 6050FS Table of contents COOLING SYSTEM______________________________________________________________ 3-151 Cooling liquid, change ___________________________________________________________ 3-154 Water filter, change _____________________________________________________________ 3-156 AIR-INTAKE SYSTEM ____________________________________________________________ 3-157 Main filter elements, removal and installation _________________________________________ 3-158 Main filter elements, checking and cleaning __________________________________________ 3-159 Safety filter element, replace______________________________________________________ 3-160 Air-intake lines_________________________________________________________________ 3-161 Dust collection _________________________________________________________________ 3-161 FUEL SYSTEM _________________________________________________________________ 3-162 Fuel system, Safety instructions ___________________________________________________ 3-162 Fuel filter, replace ______________________________________________________________ 3-162 Fuel system, venting ____________________________________________________________ 3-163 Cleaning the fuel tanks __________________________________________________________ 3-163 Water trap (option) _____________________________________________________________ 3-165 ELECTRICAL SYSTEM ___________________________________________________________ 3-167 Electrical system - Safety instructions_______________________________________________ 3-167 Alternator - Instructions __________________________________________________________ 3-167 Battery _______________________________________________________________________ 3-168 Switchgear cabinet _____________________________________________________________ 3-170 Floodlight projector, replacing the lamp _____________________________________________ 3-172 HYDRAULIC SYSTEM____________________________________________________________ 3-174 Hydraulic system - Safety instructions ______________________________________________ 3-174 Depressurizing the hydraulic system________________________________________________ 3-174 Checking the hydraulic oil level ____________________________________________________ 3-175 Changing the hydraulic oil return-flow filters (hydraulic oil reservoir) _______________________ 3-177 Bypass valves (hydraulic oil reservoir) ______________________________________________ 3-179 Replacing the bypass valves and sealing rings________________________________________ 3-179 Breather filter__________________________________________________________________ 3-180 Filter (control circuit) ____________________________________________________________ 3-181 High-pressure filter for working hydraulics ___________________________________________ 3-182 High-pressure filters for the servo circuit_____________________________________________ 3-183 High-pressure filters for feeding circuits and slewing pumps _____________________________ 3-184 High-pressure filters for slewing circuit ______________________________________________ 3-185 Changing the hydraulic oil ________________________________________________________ 3-186 Avoid mixing of different hydraulic fluids _____________________________________________ 3-186 Venting the hydraulic system _____________________________________________________ 3-190 Cleaning the hydraulic oil cooler ___________________________________________________ 3-191 Electronic excavator control ______________________________________________________ 3-192 Pressure accumulator - Emergency lowering _________________________________________ 3-193 PUMP TRANSFER GEARBOX _____________________________________________________ 3-194 Checking the gearbox oil level / Topping up with oil ____________________________________ 3-194 Changing the gearbox oil ________________________________________________________ 3-195 Gearbox, breather valve _________________________________________________________ 3-196 Pre-chamber, breather valve______________________________________________________ 3-197 Pump transfer gearbox lube oil filters _______________________________________________ 3-198 SWING GEARBOX ______________________________________________________________ 3-199 Gearbox - Checking the oil level / Topping up with oil __________________________________ 3-199

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OPERATING INSTRUCTIONS 6050 / 6050FS Table of contents Changing the gearbox oil ________________________________________________________ 3-199 Gearbox venting _______________________________________________________________ 3-200 TRAVEL GEARBOX (VALID FOR GEARBOX PN 3673978) ______________________________ 3-201 Travel gearbox - Checking the oil level / Topping up with oil _____________________________ 3-201 Travel gearbox - Changing oil _____________________________________________________ 3-202 Breather filters, clean / replace ____________________________________________________ 3-203 TRAVEL GEARBOX (VALID FOR GEARBOX PN 2763214) ______________________________ 3-204 Travel gearbox - Checking the oil level / Topping up with oil _____________________________ 3-204 Travel gearbox - Changing oil _____________________________________________________ 3-205 Pre-stage - Changing the oil ______________________________________________________ 3-205 Brake chambers - Changing oil ____________________________________________________ 3-206 Breather filters, clean / replace ____________________________________________________ 3-206 CRAWLER TRACKS _____________________________________________________________ 3-207 Track roller, Support roller________________________________________________________ 3-208 Track tensioner ________________________________________________________________ 3-209 Pressure-accumulator inspection regulations _________________________________________ 3-210 Checking the gas charging pressure in the pressure accumulator _________________________ 3-210 SWING RING ___________________________________________________________________ 3-211 Swing ring – Instructions _________________________________________________________ 3-211 Bearing races _________________________________________________________________ 3-211 CENTRAL LUBRICATING _________________________________________________________ 3-213 Design _______________________________________________________________________ 3-213 Function _____________________________________________________________________ 3-214 Filling up the grease container ____________________________________________________ 3-215 Breather filter__________________________________________________________________ 3-215 Checking the greasing pressure ___________________________________________________ 3-216 Unblocking a grease line. ________________________________________________________ 3-217 Oilfilter (hydraulic circuit grease pump) ______________________________________________ 3-218 Grease filter (Filling the grease container) ___________________________________________ 3-219 Grease filter (Grease lines) _______________________________________________________ 3-220 OTHER MAINTENANCE __________________________________________________________ 3-221 Engine _______________________________________________________________________ 3-221 Equipment, checking ____________________________________________________________ 3-222 Hydraulic ladder (optional) _______________________________________________________ 3-222 Pressure-accumulator inspection regulations _________________________________________ 3-223 Extract from the German regulations _______________________________________________ 3-223 Checking the gas charging pressure in the pressure accumulator _________________________ 3-223 ON-BOARD CRANE, DRIVE UNIT __________________________________________________ 3-224 On-board crane, lubricating_______________________________________________________ 3-225 On-Board crane, checking tightness of fastening bolts __________________________________ 3-225 PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING ______________ 3-226 Putting the excavator out of operation_______________________________________________ 3-226 Battery storage ________________________________________________________________ 3-226 Recommissioning ______________________________________________________________ 3-226

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OPERATING INSTRUCTIONS 6050 / 6050FS Table of contents NOTES________________________________________________________________________ 3-227 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 Dismantling and removal instructions ________________________________________________ 4-14 Risk of deflagrations _____________________________________________________________ 4-14 Risk of fire _____________________________________________________________________ 4-14 Disposing of the machine without polluting the environment ______________________________ 4-15 Further hazardous substances _____________________________________________________ 4-15 Appropriate disposal of batteries____________________________________________________ 4-16 NOTES_________________________________________________________________________ 4-17 5 ANNEX__________________________________________________________________________ 5-1 TROUBLESHOOTING ______________________________________________________________ 5-3 Instructions on troubleshooting ______________________________________________________ 5-3 Layout of the fault table ____________________________________________________________ 5-3 Possible causes _________________________________________________________________ 5-3 Measures ______________________________________________________________________ 5-3 Section ________________________________________________________________________ 5-3 FAULT TABLES ___________________________________________________________________ 5-4 Combustion engine - Fault table _____________________________________________________ 5-4 Working hydraulics – Fault table _____________________________________________________ 5-5 Track drive – Fault table ___________________________________________________________ 5-6 Swing mechnism – Fault table ______________________________________________________ 5-7 Central lubricating system – Fault table _______________________________________________ 5-8 Engine electronic unit, displaying stored fault codes______________________________________ 5-9 HYDRAULIC CIRCUIT DIAGRAM ____________________________________________________ 5-10 ABBREVIATIONS ________________________________________________________________ 5-11 ABBREVIATIONS _______________________________________________________________ 5-12

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OPERATING INSTRUCTIONS 6050 / 6050FS Table of contents TECHNICAL DATA _______________________________________________________________ 5-13 NOTES_________________________________________________________________________ 5-15 6 INDEX __________________________________________________________________________ 6-1

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OPERATING INSTRUCTIONS 6050 / 6050FS Introduction 1 INTRODUCTION Operating instructions

Target group

Part 1 INTRODUCTION FUNDAMENTAL SAFETY INSTRUCTIONS

Operating personnel + Inspection and servicing personnel + Repair personnel

Part 2 OPERATION

Operating personnel The operating personnel must have knowhow relevant to the operation and the application of this or comparable machines.

Part 3 INSPECTION AND SERVICING Part 4 REPAIR WORK

Inspection and servicing personnel The inspection and servicing personnel must have know-how relevant to the inspection and servicing of this or comparable machines.

Repair personnel The repair personnel must have know-how and experience relevant to the repair of this or comparable machines.

Part 5 ANNEX

Part 6 INDEX

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Operating personnel + Inspection and servicing personnel + Repair personnel Operating personnel + Inspection and servicing personnel + Repair personnel

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OPERATING INSTRUCTIONS 6050 / 6050FS Introduction

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OPERATING INSTRUCTIONS 6050 / 6050FS Introduction PREFACE About this Operating Instructions These Operation and Maintenance Manual is designed to familiarize the operator with the machine and its designated use.

The Operation and Maintenance Manual contains 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 Operation and Maintenance Manual must be supplemented by the respective national rules and regulations for accident prevention and environmental protection.

The Operation and Maintenance Manual must always be available in the driver's cab of the machine.

The Operation and Maintenance Manual 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 Operation and Maintenance Manual 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 1 be observed .

The Operation and Maintenance Manual is directed to the mining-machine specialist. It cannot provide basic know-how. This can be acquired, for example, in several days' instruction by a qualified Caterpillar Global Mining HMS GmbH mechanic or by attending an CGM HMS training course for operators or maintenance personnel.

The CGM HMS after-sales service will be pleased to deal with any queries you may have after reading through the operating instructions.

All CGM HMS Operation and Maintenance Manuals are issued in German and then translated.

Even a good translation may give rise to questions which CGM HMS 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 CGM HMS after-sales service.

Further machine documentation 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, the spare-parts list and the Technical Handbooks are marked with the serial number of the machine.

The documentation supplied with your machine is rather comprehensive. Therefore, it has been split up in several volumes: Volume 1: the present Operation and Maintenance Manual, Volume 2:

spare-parts catalog of the machine,

Volume 3:

cross reference list of spare-parts,

Volume 4:

electrical circuit diagram and key,

Volume 5:

documentation of the engine and of other components,

Volume 6:

Technical Handbook Part 1

Volume 7:

Technical Handbook Part 2

Depending on the size of your machine, the documentation can also consist of more volumes.

If you cannot find the information you are looking for in the present operating instructions please check also the other volumes of the documentation.

The Technical Handbook Part 1 also provides information on how to assemble the machine, on functions of the hydraulic system, on hydraulic circuit diagrams etc.

On taking receipt of the consignment, please check that the documentation is complete and in the language requested by you.

1

Complies with VDMA recommendation "Operating instructions"

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OPERATING INSTRUCTIONS 6050 / 6050FS Introduction WARRANTY The warranty of Bucyrus HEX presupposes among other things that the servicing works as described in the operating instructions have been performed:

Do not operate the machine  when components / assemblies are defective or missing,



by the Bucyrus HEX Service



in a workshop authorized in writing by Bucyrus HEX,

In cases of doubt seek advice from the Bucyrus HEX Service.

or  and 

by using the original spare parts of Bucyrus HEX.

The proper execution of the servicing works must be documented on the Bucyrus HEX Service checklists.

if one or several of such components of which more than one are installed in the machine have been removed.

Bucyrus HEX refuses to assume the guarantee for damage and consequential damage caused by an abusive utilization of the machine.

Therefore: Do not operate the machine,  when several track rollers or support rollers have been removed; 

when one or several slewing gearboxes have failed or been removed;



when one or several teeth on the backhoe or on the shovel are worn or missing;



when parts of the hardfacing layer on the backhoe or on the shovel are worn or missing.

Working under these circumstances results in heavy wear and possibly in severe damage and thus in high repair costs.

Such circumstances are considered by Bucyrus HEX as "abusive utilization".

Why? The machines have been designed and built on the basis of detailed calculations and so that all of the components installed absorb the occurring forces and are thus loaded to an equal extent.

Example: If the machine is used for working with, for instance, one or even several track rollers removed, the forces must be absorbed by the remaining track rollers. These are then overloaded or loaded to a greater extent than calculated.

The consequences are higher wear and consequential damage to the track rollers, but also to other components of the machine: chassis, travel gearbox and crawler track.

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OPERATING INSTRUCTIONS 6050 / 6050FS Introduction FUNDAMENTAL SAFETY INSTRUCTIONS Complies with VDMA recommendation "Operating Instructions".

Warnings and symbols The following signs are used in the operating instructions to designate instructions of particular importance: Precautionary rules and measures designed to protect the machine operator and other persons from lifethreatening danger or injuries and to prevent extensive damage.

Information and precautionary measures designed to prevent damage to the machine or other property.

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OPERATING INSTRUCTIONS 6050 / 6050FS Introduction DESIGNATED USE, UNAUTHORIZED USE The machine has been built in accordance with state-of-art standards and the recognized safety rules. Nevertheless, its use may constitute a risk to life and limb for the user or third parties or cause damage to the machine and to other material property (acceptable risk) An acceptable risk is present, e.g.: loose material or material to be loaded may drop out of the bucket or backhoe while the working equipment is being swivelled.

The machine must be used only in technically perfect condition in accordance with its designated use and the instructions set out in the operating instructions, and only by safety-conscious persons who are fully aware of the risks involved in operating the machine. Any functional disorders, especially those affecting the safety of the machine, should therefore be rectified immediately.

With attached shovel equipment, the machine is to be used solely for loosening and loading of:  sand, oil sand,  gravel,

Using the hydraulic shovel or its attachments for purposes other than or extending beyond those stated above, e.g.:  for lifting or transporting persons, 

as a working platform,



for lifting crane loads without the equipment being approved for this purpose,



for driving in posts, sheetpiles supports, etc. without the equipment being approved for this purpose,



for moving material to the side (sweeping),



for breaking down rocks by beating with the shovel or the backhoe,



for fitting or reparing of other machines

is contrary to its designated use and considered as "unauthorized use".

 blasted rock,  ore,  coal, and other raw materials.

With attached backhoe equipment, the machine can additionally also be used for excavating and loading of excavatable soils and other raw materials.

Operating the machine within the limits of the desigated use also involves observing the instructions set out in the operating instructions and complying with the inspection and maintenance directives.

Lifting eyes on the lower carriage -

are settled for transporting with a crane only.

-

must not be used for towing a machine.

Improper use may involve a life-threatening risk for operators or other personnel or may cause injury or extensive damage.

The manufacturer/supplier cannot be held liable for any damage resulting from other than the designated use. The risk involved in such misuse lies with the user.

Noise emission specifications in acc. with the 3rd Ordinance of the Machine Safety Act of 18th January 1991 resp. with EC Machine Directive, Annex I, para. 1.7.4 f.

If the earth-moving machine is operated in accordance with the designated use, the installation of driver´s seats complying with ISO 7096 ensures that the considered vibration accelerations azw (measured as per ISO 2631, Part 1) fulfill the requirements of protecting the driver against wholebody vibration according to 2002/44/EG.

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OPERATING INSTRUCTIONS 6050 / 6050FS Introduction ORGANIZATIONAL MEASURES The operating instructions must always be at hand at the place of use of the machine, e.g. by stowing them in the place provided for such purpose.

In addition to the operating instructions, observe and instruct the user in all other generally applicable legal and other mandatory regulations relevant to accident prevention and environmental protection.

Personal protective equipment and the working clothing Depending on the cleaning, servicing and/or repair activities to be performed, the personal protective equipment and the working clothing may consist of the following items: 

fall arresters



protective suit

These compulsory regulations may also deal with the handling of hazardous substances, issuing and/or wearing of personal protective equipment or traffic regulations.



helmet



goggles - e. g. for cleaning work or for welding work

The operating instructions must be supplemented by instructions covering the duties involved in supervising and notifying special organizational features, such as job organization, working sequences or the personnel entrusted with the work.



protective gloves - e.g. for work on hot units - for grinding and welding work



protective working gloves - e.g. for fitting work - for grinding and welding work



ear protectors

Personnel entrusted with work on the machine must have read the operating instructions and in particular the chapter on safety before beginning work. Reading the operating instructions after work has begun is too late. This applies especially to persons working only occasionally on the machine, e.g. during setting up or maintenance.

Check - at least from time to time - whether the personnel is carrying out the work in compliance with the operating instructions and paying attention to risks and safety factors.

For reasons of security, long hair must be tied back or otherwise secured, garments must be close-fitting and no jewellery, such as rings, may be worn. Injury may result from being caught up in the machinery or from rings catching on moving parts.

Use protective equipment wherever required by the circumstances or by law.

Observe all safety instructions and warnings attached to the machine.

See to it that safety instructions and warnings attached to the machine are always complete and perfectly legible.

In the event of safety-relevant modifications or changes in the behaviour of the machine during operation, stop the machine immediately and report the malfunction to the competent authority/person.

Never make any modifications, additions or conversions which might affect safety without the supplier's approval. This also applies to the installation and adjustment of safety devices and valves as well as to welding work on load-bearing elements.

Use only the original sparts parts of Bucyrus HEXGermany.

They are the only ones to fulfill the technical specifications of the machine.

Replace hydraulic hoses within stipulated and appropriate intervals, even if no safety-relevant defects have been detected.

Adhere to prescribed intervals or those specified in the operating instructions for routine checks and inspections.

For the execution of maintenance work, tools and workshop equipment adapted to the task on hand are absolutely indispensable.

The personnel must be familiar with the location and operation of fire extinguishers.

Observe all fire-warning and fire-fighting procedures.

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OPERATING INSTRUCTIONS 6050 / 6050FS Introduction Selection and qualification of personnel; basic responsibilities

In the event of malfunction, stop the machine immediately and lock it. Have any defects rectified immediately.

Any work on and with the machine must be executed by reliable personnel only. Statutory minimum age limits must be observed.

Start the machine from the driver's seat only.

Employ only trained or instructed staff and set out clearly the individual responsibilities of the personnel for operation, set-up, maintenance and repair.

Make sure that only authorized personnel works on or with the machine.

Define the machine operator's responsibilities giving the operator the authority to refuse instructions by third parties that are contrary to safety.

Do not allow persons to be trained or instructed or persons taking part in a general training course to work on or with the machine without being permanently supervised by an experienced person.

Work on the electrical system and equipment of the machine must be carried out only by a skilled electrician or by instructed persons under the supervision and guidance of a skilled electrician and in accordance with electrical engineering rules and regulations.

Work on chassis and brake systems must be performed by skilled personnel only, which has been specially trained for such work.

Work on hydraulic systems must be carried out only by personnel with special knowledge and experience of hydraulic equipment.

Safety instructions governing specific operational phases Standard operation

During start-up and shut-down procedures always watch the indicators in accordance with the operating instructions.

Before setting the machine in motion, make sure that nobody is at risk.

Before starting work or travelling with the machine, check that braking, signalling and lighting systems are fully functional.

Before setting the machine in motion always check that the accessories have been safely stowed away.

In conditions of poor visibility and after dark always switch on the lighting system.

Persons accopanying the driver must be seated on the passenger seat provided for this purpose.

When crossing underpasses and bridges or when passing under overhead lines always make sure that there is sufficient clearance.

Always keep a distance from the working face and from slopes.

Avoid any operation that might be a risk to machine stability.

Never travel across slopes; always keep the working equipment and the load close to the ground, especially when travelling downhill.

On sloping terrain always adapt your travelling speed to the prevailing ground conditions.

Before leaving the driver's seat always secure the machine against inadvertent movement and unauthorized use. Shut off the engines.

Avoid any operational mode that might be prejudicial to safety.

Before beginning work, familiarize yourself with the surroundings and circumstances of the site, such as obstacles in the working area and the bearing capacity of the soil.

Take the necessary precautions to ensure that the machine is in a safe and reliable state.

Operate the machine only if all protective and safety-oriented devices, such as removable safety devices, emergency shut-off equipment, soundproofing elements and exhausters, are in place and fully functional.

Check the machine at least once per working shift for obvious damage and defects. Report any changes (incl. changes in the machine's working behaviour) to the competent organization/person immediately. If necessary, stop the machine immediately and lock it.

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OPERATING INSTRUCTIONS 6050 / 6050FS Introduction Special work in conjunction with utilization of the machine and maintenance and repairs as well as troubleshooting during work; disposal of parts and consumables Observe the adjusting, maintenance and inspection activities and intervals set out in the operating instructions, including information on the replacement of parts and equipment. These activities may be executed by skilled personnel only.

Brief operating personnel before beginning special operations and maintenance work, and appoint a person to supervise the activities.

In any work concerning the operation, conversion or adjustment of the machine and its safetyoriented devices or any work related to maintenance, inspection and repair, always observe the start-up and shut-down procedures set out in the operating instructions and the information on maintenance work.

Ensure that the maintenance area is adequately secured.

If the machine is completely shut down for maintenance and repair work, it must be secured against inadvertent starting by:  removing the ignition key and  attaching a warning sign.

Carry out maintenance and repair work only if the machine is positioned on stable and level ground and has been secured against inadvertent movements.

Keep all handles, steps, handrails, platforms, landings and ladders free from dirt, snow and ice.

Clean the machine, especially connections and threaded unions, of any traces of oil, fuel or preservatives before carrying out maintenance/repair.

Never use aggressive detergents. Use lint-free cleaning rags.

Before cleaning the machine with water, steam jet (high-pressure cleaning) or detergents, cover or tape up all openings which - for safety and functional reasons - must be protected against water, steam or detergent penetration. Special care must be taken with electric motors and switch-gear cabinets.

Ensure during cleaning of the machine that the temperature sensors of the fire-warning and firefighting systems do not come into contact with hot cleaning agents as this might activate the firefighting system.

After cleaning remove all covers and tapes applied for that purpose.

After cleaning, examine all fuel, lubricant, brake and hydraulic fluid lines for leaks, loose connections, chafe marks and damage. Any defect found must be rectified without delay.

Always tighten any screwed connections that have been loosened during maintenance and repair.

Any safety devices removed for set-up, maintenance or repair purposes must be refitted and checked immediately upon completion of maintenance and repair work.

Ensure that all consumables and replaced parts are disposed of safely and with minimum environmental impact.

To avoid the risk of accidents, individual parts and large assemblies being moved for replacement purposes should be carefully attached to lifting tackle and secured. Use only suitable and technically perfect lifting gear and suspension systems with adequate lifting capacity. Never work or stand under suspended loads.

The fastening of loads and the instructing of crane operators should be entrusted to experienced persons only. The marshaller giving the instructions must be within sight or sound of the operator.

For carrying out overhead assembly work always use specially designed or otherwise safetyoriented ladders and working platforms. Never use machine parts as a climbing aid Wear a safety harness when carrying out maintenance work at heights above 1 m.

Wear an approved harness equipped with fall arresters and safety lines.

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OPERATING INSTRUCTIONS 6050 / 6050FS Introduction Warning of special dangers

Gas, dust, steam and smoke

Electric energy

Always start and operate the engine in a wellvented area;

Use only original fuses with the specified current rating. Switch off the machine immediately if trouble occurs in the electrical system.

When working with the machine, maintain a safe distance from overhead electric lines. If work is to be carried out close to overhead lines, the working equipment must be kept well away from them.

Caution, danger! Check out the prescribed safety distances.

If your machine comes into contact with a live wire  do not leave the machine  drive the machine out of the hazard zone; warn others against approaching and touching the machine  have the live wire de-energized  do not leave the machine until the damaged or contacted line has been safely de-energized.

The electrical equipment of machines is to be inspected and checked at regular intervals. Defects such as loose connections or scorched cables must be rectified immediately.

High-voltage system Floodlamps equipped with gaz discharge lamps require a high-voltage supply (ca. 25 kV).

If in an enclosed area, vent the exhaust to the outside; Do not modify or tamper with the exhaust system Diesel engine exhaust and some of its constituents are known to cause cancer, birth defects, and other reproductive harm Operate fuel-operated heating systems only on adequately ventilated premises. Before starting the machine on enclosed premises, make sure that there is sufficient ventilation.

Observe the regulations in force at the respective site.

Carry out welding, flame-cutting and grinding work on the machine only if this has been expressly authorized, as there may be a risk of explosion and fire.

Before carrying out welding, flame-cutting and grinding operations, clean the machine and its surroundings from dust and other inflammable substances and make sure that the premises are adequately ventilated (risk of explosion).

CALIFORNIA Proposition 65 Warning Diesel fuel and Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

The high voltage is generated by a ballast unit.

Switch off the electrical system of the excavator before touching the lamp or the ballast unit.

Battery Warning! Battery Posts, terminals and related accessories contain lead and lead compounds, chemicals known to cause cancer and reproductive harm. Wash hands after handling

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OPERATING INSTRUCTIONS 6050 / 6050FS Introduction Hydraulic equipment

Ether

Check all lines, hoses and screwed connections regularly for leaks and obvious damage. Repair damage immediately. Splashed oil may cause injury and fire.

The machine can be equipped with pressure vessels for cold-starting fluid (ether) installed in the engine compartment. Ether is toxic and highly flammable; the vessels are under pressure. These pressure vessels can explode if exposed to high temperatures (above 49°C / 120°F) or in the event of damage. Protect the vessels against damage and high temperatures.

Depressurize all system sections and pressure pipes (hydraulic system) to be removed in accordance with the specific instructions for the unit concerned before carrying out any repair work.

Hydraulic lines must be laid and fitted properly.

Ensure that no connections are interchanged. The fittings, lengths and quality of the hoses must comply with the technical requirements.

Noise During operation, all sound baffles of the machine must be closed.

Do not store pressure vessels with cold-starting fluid (ether) on the excavator.

Do not eat, drink or smoke when replacing pressure vessels with cold-starting fluid (ether).

Observe the instructions on the pressure vessels.

Provide for sufficient ventilation (see also Part 3 "Inspection and servicing").

Always wear the prescribed ear protectors.

Do not open empty cold-starting fluid pressure vessels (ether). Have the vessels disposed of properly.

Oil, grease and other chemical substances

For further details please refer to the instructions and safety data-sheets of the manufacturer / supplier of pressure vessels with cold starting fluid (ether).

When handling oil, grease or other chemical substances, observe the product-related safety regulations (see safety specifications).

Transporting and recommissioning

Be careful when handling hot consumables (risk of burning or scalding).

The machine must be loaded and transported only in accordance with the operating instructions.

Use only appropriate means of transport and lifting gear of adequate capacity.

The recommisioning procedure must be strictly in accordance with the operating instructions.

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OPERATING INSTRUCTIONS 6050 / 6050FS Introduction FIRE AND EXPLOSION HAZARD Safety instructions

Place suitable fire guardings (fire barriers) if open fire or flying sparks cannot be avoided during repair work.

Prior to commencing work, obtain informationon the national and corporate rules for the prevention of accidents and avoiding fires.

Apply special protection to cables, cable ducts as well as to hose and pipe lines.

Pay particular attention to hazards caused by combustible and easily flammable substances.

The engine compartment can be equipped with pressure vessels containing cold-starting fluid (ether). Ether is toxic and highly flammable; the vessels are under pressure. These pressure vessels can explode if exposed to high temperatures (above 49°C / 120°F) or in the event of damage.

Protect the pressure vessels against damage before beginning to work in or close to the engine compartment.

Obtain information on the safe handling of the fire extinguishers to be used.

Avoid smoking and open fire on, next to and below the excavator.

Combustible and easily flammable substances or liquids increase the fire and explosion hazard.

Do not store or transport flammable substances on the excavator during the work. This is also valid for pressure vessels containing flammable substances as, for instance, spray oil or cold-starting fluid (ether). They are heat-sensitive and can explode even if exposed only to intensive sunlight.

Clean the excavator carefully, if oil, grease, fuel, detergents or cold-starting fluid have been spilt over the machine. If possible, use a steam-jet cleaner for cleaning.

These substance can also ignite themselves if they come close to hot units or objects as, for instance, a turbocharger.

Even battery gases can ignite in open flames or fire.

If necessary, also cover the ground with fireprotective blankets.

Ensure sufficient ventilation.

Clean the excavator before starting a job.

Do not keep any fire extinguishers that are not suitable or have not been tested.

Do not extinguish flammable liquids with water.

Use:  dry-powder, 

carbon-dioxide or



foam extinguishing compounds.

When getting into contact with burning substances, the fire-fighting water would abruptly evaporate and distribute the substance such as oil over a wide area. Water causes short-circuits in the electrical system thus possibly entailing new hazards.

Call the fire brigade.

Have all your welding, flame cutting and grinding work approved.

Avoid parking the excavator in places where  combustible substances such as coal dust or tar are present. 

open or smouldering fire may occur.

Remove the excavator from such an area where combustible or easily flammable liquids have spilled from the excavator onto the ground.

Flying sparks (caused by welding, flame cutting, grinding, electrical short-circuit) may cause fire on the ground that can spread to the excavator.

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OPERATING INSTRUCTIONS 6050 / 6050FS Introduction NOTES ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ...................................................................................................................................................................

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OPERATING INSTRUCTIONS 6050 / 6050FS Introduction

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OPERATING INSTRUCTIONS 6050 / 6050FS Operation 2 OPERATION Operating instructions

Target group

Part 1 INTRODUCTION FUNDAMENTAL SAFETY INSTRUCTIONS

Operating personnel + Inspection and servicing personnel + Repair personnel

Part 2 OPERATION

Operating personnel The operating personnel must have knowhow relevant to the operation and the application of this or comparable machines.

Part 3 INSPECTION AND SERVICING Part 4 REPAIR WORK

Inspection and servicing personnel The inspection and servicing personnel must have know-how relevant to the inspection and servicing of this or comparable machines.

Repair personnel The repair personnel must have know-how and experience relevant to the repair of this or comparable machines.

Part 5 ANNEX

Part 6 INDEX

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Operating personnel + Inspection and servicing personnel + Repair personnel Operating personnel + Inspection and servicing personnel + Repair personnel

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OPERATING INSTRUCTIONS 6050 / 6050FS Operation

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OPERATING INSTRUCTIONS 6050 / 6050FS Operation OPERATION - SAFETY INSTRUCTIONS Operating instructions Never operate the machine before having read and understood the operating instructions.

Pay special attention to: the "Fundamental Safety Instructions" and to all warning and instruction signs attached to the machine.

Familiarize yourself with the layout, the functioning and the sense of actuation of the control elements prior to starting up the machine.

Activate the control elements from the driver's seat only.

Keep the operating instructions with the machine at all times.

Operating personnel The operating personnel must be fully informed of the operation and application of this or comparable machines.

The necessary know-how can be acquired in several days' instruction, e.g. by an Bucyrus HEX mechanic or by attending an Bucyrus HEX operator's training course.

Personal protective gear and working clothing Wear a safety helmet and working footwear with non-slip soles. Smooth soles may slip from steps and pedals resulting in injury or incorrect operation.

Wear closely fitting working clothing when operating the machine. Loose, wide garments may result in control levers being inadvertently activated

Safety belt For machines with a safety belt for operating personnel: Check the safety belt attached to the driver's seat.

In the event of damage or after an accident, have it replaced immediately.

Apply the safety belt before starting work.

State of the machine Operate the machine only in a safe state and only in accordance with its designated use. Always observe the safety instructions.

Always have inspection and maintenance work carried out on schedule.

Operate the machine only with the equipment and component combinations approved by Bucyrus HEX-Germany. Clear-cut data are given in the technical specification.

Never install and commission other equipment and component combinations without Bucyrus HEX having first inspected and approved the project.

Before starting work or travelling with the machine, check that the braking, signalling and lighting systems are fully functional.

Poor visibility may result in accidents. Always clean the windows and the glass covers of all lamps before starting the machine.

Check that all warning and instruction signs attached to the machine are present and legible.

Entering and leaving the machine Always face the machine when entering or leaving it.

Use only the ladders, steps, platforms and grab handles provided when entering and leaving the machine.

Always maintain a three point contact with the steps and grab handles.

Always keep ladders, steps and platforms in a non-slip, safe state and remove any oil, grease, soil, snow, ice and other foreign matter immediately.

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OPERATING INSTRUCTIONS 6050 / 6050FS Operation Hazard range The hazard range is that zone around the machine in which persons are within reach of loads or attachments falling as a result of operational movements by the machine, of its equipment and attachments or of swinging loads.

Operating Instructions, where to store it in the driver’s cab One copy of the Operating Instructions for the machine must be available in the driver’s cab during operation.

The binder with the Operators Instructions can be stored in the tray (Fig. 2-1:).

Persons within the hazard zone Always use the horn to warn persons in the immediate vicinity of the machine before starting up the machine.

Ensure that no one sets foot in the hazard zone of the machine. Interrupt work until such persons have left the hazard zone.

Marshallers The marshaller must keep outside the hazard zone.

Have a marshaller to assist you: 

when you have no clear overview over the hazard zone of the machine,



when reversing,



when shunting.

Fig. 2-1:

Use only those communication signals which you and the marshaller understand, or use aids for communication (e.g. walkie-talkie/camera).

Calls cannot be understood by the marshaller because of the noise made by the machine during operation.

Keep in constant contact with the marshaller.

Stop the machine immediately if you lose contact with the marshaller.

Securing the machine Secure the machine as described under "Securing the machine" before: 

mounting or dismantling the attachment,



parking the machine after daily operation,



carrying out any servicing or repair work.

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OPERATING INSTRUCTIONS 6050 / 6050FS Operation OPERATION, FIRE AND EXPLOSION HAZARD Safety instructions

Remove the excavator from such an area where combustible or easily flammable liquids have spilled from the excavator onto the ground.

Prior to commencing work, obtain informationon the national and corporate rules for the prevention of accidents and avoiding fires.

Flying sparks (caused by welding, flame cutting, grinding, electrical short-circuit) may cause fire on the ground that can spread to the excavator.

Pay particular attention to hazards caused by combustible and easily flammable substances.

Place suitable fire guardings (fire barriers) if open fire or flying sparks cannot be avoided during repair work.

Obtain information on the safe handling of the fire extinguishers to be used.

If necessary, also cover the ground with fireprotective blankets.

Avoid smoking and open fire on, next to and below the excavator.

Combustible and easily or highly inflammable substances or liquids increase the risk of fire and explosion Do not store or transport flammable substances on the excavator during the work. This is also valid for pressure vessels containing flammable substances as, for instance, spray oil or cold-starting fluid (ether). They are heat-sensitive and can explode even if exposed only to intensive sunlight.

Clean the excavator carefully, if oil, grease, fuel, detergents or cold-starting fluid have been spilt over the machine. If possible, use a steam-jet cleaner for cleaning.

These substance can also ignite themselves if they come close to hot units or objects as, for instance, a turbocharger.

Clean rubber or electrical with compressed air only.

Ensure sufficient ventilation.

Even battery gases can ignite in open flames or fire.

Avoid parking the excavator in places where 

combustible substances such as coal dust or tar are present.



open or smouldering fire may occur.

BA RH200(3 847 006.00)-EN

Clean the excavator before starting work.

Apply special protection to cables, cable ducts as well as to hose and pipe lines.

The engine compartment can be equipped with pressure vessels containing cold-starting fluid (ether). Ether is toxic and highly flammable; the vessels are under pressure. These pressure vessels can explode if exposed to high temperatures (above 49°C / 120°F) or in the event of damage.

Protect the pressure vessels against damage before beginning to work in or close to the engine compartment.

Ensure sufficient ventilation.

Do not keep any fire extinguishers that are not suitable or have not been tested.

Do not extinguish flammable liquids with water.

Use: 

dry-powder, carbon-dioxide or foam extinguishing compounds.

When getting into contact with burning substances, the fire-fighting water would abruptly evaporate and distribute the substance such as oil over a wide area. Water causes short-circuits in the electrical system thus possibly entailing new hazards.

Call the fire brigade.

Have all your welding, flame cutting and grinding work approved before starting work.

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OPERATING INSTRUCTIONS 6050 / 6050FS Operation DESCRIPTION OF THE EXCAVATOR

Fig. 2-2:

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OPERATING INSTRUCTIONS 6050 / 6050FS Operation Excavator layout

38 - Service-station (tank lift)

Fig. 2-2:

39 – On-board crane (optional)

Undercarriage

40 – Crane engine (optional)

1 - Track drive

41 – Fuel tank (crane engine, optional)

2 – Idler

42 – Battery (crane engine, optional)

3 - Track roller

43 – Hydraulic oil reservoir (crane engine, opt.)

4 - support roller

44 – Grease container of central lubricating syst.

5 - Crawler track

45 – Tool cabinet (optional)

6 - Track tensioner

46 – Ladder

7 - Slewing ring

47 – Ladder

8 - Ladder

48 – Ladder

Superstructure 11 – Engine 12 - Radiator (engine cooling liquid) 13 - Air-intake system 14 - Exhaust system

49 – Emergency ladder 50 – Counterweight 51 – Ladder 52 – Ladder 53 – Ladder

15 - Fuel Tank

Loading bucket

16 - Engine oil reservoir (optional)

61 – Boom

17 - Hydraulic oil reservoir

62 - TriPower linkage

18 – Hydraulic oil cooler

63 – Stick

19 – Reservoir (engine cooling liquid)

64 - Bottom-dump bucket

20 – Pump transfer gearbox

65 - Boom cylinder

21 - Working pump

66 - Stick cylinder

22 – Slewing pump

67 - Tipping cylinder

23 - Servo system pump

68 - Bottom-dump cylinder

24 - Gearbox circulating pump

74 - Control valves

25 - Filling pump (slewing circuit)

75 - Quick-action valve

26 - Fan drive pump (engine radiator)

Backhoe bucket

27 – Pump for fan drive and hydraulic oil cooling

63 - Stick

28 – Air conditioner

65 - Boom cylinder

29 - Slewing gear

66 - Stick cylinder

30 - Travel block and rotor

69 - Monoblock boom

31 - Driver's cab

70 - Backhoe bucket

32 - Control stand with BCS

71 - Backhoe cylinder

33 - Control-cabinet with CMS

72 - Toggle link

34 - Control-cabinet with PMS

73 - Toggle lever

35 - Fire-extinguisher

74 - Control valves

36 - Control-cabinet with battery main switch

75 - Quick-action valve

37 – Batteries

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OPERATING INSTRUCTIONS 6050 / 6050FS Operation Undercarriage

Stored Program Control (SPC)

The undercarriage of the hydraulic excavator serves as a stable base and for travelling. The crawler tracks are driven hydraulically with oil motors and travel gearboxes. Undercarriage and superstructure are connected by means of a swing ring.

The SPC controls the functions 

Engine Start,



Engine Stop,



Engine Idle,



Central lubricating system,

Superstructure



Further auxiliary functions.

The superstructure accommodates the drive and part of the hydraulic and electrical equipment.

Further information is given in the technical manual: Stored-program control.

Drive

Central Management System (CMS)

The drive unit comprises diesel engines, pump transfer gearboxes, hydraulic pumps, hydraulic cylinders and hydraulic motors.

Hydraulic system All working and travelling movements are performed hydraulically. The movements are controlled by servovalves. The working commands are initiated by hand and transmitted to the valves via control circuits. The oil supply from the superstructure to the undercarriage is ensured by the rotor.

The hydraulic system is overload-protected by pressure-relief valves. The hydraulic pumps are supplied with oil from a hydraulic reservoir.

The CMS is an electrohydraulic servocontrol. Together with the PMS, it provides for optimum interaction between drive hydraulic circuit and working movements.

The required working movements are recognized by microcontroller-assisted scanning of the operating elements (hand levers, pedals) and transmitted to electrohydraulic valves.

In the system sequence, the drive regulation is first activated to provide hydraulic working energy. Only then are working movements enabled.

Further information is given in the Technical Handbook, chapter “Electric, Electronic”.

Pump Managing System (PMS) The Pump Managing System (PMS) with overlimit regulation ensures optimum utilization of the installed or preset engine power. The electronic pump demand control prevents the machine from demanding more hydraulic power than the diesel engines can furnish. A microprocessor ensures that the hydraulic output power of the pump is optimally suited to the actual operation conditions.

The PMS box (load-limit regulator) is installed in a control cabinet in the driver's cab.

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OPERATING INSTRUCTIONS 6050 / 6050FS Operation Demand control / Zero-flow regulation In the fine-control range, swivelling of the hydraulic pumps, and thus the variation of oil flow, are proportional to control lever and pedal valve travel. This means that during the work, the pumps supply only as much hydraulic oil as required to perform the working movement. In the neutral position of the control levers, the pumps are automatically swivelled to zeroflow.

These special features offer the following advantages: 

reduced fuel consumption



minimum power losses



reduced temperature of the hydraulic oil



greater service life of hydraulic pumps and diesel engines.

Board-Control-System (BCS) The BCS is a data-evaluating and data-processing system whose function is to collect, evaluate and store data about the excavator's operating status and to display these to the operator.

The BCS is based on a micro-processor. The measured values (actual values) supplied by sensors and transducers installed in the excavator are compared to preset nominal values. Out-of-limit conditions are displayed in the form of error messages in the cab.

Critical operating conditions are additionally indicated by optical and acoustic warning signals.

Further dedails are set out in the “Operating Instructions Board-Control-System”.

Electrical system The electrical system operates on 24 volts.

Automatic engine speed reduction If the control pedals and control levers and thus the servovalves are not actuated for a period of 10 seconds or more (programable), the speed of the engines is automatically reduced to idling. Thisfunction is a further contribution to fuel economy.

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OPERATING INSTRUCTIONS 6050 / 6050FS Operation Signs Warning and instruction signs Observe the warning and instruction signs attached to the machine.

Keep all the signs legible and clean.

Replace signs immediately if they have become illegible.

New warning and instruction signs can be ordered from the CGM HMS Spare Parts Service. The ordering part numbers are set out in the spare-parts list of the machine.

Fig. 2-3: - Fig. 2-8: show the location of warning and instruction signs on the machine.

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OPERATING INSTRUCTIONS 6050 / 6050FS Operation

Fig. 2-3:

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OPERATING INSTRUCTIONS 6050 / 6050FS Operation

Fig. 2-4:

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OPERATING INSTRUCTIONS 6050 / 6050FS Operation

Fig. 2-5:

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OPERATING INSTRUCTIONS 6050 / 6050FS Operation

Fig. 2-6:

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OPERATING INSTRUCTIONS 6050 / 6050FS Operation

Fig. 2-7:

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OPERATING INSTRUCTIONS 6050 / 6050FS Operation

Fig. 2-8:

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OPERATING INSTRUCTIONS 6050 / 6050FS Operation Machine number

Engine number

The identification plate with the machine number (Fig. 2-9:) is attached to the front side of the Aframe (arrow, Fig. 2-10:).

The serial number plate (Fig. 2-11:) for the diesel engines are located on the diesel engines.

Fig. 2-11: Fig. 2-9:

Component numbers Other larger units also have identification plates indicating, among other things, their serial number.

On steel components, the Bucyrus HEX part number or the serial number may be stamped into the metal at a clearly visible place.

Fig. 2-10:

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OPERATING INSTRUCTIONS 6050 / 6050FS Operation Entering and leaving the machine, Safety instructions Risk of injury due to slipping.

Clean off oil, grease, soil, mud, snow, ice and other substances from footwear, grab handles, ladders and steps.

Keep ladders, steps, platforms and grab handles in a non-slippery condition.

Access lighting The access can be illuminated in the dark. The access lighting is switched on:  When you stand beside the excavator: By a pull switch (2, Fig. 2-13:) operated with a string from the ground. The lighting system switch is located behind the left fuel tank.  When you are in the cab: With switch (arrow, Fig. 2-14:) beside the door.

The access lighting is activated for three minutes and then switched off automatically.

For entering and leaving use only the ladders, steps, platforms and grab handles provided (see: illustration in Fig. 2-12:).

Always face the machine when entering or leaving it.

Always maintain a three point contact with the steps and grab handles.

Fig. 2-13:

Fig. 2-12:

Fig. 2-14:

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OPERATING INSTRUCTIONS 6050 / 6050FS Operation Folding ladder (optional)

Lowering the folding ladder (from the upper carriage)

Raising resp. lowering the folding ladder (Fig. 2-15:).

 Start engine.  Push lever (1, Fig. 2-16:) on control valve (2) downwards to position “ II “.

The folding ladder is lowered (Fig. 2-15:).

The folding ladder can also be lowered when the engine is stopped.

Fig. 2-15:

Raising the folding ladder (from the upper carriage)  Start engine.  Pull lever (1, Fig. 2-16:) on control valve (2) upwards to position “ I “.

The folding ladder is raised (Fig. 2-20:).

Fig. 2-17:

Lowering the folding ladder (from the bottom)  Pull down rope (3, Fig. 2-18:).

The folding ladder is lowered (Fig. 2-15:).

Fig. 2-16:

The upper carriage can only be swung when the folding ladder is raised completely (Fig. 2-20:).

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Fig. 2-18:

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OPERATING INSTRUCTIONS 6050 / 6050FS Operation Swinging ladder (optional) Raising resp. lowering the swinging ladder (Fig. 2-19:).

Lowering the swinging ladder (from the upper carriage)  Start engine.  Push lever (1, Fig. 2-20:) on control valve (2) downwards to position “ II “.

The swinging ladder is lowered (Fig. 2-19:).

The swinging ladder can also be lowered when the engine ist stopped.

Fig. 2-19:

Raising the swinging ladder (from the upper carriage)  Start engine.  Pull lever (1, Fig. 2-20:) on control valve (2) upwards to position “ I “.

The swinging ladder is raised (Fig. 2-21:).

Fig. 2-21:

Lowering the swinging ladder (from the bottom)  Pull down rope (3, Fig. 2-22:).

The swinging ladder is lowered (Fig. 2-19:).

Fig. 2-20:

The upper carriage can only be swung when the folding ladder is raised completely (Fig. 2-21:).

2-20

Fig. 2-22:

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OPERATING INSTRUCTIONS 6050 / 6050FS Operation Cab interior lamp The cab interior lighting can be switched on and off with the switches (arrow, Fig. 2-23:), (96, Fig. 2-24:) and (arrow, Fig. 2-25:) The cab interior light is supplied with power even when the electrical system is shut down.

When leaving the machine, the interior light must therefore be switched off. The batteries could be discharged if the interior light is allowed to remain on for a prolonged period.

Fig. 2-23:

Fig. 2-24:

Fig. 2-25:

BA RH200(3 847 006.00)-EN

2-21

EM027997-0

OPERATING INSTRUCTIONS 6050 / 6050FS Operation Servicing lighting

Illuminating the control column

Switch on the lamps in the modules with switches (95, Fig. 2-26: and arrow, Fig. 2-27:).

The control column front could be illuminated with a lamp (30, Fig. 2-28:).

Switch (95, Fig. 2-26:) is located in the control column in the driver's cab.

Turn lamp head from "0" to "I" to switch the lamp on.

Switch (arrow, Fig. 2-27:) is located beside the cab door.

There are also switches build in the modules.

Fig. 2-28:

Fig. 2-26:

Fig. 2-27:

2-22

BA RH200(3 847 006.00)-EN

EM027997-0

OPERATING INSTRUCTIONS 6050 / 6050FS Operation EMERGENCY STOP switch The entire electrical system is switched off with the EMERGENCY STOP switches.

In an emergency, press the EMERGENCY STOP. The EMERGENCY STOP switches are located: 

in the control column in the driver's cab (31, Fig. 2-29:) and



in the control cabinet (2, Fig. 2-30:) and



on the righthand side at the counterweight.

This latter one is to operate with the rope (3, Fig. 2-31:).

The electrical system of the excavator can be switched on after the EMERGENCY STOP switches are released.

Fig. 2-29:

 Pull the switches out.

The switching pin of the rope operated switch (Fig. 2-31:) must be pushed into its housing.

Fig. 2-30:

Fig. 2-31:

BA RH200(3 847 006.00)-EN

2-23

EM027997-0

OPERATING INSTRUCTIONS 6050 / 6050FS Operation Escape ladder The escape ladder (arrow, Fig. 2-32:) is located beside the driver´s cab.

Function of ladder locking as well as free movement of the ladder must be regularly checked accordiing to the maintenance plans.  Kick down locking lever (2, Fig. 2-33:). The escape ladder is now unlocked and moves down quickly to the ground.  Swing barrier (1, Fig. 2-33:) to the right and use the ladder to escape downwards.

Fig. 2-32:

Fig. 2-33:

2-24

BA RH200(3 847 006.00)-EN

EM027997-0

OPERATING INSTRUCTIONS 6050 / 6050FS Operation Trainer's / instructor's seat

Windscreen washer

For driver training / instructing purposes it is often required that a trainer / instructor accompanies the driver in the cab.

The reservoir of the windscreen washing system (1, Fig. 2-35:) is installed in the cab module. For the reservoir capacity refer to the "Refilling quantities - Other" table.

For the safety of the trainer / instructor during excavator operation the cab is equipped with a second seat. This seat is installed behind the driver's seat (arrow, Fig. 2-34:).  Sit down on this seat and do not forget to fasten the seat-belt (if installed).  Do not leave this seat during the training / instruction session and /or as long as the machine is in operation.

Fig. 2-35:

Fig. 2-34:

BA RH200(3 847 006.00)-EN

2-25

EM027997-0

OPERATING INSTRUCTIONS 6050 / 6050FS Operation Driver's seat The driver's seat (Fig. 2-36: and Fig. 2-37:) can be adjusted in several positions.

Never adjust the seat while driving.

Concentrate on the road to avoid accidents.

Before carrying out any seat adjustments stop the machine and set the control levers to "0"

Fig. 2-36:

2-26

BA RH200(3 847 006.00)-EN

EM027997-0

OPERATING INSTRUCTIONS 6050 / 6050FS Operation

Fig. 2-37:

BA RH200(3 847 006.00)-EN

2-27

EM027997-0

OPERATING INSTRUCTIONS 6050 / 6050FS Operation Fire extinguisher

Handling

The excavator is equipped with two fire extinguishers (arrow Fig. 2-38:).

Fig. 2-39:

 Pull out securing pin (2, Fig. 2-39:).

Fig. 2-38:

 Strike knob (3) hard, then release again.

The excavator driver and the maintenance personnel must inform themselves about how to handle the fire-extinguisher in order to be able to act fast and efficiently in case of beginning fires. Such instruction should be given by a qualified instructor.

 Operate the extinguishing gun.

Extinguishing agent Each fire-extinguisher is filled with 12 kg (26.4 lb) Glutex. This extinguishing agent is used for fighting fires of classes A, B and C. Fires are extinguished fast, perfectly and without residues.

2-28

Inspection Have the extinguisher inspected at regular intervals by an expert. This is required by local authorities and insurance companies and is in the interest of your own safety.

Have the fire-extinguisher checked at the prescribed intervals by authorized testing agencies.

BA RH200(3 847 006.00)-EN

EM027997-0

OPERATING INSTRUCTIONS 6050 / 6050FS Operation Automatic fire-extinguishing system (optional) The automatic fire-extinguishing system prevents fire from spreading. It is, however, assumed that the machine is thoroughly cleaned of combustible and easily flammable substances.

The excavator operator and the maintenance personnel must familiarize themselves with the automatic fire-extinguishing system.

Such instruction should be given by a qualified instructor.

The fire-extinguishing system is activated automatically in an emergency.

Inspection Have the extinguishing system inspected regularly by an expert. This is required by authorities and insurance companies and is in the interest of your own safety.

Have the fire-extinguishing system checked at the prescribed intervals by authorized testing agencies.

Manual activation  Pull out ring (1, Fig. 2-40:) on activating unit for corresponding extinguishing circuit.  Strike knob (2) hard.

Refill extinguishers immediately after use ready for further deployment.

In an emergency the fire-extinguishing system is actuated automatically.

Nevertheless particular extinguishing circuit e. g. engine 1 or 2 (LH or RH) can be actuated manually.

Fig. 2-40:

Fig. 2-41: shows an activating unit.

Fig. 2-41:

BA RH200(3 847 006.00)-EN

2-29

EM027997-0

OPERATING INSTRUCTIONS 6050 / 6050FS Operation Harness (optional) Elements of the harness (Fig. 2-42:- Fig. 2-44:) Pos. Designation Back support 1 Shoulder belt 2 Shoulder belt 3 Loop (chest belt) 4 Loop (chest belt) 5 Loop (back support) 6 11 Holding device 12 Fall arrester 13 Guidance line 14 Hanging up line 15 Handbag with harness 16 Snap hook 17 Hook safety device

Fig. 2-43:

Fig. 2-44:

Fig. 2-42:

Important hints Read and understand the Description of the supplier.

Before using operator shall have received adequate training.

The harness must be used by one person only.

He is responsible for the appropriate use and maintenance.

Visual inspection is recommended prior to each use; if necessary it must be checked by an expert.

Harness must be checked annualy (every 12 month) by an expert.

2-30

BA RH200(3 847 006.00)-EN

EM027997-0

OPERATING INSTRUCTIONS 6050 / 6050FS Operation Taking on harness  Take harness out of handbag (15, Fig. 2-45:).

 Pull loop (6) of the back support (1) between your legs to the front (Fig. 2-47:).  Pull loop (5, Fig. 2-48:) through loop (6).

Fig. 2-45:

 Take on shoulder belts (2 and 3, Fig. 2-46:).

Fig. 2-48:

 Pull loop (4, Fig. 2-48:) through loop (5).  Press the hooking safety device (17, Fig. 2-48:) of the snap hook (16).

Fig. 2-46:

 Pull back support (1, Fig. 2-46:) behind your body (Fig. 2-47:).

The loops (4 and 5) are in front of your body.

Fig. 2-49:

Fig. 2-47:

BA RH200(3 847 006.00)-EN

2-31

EM027997-0

OPERATING INSTRUCTIONS 6050 / 6050FS Operation

 Hang up loop (4, Fig. Fig. 2-50:) into snap hook (16).

If you have the harness put on in such a way in case of danger you can escape from the excavator (Fig. 2-52:).

Fig. 2-50:

 Release hooking safety device (17, Fig. 2-51:).

Fig. 2-52:

Fig. 2-51:

2-32

BA RH200(3 847 006.00)-EN

EM027997-0

OPERATING INSTRUCTIONS 6050 / 6050FS Operation

BA RH200(3 847 006.00)-EN

2-33

EM027997-0

OPERATING INSTRUCTIONS 6050 / 6050FS Operation MONITORING, WARNING AND CONTROL ELEMENTS

Fig. 2-53:

2-34

BA RH200(3 847 006.00)-EN

EM027997-0

OPERATING INSTRUCTIONS 6050 / 6050FS Operation (Fig. 2-53:)

No.

Element

Function

1

BCS

Electronic measuring-data collection and processing system

Collection, storing and displaying of essential operating data of the excavator.

2

Monitor

BCS

Displays the data collected.

Gives warnings and provides help, if desired.

3

UP button

Selects the BCS program, Positions the Cursor.

4

DOWN button

Selects the BCS program, Positions the Cursor.

5

ENTER button

Confirms a program, Activates a desired program.

6

BACK button

Recalls the Service Menu.

7

HOLD button

Freezes actual service data.

8

Print button

Recalls the Print Menu.

9

SERV. button

Recalls the Service Menu.

10

HELP button

Recalls the Help Menu.

11

BL + button

Adjusts BCS monitor background lighting brighter.

12

BL - button

Adjusts BCS monitor background lighting darker.

BA RH200(3 847 006.00)-EN

Symbol

2-35

EM027997-0

OPERATING INSTRUCTIONS 6050 / 6050FS Operation

Fig. 2-54

2-36

BA RH200(3 847 006.00)-EN

EM027997-0

OPERATING INSTRUCTIONS 6050 / 6050FS Operation (Fig. 2-54) No.

Element

Function

30

Lamp

Illuminates the control column.

31

Button

32

Key-switch

33

Buzzer

Emergency OFF

Symbol

Shuts off the whole electrical system, shuts the engines off.

Switches the electrical system on and off.

Gives acoustic warning signals if a fault is reported, display of the BCS shows “ENGINE STOP”.

If the buzzer (33) sounds and the BCS indicates a fault message together with “ENGINE STOP”: - Lower the equipment to the ground, - shut off engine / engines immediately.

Inform the responsible service personnel to rectify the fault. In this way major damages can be avoided.

The buzzer (33) continues to sound until the fault has been rectified.

BA RH200(3 847 006.00)-EN



Coolant level engine 1 (left) and / or engine 2 (right), too low;



Engine oil pressure engine 1 (left) and / or engine 2 (right), too low;



Engine oil temperature engine 1 (left) and / or engine 2 (right), too high;



Engine oil level engine 1 (left) and / or engine 2 (right), too low;



Distributor gearbox temperature 1 (left) and / or 2 (right) too high;



Distributor gearbox 1 (left) and / or 2 (right) contaminated;



Temperature of one or more swing pumps (1, 2, 3 and / or 4) too high;



One or more swing gearboxes (1, 2, 3 and / or 4) contaminated;



One or more swing motors (1, 2, 3 and / or 4) contaminated;

2-37

EM027997-0

OPERATING INSTRUCTIONS 6050 / 6050FS Operation

Fig. 2-55:

2-38

BA RH200(3 847 006.00)-EN

EM027997-0

OPERATING INSTRUCTIONS 6050 / 6050FS Operation (Fig. 2-55:) No.

Element

Function

33

Buzzer (continued)

Gives acoustic warning signals if a fault is reported, display of the BCS shows “ENGINE STOP”.

Symbol

If the buzzer (33) sounds and the BCS indicates a fault message together with “ENGINE STOP”: - Lower the equipment to the ground, - shut off engine / engines immediately.

Inform the responsible service personnel to rectify the fault. In this way major damages can be avoided.

The buzzer (33) continues to sound until the fault has been rectified. 

Slewing circuit temperature (1 and / or 2) too high;



Temperature of one or more swing gearboxes (1, 2, 3 and / or 4) too high;



Hydraulic oil level too low;



One or more main pumps (1, 2, 3 and / or 4) contaminated;



Lubricating system pressure too low;



Grease level in lubricating system too low;



Fault in greasing system;



On-board voltage 24 V too low.

34

Buzzer

Gives an acoutic warning signal when the stick/boom angle to too small.

35

Terminals

For electronic machine diagnostics.

36

Radio (optional)

37

Antenna (optional)

BA RH200(3 847 006.00)-EN

2-39

EM027997-0

OPERATING INSTRUCTIONS 6050 / 6050FS Operation

Fig. 2-56:

2-40

BA RH200(3 847 006.00)-EN

EM027997-0

OPERATING INSTRUCTIONS 6050 / 6050FS Operation (Fig. 2-56:) No. Element 41 Monitoring lamp

Function Not connected.

42

Monitoring lamp

Not connected.

43

Warning lamp

44

Monitoring lamp

During working operation: Warning lamp lits up permanently= A fault occurs on the left engine.

Watch the BCS-display and contact the responsible service personnel soon.

Warning lamp lits up periodicaly= A serious fault occurs on the left engine.

Shut off left engine, watch the BCSdisplay and contact the responsible service personnel immediately.

With the engine at standstill: Warning lamp 43 can display the faults stored in the fault memory of the left engine electronic unit as flashing sequences (see: "Engine electronic unit, displaying stored fault codes").

Not connected.

45

Monitoring lamp

Not connected.

46

Warning lamp

ENGINE PROTECTION (right engine 2)

47

Indicator lamp

48

Indicator lamp

Boom/stick angle (optional) Boom/stick angle (optional)

ENGINE PROTECTION (left engine 1)

BA RH200(3 847 006.00)-EN

Symbol

During working operation: Warning lamp lits up permanently= A fault occurs on the right engine.

Watch the BCS-display and contact the responsible service personnel soon.

Warning lamp lits up periodicaly= A serious fault occurs on the right engine.

Shut off right engine, watch the BCSdisplay and contact the responsible service personnel immediately.

With the engine at standstill: Warning lamp 46 can display the faults stored in the fault memory of the right engine electronic unit as flashing sequences (see: "Engine electronic unit, displaying stored fault codes").

Lamp is lit up when the boom/stick angle is in normal working range.

Lamp is lit up when the boom/stick angle is in hazard range. (the tracks may be demaged by the working equipment).

Increase the angle.

The buzzer (no. 34) sounds until the angle has resumed the normal working range.

2-41

EM027997-0

OPERATING INSTRUCTIONS 6050 / 6050FS Operation

Fig. 2-57:

2-42

BA RH200(3 847 006.00)-EN

EM027997-0

OPERATING INSTRUCTIONS 6050 / 6050FS Operation (Fig. 2-57:) No.

Element

51

Switch

Starting (left engine 1)

Starts the engine: Hold switch approx. 5 – 7 sec.

This is necessary to start and pressurize the engines prelube system.

After then the engine starts automatically.

52

Switch

Stopping (left engine 1)

Shuts off the engine.

53

Switch

Idling (left engine 1)

Shuts off the engine with 5 minutes after run.

54

Switch

55

56

57

Function

Symbol

Not connected.

With the engine at standstill push momentary Momentary switch Diagnostic ON / OFF switch to the left and hold: Stored faults in the left engines electronic unit can be displayed. Faults are displayed by warning lamp no. 43 as flashing sequences (see: "Engine electronic unit, displaying stored fault codes").

Speed adjustment

Potentiometer (left engine 1)

Momentary switch Diagnostic increment / decrement

BA RH200(3 847 006.00)-EN

Changes engine speed: 

turn CCW to limit stop idling speed



turn CW to limit stop full-load speed

Not connected.

2-43

EM027997-0

OPERATING INSTRUCTIONS 6050 / 6050FS Operation

Fig. 2-58:

2-44

BA RH200(3 847 006.00)-EN

EM027997-0

OPERATING INSTRUCTIONS 6050 / 6050FS Operation (Fig. 2-58:) No.

Element

61

Switch

Starting (right engine 2)

Starts the engine: Hold switch approx. 5 – 7 sec.

This is necessary to start and pressurize the engines prelube system.

After then the engine starts automatically.

62

Switch

Stopping (right engine 2)

Shuts off the engine.

63

Switch

Idling (right engine 2)

Shuts off the engine with 5 minutes after run.

64

Switch

65

66

67

Function

Symbol

Not connected.

With the engine at standstill push momentary Momentary switch Diagnostic ON / OFF switch to the left and hold: Stored faults in the right engines electronic unit can be displayed. Faults are displayed by warning lamp no. 46 as flashing sequences (see: "Engine electronic unit, displaying stored fault codes").

Speed adjustment

Potentiometer (right engine 2)

Momentary switch Diagnostic increment / decrement

BA RH200(3 847 006.00)-EN

Changes engine speed: 

turn CCW to limit stop idling speed.



turn CW to limit stop full-load speed.

Not connected.

2-45

EM027997-0

OPERATING INSTRUCTIONS 6050 / 6050FS Operation

Fig. 2-59:

2-46

BA RH200(3 847 006.00)-EN

EM027997-0

OPERATING INSTRUCTIONS 6050 / 6050FS Operation (Fig. 2-59:) No.

Element

Function

71

Switch

Travel motors

Switches on the fast gear (overdrive).

72

Switch

Undercarriage holding brake

CCW: brake permanently applied The excavator can not be driven

Symbol

CW:

Every time the excavator stops, the undercarriage brake is automatically applied after approx. 8 sec.

The undercarriage brake is automatically released when the travel function is activated.

Actuate switch only when the excavator is stationary. Do not use as service brake.

Activate after a fault in the central lubricating system.

73

Momentary switch Reset

74

Switch

Elecrtonic excavator Switches on the electronic servo control. control

75

Switch

Not connected.

76

Cigarette lighter

77

Switch

BA RH200(3 847 006.00)-EN

Not connected.

2-47

EM027997-0

OPERATING INSTRUCTIONS 6050 / 6050FS Operation

Fig. 2-60:

2-48

BA RH200(3 847 006.00)-EN

EM027997-0

OPERATING INSTRUCTIONS 6050 / 6050FS Operation (Fig. 2-60:) No.

Element

81

Switch

82

Switch

Function Engine speed duction

Symbol

re- CCW:

normal operation with automatic diesel engine speed reduction; active during operation pauses.

CW:

automatic speed reduction off.

Superstructure hol- Blocks the superstructure. ding brake Actuate switch only when the excavator is stationary.

Do not use as service brake.

83

Switch

Windscreen wiper

Activates permanent / intermittent wiping.

84

Switch

Screen washer

Activates the wipe / wash function.

85

Switch

Floodlamps

Switches on the floodlamps on the driver´s cab.

86

Switch

Floodlamps

Switches on the floodlamps on the hydraulic oil cooler.

87

Switch

Floodlamps

Switches on the floodlamps on the counterweight.

88

Switch

Floodlamps

Switches on the floodlamps on the platform.

BA RH200(3 847 006.00)-EN

2-49

EM027997-0

OPERATING INSTRUCTIONS 6050 / 6050FS Operation

Fig. 2-61:

2-50

BA RH200(3 847 006.00)-EN

EM027997-0

OPERATING INSTRUCTIONS 6050 / 6050FS Operation (Fig. 2-61:) No.

Element

Function

91

Momentary switch Emergency operati- Lowers the boom and stick when actuated in an emergency. on Boom/Stick

92

Switch

Counting dumper

93

Switch

Stick cylinder switch-off bypass (optional)

94

Momentary switch

Symbol

Resets the counter.

When switched it is possible to swing the uppercarriage or drive the machine even when the hydraulic ladder or the service station is in the lower position.

Risk of damaging the ladder or the service station!

Use the assistance of marshallers who are positioned beside the mache and have an overview on the safety zone.

Be careful and swing the uppercarriage and drive the excavator very slowly and only a short way.

95

Switch

Lighting

Switches on the lighting for servicing work.

96

Switch

Lighting

Switches the cab lighting on and off.

97

Switch

Windscreen wiper rear window (optional)

Activates permanent wiping.

98

Switch

Beacon (optional)

Switches the beacon on and off.

99

Terminals

BA RH200(3 847 006.00)-EN

For electronic engine diagnostics.

2-51

EM027997-0

OPERATING INSTRUCTIONS 6050 / 6050FS Operation

Fig. 2-62:

2-52

BA RH200(3 847 006.00)-EN

EM027997-0

OPERATING INSTRUCTIONS 6050 / 6050FS Operation (Fig. 2-62:) No.

Element

Function

101 Button

Counting dumpers

Reset with switch (92).

102 Button

Stick floating position (only for loading shovel equipment)

If actuated: Stick cylinders are pressurized when retracted.

103

Button

Boom floating position

Actuate button (102) only when control lever (115) is in “0“ position.

If actuated: Boom cylinders are pressurized when retracted.

Actuate button (103) only when control lever (116) is in “0“ position.

Activates the horn.

104 Button

Warning signal

105 Button

Electronic excavator control Bottom-dump bucket (only for loading shovel equipment) Travelling, left track

Switches the electronic excavator control on and off.

Opens / closes the bottom-dump bucket.

Travelling, right track

Forwards / reverse

111 Pedal

112 Pedal 113 Pedal 115 Control lever 116 Control lever 117 Button

118 Button

Bottom-dump bucket (only for loading shovel equipment By-pass for the automatically switch off for stickand /or backhoe cylinders (Option)

BA RH200(3 847 006.00)-EN

Symbol

Forwards / reverse

Lifts and lowers the bucket / backhoe bucket stick; Swings and brakes the superstructure.

Raises and lowers the boom; Tipping and rearward tilting of bucket resp. backhoe bucket.

To the left – opens the bottom-dump bucket.

To the right – closes the bottom-dump bucket.

To the left – automatically stopped stickand/or backhoe cylinders can be driven slowly to the limit stopps.

To the right – Not connected.

2-53

EM027997-0

OPERATING INSTRUCTIONS 6050 / 6050FS Operation

Fig. 2-63:

2-54

BA RH200(3 847 006.00)-EN

EM027997-0

OPERATING INSTRUCTIONS 6050 / 6050FS Operation (Fig. 2-63:) (Options. Depending on the options ordered with the machine, the described elements can be found on different positions on the control column).

No.

Element

Function

131 Pressure gauge

Engine oil pressure (engine 1 left)

Indicates the oil pressure in the diesel engine lubricating system.

132 Thermometer

Engine temperature (engine 1 left)

Indicates the cooling-water temperature.

133 Pressure gauge

Engine oil pressure (engine 2 right)

Indicates the oil pressure in the diesel engine lubricating system.

134 Thermometer

Engine temperature (engine 2 right)

Indicates the cooling-water temperature.

135 Warning lamp

Alternator (engine 1 left)

Lits up when the batteries are not recharged.

136 Warning lamp

Engine oil pressure (engine 1 left)

Lits up when the engine oil pressure is too low.

137 Warning lamp

IDLE-Auto (engine 1 left)

Lights during the engine´s run-down phase of 5 minutes.

138 Warning lamp

Engine temperature (engine 1 left)

Lits up when the engine temperature is too high.

139 Warning lamp

Cooling water level (engine 1 left)

Lits up when the cooling-water level is too low.

Symbol

free for optional

140 141 Warning lamp

Alternator (engine 2 right)

Lits up when the batteries are not recharged.

142 Warning lamp

Engine oil pressure (engine 2 right)

Lits up when the engine oil pressure is too low.

143 Warning lamp

IDLE-Auto (engine 2 right)

Lights during the eng.

144 Warning lamp

Engine temperature (engine 2 right)

Lits up when the engine temperature is too high.

145 Warning lamp

Cooling water level (engine 2 right)

Lits up when the cooling-water level is too low.

146

BA RH200(3 847 006.00)-EN

free for optional

2-55

EM027997-0

OPERATING INSTRUCTIONS 6050 / 6050FS Operation

Fig. 2-64:

2-56

BA RH200(3 847 006.00)-EN

EM027997-0

OPERATING INSTRUCTIONS 6050 / 6050FS Operation (Fig. 2-64:) (Options. Depending on the options ordered with the machine, the described elements can be found on different positions on the control column).

No.

Element

Function

151 Warning lamp

Slewing pump contaminated

1 Lights up when the slewing pump is contaminated with metal particles.

152 Warning lamp

Slewing pump contaminated

2 Lights up when the slewing pump is contaminated with metal particles.

153 Warning lamp

Slewing pump contaminated

3 Lights up when the slewing pump is contaminated with metal particles.

154 Warning lamp

Slewing pump contaminated

4 Lights up when the slewing pump is contaminated with metal particles.

155 Warning lamp

Main pump 1 con- Lights up when the main pump is contaminated with metal particles. taminated

156 Warning lamp

Main pump 2 con- Lights up when the main pump is contaminated with metal particles. taminated

157 Warning lamp

Distributor gearbox Lights up when the distributor gearbox is 1 left contaminated contaminated with metal particles.

158 Warning lamp

Slewing pump temperature

1 Lights up when the temperature in the slewing pump is too high.

159 Warning lamp

Slewing pump temperature

2 Lights up when the temperature in the slewing pump is too high.

160 Warning lamp

Slewing pump temperature

3 Lights up when the temperature in the slewing pump is too high.

161 Warning lamp

Slewing pump temperature

4 Lights up when the temperature in the slewing pump is too high.

162 Warning lamp

Main pump 3 con- Lights up when the main pump is contaminated with metal particles. taminated

163 Warning lamp

Main pump 4 con- Lights up when the main pump is contaminated with metal particles. taminated

164 Warning lamp

Distributor gearbox Lights up when the distributor gearbox is 2 right contamina- contaminated with metal particles. ted

BA RH200(3 847 006.00)-EN

Symbol

2-57

EM027997-0

OPERATING INSTRUCTIONS 6050 / 6050FS Operation

Fig. 2-65:

2-58

BA RH200(3 847 006.00)-EN

EM027997-0

OPERATING INSTRUCTIONS 6050 / 6050FS Operation (Fig. 2-65:) (Options. Depending on the options ordered with the machine, the described elements can be found on different positions on the control column).

No.

Element

Function

165 Warning lamp

Slewing motor contaminated

1 Lights up when the slewing motor is contaminated with metal particles.

166 Warning lamp

Slewing motor contaminated

2 Lights up when the slewing motor is contaminated with metal particles.

Symbol

free for optional

167 Warning lamp 168 Warning lamp

Hydraulic oil filter Lights up when the flow resistance in the filter is too high. Replace filter elements if the contaminated warning lamp fails to go out when the oil is at operating temperature.

169 Warning lamp

Min. hydraulic level

170 Warning lamp

Electronic excavator Lights up when the electronic excavator control is switched on. control ON

171 Indicator light

Hydraulic oil tank

oil Lights up when the hydraulic oil level in the hydraulic tank is too low.

Lights up when one of the shut-off valves of the hydraulic oil tank is closed When the left valve is closed, the LH engine cannot be started.

When the right valve is closed, the RH engine cannot be started.

When a shutoff valve is closed with the engines running, both engines are stopped.

172 Thermometer

Hydraulic oil

181 Control unit

Air conditioner (optional)

182 Control unit

Heating (optional)

BA RH200(3 847 006.00)-EN

Indicates hydraulic oil temperature in hydraulic tank.

2-59

EM027997-0

OPERATING INSTRUCTIONS 6050 / 6050FS Operation

Fig. 2-66:

2-60

BA RH200(3 847 006.00)-EN

EM027997-0

OPERATING INSTRUCTIONS 6050 / 6050FS Operation (Fig. 2-66:) (Options. Depending on the options ordered with the machine, the described elements can be found on different positions on or near the control column).

No.

Element

Function

191 Underpressure gauge

Air filter (left engine 1, outside)

Indicates the underpressure in the air filter.

Underpressure must be less than 25 inches (635 mm) water column.

Otherwise clean / replace the filterelement.

192 Underpressure gauge

Air filter (left engine 1, inside)

Indicates the underpressure in the air filter.

Underpressure must be less than 25 inches (635 mm) water column.

Otherwise clean / replace the filterelement.

193 Underpressure gauge

Air filter (left engine 2, inside)

Indicates the underpressure in the air filter.

Underpressure must be less than 25 inches (635 mm) water column.

Otherwise clean / replace the filterelement.

194 Underpressure gauge

Air filter (left engine 2, outside)

Indicates the underpressure in the air filter.

Underpressure must be less than 25 inches (635 mm) water column.

Otherwise clean / replace the filterelement.

201 Operating hours meter

(left eingine 1)

Sums up the operating hours of the engine; carry out servicing works accordingly.

202 Operating hours meter

(right eingine 2)

Sums up the operating hours of the engine; carry out servicing works accordingly.

Symbol

203 Clock 204 Voltmeter

BA RH200(3 847 006.00)-EN

Indicates the voltage in the electrical system.

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OPERATING INSTRUCTIONS 6050 / 6050FS Operation

Fig. 2-67:

2-62

BA RH200(3 847 006.00)-EN

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OPERATING INSTRUCTIONS 6050 / 6050FS Operation (Fig. 2-67:) (Options. Depending on the options ordered with the machine, the described elements can be found on different positions on the control column).

Symbol Funktion Pos. Benennung 211 Warning lamp

Oil interval prolong- Lamp is lit up, ing (left engine 1) flashes or pulsates,

212 Warning lamp

Oil burning left engine 1)

Lamp lits up green, when the oil burning system is ready to operate.

Additional a fault code is indicated.

213 Warning lamp

Oil burning left engine 1)

Lamp lits up red, when a fault occurs in the oil burning system.

Additional a fault code is indicated.

214 Warning lamp

Oil interval prolong- lamp is lit up, ing (right engine 2) flashes or pulsates,

215 Warning lamp

Oil burning right engine 2)

Lamp lits up green, when the oil burning system is ready to operate.

Additional a fault code is indicated.

216 Warning lamp

Oil burning right engine 2)

Lamp lits up red, when a fault occurs in the oil burning system.

Additional a fault code is indicated.

BA RH200(3 847 006.00)-EN

when one oil pump is running when both oil pump are running

when one oil pump is running when both oil pump are running

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OPERATING INSTRUCTIONS 6050 / 6050FS Operation PUTTING THE MACHINE INTO OPERATION Before daily start-up, carry out works in accordance with servicing plan T (see: Part 3 "Inspection and servicing") Increased fire and explosion hazard will exist.

Service station (tanklift) The excavator is equipped with a central service station (Fig. 2-68: resp. Fig. 2-69:) for refuelling.

The service station is attached to the frame and accessible from the ground below the uppercarriage.

A service vehicle is needed for filling and/or draining of the fluids.

Prior to your daily start-up, make sure the machine has been cleaned of combustible and easily flammable substances.

Refuelling Refuelling - Safety instructions Explosion hazard. Risk of fire.

Fuels and fuel gases are inflammable.

Avoid open flames and stop smoking.

Fig. 2-68:

Fuel may cause skin injury. Wear protective gloves or use a barrier cream.

Stand working equipment on the ground.

Shut off the engines.

Do not spill fuel and do not allow fuel to penetrate into the soil. Fuel pollutes the environment.

Wipe off spilt fuel immediately with cleaning rags or soak up with binding agents.

Fuel and cleaning material must be disposed of without polluting the environment.

Report fuel accidents immediately to the user or his representative.

Fig. 2-69:

2-64

BA RH200(3 847 006.00)-EN

EM027997-0

OPERATING INSTRUCTIONS 6050 / 6050FS Operation Express couplings are provided for refilling the following consumables: Note: Connections used may vary depending on how the machine is equipped.

Pos. Fig. 2-70:

Fluid

Express coupling for

1

Diesel fuel for lefthand and righthand fuel tank

filling

2

Cooling fluid for left engine

Filling and/or draining

3

Cooling fluid for right engine

Filling and/or draining

Fig. 2-71:

4

Gearbox oil for left pump transfer gearbox

Filling and/or draining

Lowering the service station

5

Gearbox oil for right pump transfer gearbox

Filling and/or draining

6

not used

7

not used

Draw out control knob (21, Fig. 2-71:) of valve (22) with rope (25). The service station is brought down to the lower position. Turn knob (21) by 90° and engage.

8

Engine oil for lefthand engine

Filling and/or draining

Raising the service station

9

Engine oil for righthand engine

Filling and/or draining

10

Hydraulic oil tank

Filling and/or draining

Refilling and draining

11

Grease container

filling

For filling in or for draining fluids, unscrew the cap of the corresponding express coupling (Fig. 2-70:).

Disengage control knob (21) of valve (22), turn by 90° and press in. The service station is raised to the top position.

Attach express coupling of filling hose from the service vehicle to the corresponding express coupling at the service station. Fill in or drain off fluid.

Take off filling hose and refit cap on the express coupling.

Fig. 2-70:

BA RH200(3 847 006.00)-EN

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OPERATING INSTRUCTIONS 6050 / 6050FS Operation

Assemblies resp. Measuring device reservoirs Fuel tank BCS fuel indicator (Fig. 2-72:)

Fig. 2-72:

2-66

Remarks Switch on the monitoring system by using toggle switch (23). The indicator light (22) comes on.

Fill in fuel via express coupling (1, Fig. 2-73:).

The indicator light (32) comes on when the LH fuel tank is full.

Stop filling when the fuel tank is full.

The indicator light (33) comes on when the RH fuel tank is full.

Stop filling when the fuel tank is full.

Switch off the monitoring system by using toggle switch (23), indicator light (22) is off.

Fig. 2-73:

BA RH200(3 847 006.00)-EN

EM027997-0

OPERATING INSTRUCTIONS 6050 / 6050FS Operation

Assemblies resp. Measuring device reservoirs Pump transfer Dipstick (arrow, Fig. 2-74:) gearbox

Remarks

Engine

Dipstick (1, Fig. 2-75:)

Stop filling when the oil reaches the "max" mark on the dipstick (see: chapter "Engine - engine oil level/filling in oil").

Engine oil tank

Dipstick (arrow, Fig. 2-76:)

Stop filling when the oil reaches the "max" mark on the dipstick (see chapter "Engine - Checking the oil level in the engine oil reservoir / Topping up").

Stop filling when the oil reaches the "max" mark on the dipstick (see: Part 3, chapter "Pump transfer gearbox Checking the gearbox oil level/Filling in oil").

Fig. 2-74: Fig. 2-76:

Fig. 2-75:

BA RH200(3 847 006.00)-EN

2-67

EM027997-0

OPERATING INSTRUCTIONS 6050 / 6050FS Operation

Assemblies resp. Measuring device reservoirs

Remarks

Hydraulic oil tank

Checking the oil level: Stand working equipment on the ground as shown on sign (2).

Check oil level at an oil temperature of ca. 50 °C / 122°F, with the engines stationary.

Fill in oil through express coupling (10, Fig. 2-79:) when the oil level in the inspection glass has dropped below the "min" mark on sign (2).

Stop filling if the acoustic warning signal “Travel Alarm” sounds and oil reaches the "max" mark on sign (2) near the inspection glass (see: chapter "Hydraulic system Checking the hydraulic oil level / Refilling hydraulic oil").

Fig. 2-77:

Inspection glass (1, Fig. 2-77:), sign (2, Fig. 2-77: and Fig. 2-78:)

Fig. 2-79:

Fig. 2-78:

2-68

BA RH200(3 847 006.00)-EN

EM027997-0

OPERATING INSTRUCTIONS 6050 / 6050FS Operation

Assemblies resp. Measuring device reservoirs Cooling system reservoir

Remarks

Level indicator (4, Fig. 2-80:) Fill in cooling liquid via express couplings (2 and 3, Fig. 2-82:). Stop filling when the level indicator indicates maximum filling level. (see: chapter "Cooling system Cooling liquid").

Grease container BCS display (Fig. 2-81:) – cental lubricating system

BCS gives a warning if the grease container is nearly empty.

Switch on the display system (optional) with the toggle switch (23, Fig. 2-83:), indicator lamp (22) comes on.

Fill in grease via express coupling (11).

Stop filling when the grease container is full, the indicator lamp (34) lights up.

On completion of filling, switch the display system off again with the toggle switch (23), indicator lamp (22) is off.

Fig. 2-80:

Fig. 2-82:

Fig. 2-81:

Fig. 2-83:

BA RH200(3 847 006.00)-EN

2-69

EM027997-0

OPERATING INSTRUCTIONS 6050 / 6050FS Operation Switching the electrical system on and off The electrical system is switched on with keyswitch (32, Fig. 2-84:).  Insert key into key-switch and turn to the right.

Battery main switch The battery main switch is installed in the control cabinet (1, Fig. 2-85:) behind the hydraulic reservoir. The battery main switch disconnect the complete electrical system from the batteries. In the "OFF" position, the battery main switch 

prevents unauthorized starting of the engines,



protects the batteries against inadvertent discharge.

Only the automatic fire-extinguishing system (optional) remains connected to the power supply even when the battery main switch is in the "OFF" position.

Fig. 2-84: Fig. 2-85:

2-70

BA RH200(3 847 006.00)-EN

EM027997-0

OPERATING INSTRUCTIONS 6050 / 6050FS Operation STARTING AND STOPPING THE ENGINES Starting the engines Start and operate combustion engines only on well-ventilated premises.

Exhaust gases from diesel engines and some of their constituents may cause cancer, birth defects and other reproductive harm.

In closed rooms, exhaust gases must be evacuated to the outside.

Do not work on the exhaust system an do not make any modifications to it.

Fig. 2-87:

All control levers and pedals must be in position "0".

 Activate the EMERGENCY SHUT-OFF switches (31, Fig. 2-86: and 2, Fig. 2-87:).  Turn engine speed control (56 and 66, Fig. 2-86:) to the left against the limit stop (idling speed).  Insert the key into the key-switch (32) and turn clockwise.

Activate the horn before you start the engines to give a warning signal to people around.

Start the engines one after the other.

Fig. 2-86:

 Press button (51) for the lefthand engine.

Release button (51) as soon as the engine has fired.  Press button (61) for the righthand engine.

Release button (61) as soon as the engine has fired.

BA RH200(3 847 006.00)-EN

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OPERATING INSTRUCTIONS 6050 / 6050FS Operation

Do not run engines at full load unless they have been allowed to run for at least 3 minutes at idling.

Repeat the starting procedure if one of the engines does not fire. Repeat starting procedure not more often than three to four times. Do not operate the starter for more than 10 seconds.

If, after starting, the BCS or the engine monitoring devices (Fig. 2-88:) indicates a fault 

of the PMS,



because of insufficient engine oil pressure,



of the alternator,

stop the engine concerned immediately.

Locate the cause of the fault and rectify before restarting the engine.

Starting the engines at low temperatures If the machine is used in low temperatures, the engine may be equipped with a cold-starting device.

The pressure vessel containing the cold-starting fluid (ether) can be installed in or near the engine compartment.

The vessel is screwed into an electro-mechanical metering valve. When the engine is started at temperatures below 0°C (32°F), this valve is activated automatically by the engine electronics and injects a precisely metered amount of cold-starting fluid into the air intake duct of the engine.

Ether is toxic and highly inflammable. Safety instructions and information concerning the handling of pressure vessels for cold-starting fluids (ether) can be found in the following chapters: "Fundamental safety instructions", "Inspection and servicing - Safety instructions", "Cold-starting fluid (ether) - Replacing the pressure vessel".

Fig. 2-88:

2-72

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EM027997-0

OPERATING INSTRUCTIONS 6050 / 6050FS Operation Shutting off the engines

Emergency - stop

During interruptions of the work and after the work, stand working equipment on the ground.

In case of emergency, e.g. if buzzer (33, Fig. 2-90:) sounds, the engine can be shut off from full load.

Do not shut off the engines before the working equipment rests on the ground.  Turn speed control knob (56 and 66, Fig. 2-89:) counter-clockwise to the limit stop (idling speed).

To do so:  Depress stop-switch (31) (the whole electrical system is switched off).

The engines are shut off.  Turn key in key-switch (32) counter-clockwise and withdraw.

Fig. 2-90:

Fig. 2-89:

Do not shut off the engine out of full load.

The engine should be run at no more than one-half of the rated rpm for another 5 minutes to allow the lubricating oil and the cooling liquid to dissipate the combustion heat from the combustion chamber and from bearings and shafts.  Depress key (52) for the lefthand engine.  Depress key (62) for the righthand engine.  Turn key in key-switch (32) counter-clockwise and withdraw (electrical system without current).

BA RH200(3 847 006.00)-EN

2-73

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OPERATING INSTRUCTIONS 6050 / 6050FS Operation AIR CONDITIONER (OPTION) Ventilation / Heating

Control panel (Dual) (Fig. 2-92:)

The air needed for ventilation and/or heating is sucked in from outside the cab by a blower and ducted to the air outlets (1, 2, 3, Fig. 2-91:).

Each outlet can be adjusted independently for the amount and direction of air required.

If necessary, the air in the cab is sucked in through the filters and recirculated.

Fig. 2-92:

1

Rotary switch

selects the intensity level of the blower (3 levels)

2

Rotary switch

selects the desired control function (heating, cooling, ventilation, defrosting)

Fig. 2-91:

3

Rotary switch

The air conditioner control elements are located in the satellite (181).

selects the intensity level of the blower (3 levels)

4

Rotary switch

selects the desired control function (heating, cooling, ventilation, defrosting)

5

Thermostat

sets the desired temperature inside the cab

6

Thermostat

sets the desired temperature inside the cab

Do not switch the air conditioner to "cooling“ when the back-up heating is on.

2-74

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OPERATING INSTRUCTIONS 6050 / 6050FS Operation Back-up heating (option)

Control panel (Eberspächer)

The back-up heating control elements are located in the satellite (182, Fig. 2-93:).

(Fig. 2-94:)

Fig. 2-94: Fig. 2-93:

Do not switch on the back-up heating when the air conditioner is set to ”cooling”.

BA RH200(3 847 006.00)-EN

1

Pushbutton

set heating time

2

Pushbutton

heating time preselect

3

Pushbutton

heating on / off

4

Pushbutton

change set data

5

Pushbutton

change set data

6

Symbol

change set data

7

Symbol

radio remote-control

8

Symbol

time and day of the week

9

Symbol

temperature

10 Symbol

operation

11 Selector

temperature

2-75

EM027997-0

OPERATING INSTRUCTIONS 6050 / 6050FS Operation Control panel (Fig. 2-95:)

1

Indicator lamp

heating ON

2

Indicator lamp

blower ON

3

Indicator lamp

heating

4

Indicator lamp

cooling

5

Switch

heating ON

6

Switch

blower ON

7

Indicator lamp

blower level 3

8

Indicator lamp

blower level 2

9

Indicator lamp

blower level 1

Fig. 2-95:

2-76

BA RH200(3 847 006.00)-EN

EM027997-0

OPERATING INSTRUCTIONS 6050 / 6050FS Operation MAXIMUM MACHINE INCLINATIONS, INFORMATION

The working performance of the machine is especially economical when the machine stands on firm and level ground.

The machine must not exceed the inclinations indicated for working, travelling and servicing operations and during downtimes. The values specified in the tables below (next page) are valid for all types of working equipment.

A loss of performance and higher wear must be accepted when the machine works in an inclined position, e.g. when building a ramp or when slewing uphill.

If the maximum inclinations are exceeded, there is a risk of severe damage to the engines due to insufficient lubrication. In the event of extreme inclinations the machine can topple over.

For the building of ramps, the values specified in the table "Maximum inclinations during working operations" may be exceeded. In this case, however, a reduced service life of the components can be expected.

During downtimes, the machine must be parked in such a way that its inclination does not exceed 3° / 5.2 %.

Maximum machine inclinations during working operations:

forward inclination

rearward inclination

side inclination

5° / 8.7%

5° / 8.7%

5° / 8.7%

Maximum machine inclinations during travelling: Type

6050

Engine

Forward

Rearward

Side

deg / %

deg / %

KTTA38

30° / 57.7%

30° / 57.7%

30° / 57.7%

K1500E

30° / 57.7%

30° / 57.7%

30° / 57.7%

Type

Engine

deg / % 6050

QSK38

Forward

Rearward

deg / %

deg / %

25° / 46.6%

25° / 46.6%

Side deg / % 25° / 46.6%

Maximum machine inclinations during maintenance operations:

forward inclination

rearward inclination

side inclination

0° - 2° / 3.4%

0° - 2° / 3.4%

0° - 2° / 3.4%

BA RH200(3 847 006.00)-EN

2-77

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OPERATING INSTRUCTIONS 6050 / 6050FS Operation TRAVELLING, SAFETY INSTRUCTIONS Have the attachment raised only so far as to permit the machine to be driven under overhead power lines without any risk.

Close the cab door.

If the machine is fitted with a safety belt for the operator, fasten the belt.

If the superstructure is turned by more than 90° from the BASIC POSITION, the excavator travels in the opposite direction to that selected.

If the position of the superstructure in relation to the undercarriage is not exactly known, touch the accelerator lightly to see which direction the machine takes, before initiating the full travelling movement.

Never drive across slopes.

Take the utmost care on slippery, greasy ground.

Sound the horn to warn persons in the immediate vicinity before starting travelling.

Do not exceed the maximum machine inclination (see “Maximum machine inclinations” chapter).

Fig. 2-97:

Running-in specifications for components of the crawler tracks Prior to initial commissioning and/or after repair work, run in the idlers, track rollers and support rollers as follow:  Raise the equipment (Fig. 2-96: and Fig. 2-97:).  Drive the excavator in reverse approx. 50 m (164 ft).  Drive the excavator in forwards approx. 50 m (164 ft).  Stop the excavator.  Measure the temperature at each dler, track roller and support roller with an infrared thermometer. (at a temperature of approx. 100° C (212°F) wait for idlers, track rollers and support rollers to cool down).  Repeat this running-in procedure up to 10 times.  Check all idlers, track rollers and support rollers for leaks.

Fig. 2-96:

2-78

The engines must be at operating temperature before being subjected to full load.

If the machine is to be driven a longer distance, the superstructure must be secured against turning by means of the superstructure holding brake.

BA RH200(3 847 006.00)-EN

EM027997-0

OPERATING INSTRUCTIONS 6050 / 6050FS Operation Superstructure basic position

Travel forwards/backwards

Travel direction and sense of actuation of pedals (112 and 113, Fig. 2-99:) are identical only when the excavator is in its BASIC POSITION (Fig. 2-98:).

Travelling forwards:  depress pedals (112 and 113) forwards.

The excavator travels in the direction of the idler (2, Fig. 2-98:).

Travelling backwards:  depress pedals (112 and 113, Fig. 2-99:) backwards.

The excavator travels in the direction of the drive sprocket (4, Fig. 2-98:).

During travelling, an acoustic warning signal sounds (Travel Alarm).

Fig. 2-98:

If the superstructure is swung out of its basic position by more than 90° (Fig. 2-100:), the excavator moves in a direction opposite to that expected when pedals (112 and 113, Fig. 2-99:) are depressed.

Fig. 2-100:

The pedals return automatically to their "0" positions when released.

Reverse the excavator only over short distances and with the assistance of marshallers because of restricted rear-view conditions.

Do not travel across slopes.

When travelling uphill or downhill, the travel drive must always be at the rear.

Fig. 2-99:

If the operator is not completely sure of the position of the superstructure with regard to the undercarriage, pedals (112 and 113) should be depressed slightly in order to find out which way the excavator moves before initiating the full travelling movement.

BA RH200(3 847 006.00)-EN

Drive only in the basic position of the excavator and only forwards.

Be extremely careful on slippery and greasy ground.

Do not exceed the maximum machine inclination (see “Maximum machine inclinations” chapter).

All instructions with regard to travelling speed regulation and drive direction control are applicable only as long as the crawler tracks have sufficient grip and do not slip.

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OPERATING INSTRUCTIONS 6050 / 6050FS Operation Regulating travelling speed Travelling on level ground Regulate the travelling speed with  pedals (112 and 113, Fig. 2-101:) and  Switch (71, Fig. 2-102:) to the right (slow gear) All forward/reverse travel movements are possible with this gear.  Switch (71, Fig. 2-102:) to the left (fast gear) The excavator can be travelled only parallel forwards with this fast gear.

The travel gearbox changes automatically into the 1st gear as soon as another travelling function (e.g. reversing, cornering) is initiated.

Turn speed regulator (56 and 66) fully clockwise (full-throttled position) Change speed range only when the excavator is stationary.

Fig. 2-102:

Travelling uphill and downhill Read and observe the "Travelling Safety instructions" chapter.

 Depress padals (112 and 113, Fig. 2-101:) fully to the limit stop.  Regulate the travel speed only with the engines speed control.

When travelling downhill, the travel retarder valve acts as a speed limiter.

Fig. 2-101:

The travel retarder valve works correctly if pedals (112 and 113) are fully depressed down to the limit stop.

Should the travelling speed become too high when travelling downhill release pedals (112 and 113) to stop the excavator.

2-80

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OPERATING INSTRUCTIONS 6050 / 6050FS Operation Cornering To take a right-hand corner forwards depress only pedal (112, Fig. 2-103:) forwards.

To take a lefthand corner forwards  depress only pedal (113) forwards.

This way of working is contrary to the excavator'sdesignated use.

There is a risk of accident. Moreover, the tracks, swing gear, roller bearing swing ring, backhoe or bucket back-wall and the front part of the bucket are subjected to inadmissibly high stresses.

Turning To turn to the right depress pedal (112) forwards and pedal (113) backwards.

To turn to the left depress pedal (113) forwards and pedal (112) backwards.

Fig. 2-104:

Fig. 2-103:

Note Change the position of the undercarriage - parallel or perpendicular to the working face - only by cornering forwards/backwards (Fig. 2-104:).

Fig. 2-105:

Cornering to the left: forwards

from pos. 1 to pos. 2

backwards

from pos. 2 to pos. 3

forwards

from pos. 3 to pos. 4

The same procedure should be adopted if the excavator is to be driven out of depressions (Fig. 2-105:): Cornering to the left

from pos. 1 to pos. 2

Cornering to the right

from pos. 2 to pos. 3

Never use the working equipment to raise one side of the undercarriage and then turn the undercarriage by initiating the swinging and/or the travelling function.

BA RH200(3 847 006.00)-EN

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OPERATING INSTRUCTIONS 6050 / 6050FS Operation Travelling over long distances Travel only forwards with the excavator in its basic position.

Travelling backwards over longer distances could damage parts of the undercarriage.

Do not exceed the maximum machine inclination (see “Maximum machine inclinations” chapter).

Backhoe bucket equipment (Fig. 2-107:):  Fully extend boom cylinder 1.  Retract backhoe cylinder 2.  Retract stick cylinder 3.  Extend backhoe cylinder 2 and stick cylinder (3) to such an extent as to reach the position of the equipment shown in (Fig. 2-107:).

Read and observe the "Travelling – Safety instructions" chapter.

When travelling, pay attention to sufficient headroom, e. g. under cable bridges or high-tension cables.

Keep the loading or the backhoe bucket close to the ground. For a more uniform loading of the tracks, the equipment must, however, be kept at a steep angle (Fig. 2-106: / Fig. 2-107:).

Fig. 2-107:

Lower the equipment when travelling underneath obstacles.

If the equipment position must be changed:  stop the excavator,  change the position,  continue to travel.

After travelling for 15 minutes without interruption, stop the excavator and check the temperatureof the track rollers.

Fig. 2-106:

If the temperature does not exceed ca. 100° C (212°F):

Loading bucket equipment (Fig. 2-106:):

 Continue travelling.

 Fully extend boom cylinder (1).

In case of higher temperatures:

 Extend bucket cylinder 2.  Extend stick cylinder 3.  Retract bucket cylinder 2 and stick cylinder (3) to such an extent as to reach the position of the equipment (Fig. 2-106:).

2-82

 Stop travelling. Resume travelling only after the track rollers have cooled down to ca. 40° C (104°F).

BA RH200(3 847 006.00)-EN

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OPERATING INSTRUCTIONS 6050 / 6050FS Operation Emergency machine drive Moving the excavator after failure of the hydraulics The weight of the excavator, the resistance of the crawler tracks and the high reduction in the travel gearboxes make towing or pushing of the excavator in the event of a failure or of defects in the hydraulic system impossible.

Required equipment 

a self-propelled machine with a dual-circuit hydraulic system max. working pressure: 380 bars / 5511 psi min. working pressure: 220 bars / 3191 psi pump discharge rate: 150 l/min / 39.6 gal/min

These are minimum values. The pump discharge rate indicated corresponds to an excavator travelling speed of ca. 3 m/min (10 ft/min). 

4 high-pressure hoses ca. 11 m (36 ft) long; DN 40 1 ½“ SAE Connection at one end; ready for connection to the auxiliary machine at the other.



4 plugs (high-pressure type) for 6000 PSI 1 ½“ SAE connections.

Fig. 2-108:

The excavator can therefore only be moved with the help of another machine (Fig. 2-108:) (wheel loader or grader). The machine used as auxiliary machine must be equipped with a dual-circuit hydraulic system.

BA RH200(3 847 006.00)-EN

2-83

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OPERATING INSTRUCTIONS 6050 / 6050FS Operation Positioning of the machines

Emergency travel

The auxiliary machine is driven close to the RH200 from behind (Fig. 2-108:).

 Start up the engine of the auxiliary machine.

The brakes of the RH200 are released by travel pressure.

Loosen the high-pressure lines (1, 2, 3 and 4, Fig. 2-109) and close the open ends of the hoses.  Connect the hoses from the auxiliary machine to the ports of the "travel hydraulics" of the excavator.

 Initiate the travelling movements carefully with the control levers. Adjust the direction and travelling speed of both tracks accordingly.

 High-pressure hoses (1 and 2) - circuit 1 on auxiliary machine

 Shift the control lever to the final position.

Make sure the auxiliary machine is able to "follow"

 High-pressure hoses (3 and 4) - circuit 2 on auxiliary machine

The RH200 can be steered as usual by releasing the one or the other control lever briefly.

Do not allow pressure in control line to rise above 30 bars / 435psi as this will shift the track gears into their “fast” ranges.

Drive the excavator out of the hazard zone only.

Fig. 2-109 :

2-84

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OPERATING INSTRUCTIONS 6050 / 6050FS Operation Superstructure holding brakes

Track parking brake

The excavator is equipped with four superstructure holding brakes integrated in the swing gearboxes.

The superstructure holding brakes are used to block the superstructure and the undercarriage.

The excavator is equipped with four track brakes integrated in the track drives.

The superstructure holding brakes are parking brakes.

Switch the parking brakes on by means of switch (82, Fig. 2-110:): 

when the excavator is parked,



when travelling over longer distances.

The track brakes are parking brakes which relieve the hydro-static travel drives during working operation and which protect the excavator against rolling forwards and backwards.

The brakes are controlled by means of the travel pedals (112 and 113, Fig. 2-111:). In neutral position of the pedals, the brakes are applied and the excavator is braked. During travelling, the brakes are released.

The track brakes can also be activated with switch (72, Fig. 2-110:).

Depending on switch position, the brakes are permanently engaged or are automatically applied after ca. 8 sec. each time the excavator stops.

With this switch position, the brakes are released as soon as the "Travel" function is activated.

Fig. 2-110: Fig. 2-111:

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OPERATING INSTRUCTIONS 6050 / 6050FS Operation TRANSPORTING THE MACHINE Transport - Safety instructions The machine must be loaded and transported only after all safety regulations have been observed and complied with.

Entrust loading and transporting of the machine to a company experienced in the transport of heavy equipment.

The responsability for loading and transporting lies with the transport company or their representative.

Remove oil, grease, soil, mud, snow, ice and other materials from the excavator's crawler tracks and from ramps and loading platforms of the transport vehicle to minimize slipping.

Transport The dimensions and the service weight of the fully assembled excavator do not allow the excavator to be transported in an undismantled state on a lowbed trailer over public roads.

Therefore, the excavators components and modules must be dismantled beforehand.

Suspensions points as well as the center of gravity are marked on the modules (see example, Fig. 2-112:).

Dimensions and weights of the machines modules can be found in the annex, chapter “Technical Data” as well as in the “Technical Handbook”.

Secure the transport vehicle against rolling away.

Use only tying equipment of sufficient strength (the weights and dimensions of the excavator are set out in the "Technical specifications").

Fig. 2-112:

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OPERATING INSTRUCTIONS 6050 / 6050FS Operation WORKING OPERATION - SAFETY INSTRUCTIONS Read the sections "Fundamental safety instructions" and "Operation, safety instructions" carefully and observe the instructions given in them.

Inspect the site for underground gas, power and water lines before starting work. Any damage to such lines is a risk to life!

Clean off any earth, mud, snow, ice, grease and oil adhering to your working footwear before operating the machine. There is otherwise a risk of slipping off the pedals and initiating inadvertent movements.

Sound the horn to warn persons in the immediate vicinity before starting work.

Stop work if anyone is in the hazard range of the machine. Make sure they have left the hazard range before resuming work.

Never operate the machine unless it is standing on a reasonably horizontal, flat surface. The stability of the machine is otherwise at risk.

Ensure that the attachment has adequate clearance below overhead power lines and structures.

Trenches and working faces may give way. Keep well clear of them.

Do not operate the machine, 

when several track rollers or support rollers have been removed;



when one or several slewing gearboxes have failed or been removed;



when one or several teeth on the backhoe or on the shovel are worn or missing;



when parts of the hardfacing layer on the backhoe or on the shovel are worn or missing.

Running-in instructions for hydraulic cylinders Compression of an oil/air compound in a hydraulic cylinder may result in detonations which might damage pistons and sealing rings.

Prior to initial commissioning and/or after repairs, run in the hydraulic cylinders as follows:  Start up the engines and run at low speed.

The pressure-limiting valve in the hydraulic system must not respond  In the first two working cycles, retract and extend the pistons of the hydraulic cylinders to max. ½ to ¾ (not to the limit stop).

Never change direction suddenly. The waiting time between changes of direction must be at least 4 seconds.  In the next eight working cycles, retract and extend the pistons of the hydraulic cylinders to the limit stop. The waiting time between changes of direction must be at least 4 seconds.  When all hydraulic cylinders have been run in, the excavator can operate at a higher engine speed.

Warming-up-phase for the hydraulic system At low temperatures, bring the engines down to moderate speed, then activate all hydraulic functions for about 10 minutes (bring to service temperature). For further instructions, see section "Lubricants".

If the BCS indicates problems with the cooling liquid temperature, engine oil pressure, coolant level, alternator or hydraulic oil filter control (with hydraulic oil at service temperature) light up: Lower the working equipment and shut off engines.

Working under these circumstances results in heavy wear and possibly in severe damage and thus in high repair costs.

Such circumstances are considered by Bucyrus HEX as "abusive utilization".

Bucyrus HEX refuses to assume the guarantee for damage and consequential damage caused by an abusive utilization of the machine.

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OPERATING INSTRUCTIONS 6050 / 6050FS Operation

Avoid extreme positions of the working equipment Parts of the attachment may damage the machine if they are moved into extreme positions (see illustrations Fig. 2-113 - Fig. 2-117).

Work carefully, avoiding extreme positions of this kind.

Fig. 2-115

Fig. 2-113

Fig. 2-116

Fig. 2-114

Fig. 2-117

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OPERATING INSTRUCTIONS 6050 / 6050FS Operation WORKING OPERATION Before starting work Prior to initial commissioning and after repairs on the central lubricating system or the hydraulic cylinders, move the unloaded equipment for abt.

5 minutes.

This is required to ensure an adequate supply of grease to the cylinder bearings when the work starts.

Warming up: At low outside temperatures it is necessary to run the hydraulic system up to operating temperature.

The temperatures at which warming up is necessary depend on the type of hydraulic oil used; see also "Oils for hydraulic systems".

Swing the superstructure The superstructure can only be swung if the superstructure holding brakes are released.  To swing the superstructure to the right: shift control lever (115, Fig. 2-118:) to the right.  To swing the superstructure to the left: shift control lever (115) to the left.

After releasing, the control lever returns automatically to position "0". But the superstructures motion will not be braked automatically then. To bring the superstructure to standstill, shift control lever (115) into the opposite direction of superstructures motion (countering).

Braking the superstructure The superstructure is braked only by setting control lever (115, Fig. 2-118:) into the opposite direction (countering).

 Run the diesel engines at ca. 2/3 full speed and start to perform no-load working movements for abt. 10 minutes with the excavator.

The superstructures motion will not be braked automatically when releasing control lever (115) To bring the superstructure to standstill, shift control lever (115) into the opposite direction of superstructures motion (countering).

Only in an emergency apply superstructure holding brake with switch (82, Fig. 2-119:).

Fig. 2-118:

Switching on the electronic excavator control You can only move the working equipment after the electronic excavator control is switched on via “SERVO” switch (74, Fig. 2-118:) in the control column and the switch inside the driver’s seat (105).

Electronic excavator control activated operator is sitting on his seat.

Electronic excavator control deactivated driver's seat is empty.

Fig. 2-119:

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OPERATING INSTRUCTIONS 6050 / 6050FS Operation Working movements When released, all control levers for working operation return automatically to position "0".

Level a surface only in the bucket's digging direction. Never "beat" or "sweep" with the bucket.

Do not level off a surface with the front shell of the bucket open.

Close bucket completely before beginning to dig.

Before starting work, activate the horn to give a warning signal to all people around.

Fig. 2-120:

Do not exceed the maximum machine inclination (see “Maximum machine inclinations” chapter).

Filling and emptying the bucket or the backhoe

Raising and lowering the boom  To raise the boom: pull control lever (116, Fig. 2-120:) backwards.  To lower the boom: push control lever (116) forwards.  To lower the boom with pressure: depress button (103) and push control lever (116) forwards.

Extending and retracting the bucket or backhoe bucket stick

 To fill/tip back the bucket: shift control lever (116) to the left.  To empty the bucket by dumping/tipping: shift control lever (116) to the right.

Opening and closing the bottom-dump bucket  To open the bucket: press pedal (111) forwards or press button (117) to the left.  To close the bucket: press pedal (111) backwards or press button (117) to the right.

 To extend the stick: push control lever (115) forwards.  To retract the stick: pull control lever (115) backwards.  To retract the stick with pressure: (only on bottom-dump bucket equipment) depress button (102) and push control lever (115) backwards.

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OPERATING INSTRUCTIONS 6050 / 6050FS Operation After daily operation Parking the machine  Park the machine on level and stable ground. This is particularly important in winter to avoid freezing of the tracks.  Stand the working equipment on the ground.  Shut off the engines.

Escaping oil pollutes the environment.

Repair leaks immediately (or have them repaired).Report oil accidents to the user of the machine.

 Shift both control levers into all directions todepressurize the hydraulic cylinders.

 Check the superstructure, undercarriage and the working equipment for damage and all steel components for cracks or fractures.

 Withdraw the key from the electrical system key-switch.

 Report detected damage immediately to the user.

 Close the cab window.

 Clean off gross dirt, ice and snow from the fins and the fan wheel of the hydraulic oil cooler.

 Lock the cab door and all lockable hatches and covers on the machine.  Clean the machine of coarse dirt as well as of combustible and easily flammable substances, if possible with a stream jet (rubber parts and electric components with compressed air - refer to information label) Otherwise, the fire and explosion hazard will exist.  Fill up the fuel tanks.  Inspect the engines, the hydraulic system, the track rollers, support rollers, idlers and gearboxes visually for leaks.

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OPERATING INSTRUCTIONS 6050 / 6050FS Operation ASSEMBLING WORKING EQUIPMENT - SAFETY INSTRUCTIONS

Securing the working equipment

Personel

Stand working equipment on the ground in such a way that no movements can be made if mechanical or hydraulic connections become detached.

Assembly work may be carried out only by operating or maintenance personnel who have the necessary know-how at their disposal.

If such know-how is lacking, meticulous instruction must be given by experienced personnel, e.g. from Bucyrus HEX. The operating manual, and in particular the section headed "Fundamental Safety Instructions", must have been read and understood.

Only such persons may start up the machine during assembly work in order to adjust the attachments.

Incorrect operation of the machine or the attachments may give rise to life-threatening situations.

Personal protective gear and working clothes Wear closely fitting working clothing when working on the machine. Loose, wide garments may catch on machine parts and result in injury.

Wear a safety helmet, safety footwear and gloves.

Tools and auxiliaries Tools, hoists, slings, trestles and other devices must be in a reliable, safe state.

Metal splinters may cause injury when accessory bolts are being driven in or out. A brass or copper mandrel should therefore be used for this purpose, and goggles must be worn.

Secure any equipment or component which is to be mounted or dismantled, or whose position is to be changed, with hoists or appropriate slinging/supporting devices to prevent them from moving, slipping or falling inadvertently.

Securing the machine Carry out work on the attachment only if the machine is secured as described in the "Securing the machine" section.

Selecting the attachments The machine can be equipped with various attachments. The components of the attachments are assembled with hydraulic cylinders and connectors. Components can be combined in various ways for optimum adaptation of the attachments to the specific application.

Operate the machine only with the equipment and component combinations expressly approved by Bucyrus HEX for this type of machine.

Never install and commission other equipment and component combinations without Bucyrus HEX first having inspected and approved the project in writing.

Protective roof against falling objects The machine is equipped with an integrated cabprotection roof (FOPS).

Use only the steps, platforms and handrails when climbing onto or off the machine.

Always keep steps and platforms in a non-slip state. Remove any oil, grease, earth, clay, snow, ice and other foreign matter immediately.

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OPERATING INSTRUCTIONS 6050 / 6050FS Operation Securing the machine Risk of injury The machine must not be started by unauthorized persons.

Secure the machine as described below: 

before carrying out any fitting and modification work on the working equipment,



before carrying out any servicing and repair work on the machine.

Therefore, secure the machine.

Observe the accident prevention regulations.

 Park the machine on level and stable ground.

Depressurize pipeline systems, on which work is to be carried out, by appropriate measures.

 Stand the working equipment on the ground.

Protective shrouds of moving machine parts may only be opened or removed when the drive unit is stationary and protected against inadvertent starting.

 Depressurize the hydraulic system.

 Shut off the engines.  Withdraw the key from the key-switch.

Before carrying out fitting works, the machine and the equipment must be protected against inadvertent starting by placing chocks under the tracks and by standing the working equipment on the ground.

Hydraulic and lubricating systems Close all open bores, pipe and hose connections with pressure-resistant plugs.

Refill collected hydraulic oil back into the hydraulic system only through the return-flow filters. Dispose of non re-usable oils without polluting the environment.

All components of Bucyrus HEX machines have been carefully purpose-coordinated. Trouble-free operation and a long service life can only be achieved with original Bucyrus HEX spare parts.

Respect the sequence of working operations when fitting or replacing the attachments. The sequence has been determined and tested by qualified experts.

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OPERATING INSTRUCTIONS 6050 / 6050FS Operation CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS) Use "GLEITMO 815" anti-corrosive agent only.

Other agents are not approved by Bucyrus HEX. All pins and bearings (bushings and hubs) of the working equipment or in equipment componenents must be treated with "GLEITMO 815" anticorrosive agent before fitting.

Doing so  permits easy fitting and dismantling 

protects against rust, oxidation and similar wear



prevents seizing and fretting corrosion in nonmoving parts of bearings.

This is achieved by aluminium and copper particles forming a protective layer on the metal. This layer removes surface irregularities and does not sweat, seize or harden.

Application of GLEITMO 815  Clean off grease, oil, dirt and corrosion protection agents from pins and bearings using white spirit or diesel fuel.

Rust patches must be thoroughly removed, if any.

All parts must present a dry, bright metal surface.  Apply a thin layer of GLEITMO 815 on pins and all bearings using a brush or a spray can.

Pin shafts and bearings must be completely co-vered by the protective layer.

If the protective layer of a pin already treated with GLEITMO 815 is damaged, these areas must be touched up before fitting the part.  Fitting and securing of pins If the pin is too heavy to be fitted manually, apply GLEITMO 815 at first only on abt. a quarter of the pin's length Then position pin by means of a lifting gearready for fitting.

Apply GLEITMO 815 on the remaining length of pin shaft, fit pin and secure.

Part no. for "GLEITMO 815" is 2764305, available from Bucyrus HEX Spare-Parts Service

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OPERATING INSTRUCTIONS 6050 / 6050FS Operation ON-BOARD CRANE (OPTIONAL) The on-board crane is designed for lifting heavy parts only.

On-board crane, monitoring, warning and control elements (Fig. 2-121:)

Do not lift persons.

Observe all national directives as well as specific regulations relevant to crane operation.

Personel Crane work may be carried out only by operators who have the necessary know-how and the permission to operate cranes.

If such know-how or such permission is lacking, meticulous instruction must be given by experienced personnel, e.g. from CGM HMS. Incorrect operation of the crane may give rise to life-threatening situations.

Fig. 2-121:

Pos. Element 1 Monitoring lamp 2 Warning lamp 3 Warning lamp 4 Monitoring lamp 5 Key-switch

10 11 12

Button Monitoring lamp Knob Monitoring lamp Warning lamp Button Button

21

Control lever

22 23 24

Control lever Control lever Control lever

6 7 8 9

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Function Alternator Engine oil pressure Engine temperature Air filter Electrical system ON/OFF Start engine of drive unit Preheating system (option) Engine speed variation Crane in operation Malfunction EMERGENCY STOP Emergency lowering of winch Extending and retracting of boom extension Folding the boom Swinging the boom Winch up / down

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OPERATING INSTRUCTIONS 6050 / 6050FS Operation On-board crane, putting into operation Risk of serious injuries due to movements of the crane.

Put the crane into operation only after all persons have left the danger area.

Do not exceed the maximum lifting capacity (observe the lift capacity chart attached to the boom).

On-board crane, drive unit The drive unit (Fig. 2-122:) supplies the crane with hydraulic power. So the on-board crane is functional without the shovel’s engines running.

The drive unit comprises the diesel engine, fuel tank, starter batteries and the hydraulic system.

The drive unit is equipped with an Emergency OFF push switch (arrow, Fig. 2-122:).

In case of emergency push switch, the engine of the drive unit comes to standstill.

Prior to each deployment: Carry out all maintenance work as listed in the “Inspection and Servicing Plans “T” and “W”.

To start the drive unit:  Turn key-switch (5, Fig. 2-121:) to position ON.  Press button (6), engine will start.

The crane control unit is equipped with an Emergency OFF push switch (11).

In case of emergency push switch, the engine of the drive unit comes to standstill.

After finishing work block the boom, then stop the engine (see chapter “On-board crane, - blocking the boom in position of rest”).

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Fig. 2-122:

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OPERATING INSTRUCTIONS 6050 / 6050FS Operation On-Board crane, – blocking the boom in position of rest Movements and accelerations produced by working operations of the machine can cause damage to the swing drive of the on-board crane, if the crane is not blocked.

The hydraulic on-board crane must therefore be blocked in its position of rest.

Risk of serious injuries due to movements of the crane.

Put the crane into operation only after all persons have left the danger area.

To block the boom:  Retract the boom completely.  Swing the boom in the direction of the blocking device (Fig. 2-123:) and lower it.  Withdraw the cotter pin at the tip of the boom.  Extend the boom carefully until the tip engages the blocking device (arrow, Fig. 2-123:).  Reinsert and lock the the cotter pin.

On-board crane, checking Extract from the inspection and testing regulations The on-board crane is approved in accordance with the Accident Prevention Regulations for Cranes (BGV D6, applicable only in Germany).

The on-board crane must be inspected regularly in accordance with the regulations in force in the country of use.

The inspections must be requested by the user of the crane. The expert or specialist entrusted with the inspection can be appointed at the user's discretion.

The user must ensure, however, that the appointed person meets the requirements.

The user is obliged to make available all documents required for the inspection and to ensure the smooth running of the inspection. He is furthermore obliged to provide, if required, crane operators and auxiliary personnel and the required test loads.

The result of the inspection is to be documented in an inspection record signed by the inspector.

The inspection record serves as proof on the part of the user that the inspections have been carried out. The inspection record must contain all data required for crane identification and for the performance of further regular inspections.

Fig. 2-123:

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OPERATING INSTRUCTIONS 6050 / 6050FS Operation OPTIONAL EQUIPMENT Monitoring cameras This excavator is equipped with two monitoring cameras: •

one mounted on the counterweight, looking backwards;

•

one mounted on the hydraulic oil cooler module, looking to the right.

The two cameras and the belonging LCD-diplay are operational after the electrical system of the machine has been activated with the key operated switch.

Both cameras transmit their images to the same LCD-display. The display is mounted near the control column.

Fig. 2-124:

For toggling between the camera images beeing displayed, press the key in the left joystick (arrow, Fig. 2-124:).

Additional information can be found in the manuals of the camera manufacturer (see Volume 5 of the Technical Documentation "Components").

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OPERATING INSTRUCTIONS 6050 / 6050FS Operation NOTES ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ................................................................................................................................................................... ...................................................................................................................................................................

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OPERATING INSTRUCTIONS 6050 / 6050FS Operation

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing 3 INSPECTION AND SERVICING

Operating instructions

Target group

Part 1 INTRODUCTION FUNDAMENTAL SAFETY INSTRUCTIONS

Operating personnel + Inspection and servicing personnel + Repair personnel

Part 2 OPERATION

Operating personnel The operating personnel must have knowhow relevant to the operation and the application of this or comparable machines.

Part 3 INSPECTION AND SERVICING Part 4 REPAIR WORK

Inspection and servicing personnel The inspection and servicing personnel must have know-how relevant to the inspection and servicing of this or comparable machines.

Repair personnel The repair personnel must have know-how and experience relevant to the repair of this or comparable machines.

Part 5 ANNEX

Part 6 INDEX

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Operating personnel + Inspection and servicing personnel + Repair personnel Operating personnel + Inspection and servicing personnel + Repair personnel

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing INSPECTION AND SERVICING SAFETY INSTRUCTIONS Operating manual No inspection and servicing work must be carried out until the operating manual has been read and understood.

Pay special attention to: „Fundamental safety instructions" and all warnings and safety instructions attached to the machine.

The operating manual lists all jobs to be done. The descriptions of job sequences, however, provide only Experienced personnel with the necessary instructions.

The operating manual must be kept with the machine at all times.

Inspection and servicing personnel Inspection and servicing personnel must have the necessary know-how on the inspection and servicing of this or comparable machines.

The necessary know-how can be acquired in a several day's instruction, e.g. by an Bucyrus HEX mechanic or by attending an Bucyrus HEX training course.

Securing the working equipment Stand working equipment on the ground in such a way that no movements can be made if mechanical or hydraulical connections become detached.

Secure any equipment or component which is to be mounted or dismantled, or whose position is to be changed, with hoists or appropriate slinging / supporting devices to prevent them from moving, slipping or falling inadvertently.

Securing the machine Carry out servicing work only if the machine is secured as described in the section "Securing the machine".

Climbing onto and off the machine Use only the ladders, steps, platforms and handrails provided when climbing onto or off the machine.

Always keep ladders, steps, platforms and handrails in a non-slip, safe state and remove any oil, grease, soil, clay, snow, ice and other foreign matter immediately.

Always face the machine when climbing on and off.

Checking the state of tools Personal protective equipment and working clothing

Use only fully functional, reliable tools.

Wear closely fitting working clothing when working on the machine. Loose, wide garments may catch on machine parts and result in injury.

Wrenches of the wrong size, for example, may slip and cause injury.

Wear a safety helmet, safety footwear, gloves and, in the event of high noise levels, ear protectors.

Cleaning jobs

Select the right tool for the job.

Prior to commencing work, clean your working area, if necessary and possible, with a stream jet (rubber parts and electric components with compressed air - refer to information label).

Use only lint-free cleaning rags when working on the hydraulic system or the engines.

Cleaning agents and solvents may give off harmful, readily flammable vapours. Never work with such agents except on well ventilated premises; never inhale the vapours and never smoke.

Prevent solvents and cleaning agents from coming into contact with your skin.

Wear gloves.

Observe the instructions on the packaging.

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing Handling flammable liquids

Visisble oil losses

When handling flammable liquids:  never smoke,

Have any visible leakage repaired immediately.



keep away from unshielded light sources and naked flames,

Soak up any oil that has escaped with a binding agent.

Fuel and other consumables often have low flash points and are readily ignited. Never attempt to extinguish burning liquids with water.

Sweep up binding agent and dispose of it separately from other waste.

Use:  dry powder,

Relieving residual pressure in the hydraulic system



carbon dioxide or



foam extinguishers.

Only unpressurized hydraulic systems may be opened. Even when a machine is parked on a horizontal surface with ist attachments supported on the ground and its driving motors switched off, there may still be substantial residual pressure in parts of the hydraulic system, e.g. primary pressure from the last hydraulic movements prior to stopping the machine.

Water used for extinguishing purposes would vapourize instantaneously on contact with burning substances and spread burning oil, for example, over a wide area. Water generates short circuits in the electrical system, possibly producing hazards.

Notify the fire brigade.

Fastening and securing elements Check fastening and securing elements, e.g. bolts, nuts, washers, before using them again.

Replace any damaged parts.

Escaping oil is an environmental hazard.

Residual pressure is reduced only gradually. If an intervention into the hydraulic system is to be undertaken immediately after stopping, the system must be depressurzized: (do not leave the driver's seat)  Stand working equipment on the ground,  Shut off the engines,

Spare parts Use only the original sparts parts of Bucyrus HEX.

 Move all control levers and pedals repeatedly into all ndirections.

They are the only ones to fulfill the technical specifications of the machine.

Handling oils and greases

Screwed connections, piping, hydraulic hoses

Hot lubricant or hydraulic oil emerging uncontrolled from the system may result in severe burns.

Repair any leakage in the piping and hose system immediately.

Never set foot withing reach of the emerging oil jet.

A fine, highly pressurized jet of hydraulic oil can penetrate the skin.

Avoid contact with the skin. Wear gloves and firm protective clothing.

Used oil may be harmful to the skin.

Clean soiled skin thoroughly with warm soapy water and apply a barrier cream. Never use fuels or solvents for cleaning the skin.

If you have swallowed any oil, avoid vomiting but consult a doctor immediately.

Never search for leakages with the fingers, but use a piece of cardboard and always wear goggles.

If oil has penetrated into the skin, consult a doctor immediately.

Never repair damaged piping; always replace them.

Replace hydraulic hoses immediately on detecting any damage or moist areas.

Tighten leaking screw plugs only when the system is depressurized.

Escaping oil is an environmental hazard.

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing Non-polluting disposal Dispose of oils, greases, cooling liquids, detergents, solvents and oil-containing components, such as filters, cleaning rags, replaced wearing parts and unusable machine parts, without polluting the environment and separately from other waste.

Seals After replacing parts or after opening housings replace seals. Always use new seals and gaskets.

Clean sealing faces prior to assembly.

Individual spares may contain asbestos. Such spares or their packaging are marked with:

Do not dispose of these substances together with household wastes.

Never process spares containing asbestos mechanically. Inhaling asbestos dust is a health hazard.

Fill these substances into the containers provided for such purposes.

Clean sealing faces prior to assembly.

Like any other oil, also bio-degradable, "environmental-friendly" hydraulic oil must be disposed of separately.

Engine exhaust gases

Do not allow oils and oily wastes to penetrate into the soil or into water. They are an environmental hazard.

Used pressure vessels for cold-starting fluid (ether) must be disposed of properly. Contact the supplier with regard to disposal / return of the vessels.

Even apparently empty pressure vessels can contain rests of ether and therefore explode if they are damaged or heated up above 49°C / 120°F. They must therefore be handled in the same way as full pressure vessels.  Do not keep them on the machine. 

Do not damage or open the vessels.



Do not expose the vessels to great heat or direct sunlight.



Do not dispose of in fire.



Keep the vessels in a place inaccessible to unauthorized persons.



Dispose of the vessels properly.

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Start and operate combustion engines only on well-ventilated premises.

In closed rooms, exhaust gases must be evacuated to the outside; Do not work on the exhaust system an do not make any modifications to it;.

Exhaust gases from diesel engines and some of their constituents may cause cancer, birth defects and other reproductive harm.

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing Handling batteries

Handling of cold-starting fluid (ether)

Battery Posts, terminals and related accessories contain lead and lead compounds, chemicals known to cause cancer and reproductive harm.

Wash hands after handling.

The engine compartment can be equipped with pressure vessels containing cold-starting fluid (ether).

Batteries give off explosive gases.

Never handle batteries close to naked flames and unshielded light sources, never smoke.

Battery acid is toxic and corrosive.

Avoid any contact with the skin, mouth, eyes and clothing. Avoid spilling battery acid or inhaling the vapours.

Wear gloves, firm protective clothing and goggles when handling batteries.

If the skin is splashed with acid, rinse thoroughly with running water and consult a doctor.

If the eyes are splashed with acid, rinse thoroughly with running water and consult a doctor immediately.

Never set tools down on the battery. They may induce a short circuit, causing irreparable damage to the battery and injuring persons.

Never wear metal necklaces, bracelets or watchstraps when working on the battery. The metal parts may induce a short-circuit resulting in burns.

Dispose of used batteries separately from other waste in the interests of environmental protection.

Before working on the electrical system Before performing work on the electrical system where tools, spare parts, etc. can come into contact with electrical conductors or contacts, the battery must be disconnected.

Disconnect first the negative and then the positive terminal.

Ether is toxic and highly flammable; the vessels are under pressure. These pressure vessels can explode if exposed to high temperatures (above 49°C / 120°F) or in the event of damage.

Protect the pressure vessels against damage before beginning to work in or close to the engine compartment.

Read and observe the instructions on the pressure vessels.

For further details please refer to the instructions and safety data-sheets of the manufacturer / supplier of pressure vessels with cold starting fluid (ether).

Provide for sufficient ventilation.

Do not eat, drink or smoke when replacing an empty vessel.

Do not inhale the vapours of escaping cold-starting fluid.

In contact with the skin, ether can cause frostbites and irritations. Avoid skin contact.

Wear suitable protective gloves and goggles.

Even apparently empty pressure vessels can still contain rests of ether and therefore explode if they are damaged or heated up above 49°C. They must therefore be handled in the same way as full pressure vessels.  Do not keep them on the machine. 

Do not damage or open the vessels.



Do not expose the vessels to great heat or direct sunlight.



Do not dispose of in fire.



Keep the vessels in a place inaccessible to unauthorized persons.



Dispose of the vessels properly.

After the work: Reconnect first the positive and then the negative terminal.

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing Selecting oils and greases Use the recommended qualities only, matching viscosities with the temperature level.

After servicing To prevent corrosion, coat all bright metal parts with a grease film.

On completing work, re-install all protective devices.

Filters Replace / clean all filter elements or filter cartridges within the specified periods.

Never start up the drive motors while work is being done on the machine.

Carry out performance tests with the machine.

All filters are coordinated carefully with the equipment. Original Bucyrus HEX parts must be used to ensure smooth running and a long service life of the engine and the hydraulic units.

Sealing elements When dismantling parts, watch for sealing elements.

Check sealing elements prior to installation and replace any that are even slightly damaged.

When assembling, ensure a perfect fit.

Oil-level check and oil change Position the machine horizontally.

Change the oil when the machine is at operating temperature. Warm oil flows better and carries suspended particles (carbon or abraded matter) better.

Lubricating Clean the lubricating nipple, then lubricate as scheduled.

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing INSPECTION AND SERVICING WORK, FIRE AND EXPLOSION HAZARD Safety instructions Prior to commencing work, obtain informationon the national and corporate rules for the prevention of accidents and avoiding fires.

Pay particular attention to hazards caused by combustible and easily flammable substances.

Obtain information on the safe handling of the fire extinguishers to be used.

Avoid smoking and open fire on, next to and below the excavator.

Place suitable fire guardings (fire barriers) if open fire or flying sparks cannot be avoided during repair work.

If necessary, also cover the ground with fireprotective blankets.

Apply special protection to cables, cable ducts as well as to hose and pipe lines.

Have all your welding, flame cutting and grinding work approved before starting work.

The engine compartment can be equipped with pressure vessels containing cold-starting fluid (ether). Ether is toxic and highly flammable; the vessels are under pressure. These pressure vessels can explode if exposed to high temperatures (above 49°C / 120°F) or in the event of damage.

Protect the pressure vessels against damage before beginning to work in or close to the engine compartment.

Ensure sufficient ventilation.

Even battery gases can ignite in open flames or fire.

Do not keep any fire extinguishers that are not suitable or have not been tested.

Combustible and easily or highly inflammable substances or liquids increase the risk of fire and explosion. This is also valid for pressure vessels containing flammable substances as, for instance, spray oil or cold-starting fluid (ether). They are heat-sensitive and can explode even if exposed only to intensive sunlight.

Do not extinguish flammable liquids with water.

Use:  dry-powder, carbon-dioxide or foam extinguishing compounds.

These substance can also ignite themselves if they come close to hot units or objects as, for instance, a turbocharger.

Do not store these substances on the excavator. If combustible, easily or highly flammable substances or liquids were used during maintenance operations, they must be completely removed from the excavator at the end of the work.

When getting into contact with burning substances, the fire-fighting water would abruptly evaporate and distribute the substance such as oil over a wide area. Water causes short-circuits in the electrical system thus possibly entailing new hazards.

Call the fire brigade.

Clean the excavator carefully after the maintenance, if oil, grease, fuel, detergents or coldstarting fluid have been spilt over the machine. If possible, use a steam-jet cleaner for cleaning.

Avoid parking the excavator in places where  combustible substances such as coal dust or tar are present. 

open or smouldering fire may occur.

Remove the excavator from such an area where combustible or easily flammable liquids have spilled from the excavator onto the ground.

Flying sparks (caused by welding, flame cutting, grinding, electrical short-circuit) may cause fire on the ground that can spread to the excavator.

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing INSPECTION AND SERVICING PLANS - INSTRUCTIONS Intervals The inspection and Servicing plan lists all jobs which have to be done on the machine at regular intervals.

The individual inspection and Servicing plans are marked with letters providing a link between the operating hours (OH) recorded by the hours-run meter of the machine and the inspection and sServicing plans.

Plan V N

Do all jobs .... ...once prior to initial commissioning. ...after initial commissioning and during the running-in period (after 100 OH). ...every 10 OH or every working shift 1) T ...every 60 OH or weekly . 2 W ...after every 250 OH. A ...after every 500 OH. B ...after every 1000 OH. C ...after every 5000 OH. D ...after every 10000 OH. E OH = Bh = Operating hours

Change of engine oil The intervals stated for changing the engine oil apply to fuels with a sulphur content of ≤ 0.5% and a permanent ambient temperature down to –10° C (14 °F).

In case of higher sulphur content and/or a permanent ambient temperature of below –10° C (14 °F), shorter intervals are required.

Air-intake system The air filter must be serviced only if the BCS soindicates. Replace the filter elements after one year at the latest.

Oils / Greases For the specification of oils and greases to be used refer to the "Lubricants" section.

The numerals mentioned in the "Oil / Grease" column in the inspection and Servicing plans have the following meaning: Oils for combustion engines and comI pressors Oils for hydraulic systems II IIIa, b, c Oils for gearboxes Greases for bearings and swing rings V

Cleaning jobs Cleaning jobs, especially on cooling systems, must be done at shorter intervals if the machine is exposed to severe dust build-up.

Components The maintenance intervals for components, e.g. engine and gearbox, are listed in the following Bucyrus HEX maintenance schedules.

It is possible that the manufacturer's documentation for these components states intervals deviating from the above-mentioned intervals.

In such case, only the maintenance intervals specified by Bucyrus HEX shall apply.

If the engine oil change intervals are not reached within 6 months, the oil must be changed at least after 6 months.

2

Whichever comes first.

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing Plan V Plan V - Once prior to initial commissioning Page 1 of 2 Location

Servicing work

Engine Engine oil tank (optional) Cooling system Cooling liquid Electrical system Battery Lighting

Check oil level Check oil level

Monitoring, warning and control elements

Check function of monitoring, warning and control elements Check emergency OFF function Check function Check function of working and travelling movement Check pressure (see: Technical handbook) Check oil level Vent (see: chapter “Venting hydraulic system“) Check oil level

BCS Hydraulic system

Hydraulic oil reservoir Hydraulic cylinders Pump tranfer gearbox - Pre-chambers - Expansion reservoir Swing gearbox Travel gearbox (Gearbox partno. 2763214 only) - Pre-chamber / spur wheel section - Brake chambers Travel gearbox (Gearbox partno. 3673978 only) - Hydraulic motor chambers Swing ring Internal gearing Undercarriage Track roller Support roller Track tensioning device Idler

3

Quantity/ No. 2 2

Check

2

Check liquid level Check operation

6

1

1

2

Check oil level Check oil level Check oil level

2 4 2

Check oil level Check oil level Check oil level

2x1 2x2 2

Check oil level

2x2

Check grease filling Check for leaks and free movement Check grease filling, fill in grease 3 Check for leaks and free movement Check pressure (see „Technical Handbook“) Check for leaks and free movement

1 2x6 2x2 2 2

Valid for machines with automatic greasing system for the undercarriage

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing

Plan V - Once prior to initial commissioning Page 2 of 2 Location Central lubricating system Grease container Greasing and pause cycles Level control Service – Station (tanklift) Air conditioner (optional) - Compressor Ramp-type ladder (optional) - Lubricating points On-board crane (optional) - Fastening bolts - Bearings - Joint (column / boom) - Cylinder bearing - Swing ring Hydraulic oil reservoir

Crane drive engine

- Battery Escape ladder (optional) - Locking device - Ladder Harness (optional) - Harness holding device on cab roof All lines, fittings and connections All articutated joints and hinges

3-112

Servicing work

Quantity/ No.

Check filling level Check setting Check function Check operation Check oil level Lubricate Check for tightness Lubricate Lubricate Lubricate Grease Check oil level (see: “On-Board Crane“ operating instructions) Check oil level (see: “Crane drive Engine“ operating instructions) Check liquid level Check function Check function Check free movement Check completeness and condition Check for tightness Inspect visually for leaks, wearing marks Grease

16 4 2 5 1 1

1

2

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing Plan N Plan N – After initial commissioning and during the running-in period (after 100 OH) Page 1 of 2 Location

Engine - Bearing - Fastening bolts Cooling system Cooling liquid filter Radiator - Bearing - Fastening bolts Hydraulic system Oil cooler - Bearing - Fastening bolts Return-flow filter Magnetic rod Pressure accumulator – emergency lowering Pressure accumulator - ramp-type ladder (optional) Pump transfer gearbox - Pre-chambers - Fastening bolts Swing gearbox - Fastening bolts Travel gearbox (Gearbox partno. 2763214 only) - Pre-chamber / spur wheel section - Brake chambers - Magnetic plugs - Fastening bolts Travel gearbox (Gearbox partno. 3673978 only) - Hydraulic motor chambers - Magnetic plugs - Fastening bolts

4

Servicing work

Quantity/ No.

Check for tightness (see „Technical Handbook“) Replace

2x2

Check for tightness (see „Technical Handbook“)

Check for tightness (see „Technical Handbook“) Replace Clean Check function Check function

2x7 1 1 1

Change oil Change oil Check for tightness (see „Technical Handbook“) Change oil Check for tightness (see „Technical Handbook“) Change oil

24 2x54

Change oil Change oil Check / clean Check for tightness (see „Technical Handbook“) Change oil

2x14 2x24

Change oil Check / clean Check for tightness (see „Technical Handbook“)

2x24

44 24

24

see: “Refilling quantities – Oil“ table

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing

Plan N – After initial commissioning and during the running-in period (after 100 OH) Page 2 of 2 Location Swing ring Fastening bolts (swing ring, undercarriage and superstructure) Superstructure Fastening bolts, especially at superstructure / pedestal / driver´s cab Undercarriage Fastening bolts - car body – track frame; - support rollers – track frame; - track rollers – track frame All lines, fittings and connections

3-114

Servicing work

Quantity/ No.

Check for tightness (see „Technical Handbook“) Check for tightness (see „Technical Handbook“) Check for tightness (see „Technical Handbook“)

Inspect visually for leaks, wearing marks

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing Plan T and W Plan T - Every 10 OH or every working shift (whichever comes first) Plan W - Every 60 OH or every working week (whichever comes first) Page 1 of 2 Location

Servicing work Check oil level

Quantity/ No. 2

Plan T 

Plan W 

Engine Engine oil tank

Check oil level

2





Cooling system Cooling fluid level

Check

2





Radiator

Check / clean

2





Fuel system Fuel filter Water trap (optional) Fuel tanks Air-intake system Intake and clean-air lines

Drain off water Drain off water Drain off water and dirt Check BCS – indication Check for tightness and leaks

2x2 2x1 2 1

  

    

Electrical system Lighting

Check operation





Switchgear cabinet - Breather filter - Dust trap - EMERGENCY OFF button

Remove dust Check function

Monitoring, warning and control elements BCS

Check function of monitoring, warning and control elements Check function

Hydraulic system

Check function of working and travelling movement Inspect visually for leaks

 

1 3 









 

Hydraulic oil reservoir Oil cooler

Check oil level Check / clean

1 4



 

Fan wheel

Check condition

4





Check function Check free movement Check completeness and condition Check for tightness

   

   

Attach to the holding device Check oil level



 

Escape ladder (optional) - Locking device - Ladder Harness (optional) - Harness holding device on cab roof - Harness Pump transfer gearbox - pre-chambers expansion reservoir Oil filter (tell-tale) Swing gearbox

Check oil level Check Check oil level

2 2x1 4

 

  

Travel gearbox

Check for leaks

2





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2

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing

Plan T - Every 10 OH or every working shift (whichever comes first) Plan W - Every 60 OH or every working week (whichever comes first) Page 2 of 2 Location

Servicing work

Undercarriage Tracks

Inspect track tension visually

Track roller

Check for leaks and free movement

2x6



Support roller

Check for leaks and free movement

2x2



Idler

Check for leaks and free movement

2



Central lubricating system Grease container Lubricating points Air conditioner (optional) On-board crane (optional) 5 Fastening bolts Crane drive engine

Quantity/ No.

Plan T

Plan W

2





Check filling level Check visually (see: “Air Conditioning manual)

1

Check for tightness Check oil level (see: “Crane drive Engine“ operating instructions) Check oil level Check

16 1

Hydraulic oil reservoir - Reflow filter (contamination indicator) Check condition Fire extinguisher Automatic fire-extinguishing sys- Check control module tem (optional) All lines, fittings and connections Inspect visually for leaks, wearing marks Visual check / overall cleaning Excavator







  

1 1 2

 

 



 

5 Before each deployment of the crane

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing Plan A – E Plan A - after every 250 OH (at 250, 750, 1250 ... OH)

Plan B - after every 500 OH (at 500, 1500, 2500 ... OH)

Plan C - after every 1000 OH (at 1000, 2000, 3000, 4000 ... OH)

Plan D - after every 5000 OH (at 5000, 15000, 25000 ... OH)

Plan E - after every 10000 OH (at 10000, 20000, 30000, ... OH)

Page 1 of 8 Location Servicing in acc. with W or T Monitoring, warning and control elements - Joystick - Control spool - Pedal - Control spool (machine with loading shovel) - Control spool (machine with backhoe bucket)

6

Servicing work

Quant. / Nos.

Plan Plan Plan Plan Plan A B C D E     

Clean, then grease lightly

2x46







Clean, then grease lightly

3x26







Clean, then grease lightly

2x26







apply a thin layer of low temperature grease

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing

Plan A - after every 250 OH (at 250, 750, 1250 ... OH)

Plan B - after every 500 OH (at 500, 1500, 2500 ... OH)

Plan C - after every 1000 OH (at 1000, 2000, 3000, 4000 ... OH)

Plan D - after every 5000 OH (at 5000, 15000, 25000 ... OH)

Plan E - after every 10000 OH (at 10000, 20000, 30000, ... OH)

Page 2 of 8 Location

Servicing work

Engine

Change oil Clean

- Bearing - Fastening bolts - Rubber bearing Centrifuge - Rotor seal - Casing seal V-belt Inspection and servicing Engine with engine oil reservoir

Check tightness Check condition Clean Replace Check /replace Check tension Check condition (see: Operation and Maintenance Manual for the engine) Carry out oil analysis Change oil Clean

- Bearing - Fastening bolts - Rubber bearing Engine oil reservoir - Oilfilter Centrifuge - Rotor seal - Casing seal V-belt Inspection and servicing

7

Check tightness Check condition Change oil Clean Change Clean Replace Check /replace Check tension Check condition (see: Operation and Maintenance Manual for the engine)

Quant. / Nos. 27

Plan Plan Plan Plan Plan A B C D E        

2

  

  

       

2











 

 

 

          

          

          

2x1 2x1 2x1

27

27 2x2 2x1 2x1 2x1

2

  

  

       

       

see “Filling quantities – Oil“ table

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing

Plan A - after every 250 OH (at 250, 750, 1250 ... OH)

Plan B - after every 500 OH (at 500, 1500, 2500 ... OH)

Plan C - after every 1000 OH (at 1000, 2000, 3000, 4000 ... OH)

Plan D - after every 5000 OH (at 5000, 15000, 25000 ... OH)

Plan E - after every 10000 OH (at 10000, 20000, 30000, ... OH) Page 3 of 8 Location

Servicing work

Engine with engine oil reservoir and CENTINEL (optional)

Carry out oil analysis

Change oil Clean - Bearing - Fastening bolts - Rubber bearing Engine oil reservoir - Oil filter Centrifuge - Rotor seal - Casing seal V-belt Inspection and servicing Cooling system Water filter Radiator - Check tightness - Fastening bolts - Rubber bearing Cooling liquid

Anti-freeze Lines Hose clamps

Check tightness Check condition Change oil Clean Change Clean Replace Check /replace Check tension Check condition (see: Operation and Maintenance Manual for the engine) Inspect visually for leaks Replace

Check tightness Check condition Check DCA-4 concentration (see: Operation and Maintenance Manual for the engine) Change Check Check for leaks Check tightness

8

see “Filling quantities – Oil“ table

9

Cooling-liquid replacement after 2 years at the latest

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Quant. / Nos. 2

Plan Plan Plan Plan Plan A B C D E     

28 

 

 

          

          

2

  

  

          

2x2

 

 

 

 

 



  

  

  



  

  

   

28 2x2 2x1 2x1 2x1

19 

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing

Plan A - after every 250 OH (at 250, 750, 1250 ... OH)

Plan B - after every 500 OH (at 500, 1500, 2500 ... OH)

Plan C - after every 1000 OH (at 1000, 2000, 3000, 4000 ... OH)

Plan D - after every 5000 OH (at 5000, 15000, 25000 ... OH)

Plan E - after every 10000 OH (at 10000, 20000, 30000, ... OH) Page 4 of 8 Location Fuel system Fuel filter Water trap (optional) - Filterelement Air-intake system Main filter element Safety filter element Air-intake line and clean-air line Hoses Electrical system Battery cable connections Battery Switchgear cabinet - Breather filter - Filter element

10

Servicing work

Quant. / Nos.

Replace Clean Replace

2x2 2x1 2x1

Check / replace Replace Check for tightness and leaks

2 x 4 10 2 x 4 11

Plan Plan Plan Plan Plan A B C D E  

 

  

  

  

  

  

  





Replace 

Check for tightness Check fluid level

6

Clean Replace

1 1

 

 

 

 





 

 

Replacement of main filter element after one year resp. after 3 cleaning cycles

11

Replacement of safety filter element after one year resp. after 3 cleaning cycles of the main filter element at the latest

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing

Plan A - after every 250 OH (at 250, 750, 1250 ... OH)

Plan B - after every 500 OH (at 500, 1500, 2500 ... OH)

Plan C - after every 1000 OH (at 1000, 2000, 3000, 4000 ... OH)

Plan D - after every 5000 OH (at 5000, 15000, 25000 ... OH)

Plan E - after every 10000 OH (at 10000, 20000, 30000, ... OH) Page 5 of 8 Location

Servicing work

Quant. / Nos.

Plan Plan Plan Plan Plan A B C D E

Hydraulic system

Check pressure (see: Technical handbook)







- Fastening bolt

Check for tightness







- Rubber bearing

Check condition







Return-flow filter

Replace

2x7







High-pressure filter

Check / clean

4



Oil cooler - Bearing













Replace

4

Magnetic rod

Check / clean

1

Bypass valve (working circuit)

Check / clean filter sieve

4













































Filter (pilot control circuit)

Check for contamination and damage Replace

2x1

Filter (control circuit)

Check for contamination and damage Replace

1

Filter (auxiliary control circuit)

Check for contamination and damage Replace

Filter (swing pump feed circ.)

Check / clean

2x2

Replace

2x2





Replace

2





Breather filter Hydraulic oil reservoir

Carry out oil analysis Change oil

Pressure accumulators Cylinder (seals and guide rings)

12

Check pressure (see: Technical handbook) Replace

1

1 1 1

1 1 12 13







   

see: “Refilling quantities – Oil“ table

13

Unless it is regulary analyzed, the hydraulic oil must be changed every 5000 OH or after 3 years at the latest

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing

Plan A - after every 250 OH (at 250, 750, 1250 ... OH)

Plan B - after every 500 OH (at 500, 1500, 2500 ... OH)

Plan C - after every 1000 OH (at 1000, 2000, 3000, 4000 ... OH)

Plan D - after every 5000 OH (at 5000, 15000, 25000 ... OH)

Plan E - after every 10000 OH (at 10000, 20000, 30000, ... OH) Page 6 of 8 Location

Servicing work

Pump transfer gearbox

- Breather filter

Carry out oil analysis Change oil Clean Replace Change oil Clean Check tightness Check for contamination and damage Replace Carry out oil analysis Change oil Replace

Travel gearbox (gearbox

Carry out oil analysis

- Breather filter - Pre-chamber - Breather filter Fastening srews Oil filter

Swing gearbox

Quant. / Nos. 2 2 14 15 2x1 2x1 2x5 2x1 2x1

Plan Plan Plan Plan Plan A B C D E                          



 

   

2









Check oil level Change oil Clean Check oil level Change oil Check oil level Change oil Clean Replace Carry out oil analysis

2 2 14 2x6 2x2 2 x 2 14 2 x 1 14 2 x 1 14 2x1 2x1 2







 





         

         

Check oil level Change oil Clean Check oil level Change oil Replace

2 2 14 2x6 2x2 2 x 2 14 2x3

     

     

2x1 4 4 14 4x1

   

partno. 2763214 only)

- Magnetic plugs - Brake chambers Pre-chamber - Magnetic plugs Breather filter Travel gearbox (gearbox

 









 

partno. 3673978 only)

- Magnetic plugs - Hydraulic motor chambers Breather filter

14



see: “Refilling quantities – Oil“ table

15

When using TM Gearoil CLP 220 LT (Bucyrus HEX partno. 6002885): carry out oil analysis after 1000OH, oil change after 2000OH.

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing

Plan A - after every 250 OH (at 250, 750, 1250 ... OH)

Plan B - after every 500 OH (at 500, 1500, 2500 ... OH)

Plan C - after every 1000 OH (at 1000, 2000, 3000, 4000 ... OH)

Plan D - after every 5000 OH (at 5000, 15000, 25000 ... OH)

Plan E - after every 10000 OH (at 10000, 20000, 30000, ... OH) Page 7 of 8 Location

Servicing work

Swing ring Gearing / pinion Fastening bolts (swing ring, undercarriage and superstructure)

Check grease filling Check condition Check for tightness (see: Technical Handbook)

- Diaphragm

Replace bolts first after 40000 OH, then every 10000 OH (see Technical Handbook) Check wear (see: Technical Handbook) Check pressure (see: Technical handbook) Replace

Track roller (optional)

Grease

Central lubricating system

Check function

Undercarriage Diaphragm accumulator

Oilfilter (hydraulic circuit grea- Check for contamination and se pump) damage Replace Grease filter (filling grease Check for contamination and container) damage Replace Grease filter (grease lines) Check for contamination and damage Replace Grease container, breather Replace Air conditioner resp. Heating - Air suction filter mat

(see: Air conditioner manual)

Quant. / Nos. 1

Plan Plan Plan Plan Plan A B C D E          





























1







1 1





 

1 2





 





 















2 2 2x6 

2 1 6

Ramp-type ladder - Greasing points

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Lubricate



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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing

Plan A - after every 250 OH (at 250, 750, 1250 ... OH)

Plan B - after every 500 OH (at 500, 1500, 2500 ... OH)

Plan C - after every 1000 OH (at 1000, 2000, 3000, 4000 ... OH)

Plan D - after every 5000 OH (at 5000, 15000, 25000 ... OH)

Plan E - after every 10000 OH (at 10000, 20000, 30000, ... OH) Page 8 of 8 Location On-board crane (Option) 16 - Bearing - Joint (column / boom) – Cylinder bearing – Swing ring Hydraulic system – Return-flow filter – Breather filter

Crane drive engine - Oil filter – Fastening bolts – Fuel filter – Air filter – Battery cable connection

Steel components

Modules – Fastening bolts All articulated joints and hinges

Servicing work

Lubricate Lubricate Lubricate Grease Change oil Replace Replace see: “On-Board Crane“ operating instructions Clean Change oil Replace Check for tightness Replace Replace Check for tightness see: “Crane Drive Engine“ operating instructions Visual inspection acc. to "Structural Inspection Report every 500 OH" 18 If any suspect areas have been found additional testing is required: For detailed crack analysis prepare the surface of the relevant area to be inspected and carry out the dye penetrant, magnetic powder or ultrasonictest.18 Check for tightness Grease

16

Do all servicing jobs at least once a year and when necessary

17

see: “Refilling quantities – Oil“ table

Quant. / Nos.

Plan Plan Plan Plan Plan A B C D E

4 2 5 1 1 17 1 1 



































 

 

 

1 1 17 1 1 1 1 2

18

"Structural Inspection Reports" for inspections every 500 OH and every 5000 OH can be downloaded from the CGM HMS GmbH website www.bucyrus-hex.de, section "Support, Warranty".

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing LUBRICATING CHART – GREASE

Fig. 3-1:

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing Lubricating chart – Grease (legend) No. Greasing point 1 3

Central lubricating system – grease container Track roller (Option)

4

Ramp-type ladder

5

On-board crane (Option)

6

Number

Lubricant properties

1 2x6

V 19 Tribol Bucyrus HEX part no. 2764564

Grease every .... operating hours 10 1000

V 19

1000 250

V 19

- Bearing - Joint (column / boom)

4 2

250 250

- Cylinder bearing

5

- Swing ring

1

Graphitespray

250

2 x 4 20 3 x 2 20

V 19

1000 1000

250

Monitoring, warning and control elements - Joystick - Pedal

All other greasing points are supplied with grease by the central lubricating system.

Filling quantities – Grease Greasing point Central lubricating system – grease container (different containers available) Internal gearing – Roller-bearing swing ring Idler (permanent grease filling) Track rollers (permanent grease filling)

Support rollers (permanent grease filling)

19

see: "LUBRICANTS" section.

20

apply a thin layer of low temperature grease

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Lubricant properties

Filling quant. in kg lb appr. 1000

appr. 2205

appr. 300 2 x appr. 25

appr. 662 2 x appr. 55

12 x appr.

21

12 x appr.

46.3

4 x appr. 14

4 x appr. 31

V 19

Tribol Bucyrus HEX part no.

2764564

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing INSPECTION PLAN - OIL

Fig. 3-2:

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing Inspection plan – Oil (legend) No. Location

21

Number

Lubricant properties 21

Check oil level every ... OH 10

Change oil every ... OH 250

10

1000

1

Engine

2

1

Engine with engine oil reservoir (optional)

2

I I

1

Engine with engine oil reservoir and CENTINEL (optional)

2

I

10

5000

3

Hydraulic system

1

10

10000 22

4

Pump transfer gearbox

2

II III.a

60

1000

5

- Pre-chambers Swing gearbox

2x5 4

10 10

1000 1000

6

Travel gearbox

2

500

5000

500

5000

500

5000

7

- Pre-chamber / spur wheel section (gearbox PN 2763214 only) - Brake chambers / hydraulic motor chambers On-board crane (optional)

10

250 23

10

1000 24

2x1

III.b III.a

2x2

- Crane drive engine

1

- Hydraulic oil reservoir

1

I II

see: "LUBRICANTS" section

22

Change hydraulic oil every 5000 OH unless the oil is analyzed at regular intervals, but not later than every 3 years.

23

Change oil at least once a year.

24

Change hydraulic oil at least once a year.

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing Filling quantities - oil Location Engine

Filling quantity litres gal 2 x approx. 185 2 x approx. 48.9

Engine oil tank

2 x approx. 625

2 x approx. 165

Hydraulic oil reservoir Hydraulic system Pump transfer gearbox - Pre-chambers (working pumps)

approx. 7500 approx. 5200 2 x approx. 85 8 x approx. 1,5

approx. 1981 approx. 1374 2 x approx. 22.5 8 x approx. 0.4

- Pre-chambers (swing pumps) - Pre-chambers (servo pumps) Swing gearbox

4 x approx. 0,4 2 x approx. 0,2 4 x approx. 38

4 x approx. 0.1 2 x approx. 0.05 4 x approx. 10

Travel gearbox (gearbox PN 2763214) - Pre-chamber / spur wheel section

2 x approx. 145 2 x approx. 10

2 x approx. 38.3 2 x approx. 2.6

- Brake chambers

4 x approx. 0,3

4 x approx. 0.08

Travel gearbox (gearbox PN 3673978) - Hydrauli motor chambers On-board crane (optional) - Crane drive engine

2 x approx. 165 2 x approx. 3,5

2 x approx. 43.6 2 x approx. 0.9

approx. 5,5

approx. 1.45

approx. 50

approx. 13.2

- Hydraulic oil reservoir

Oil

I I II III.a III.b III.a III.a I II

Filling quantities – other Location

Filling quantity litres

Cooling system - engine

gal

2 x approx. 290 2 x approx. 76.6

Fuel tank

2 x approx.

5350

2 x approx.

1410

Fuel tank, crane drive engine (optional)

approx. 20

approx. 5.3

Screen washer

approx. 13

approx. 3.4

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing LUBRICANTS

Avoid mixing of different hydraulic fluids

Notes on the selection of oils and greases

The machine has been run in at the factory with BM Long Term Hydraulic Fluid HSS (Part-No. 2482971). Bucyrus HEX recommends using this high-grade hydraulic fluid also in operation as it has been made especially for use in these machines to which it is also perfectly adapted.

Original Bucyrus HEX oils and greases Besides regular and careful maintenance, the quality of the oils and greases used in the machine has a decisive influence on high performance, reliability and long service life of a machine and of its units and assemblies.

The lubricants tables in the Bucyrus HEX Operating Instructions contain specifications for the oils and greases that are approved for use in Bucyrus HEX machines. These oils and greases are especially adapted to Bucyrus HEX machines and their units and assemblies.

Other oils and greases which do not fulfil the requirements of the specifications can be the cause of premature wear or of damage to and failures of machine units and assemblies.

For this reason, Bucyrus HEX only approves the use of the specified oils and greases.

All other qualities are not approved.

Alternative oils and greases The oils and greases filled into the machine must meet at least the specifications mentioned in the lubricants tables of the Bucyrus HEX Operating Instructions.

In the event of damage to the machine or to its units and assemblies caused by the use of alternative oils and greases that are not compatible with Bucyrus HEX specifications, Bucyrus HEX does not assume any responsibility and does not accept any warranty claims.

If oil analyses are performed regularly and with positive results, the BM Long Term Hydraulic Fluid can remain in the machine for up to 10 000 operating hours.

If an alternative hydraulic fluid is to be used, it must fulfil the same specifications. Please note that the change interval for alternative fluids is fixed at 5 000 operating hours.

There is an increased risk of damage to hydraulic components, if different hydraulic fluids are mixed during topping up as well as when changing over to a fluid of a different type or from another manufacturer.

For topping up, it is therefore necessary to use only same hydraulic fluid as the one that is already in the hydraulic system.

When changing over to an alternative hydraulic fluid, please observe that there is always a small amount of old fluid remaining in the hydraulic system even after the system has been emptied. The mixing of this residual amount of old fluid with the new alternative fluid reduces the properties of the fluid dramatically and can cause damage to components of the hydraulic system in operation.

To avoid this result, the change-over to the alternative fluid must be performed in strict compliance with the manufacturer's prescriptions. The manufacturer must confirm that his hydraulic fluid is compatible with the BM Long Term Hydraulic Fluid.

The remaining amount of old fluid must not exceed 2% of the total volume. This can only be achieved by repeated flushing with the total fluid volume.

If the remaining amount of fluid exceeds 2% of the total volume, the fluid becomes a detrimental "mixed fluid".

The operation of the system with mixed fluids must by all means be avoided.

Bucyrus HEX assumes no warranty for damage caused as a result of the machine having been operated with consumables of inappropriate specification or with mixed fluids.

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing

I.

Oils for combustion engines

Fig. 3-3:

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II.

Oils for hydraulic system

Fig. 3-4:

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing III.a Oils for pump gearboxes and travel gearboxes

Fig. 3-5:

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing III.b Oils for swing gearboxes

Fig. 3-6:

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing V. Greases for bearings, swing rings and track system (Central lubrication system)

Fig. 3-7:

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing Grease for idlers, track rollers and support rollers (Lifetime lubrication)

Fig. 3-8:

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing Coolant for use on all combustion engines

Fig. 3-9:

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing SERVICING WORK Hose line for oil and cooling liquid changes Collect escaping oil and cooling liquid and discard without polluting the environment.

The engines, the hydraulic oil reservoir, the pump transfer gearboxes, the swing gearboxes and the radiators (engine cooling liquid) are moreover equipped with automatic drain valves (1, Fig. 3-11:).

These automatic drain valves permit oil- and cooling-liquid changes without polluting the environment.

Carry out oil changes when the machine is at operating temperature; warm oil drains away more easily.

Filling and draining is can be done by means of a hose through the service station (tanklift) (Fig. 3-10:).

For filling and draining, a flexible hose is connected to the express coupling on the service station and to the service vehicle at the other end.

The filling operations require an overpressure, whereas the draining operations require low pressure.

Fig. 3-11:

Change oil or cooling liquid as follows:  Place a collecting recipient for used oil or cooling liquid under the corresponding automatic drain valve. For the recipient capacity refer to the "Refilling quantities - Oil" table or to the "Refilling quantities - Other" table.  Unscrew protective cap from automatic drain valve.  Screw on hose line (2) to open the valve, so that the oil or the cooling liquid can flow out.

Fig. 3-10:

 When the oil or the cooling liquid has drained away, unscrew hose line to allow the valve to close automatically.  Screw protective cap back in place.

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing ENGINE Engine - Safety instructions Start and operate combustion engines only on well-ventilated premises.

In closed rooms, exhaust gases must be evacuated to the outside.

Do not work on the exhaust system an do not make any modifications to it.

Exhaust gases from diesel engines and some of their constituents may cause cancer, birth defects and other reproductive harm.

Read and observe: "Inspection and Servicing – Safety Instructions" and the engine operating instructions.

Before cleaning the engines Exhaust pipes and turbo chargers in the engine compartments are covered with special heat-insulating material.

This material must not be spraywashed with steam-jet cleaners or high-pressure cleaners. It will be damaged. Therefore cover all the insulating material with plastic foils before using steam-jet cleaners or highpressure cleaners inside the engine compartments.

Retensioning the alternator belt

Risk of injury from hot or rotating parts of the engine.

Checking and adjusting the valve clearance

Shut off engines and allow to cool down.

These and other servicing works are described in the engine manufacturer's operating instructions.

Secure the machine as described in the "Securing the machine" section.

Before starting inspection and maintenance work, secure the machine as described in the “Securing the machine “ section.

Protect the skin from potentially harmful contact with engine oil.

Wear protective gloves and firm working clothing.

The engine compartment can be equipped with pressure vessels containing cold-starting fluid (ether).

Ether is toxic and highly flammable; the vessels are under pressure. These pressure vessels can explode if exposed to high temperatures (above 49°C / 120°F) or in the event of damage. Protect the pressure vessels against damage before beginning to work in or close to the engine compartment.

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing Engine oil, checking the level / topping up The actual pressure of the engine oil and engine oil temperature is constantly monitored by the BCS (Fig. 3-12:) when the machine is in operation.

 Draw out dipstick a second time. The oil level should now lie between the marks (arrows, Fig. 3-14:). If the oil level is at the "min" mark or below, top up with engine oil through filler tube (2, Fig. 3-13:).

BCS give acoustic warnings to the operator if the engine oil temperature too high or the oil pressure is too low.

Fig. 3-14:

Fig. 3-12:

Engine oil can also be filled in from the service station (Fig. 3-15:) through  express coupling (8) for the lefthand engine, 

express coupling (9) for the righthand engine,

(see chapter "Changing the engine oil").

Fig. 3-13:

 Park the machine on a horizontal surface and secure against inadvertent movements.

Fig. 3-15:

 Shut off engines.  Draw out oil dipstick (1, Fig. 3-13:).  Wipe oil off the dipstick with a clean, lintfree cleaning rag and re-insert.

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing Engine oil reservoir, checking the oil level / topping up If required the oil pan of the engine is automatically filled up with engine oil from the engine oil reservoir.

That means the engine oil pan of the engine is sufficient filled up with engine oil as long as engine oil is in the engine oil reservoir.

Check oil level in the engine oil reservoir regulary and fill up if neccessary.  Park the machine on a horizontal surface and secure against inadvertent movements.  Shut off engines.  Unlock the oil dipstick (arrow, Fig. 3-16:) and withdraw.

Fig. 3-16:

 Wipe oil off the dipstick with a clean, lintfree cleaning rag and re-insert.  Draw out dipstick a second time. The oil level should lie at the mark. If the oil level is below, the engine oil is filled in from the service station (Fig. 3-17:) through - express coupling (6) for the lefthand engine oil reservoir, - express coupling (7) for the righthand engine oil reservoir. (see section “Engine oil reservoir (optional), draining the oil off”).

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Fig. 3-17:

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing Engine oil, change Risk of scalding from hot engine oil.

Read and observe: "Inspection and servicing – Safety instructions".

The engines may also be hot. Wear protective gloves and firm working clothing.

Collect escaping oil and discard without polluting the environment.

Drawing off engine oil with the service station.  Bring engine oil to operating temperature.

Fig. 3-18:

 Park the machine on a horizontal surface and secure.  Shut off the engines.  Draw off the engine oil through: 

express coupling (8, Fig. 3-18:) for the lefthand engine,



express coupling (9) for the righthand engine.

 Unscrew cap of express coupling and connect hose line of the service vehicle.

The hose line and its use are described in the "Hose line for oil and cooling liquid changes" section.

After the engine oil has been drawn off:  Replace the engine oil filters.  Remove the hose line. The express coupling closes automatically.  Screw on protective cap.

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing Filling in engine oil  Fill in engine oil through filler tube (2, Fig. 3-19:) until the oil level has reached the "max" mark (Fig. 3-20:) on dipstick (1).

Filling in engine oil through the service station (optional) Fill in engine oil through:  express coupling (8, Fig. 3-21:) for the lefthandengine, 

express coupling (9) for the righthand engine,

until the oil level has reached the "max." mark (Fig. 3-20:) on dipstick (1, Fig. 3-19:).  Unscrew cap of express coupling and connect filling hose of the service vehicle.

Fig. 3-19:

The hose line and its use are described in the "Hose line for oil and cooling liquid changes" section.  Start the engines and allow to run at idling for abt. 2 minutes.  Check oil level at dipstick (1, Fig. 3-19:) and top up with oil to the "max" mark (Fig. 3-20:if required.  Remove the filling hose.

The express coupling closes automatically.

Fig. 3-20:

 Screw on protective cap.

Fig. 3-21:

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing Engine oil reservoir (optional), draining the oil off Risk of scalding from hot engine oil.

Read and observe: "Inspection and servicing – Safety instructions".

Draining the oil off the engine oil reservoir  Bring engine oil to operating temperature.  Park the machine on a horizontal surface and secure engine oil reservoir.  Shut off the engines.

The engine oil reservoirs may also be hot. Wear protective gloves and firm working clothing.

Collect escaping oil and discard without polluting the environment.

Draw off engine oil with the service station (Fig. 3-22:) through  express coupling (6) for the lefthand engine oil reservoir, 

express coupling (7) for the righthand engine oil reservoir.

 Unscrew cap of express coupling and connect hose line of the service vehicle.

The hose line and its use are described in the "Hose line for oil and cooling liquid changes" section.  Remove the hose line.

The express coupling closes automatically.  Screw on protective cap.  After the engine oil has been drawn off: Replace the engine oil filter.

Fig. 3-22:

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing Filling in engine oil The engine oil is filled in with the service station (Fig. 3-23:) through  express coupling (6) for the lefthand engine oil reservoir, 

express coupling (7) for the righthand engine oil reservoir,

until the oil level reches the mark on the dipstick (2, Fig. 3-24:).  Unscrew cap of express coupling and connect hose line of the service vehicle.

The hose line and its use are described in the "Hose line for oil and cooling liquid changes" section.  Start the engines and allow to run at idling for abt. 2 minutes.

Fig. 3-23:

 Check oil level and top up with engine oil until the oil level has reached the mark on dipstick (2, Fig. 3-24:).  Remove the hose line.

The express coupling closes automatically.  Screw on protective cap.

Fig. 3-24:

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing Oil change prolongation system, replacing the oil filter

Oil filters Carry out servicing of the full-flow oil filters (2, Fig. 3-25:) in accordance with the engine operating instructions.

Read and observe: "Inspection and servicing – Safety instructions".

Risk of scalding from hot engine oil.

The filter housing may also be hot.

Wear protective gloves and firm working clothing.

Collect escaping oil and discard with-out polluting the environment

Fig. 3-25:

Replacement  Shut off the engines.  Unscrew the filters.  Install new filter together with slightly oiled sealing ring and tighten by hand.

Thereafter  Allow engines to run at idling for a short while and check filters for tightness and leaks before shutting off the engines.  Check oil level after abt. 10 minutes and top up, if required.

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing Eliminator filter and centrifuge (optional) Risk of injury due to rotating parts inside the centrifuge.

The rotor of the centrifuge must be stationary.

The pressure in the centrifuge must have disappeared.

Read and observe: "Inspection and servicing - Safety instructions" and the “Moatti Lube Oil Filter Instruction Book”.

Centrifuge Servicing: Engine oil impurities filtered out in the eliminator filters (1, Fig. 3-26:) are transported to the centrifuge (2) where they are filtered out by centrifugal force.  Shut off engines.  Wait for 5 - 10 min.

Dismantling the centrifuge Risk of injury due to rotating parts inside the centrifuge.

The rotor of the centrifuge must be stationary.

The eliminator filter may be hot. Wear protective gloves and firm protective clothing.

Collect escaping oil and discard without polluting the environment.

Impurities in the engine oil are filtered out in the eliminator filter (1, Fig. 3-26:).

Most of the cleaned engine oil flows back to the engine after being cleaned.

A small quantity of the engine oil flows in the bypass to the centrifuge (2).

The eliminator filter is self-cleaning and maintenance-free (see “Moatti Lube Oil Filter Instruction Book”).

The pressure in the centrifuge must have been eliminated.

The rotor may be hot. Wear protective gloves and firm protective clothing.  Slacken screws (2, Fig. 3-27:).  Slacken hollow screw (6) and remove together with cover (1).  Withdraw rotor housing (4) and set down on a timber base.  Unscrew nut (3) and remove rotor housing (4).  Remove dirt in rotor housing by tapping lightly.

Fig. 3-26:

Fig. 3-27:

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing  Withdraw plate assembly (12, Fig. 3-28:) from rotor (13).

The plates may have sharp edges.

 Remove clip (14, Fig. 3-29:) and distributor plate (15).  Remove plates (16) and end plate (17) from distributor (18).

Cleaning the centrifuge  Check the inside of the rotor housing.  Remove any dirt deposits without damaging the surface of the rotor housing. If necessary, clean all centrifuge parts in diesel fuel. Remove all residual dirt particles with compressed air or an air/water pistol.

Adhering dirt unbalances the rotor and may damage the bearings.

Assembling the centrifuge The plates (16, Fig. 3-29:) have 4 possible opposing positions.

 Place paper filter into the rotor cap (4, Fig. 3-28:).  Assembly is done in the reverse sequence to dismantling.  Run engines at idling speed for a short time and check centrifuge for leaks.

Fig. 3-28:

 Shut off engines.  Check oil level after ca. 10 minutes; top up if necessary.

Fig. 3-29:

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing Cold-starting fluid (ether) - Replacing the pressure vessel

If the machine is used in low temperatures, the engine may be equipped with a cold-starting device.

Read and observe: "Inspection and servicing Safety instructions"

The pressure vessel containing the cold-starting fluid (ether) can be installed in or near the engine compartment.

Risk of injury Cold-starting fluid is composed mainly of ether.

Ether is toxic when the mists and vapours are inhaled. Ether is harmful to the eyes, the skin, the respiratory system and the central nervous system.

Prolonged inhalation of ether can be fatal.

In contact with the skin, ether can cause frostbites and irritations.

Ether is toxic and highly flammable; the vessels are under pressure.

These pressure vessels can explode if exposed to high temperatures (above 49°C/ / 120°F) or in the event of damage.

Before replacing an empty pressure vessel: Read and observe the instructions on the pressure vessels.

Replacing the pressure vessel:  Remove the clamp around the pressure vessel.  Unscrew the pressure vessel carefully from the metering valve.  Remove the used seal from the metering valve.  Insert a new seal into the valve (supplied with the new pressure vessel).  Screw the new pressure vessel onto the metering valve and tighten by hand.  Fasten the clamp round the pressure vessel.

For further details please refer to the instructions and safety data-sheets of the manufacturer / supplier of pressure vessels with cold starting fluid (ether).

Even apparently empty pressure vessels can contain rests of ether and therefore explode if they are damaged or heated up above 49°C / 120°F. They must therefore be handled in the same way as full pressure vessels.  Do not keep them on the machine.

Provide for sufficient ventilation of the surroundings.



Do not damage or open the vessels.



Do not expose the vessels to great heat or direct sunlight.

Do not eat, drink or smoke when replacing an empty vessel.

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The vessel is screwed onto an electro-mechanical metering valve. At temperatures below 0°C (32°F), this valve is activated automatically by the engine electronics and injects a precisely metered amount of cold-starting fluid into the air intake duct of the engine.



Do not dispose of in fire.

Do not inhale the vapours of escaping cold-starting fluid (ether).



Keep the vessels in a place unaccessible to unauthorized persons.

Avoid skin contact. Wear suitable protective gloves and goggles.



Dispose of the vessels properly.

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing COOLING SYSTEM

Temperature

Risk of scalding from hot cooling liquid.

The cooling liquid circuit is controlled by a thermostat. The max. admissible temperature is ca. 100° C (212°F).

Read and observe: "Inspection and servicing - Safety instructions".

In case of higher temperatures, the BCS displays a warning on the screen (Fig. 3-30:).

Secure the machine as described in the "Securing the machine" section.

Shut off the engines and allow to cool down.

Collect escaping cooling liquid and discard without polluting the environment.

Protect the skin from contact with cooling liquid.

Skin contact with cooling liquid is a potential health hazard.

Wear protective gloves and firm working clothing.

Fig. 3-30:

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing Radiators The radiators are located on the superstructure in the counterweight module.

Weekly checks:  Check radiator fins for dirt and clean, if required.

Cooling-liquid level An insufficient cooling-liquid level is displayed on the BCS screen (Fig. 3-31:).

The radiator caps (1, Fig. 3-32:) are accessible from above.

Risk of scalding from hot cooling liquid. Open radiator cap cautiously.

Fig. 3-31:

 Turn radiator cap (1) back to the first notch.  When the pressure has been released turn cap into the "open" position and remove.

The level indicator (4, Fig. 3-32:) shows the liquid level.

The cooling-liquid level should be between the “FULL” and the “LOW” marking. Top up with cooling liquid, if required.

Fig. 3-32:

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing Topping up cooling liquid The cooling-liquid level should be between the “FULL” and the “LOW” marking of level indicator (4, Fig. 3-33:). Top up with cooling liquid, if required.  Fill cooling liquid through filler tube (1, Fig. 3-33:) into the cooling system or use the service station, see “Topping up cooling liquid using the service station”.

Do not fill in cold cooling liquid when the engine is at operating temperature.

Before refilling, allow engine to cool down to below 50° C (122°F).

For topping up of the cooling system use specially prepared water only.

Specially prepared water must consist of:  calcium-free water, distilled water, rain water, and 

anti-freeze compound.

The anti-freeze compound must always be filled into the system independent of climatic conditions.

In this case, it serves as corrosion protection for the cooler made of aluminum.

The mixing ratio of anti-freeze compound / cooling water must be at least 50 % : 50 % (anti-freeze protection down to -40 °C / -40°F).

For use at lower temperatures, the amount of antifreeze must be increased accordingly.

After filling in cooling liquid allow the engines to run for short period to eliminate air voids before topping up with cooling liquid until the cooling liquid level lies between the “FULL” and the “LOW” mark of the level indicator (4, Fig. 3-33:).

In case of significant cooling-liquid losses, the whole cooling system must be checked for leaks.

Check regularly:  all lines for leaks and all hose clamps for tightness.

Fig. 3-33:

Checking the DCA concentration Observe the instructions of the engine manufacturer with regard to the DCA concentration (see engine manufacturer's operating instructions).

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing Topping up cooling liquid using the service station

Cooling liquid, change Risk of scalding from hot cooling liquid.

The cooling liquid can also be filled in with the service station (Fig. 3-34:) through  express coupling (2) for the lefthand engine, 

express coupling (3) for the righthand engine.



Unscrew cap of express coupling. Connect the filling hose of the service vehicle.

The hose line and its use are described in the "Hose line for oil and cooling liquid changes" section. 

Remove hose.

The express coupling closes automatically.



Screw on protective cap.

Read and observe: Inspection and servicing – Safety instructions.

Shut off the engines and allow to cool down.

The radiators may also be hot. Wear protective gloves and firm working clothing.

Collect escaping cooling liquid and discard without polluting the environment.

The cooling liquid must be changed regularly and after two years at the latest.

Drawing off cooling liquid

Fig. 3-34: Fig. 3-35:

The cooling liquid can also be drawn off with the service station (Fig. 3-35:) through  express coupling (2) for the lefthand cooling circuit, 

express coupling (3) for the righthand cooling circuit.

 Unscrew cap of express coupling. Connect hose line of the service vehicle.

The hose line and its use are described in the "Hose line for oil and cooling liquid changes" section.  Remove hose line.

The express coupling closes automatically.  Screw on protective cap

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing Filling in cooling liquid

Testing the cooling liquid composition

 Shut off the engines.

The engine operating instructions contain a detailed description of how to prepare and test the cooling liquid composition. In case of imminent frost check that the factory-adjusted anti-freeze concentration is sufficient for the expected temperatures.

 Fill in cooling liquid with the service station (Fig. 3-36:) through: 

express coupling (2) for the lefthand cooling circuit,



express coupling (3) for the righthand cooling circuit.

 Unscrew cap of express coupling.

Connect hose of the service vehicle.

Check the cooling liquid in the cooling system regularly to ensure that the water filter replacement interval resp. the DCA4 mixture is sufficiently concentrated to prevent corrosion under the corresponding operating conditions.

The hose line and its use are described in the "Hose line for oil and cooling liquid changes" section.  Remove hose from express coupling.

The coupling closes automatically.  Screw on protective cap.

Fig. 3-36:

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing Water filter, change Risk of scalding from hot cooling liquid.

Read and observe: "Inspection and servicing – Safety instructions".

The filter housings may be hot, too. Wear protective gloves and firm working clothing.

Collect escaping cooling liquid and discard without polluting the environment.

Replace water filter regularly according to the maintenance plans:  Close valve (2, Fig. 3-37:).

Fig. 3-37:

 Unscrew water filter (1).  Screw on new water filter until the sealing ring contacts the filter head. Continue to tighten the filter by another ½ to ¾ turn.

Tightening the filter element with a tool can damage or deform the filter head.  Open valve (2).  After a short period of working time, check for leaks.

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing AIR-INTAKE SYSTEM Wear fall arresters.

Risk of injury caused by rotating or hot parts of the engine.

Shut off the engines before working on the air-intake system.

Secure the machine as described in the "Securing the machine" section.

Read and observe the "Engine - Safety instructions" chapter.

Do not start the engine when parts of the air-intake system have been detached.

Fig. 3-38:

Engine damage may occur if the engine is allowed to draw in unfiltered air.

Each engine is equipped with four dry-air filters (Fig. 3-38:) consisting of main and safety filter element.

Insufficient air-intake performance, caused by a contaminated main filter element, is displayed on the BCS-screen (Fig. 3-39:).

Clean or renew main filter elements only if the BCS displays a warning on the screen (Fig. 3-39:) with the engines running at high speed.

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Fig. 3-39:

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing Main filter elements, removal and installation  Unscrew nut (1, Fig. 3-40:) and remove cover (2).  Unscrew nut (4) and withdraw main filter element (5). Do not loose the washer under nut (4).  Replace or clean main filter element.

During the removal of the main filter element, the safety element (7, Fig. 3-41:) must remain in the filter housing.

New or cleaned main filter elements should always be at hand to shorten excavator downtimes.

Fig. 3-40:

Before installing the filter element, clean contact faces at cover (2, Fig. 3-40:) and at filter housing.  Put on cover (2) and tighten nut (1).

Fig. 3-41:

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing Main filter elements, checking and cleaning Examine the filter paper of the element with a lamp which is introduced into the element (Fig. 3-42:).

Any damage is then clearly visible.

Replace damaged or deformed elements immediately.

Check element seal. When the seal is damaged, the filter element must be replaced, too.

Cleaning with compressed air is suitable if the filter element is to be re-used immediately.

Blow filter element (Fig. 3-43:) clean with dry compressed air from the inside by moving the compressed-air gun up and down.

Fig. 3-42:

The pressure at the nozzle must not exceed 3 bars / 43 psi.

Cleaning is terminated when all visible dust has been blown out of the filter element.

Never clean filter element by beating against hard objects.

Replace the main filter element after 1000 operating hours or 3 cleaning cycles; and, after one year of operation at the latest.

Fig. 3-43:

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing Safety filter element, replace Replace the safety filter elements (7, Fig. 3-44:) after 1000 operating hours or 3 cleaning cycles; after one year of operation at the latest.

Never clean the safety filter element, but always renew.

 Remove main filter element (5, Fig. 3-45:) as described above.  Check the vacuum indicator (6, Fig. 3-44: resp. arrow Fig. 3-46:) whether - the green spot is visible; in this case the safety filter must not be replaced - the green spot is not visible; in this case the safety filter must be replaced.

Fig. 3-44:

 Unscrew vacuum indicator (6) and withdraw safety filter element (7).  Install the new safety filter element and a cleaned or a new main filter element.

Fig. 3-45:

Fig. 3-46:

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing Air-intake lines

Dust collection

At regular intervals:  check intake lines for leaks and hose clamps for tightness;

Dust accumulating on the filter-housing bottom is constantly sucked away by the exhaust system during operation.

 replace hoses between filter housing and engine.

The non-return valves (1, Fig. 3-47:) in the suction lines prevent engine exhaust gases from being sucked in.

During all works on the air-intake system ensure proper sealing to prevent unfiltered air from reaching the engines.

At regular intervals:  check suction lines for leaks and hose clamps for tightness.

Fig. 3-47:

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing FUEL SYSTEM Fuel system, Safety instructions

Fuel filter, replace Read and observe the "Inspection and servicing – Safety instructions" chapter.

Read and observe the "Inspection and servicing – Safety instructions" chapter.

Before working on the fuel system:  shut off the engines, 

secure the machine as described in the "Securing the machine" section,



keep away naked flames,



do not smoke.

Collect escaping fuel and discard without polluting the environment.

Collect escaping fuel and discard without polluting the environment.

Avoid skin contact with diesel fuel.

Diesel fuel may cause skin injury.

Wear firm working clothing.

Wear protective gloves or use a barrier cream.

Avoid skin contact with diesel fuel.

Diesel fuel may cause skin injury.

Wear firm working clothing.

Wear protective gloves or use a barrier cream.

Fig. 3-48:

 Unscrew filters (5, Fig. 3-48:).  Fill new filters with clean fuel and screw them onto the filter head by hand.  Continue to tighten filters by a further ½ to ¾ turn.

Tightening the filter element with a tool may damage or deform the filter head.

The fuel filters (5) serve at the same time as water separators.  Open valve (6) and drain off water until fuel emerges.  Close valve (6).

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing Fuel system, venting

Cleaning the fuel tanks

The fuel tanks are vented with breather valves (3, Fig. 3-49:).

Explosion hazard.

Do not use white spirit, paraffin oil or other solvents.

For flushing and cleaning use diesel fuel.

Clean breather valves regularly.  Remove breather valve, flush with paraffin oil and blow clean with compressed air.

Read and observe the "Inspection and servicing, Safety instructions" chapter.

Avoid skin contact. Skin contact with diesel fuel may cause skin injury.

Wear firm working clothing.

Wear protective gloves or use a barrier cream.

Fuel must be prevented from penetrating into the soil. Keep fuel for re-use or discard without polluting the environment.

Fig. 3-49:

 Use up as much fuel as possible.  Check how much fuel remains in the tank and place a collecting recipient of sufficient size under the drain plugs of the tanks.  Loosen drain plug (5, Fig. 3-50:) at fuel the tank and drain off fuel.  Flush tank with diesel fuel.  Screw automatic drain plug backs (5) in place.

Fig. 3-50:

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing  Fill in fuel through the strainer in filler tube (2, Fig. 3-51:)  Fuel can also be filled into both fuel tanks through the service station (1, Fig. 3-52:).

Fig. 3-52:

Fig. 3-51:

 Unscrew cap of express coupling.

Connect filling hose of the service vehicle.

The hose line and its use are described in the "Hose line for oil and cooling liquid changes" section.

The filling level is displayed on the BCS screen (Fig. 3-53:).  Remove filling hose.

The express coupling closes automatically.

Fig. 3-53:

 Screw on protective cap.

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing Water trap (option)

Draining off water

Water contained in the fuel is removed by the water trap (Fig. 3-54:).

Carry out the following works in accordance with the servicing schedule and at regular intervals:  Loosen venting plug (9, Fig. 3-55:) and leave drain valve (3) open until there is no more water in the diesel fuel flowing out of the valve.

Collect escaping liquid in a recipient suitable for diesel fuel and discard without polluting the environment.

The liquid flowing out of the valve flushes and cleans the filter element(6) von from top to bottom.  Close drain valve (3) and tighten venting plug (9).

Fig. 3-54:

Fig. 3-55:

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing Checking / cleaning the filter element

 Clean recipient (1) and filter housing (4).  Loosen flange (2).

Replace filter element (6, Fig. 3-56:) only when the suction resistance is too high.

 Take off recipient (1) and clean with diesel fuel  Check cover sealing and replace, if necessary.  Attach recipient (1) with flange (2) at filter housing (4).

Check for proper sealing.

Fig. 3-56:

 Loosen venting plug (9) and leave drain valve (3) open until the reservoir is completely empty.

Collect escaping liquid in a recipient suitable for diesel fuel and discard without polluting the environment.  Remove cover (5).  Remove spring holder (7) and filter element (6) from filter housing (4).  Check / replace filter element (6).  Clean filter housing (4) using diesel fuel.  Check cover sealing and replace,if necessary.  Insert filter element (6) and spring housing (7) into filter housing (4).  Fasten cover (5) on filter housing (4).

Check for proper sealing.

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing ELECTRICAL SYSTEM Electrical system - Safety instructions

Alternator - Instructions Never disconnect cables from the alternator, regulator and the battery when the engine is running to avoid damage to the alternator and regulator.

Risk of injury caused by battery acid and gases.

Do not interchange the cables when connecting the battery (observe polarity).

Read and observe the "Inspection and servicing – Safety instructions" chapter.

Carry out voltage and continuity checks only by means of a test lamp or a measuring instrument.

Do not check by "touching ground" with a bare wire. The short-circuit thus produced damages the alternator and the regulator.

Wear goggles, working gloves and firm working clothing.

The electrical circuit diagrams are annexed to thespare-parts list. Further information can be found in the Bucyrus HEX Technical Handbook "Working with circuit diagrams".

Carry out voltage and continuity checks only by means of a test lamp or a measuring instrument.

Do not check by "touching ground" with a bare wire. The short-circuit thus produced damages the alternator and the electronic modules of the PMS.

The electrical system switch-cabinet is located behind the hydraulic reservoir. The cabinet is described in the spare-parts list together with the designation of the electrical components.

Cables and cable lugs must not get in contact with other metal parts. Replace broken or damaged cables and the respective cable lugs.

If a bulb does not work after replacement, the pertaining fuses, connection cables and contacts must be checked.

Gas-discharge lamps (optional) are operated with high voltage.

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing Battery Warning! Battery Posts, terminals and related accessories contain lead and lead compounds, chemicals known to cause cancer and reproductive harm.

Wash hands after handling.

Checking the battery fluid level (Not applicable in case of maintenance-free batteries)  Unscrew caps (Fig. 3-57:).  If checking inserts are provided, the battery acid must reach up to their bottom.  If no checking inserts are provided, insert a clean wooden rod into the battery until it contacts the upper edge of the cell plates. The rod must be moistened over at least 10 mm / 0.4“.

Removing and installing the battery The acid temperature must be 20 ° C / 68° F.  Unscrew caps of the battery (Fig. 3-57:).  Measure the acid density of the battery using a commercial acid tester (Fig. 3-57:).

The acid density measured is in direct correlation with the battery charge.

Acid density kg / dm3 Charge Normal Tropical conditicondition ons 1,28 1,23 fully charged 1,20 1,12 half charged, recharge 1,12 1,08 discharged, recharge immediately

 If the fluid level is too low, top up with distilled water only.

Fig. 3-57:

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing Removing and installing the battery Read and observe the "Inspection and servicing – Safety instructions" chapter.

Wear protective gloves and firm working clothing.

Shut off the engines before removing the batteries to avoid damaging the alternator and the regulator.

Turn key in key-switch to position "0" and withdraw.

Disconnect and reconnect the terminal clamping lugs in the prescribed order.

Disconnecting and connecting in the wrong order may cause short-circuits.

The batteries (1, Fig. 3-58:) are located behind the hydraulic reservoir. The 12-volt batteries are connected in series and in parallel, so that the system voltage is 24 volts.

 Detach battery holder (3).  Disconnect the cable lug from the negative terminal of the battery.  Disconnect the cable lug from the positive terminal of the battery.  Insulate the cable lugs.  Lift battery out of battery box.

Before installing new batteries, the contact faces of the battery terminal posts and the cable lugs must be cleaned down to the bright metal.  Install the new batteries.  Connect the cable lug to the positive terminal of the battery. Tighten the clamping screws of the cable lugs. Do not use too much force to avoid deformation.  Connect the cable lug to the negative terminal of the battery.  Apply special terminal grease or acid-free vaseline on the battery terminal posts and clamping lugs. Loose or corroded clamping lugs will lead to alternator or regulator overloading.

Fig. 3-58:

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing Switchgear cabinet Breather filter In the switchgear cabinet, the air is drawn in by a ventilator via the filter (Fig. 3-59:).

Emptying dust trap  Press dust trap (14, Fig. 3-59:) and hold until the dust trap is empty.

Emptying the dust collector  Loosen clamps (11, Fig. 3-59:).  Remove dust collector (12) and empty.

Fig. 3-59:

Filter element  Remove the dust collector (12, Fig. 3-59:).  Withdraw filter element (13, Fig. 3-60:).  Replace or clean filter element (13).  Refit dust collector (12, Fig. 3-59:).

Fig. 3-60:

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing Checking and cleaning the filter element Check the filter paper of the element by inserting a lamp into the element (Fig. 3-61:). Any damage can then be seen.

Replace damaged or distorted element immediately.

 Check element seal. If damaged, replace filter element too.

Cleaning with compressed air allows the filter element to be re-used immediately.  Blow filter element (Fig. 3-62:) dry with compressed air by moving the compressed-air piston up and down inside it.

Fig. 3-61:

The pressure at the nozzle must not exceed 3 bars / 43 psi.

Cleaning is completed when no more dust is seen to leave the filter element.

Never clean filter element by beating it against hard objects.

Replace main filter element after 1000 operating hours or 3 cleaning cycles, but not later than after one year of operation.

Fig. 3-62:

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing Floodlight projector, replacing the lamp Safety instructions The floodlight projectors use xenon technology.

The lamp is not a usual incandescent lamp, but a gas discharge lamp which is operated with a ballast unit. The ballast unit is integrated in the floodlight projector.

When the projector is turned on, the ballast unit generates a high-voltage pulse of up to 25000 volts to start the xenon lamp.

Warning!

This high-voltage pulse can be a lifethreatening risk, if a person comes into contact with any of the live components. This can be the case, for instance,  if the lamp is operated improperly, 

if the projector housing is opened in an inapropriate way or



by sticking one's hand into an opened or damaged projector.

Protect yourself from potential risks by reading and by observing the following safety instructions.

Always switch off the projector and disconnect it from its power supply before replacing the Xenon lamp.

Allow the xenon lamp to cool off before removing it from the projector.

Wear googles and safety gloves when replacing the lamp.

Never stick your hand into the lampholder. The contacts may still be live with residual voltage.

Never switch on the projector when the xenon lamp has been removed.

There is a risk of voltage discharge and damage to the lampholder.

The glass body of the xenon lamp is filled with different gases and metal gases and is under gauge pressure (risk of injury from splinters) If the xenon lamp breaks apart in closed room (workshop), all persons must leave the room and the room must be ventilated for at least 20 minutes to exclude any health risks caused by gases.

Further instructions Always hold the xenon lamp by the base. Never touch the glass bulb. Sweat and grease from the skin would evaporate when the lamp is in operation and obscure the reflector.

If the fingers have nevertheless come into contact with the glass bulb, the fingerprints must be removed with a clean cloth and some alcohol.

The replaced Xenon lamp must be disposed of as special waste.

Never switch on projectors when housing or electrical wiring is damaged.

Have damaged projectors be replaced by a qualified electrician as soon as possible.

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing Replacing a defective Xenon-lamp Read and observe the: „Floodlight projector, replacing the lamp, Safety instructions“.  Switch off the projector, shut off the engines and cut out the battery main switch.  Wait until the housing of the floodlight projector has cooled down.  Withdraw the power supply connector from the projector.

Fig. 3-63

 Remove four screws (1, Fig. 3-63) and withdraw the reflector (2) from the projector housing.  Withdraw connector (Fig. 3-64) from Xenon lamp socket.  Unscrew Xenon lamp holding clamp (Fig. 3-65).  Remove the defective Xenon lamp and replace by a new one. Do not touch the glass bulb of the lamp.  Reinstall the new lamp. Screw lamp holding clamp back in place.  Plug the power supply connector onto the lamp.

Fig. 3-64

 Re-assemble the housing.

Fig. 3-65

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing HYDRAULIC SYSTEM Hydraulic system - Safety instructions Read and observe the "Inspection and servicing – Safety instructions" chapter.

Before working on the hydraulic system, make sure that the system is without pressure and that the residual pressures have also been eliminated.

Shut off the engines.

Risk of burning caused by hot hydraulic components (e.g. hydraulic oil reservoir, cylinder, valves).

Depressurizing the hydraulic system Hydraulic systems may only be opened if they are completely depressurized. Even when an excavator is parked on a horizontal surface with the working equipment resting on the ground (Fig. 3-66: and Fig. 3-67:) and with its drive engines stationary, there may still be a considerable amount of residual pressure in parts of the hydraulic system, as e.g. the primary pressure resulting from the last hydraulic movements before the immobilization.

Residual pressures disappear only gradually. If work is to be carried out on the hydraulic system immediately after the immobilization, the system must be freed from pressure, i.e. depressurized:

Secure the machine as described in the "Securing the machine“ section.

Avoid skin contact with hydraulic oil.

Contact with hydraulic oil can cause skin injury.

Wear protective gloves and firm working clothing.

Fig. 3-66:

 Locate the system section to be opened.  Depressurize the section to be opened. If required, the necessary measures described must be combined.  Open the depressurized system section with caution.

Fig. 3-67:

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing Examples of system sections:

Checking the hydraulic oil level

1) working hydraulics

 Bring hydraulic oil to operating temperature (abt. 50 °C / 122 °F).

2) servo control circuit 3) precharged return-flow line

 Park the machine on a horizontal surface.

Depressurizing

 Move all hydraulic cylinders to their central positions.

 Park the excavator on a horizontal surface.  Set the working equipment on the ground.

The oil level must lie between the “min” and the “max” marks of sign (2, Fig. 3-69:) near the inspection glass (1).

 Shut off the drive engines, keep sitting on the operator’s seat.  Do not switch off the electrical system Sections 1 and 2: servo control and working hydraulics  Shift both control levers and all pedals repeatedly into all directions (Fig. 3-68:).

Fig. 3-69:

The hydraulic oil level is monitored by the BCS. The BCS displays a warning on the screen (Fig. 3-70:) if the hydraulic oil level is too low or too high.

Shut off the engines, locate cause and rectify.

Fig. 3-68:

Section 3: Return-flow line After shutting down the engine, the precharging pressure decreases rapidly through the precharging valve. No measures are required before opening the return-flow line.

Detailled information can be found in the Technical Handbook, chapter 8: Hydraulic System”.

Fig. 3-70:

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing

Fig. 3-73:

Fig. 3-71:

Stand working equipment on the ground as shown on the sign (Fig. 3-71:).

Sign (2, Fig. 3-72:) is attached beside the inspection glass tube (1).

Hydraulic oil (oil grade see: "LUBRICANTS" section) can also be filled in by means of the service station (Fig. 3-74:).  Unscrew cap of express coupling (10).

Connect filling hose express coupling of the service vehicle.

The use of the hose line is described in the "Hose line for oil and cooling liquid changes" section.  Fill in hydraulic oil until the oil level lies between the “min” and the “max” marks of sign (2, Fig. 3-72:) near the inspection glass (1).

The acoustic warning signal “Travel Alarm” sounds.  Unscrew the hose line; the express coupling closes automatically.  Screw protective cap back in place.

Fig. 3-72:

Fill in hydraulic oil through the return-flow filters:  Remove cover (19, Fig. 3-73:).  Fill in hydraulic oil through the opening until the oil level lies between the “min” and the “max” marks of sign (2, Fig. 3-72:) near the inspection glass (1). (oil grade see: "Refilling quantities - Oil").  Before fitting the cover (19), check the sealing ring and replace, if damaged.

Fig. 3-74:

 Fit cover together with sealing ring.

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing Changing the hydraulic oil returnflow filters (hydraulic oil reservoir) Risk of scalding caused by hot hydraulic oil.

Read and observe the "Inspection and servicing – Safety instructions" chapter.

The return-flow filters must be replaced:  when servicing works in accordance with the servicing plan are carried out; 

when the BCS displays a warning on the screen (Fig. 3-75:). In this case, the filter elements (9, Fig. 3-76:) are heavily contaminated;



after repairs on the hydraulic system;



in case of damage.

Shut off the engines.

The hydraulic oil reservoir itself may also be hot.

Wear protective gloves and firm working clothing.

Avoid skin contact. Skin contact with hydraulic oil may cause skin injury.

Collect escaping hydraulic oil and discard without polluting the environment.

Fig. 3-75:

 Remove cover (3) together with sealing ring (5) and retaining disk (7).  Remove cap (8) and sealing ring (10).  Withdraw filter element (9) and sealing ring (11) from basket (12).  Insert a new filter element.

If a filter element (9) is damaged, remove basket (12) and check/clean.

Fig. 3-76:

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing  Loosen screws (13, Fig. 3-77:) and take off spring clip (14) and disk (15).  Remove basket (12) and clean in paraffin oil.  Install basket (12).  Insert filter element (9) together with sealing ring (11) and cap (8) with sealing ring (10).  Refit cover (3).  Clean the magnetic rod.

The magnetic rod is located under cap (19).

If metal filings are detected, locate cause and rectify.

Contact the Bucyrus HEX Service, if required.

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Fig. 3-77:

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing Bypass valves (hydraulic oil reservoir) Risk of scalding caused by hot hydraulic oil.

Read and observe the "Inspection and servicing – Safety instructions" chapter.

 Check sealing ring for damage and replace, if required.  Re-assemble the bypass valve.  Check sealing ring (24) for damage and replace, if required.  Insert bypass valve and fasten with screws (22).

Shut off the engines.

The hydraulic oil reservoir itself may also be hot.

Wear protective gloves and firm working clothing.

Avoid skin contact. Skin contact with hydraulic oil may cause skin injury.

Collect escaping hydraulic oil and discard without polluting the environment.

Cleaning the filter screens

Fig. 3-79:

Replacing the bypass valves and sealing rings  Remove bypass valve as described under "Cleaning the filter screens".  Re-assemble the bypass valve with a new screen (23, Fig. 3-78:) and a new sealing ring.

Fig. 3-78:

 Remove cover (3, Fig. 3-78:) together with sealing ring (36).

 Insert bypass valve with new sealing ring (24) and fasten with screws (22).

 Unscrew screws (22). Withdraw bypass valve.  Take off screen (23) together with sealing ring and clean in white spirit or paraffin oil. Replace, if required.

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing Breather filter Risk of scalding caused by hot hydraulic oil.

Replacing the filter elements The breather filters (20, Fig. 3-80:) ensure venting of the hydraulic oil reservoir at varying hydraulic oil levels.

Read and observe the "Inspection and servicing – Safety instructions" chapter.

Shut off the engines.

The hydraulic oil reservoir itself may also be hot.

Wear protective gloves and firm working clothing.

Avoid skin contact. Skin contact with hydraulic oil may cause skin injury.

Collect escaping hydraulic oil and discard without polluting the environment.

Fig. 3-80:

 Unscrew screws (21). Remove holder (22) and withdraw filter element (20).  Check filter element and replace, if required.

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing Filter (control circuit) Risk of scalding caused by hot hydraulic oil.

Read and observe the "Inspection and servicing – Safety instructions" chapter.

Replacing the filter element The control circuit is equipped with a high-pressure filter (Fig. 3-81:).

Change filter element regulary and when the BCS indicates a contamination.

Shut off the engines.

The hydraulic oil reservoir itself may also be hot.

Wear protective gloves and firm working clothing.

Avoid skin contact. Skin contact with hydraulic oil may cause skin injury.

Collect escaping hydraulic oil and discard without polluting the environment.

Fig. 3-81:

 Unscrew filter housing (5, Fig. 3-81:).  Withdraw filter element (6) from filter housing (5).  Clean filter housing (5) and the sealing face at the filter head (9) with white spirit or paraffin oil.  Insert new filter element into filter housing (5) and refit to the filter head with new, lightly oiled sealing ring (8).  Check for leaks after putting the filter into operation.

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing High-pressure filter for working hydraulics To filter the hydraulic oil on the high-pressure side of the working hydraulic system, the machine is equipped with four high-pressure filters (9, Fig. 3-82:).

Checking/cleaning the filter elements  Unscrew drain plug (11, Fig. 3-83:) and drain the hydraulic oil from the filter housing (9).

(Place a suitable resipient under the filter housing).  Unscrew filter housing (9).  Disengage filter element (15) with a slight turn from ist retaining catch and withdraw from filter housing (9).  Clean filter element (15) in white spirit or paraffin oil.  Replace filter element (15) if it is damaged.  Check seals (10 and 14) and replace, if required.  Re-assemble the filter element in reverse order.  Check for leaks after putting the filter into operation.

Fig. 3-82:

Risk of scalding caused by hot hydraulic oil.

Read and observe the "Inspection and servicing – Safety instructions" chapter.

Shut off the engines.

The hydraulic oil reservoir itself may also be hot.

Wear protective gloves and firm working clothing.

Avoid skin contact. Skin contact with hydraulic oil may cause skin injury.

Collect escaping hydraulic oil and discard without polluting the environment.

Fig. 3-83:

Replacing the filter elements  Detach the filter element as described under "Checking / cleaning the filter elements".  Clean filter housing (9, Fig. 3-83:) and the sealing faces at the filter head with white spirit or paraffin oil.  Insert new filter element into filter housing (9) and refit to the filter head with new, lightly oiled sealing rings (10 and 14) and a new retaining ring (13).

Check high-pressure filter for leaks after putting it into operation.

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing High-pressure filters for the servo circuit

Checking/cleaning the filter elements

The excavator is equipped with two high-pressure filters (Fig. 3-84:) for the servo circuit. Both filters are located in front of the hydraulic oil reservoir.

 Remove filter housing and pour out used oil.

 Detach flange (4, Fig. Fig. 3-85:).

 Withdraw filter element (6) from filter housing (5).  Clean filter housings and sealing faces at filter head with white spirit or paraffin oil.  Insert new filter element into filter housing (5) and refit to filter head with a new, lightly oiled sealing ring (8).

Check the high-pressure filter for leaks after putting it into operation.

Fig. 3-84:

Risk of scalding caused by hot hydraulic oil.

Read and observe the "Inspection and servicing – Safety instructions" chapter.

Shut off the engines.

The hydraulic oil reservoir itself may also be hot.

Wear protective gloves and firm working clothing.

Avoid skin contact. Skin contact with hydraulic oil may cause skin injury.

Collect escaping hydraulic oil and discard without polluting the environment.

Fig. 3-85:

Replacing the filter elements  Detach the filter elements as described under "Checking the filter elements".  Install new filter element (6, Fig. 3-85:) and reassemble with a new, lightly oiled sealing ring (7).

Check the high-pressure filter for leaks after putting it into operation.

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing High-pressure filters for feeding circuits and slewing pumps

Checking/cleaning the filter element

The excavator has four high-pressure filters (Fig. 3-86:) for the feeding circuits of the slewing pumps.

Two high-pressure filters each are installed beside the pump transfer gearbox.

 Remove filter housings and pour out used oil.

 Detach flange (4, Fig. 3-87:).

 Withdraw filter element (6) from filter housing (5).  Clean filter housings and sealing faces at filter head with white spirit or paraffin oil.  Insert new filter element into filter housing (5) and refit to filter head with a new, lightly oiled sealing ring (8).

Check the high-pressure filter for leaks after putting it into operation.

Fig. 3-86:

Risk of scalding caused by hot hydraulic oil.

Read and observe the "Inspection and servicing – Safety instructions" chapter.

Shut off the engines.

The hydraulic oil reservoir itself may also be hot.

Wear protective gloves and firm working clothing.

Avoid skin contact. Skin contact with hydraulic oil may cause skin injury.

Collect escaping hydraulic oil and discard without polluting the environment.

Fig. 3-87:

Replacing the filter elements  Detach the filter elements as described under "Checking the filter elements".  Install new filter element (6, Fig. 3-87:) and reassemble with a new, lightly oiled sealing ring (7).  Check the high-pressure filter for leaks after putting it into operation.

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing High-pressure filters for slewing circuit The excavator has two high-pressure filters (Fig. 3-88:)

Checking/cleaning the filter elements  Unscrew filter housing (42, Fig. 3-89:) and pour out oil.  Withdraw filter element (43) from filter housing (42).  Clean filter housings and sealing faces at filter head with white spirit or paraffin oil.  Insert new filter element into filter housing (42) and refit to filter head with a new, lightly oiled sealing ring (46).

Check high-pressure filter for leaks after putting it into operation.

Fig. 3-88:

Read and observe: "Inspection and servicing - Safety instructions".

Shut off the engines.

Risk of scalding from hot hydraulic oil.

The filter housings may also be hot.

Fig. 3-89:

Avoid potentially harmful skin contact with hydraulic oil.

Replacing the filter elements

Wear protective gloves and firm protective clothing.

Collect escaping hydraulic oil and discard without polluting the environment.

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 Detach the filter elements as described under "Checking the filter elements".  Install new filter element and reassemble.

Check high-pressure filter for leaks after putting it into operation.

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing Changing the hydraulic oil Read and observe the "Inspection and servicing - Safety instructions" chapter.

Shut off the engines.

Risk of scalding caused by hot hydraulic oil.

The hydraulic oil reservoir itself may also be hot.

Avoid skin contact.

Skin contact with hydraulic oil may cause skin injury.

Wear protective gloves and firm working clothing.

Collect escaping oil and discard without polluting the environment.

Do not start up the drive engines when the hydraulic oil reservoir is empty. The hydraulic pumps may be destroyed if they are allowed to run dry.

Avoid mixing of different hydraulic fluids The machine has been run in at the factory with BM Long Term Hydraulic Fluid HSS (Part-No. 2482971). CGM HMS GmbH recommends using this high-grade hydraulic fluid also in operation as it has been made especially for use in these machines to which it is also perfectly adapted.

If oil analyses are performed regularly and with positive results, the BM Long Term Hydraulic Fluid can remain in the machine for up to 10 000 operating hours.

If an alternative hydraulic fluid is to be used, it must fulfil the same specifications. Please note that the change interval for alternative fluids is fixed at 5 000 operating hours.

There is an increased risk of damage to hydraulic components, if different hydraulic fluids are mixed during topping up as well as when changing over to a fluid of a different type or from another manufacturer.

For topping up, it is therefore necessary to use only same hydraulic fluid as the one that is already in the hydraulic system.

When changing over to an alternative hydraulic fluid, please observe that there is always a small amount of old fluid remaining in the hydraulic system even after the system has been emptied. The mixing of this residual amount of old fluid with the new alternative fluid reduces the properties of the fluid dramatically and can cause damage to components of the hydraulic system in operation.

To avoid this result, the change-over to the alternative fluid must be performed in strict compliance with the manufacturer's prescriptions. The manufacturer must confirm that his hydraulic fluid is compatible with the BM Long Term Hydraulic Fluid.

The remaining amount of old fluid must not exceed 2% of the total volume. This can only be achieved by repeated flushing with the total fluid volume.

If the remaining amount of fluid exceeds 2% of the total volume, the fluid becomes a detrimental "mixed fluid".

The operation of the system with mixed fluids must by all means be avoided.

CGM HMS GmbH assumes no warranty for damage caused as a result of the machine having been operated with consumables of inappropriate specification or with mixed fluids.

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing Drawing off hydaulic oil  Bring the hydraulic oil to operating temperature (abt. 50 ° C / 122°F).  Retract the hydraulic cylinders as far as possible and stand the working equipment on the ground.  Shut off the engines.

Drain the hydraulic oil at express coupling (1, Fig. 3-90:).

Drawing off hydaulic oil The hydraulic oil can also be drawn off through the service station (Fig. 3-91:).  Bring hydraulic oil to operating temperature (ca. 50° C / 122°F).  Retract hydraulic cylinders as far as possible and stand working equipment on the ground.  Shut off the engines.  Unscrew cap of express coupling (10).  Connect hose line of the service vehicle.

The hose line and its use are described in the "Hose line for oil and cooling liquid changes" section.

Fig. 3-90:

 Place suitable recipients under the drain valve (1) of the hydraulic oil reservoir. For the required capacity refer to the "Filling quantities Oil" table.

The use of the hose line is described in the "Hose line for oil and cooling-liquid changes" section.  Unscrew the hose line; the oil drain valve closes automatically.

Fig. 3-91:

 Remove hose line. The coupling closes automatically.  Screw on protective cap.

 Screw protective cap back in place.

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing Cleaning the hydraulic oil reservoir Explosion hazard.

Read and observe the "Inspection and servicing - Safety instructions" chapter.

Shut off the engines.

Do not use white spirit, paraffin oil or other solvents for cleaning.

Use diesel fuel or a special flushing oil.

Avoid skin contact.

Skin contact with hydraulic oil may cause skin injury.

Wear protective gloves and firm working clothing.

Fig. 3-92:

Dispose of contaminated hydraulic oil without polluting the environment and separately from other waste.  Drain off hydraulic oil as described under "Draining off the hydraulic oil".  Remove cap (3, Fig. 3-92:).  Detach the return-flow filter.  Place a collecting recipient for the flushing oil under the hydraulic oil reservoir.  Clean the inside of the hydraulic oil reservoir with diesel fuel or flushing oil.

Remove all sediments and also the residues of the cleaning agent thoroughly.  Refit cap (3).

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing Filling in hydraulic oil Fill in hydraulic oil through the return-flow filters.  Remove cap (19, Fig. 3-93:).  Fill in hydraulic oil through the opening until the oil level lies between the “min” and the “max” marks of sign (2, Fig. 3-94:) near the inspection glass (1). (oil grade see: "LUBRICANTS" section).

Hydraulic oil can also be filled by means of the service station (Fig. 3-95:).  Unscrew cap of express coupling (10).  The use of the hose line is described under "Hose line for oil and cooling-lequid changes".

Connect filling hose express coupling of the service vehicle. Fill in hydraulic oil until the oil level lies between the “min” and the “max” marks of sign (2, Fig. 3-94:) near the inspection glass (1). (oil grade see: "LUBRICANTS" section).

The acoustic warning signal “Travel Alarm” sounds.

Fig. 3-93:

Fig. 3-95:

 The oil level is also displayed on the BCSscreen (Fig. 3-96:).  Vent the hydraulic system.  Check the oil level in the hydraulic oil reservoir. Top up with oil, if required.  Unscrew the hose line. The express coupling closes automatically.  Screw protective cap back in place.

Fig. 3-94:

 Vent the hydraulic system.  Check the oil level in the hydraulic oil reservoir. Top up with oil, if required.  Refit cap (19, Fig. 3-93:).

Fig. 3-96:

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing Venting the hydraulic system Hydraulic pumps, hydraulic motors, hydraulic cylinders, travel brake valves, suction lines of hydraulic pumps, oil cooler manifolds and the servo control system must be vented  after assembly on site and prior to initial commissioning, 

before each recommissioning of the excavator, e.g. after extensive repair work to the hydraulic system or after prolonged downtimes,



after each hydraulic oil change,



after replacement of hoses or lines.

Venting the hydraulic components 

Fig. 3-98:

Hydraulic pumps and hydraulic motors (with electric motors shut off):

Always admit oil first to that side of the cylinder where the piston (2) is. This is

Open the highest leakage oil port and fill in clean hydraulic oil up to the lower edge of the opening.

• the piston-side port (3) when the piston rod is retracted (1, Fig. 3-97:), • the rod-side port (4) when the piston rod is extended (1, Fig. 3-98:).

Check the hydraulic system under load. Pay attention to noises produced by the hydraulic pump or the hydraulic motors. Abrupt movements of the working equipment are a sign of entrapped air in the system. Remaining air pockets can be eliminated by actuating all hydraulic functions. 

If, for assembly reasons, the piston rod is inmiddle position, admit oil first to the piston-side port (4).

When oil is admitted for the first time to the cylinder, the oil flow must be reduced. Therefore extend or retract the piston rod as slowly as possible.

Hydraulic cylinder: Before the initial admission of the cylinder with oil, the piston must be in either of the two extreme piston positions. In other words, the piston rod (1, Fig. 3-97: and Fig. 3-98:) must be either completely retracted or completely extended.

The screws/nozzles of the following components must be opened until oil emerges bubble-free from the opening: Always vent only the system section that has been opened.



the travel brake valve at the venting screw,



the oil cooler manifold at the mini-measuring ports,



the servo system at the venting screws of the control blocks (under the servo caps),



the intake line at the venting screw (with drive motors stationary).

Fig. 3-97:

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing Cleaning the hydraulic oil cooler Risk of injury from rotating cooler fan blades.

Never start cleaning work until the cooler fan blades have stopped turning.

Cleaning The hydraulic oil coolers are located in the oil cooler module.

Clean the hydraulic oil coolers at regular intervals.  Shut off the engines.  Remove any accumulated dirt.  Clean the fan blades (2, Fig. 3-99:).

Shut off the engines.

The hydraulic oil coolers reach the same temperature as the hydraulic oil. Risk of burning.

 Clean the radiators with a jet of water or compressed air from outside to inside.

Allow the hydraulic oil cooler to cool down.

 Leave hydraulic oil coolers to dry.

Wear protective gloves and firm protective clothing.

 Check the hydraulic motors (1) for free movement.

If the machine is used in places with heavily contaminated ambient air, the hydraulic oil coolers must be cleaned more often than specified in the servicing plan.

In winter-time, check that the fans (2) turn freely and that the cooling fins are free from ice and snow.

The speeds of the fan motors (1, Fig. 3-99:) are thermostat-controlled. The fan motors run at maximum speed when the hydraulic oil temperature reaches ca. 60°C / 140°F.

Fig. 3-99:

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing Electronic excavator control Joystick At regular intervals acc. to the maintenance plans:  Loosen gaiter and move upwards.  Apply a thin layer of low temperature grease on the control spools, the actuator plate above and the cardan joint of the joysticks (arrows, Fig. 3-100:) to prevent jamming of the joysticks.

Pedal At regular intervals acc. to the maintenance plans:  Remove old grease and dirt from the control spools and the actuator plate of the pedals (arrows, Fig. 3-101:).  Apply a thin layer of low temperature grease on the control spools of the pedals to prevent jamming of the control spools.

 Refit gaiter using a cable strap.

Fig. 3-101:

Fig. 3-100:

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing Pressure accumulator - Emergency lowering To permit the working equipment to be lowered in an emergency, the machine is equipped with a pressure accumulator (1,Fig. 3-102:).

The pressure accumulator (1) is located in the superstructure and is accessible from the ground.

Extract from the German regulations The accumulator vessel must not be subjected to welding, soldering or any other mechanical work.

Work on systems containing accumulators (repairs, connection of pressure gauges or similar work) may be carried out only when the fluid pressure has been released

Extract from the German acceptance regulations Hydraulic accumulators are pressure vessels and are therefore subject to the "Druckbehälterverordnung (DruckbehV)" [Pressure Vessel Regulations].

Their installation, equipment and operation are governed by the "Technische Regeln Druckbehälter (TRB)" [Technical Rules for Pressure Vessels]. The pressure vessels of hydraulic accumulators are classified by the admissible operating pressure p in bars, the capacity l in liters and the product of pressure and capacity p x l. Depending on the class to which the accumulator belongs, the following inspections are mandatory:

Fig. 3-102:

Pressure-accumulator inspection regulations The following regulations are applicable only in Germany. Please observe the relevant regulations in force in your own country.

Group II p ≥ l bar and p·x l ≤ 200

Checking the gas charging pressure in the pressure accumulator After commissioning (new installation or repair), the gas charging pressure in the pressure vessel must be checked at least once during the first week. If no pressure loss is detected, the second pressure test must be performed after ca. 3 months. If no pressure loss is detected in this test either, the testing interval can be fixed at once pressure test each year.

Inspections prior to commissioning at the factory at the place of use Pressure testing Inspection certificate Prototype and pressure test (Check of correctness and certified by the manufacturer correct installation) issued by an expert

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Regular inspections Inspection schedule to be drawn up by end user, based on experience with type of operation and fluid.

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing PUMP TRANSFER GEARBOX Read and observe: "Inspection and servicing - Safety instructions.

Shut off the engines.

The gearbox housings may be hot, too.

Secure the machine as described in the "Securing the machine" section.

Protect the skin from contact with gearbox oil.

Skin contact with cooling liquid is a potential health hazard.

Wear protective gloves and firm working clothing.

Pre-chamber Checking oil level The oil level in the pre-chambers is visually at the inspection glas (3, Fig. 3-104) in expansion reservoir (1).

The oil level should reach up at least to the middle of the inspection glas (3). Top up with gearbox oil, if required. Oil grade see: „LUBRICANTS“.  Unsrew breather filter (2).  Fill in oil up at least to the middle of the inspection glass (3).  Screw breather filter back in place.

Checking the gearbox oil level / Topping up with oil Park the machine as described in the "Securing the machine" section.  Unscrew dipstick (1, Fig. 3-103:) and wipe.  Insert dipstick (1) again as shown and withdraw a second time.

Oil level should lie between the two dipstick markers. Top up with oil if required.

Oil grade see: „LUBRICANTS“.  Screw in dipstick (1) again.

Fig. 3-104

Fig. 3-103:

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing Changing the gearbox oil

Filling in oil

Carry out oil change when oil is nearly at operating temperature. All suspended particles and contaminations will be rinsed out with the old oil.

 Fill in oil through the bore of breather valve (2, Fig. 3-106:). The oil level must reach the upper mark on dipstick (1).

Drawing off oil The gearbox oil is drained with the service station (Fig. 3-105:) through  express coupling (4) for the lefthand pump transfer gearbox, 

The gearbox oil can also be filled in with the service station (Fig. 3-105:) through  express coupling (4) for the lefthand pump transfer gearbox, 

express coupling (5) for the righthand pump transfer gearbox.

express coupling (5) for the righthand pump transfer gearbox.

Fig. 3-105:

 Unscrew cap of express coupling and connect hose line of the service vehicle.

The hose line and its use are described in the "Hose line for oil and cooling liquid changes" section.  Remove hose after the oil has been drawn off.

The coupling closes automatically.  Screw on protective cap.

Fig. 3-106:

 Unscrew cap of express coupling and connect hose line of the service vehicle.

The hose line and its use are described in the "Hose line for oil and cooling liquid changes" section.

The oil level must reach the upper mark on dipstick (1, Fig. 3-106:).  Remove hose after the oil has been filled in.

The coupling closes automatically.  Screw on protective cap.

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing Pre-chamber

Gearbox, breather valve

Draining off oil  Prepare a collecting recipient for used oil.

The gearbox is vented through breather valve (2, Fig. 3-108:).

Choose the required capacity in accordance with the "Filling quantities - Oil" table.  Unscrew plug (7, Fig. 3-107) and drain off oil.

Clean breather valve (2) in accordance with the servicing plan.

 Screw plug (7) back in place.

Filling in oil  Filling in oil see “Check oil level”.

 Unscrew breather filter (2), clean with white spirit or paraffin oil and blow dry with compressed air.  Screw breather filter (2) back in place.

Fig. 3-108:

Fig. 3-107

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing Pre-chamber, breather valve The pre-chambers are vented through breather valve (2, Fig. 3-109:).

Clean breather valve (2) in accordance with the servicing plan.  Unscrew breather filter (2), clean with white spirit or paraffin oil and blow dry with compressed air.  Screw breather filter (2) back in place.

Fig. 3-109:

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing Pump transfer gearbox lube oil filters Check filter tell-tales (1, Fig. 3-110:) regulary - at operating temperature - for indication of contamination.

If the red sector is visible through transparent cap (2), the filter element must be cleaned or changed.  Remove flange (3, Fig. 3-111:).  Pour oil out of filter pot (4) and remove filter element (5).  Clean filter element in spirits or petroleum;  change if damaged

Fig. 3-110:

 Clean filter head (6, Fig. 3-110:) and filter pot (4). Check o-ring (7, Fig. 3-111:) for damage; change if necessary.  Oil the o-ring lightly. Place filter element into filter pot and re-assemly.  Check filters for leakages after recommencing operation.

Filter element (5) must be changed after having been cleaned 8 - 10 times; at the latest however, after 1000 operating hours.

Fig. 3-111:

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing SWING GEARBOX Read and observe: "Inspection and servicing - Safety instructions.

Shut off the engine The gearbox housings may be hot, too.

Secure the machine as described in the "Securing the machine" section.

Changing the gearbox oil Carry out oil change when oil is nearly at operating temperature. All suspended particles and contaminations will be rinsed out with the old oil.  Prepare a collecting recipient for used oil.

Choose the required capacity in accordance with the "Refilling quantities - Oil" table.

Protect the skin from contact with gearbox oil.

Skin contact with cooling liquid is a potential health hazard.

Wear protective gloves and firm working clothing.

Fig. 3-113:

Draining off oil Fig. 3-112:

Gearbox - Checking the oil level / Topping up with oil  Park the machine as described under "Securing the machine".  Screw out dipstick (1, Fig. 3-103:) and wipe clean.

 Attach hose (8, Fig. 3-113:) to drain valve (7) and drain off oil completely.

The use of the oil draining hose is described in the "Hose line for oil and cooling liquid changes" chapter.

The drain valve (7, Fig. 3-113:) is accessible from the undercarriage.  Remove hose. The oil drain valve closes automatically.for oil and cooling liquid change" section.

 Insert dipstick (1) fully again (do not screw in) and withdraw a second time.

The oil level must reach up at least to the lower mark on dipstick (1). Top up with gearbox oil, if required.  Screw dipstick (1) back in place.

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing Filling in new oil / Topping up

Gearbox venting

 Unscrew plug (4, Fig. 3-114:) and fill in new oil.

The gearbox is vented through breather filter (2, Fig. 3-114:).

Clean breather filter in accordance with the servicing plan.  Unscrew breather filter (2), clean in white spirit or paraffin oil and blow dry with compressed air.

 Check oil level with dipstick (1, Fig. 3-114:).  Screw in plug (4) again.

 Screw breather filter (2) back in place.

Fig. 3-114:

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing TRAVEL GEARBOX (VALID FOR GEARBOX PN 3673978) Read and observe: "Inspection and servicing - Safety instructions.

Secure the machine as described in the "Securing the machine" section.

Shut off the engines.

Travel gearbox - Checking the oil level / Topping up with oil  Open cover of travel motors.  Check oil level at the inspection glass (Fig. 3-115:).

The oil level should reach the center of the inspection glass. Top up with oil if required through the bore of plug (3, Fig. 3-116:).

Oil grade see: „LUBRICANTS“.

The gearbox housings may be hot, too. Wear protective gloves and firm working clothing.

Skin contact with cooling liquid is a potential health hazard. Protect the skin from contact with gearbox oil.

Oil grade see: „LUBRICANTS“.

Fig. 3-115:

Fig. 3-116:

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing Hydraulic motor chamber - Check the oil level  Unscrew control plug (6, Fig. 3-117:).

The oil level should reach up to the lower end of the opening. Top up with oil through the opening of breather filter (5) if required.  Screw in plug (6) back in place.

Hydraulic motor chamber - Top up with oil (Oil grade see: „LUBRICANTS“).  Unscrew the breather filter (5, Fig. 3-123:).  Fill in gearbox oil through the bore of breather filter until the oil level reaches up to the lower edge of the bore of plug (6).  Screw checking plugs (6) back in place, screw breather filters (5) back in place.

Travel gearbox - Changing oil Carry out oil change when oil is nearly at operating temperature. All suspended particles and contaminations will be rinsed out with the old oil.

(Oil grade see: „LUBRICANTS“).

Draining off oil  Move the excavator into such a position that the screw plugs (1, 2 and 3, Fig. 3-118:) are in the displayed position.  Place a collecting recipient for used oil under the travel gearbox.

Choose the required capacity in accordance with the "Refilling quantities - Oil" table.  Unscrew drain plug (2) and drain off the oil completely.

Slackening plug (3) allows the oil to run out more readily.  Clean screw plugs (2 and 3)  Screw screw plug (2) back in place.

Filling in oil  Unscrew screw plugs (1 and 3).  Fill in oil through opening in plug (3) until it flows out of opening in plug (1).  Screw plugs (1 and 3) back in place.

Fig. 3-117:

Fig. 3-118:

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing Hydraulic motor chamber – Changing oil Draining off oil

Breather filters, clean / replace  Unscrew breather filters (1 and 5, Fig. 3-120:) and clean in white spirit or parafin.

 Place a collecting recipient for used oil under the hydraulic motor chamber.

Choose the required capacity in accordance with the "Refilling quantities - Oil" table.  Unscrew drain plug (7, Fig. 3-119:) and checking plug (6) and drain off the oil completely.

Slackening breather filter (5) allows the oil to run out more readily.  Clean screw plugs (6 and 7)  Screw drain plug (7) back in place.

Filling in oil (Oil grade see: „LUBRICANTS“).

Fig. 3-120:

 Unscrew breather plug (5).  Fill in oil through the bore until it flows out of the bore of plug (6).  Screw plug (6) back in place, screw breather plug (5) back in place.

Fig. 3-119:

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing TRAVEL GEARBOX (VALID FOR GEARBOX PN 2763214) Read and observe: "Inspection and servicing - Safety instructions.

Secure the machine as described in the "Securing the machine" section.

Shut off the engines.

Pre-stage - Check the oil level / Top up with oil  Open cover of travel motors.  Check oil level at the inspection glass (arrow, Fig. 3-122:). The oil level should reach the center of the inspection glass.

Top up with oil if required through the bore of plug (4).

Oil grade see: „LUBRICANTS“.

The gearbox housings may be hot, too. Wear protective gloves and firm working clothing.

Skin contact with cooling liquid is a potential health hazard. Protect the skin from contact with gearbox oil.

Oil grade see: „LUBRICANTS“.

Travel gearbox - Checking the oil level / Topping up with oil  Move the excavator into such a position that the screw plugs (1, 2 and 3, Fig. 3-121:) are in the displayed position.  Unscrew checking screw (1).

The oil level should reach up to the lower edge of the opening. Top up with oil, if required.  Screw checking plug (1) back in place.

Fig. 3-122:

Brake chambers - Checking the oil level / Topping up with oil  Unscrew checking screws (6, Fig. 3-123:).

The oil level should reach up to the lower edge of the opening. Top up with oil, if required.

Oil grade see: „LUBRICANTS“.  Screw checking plugs (6) back in place.

Fig. 3-121:

Fig. 3-123:

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing Travel gearbox - Changing oil

Pre-stage - Changing the oil

Carry out oil change when oil is nearly at operating temperature. All suspended particles and contaminations will be rinsed out with the old oil.

Draining off oil

(Oil grade see: „LUBRICANTS“).

Draining off oil  Move the excavator into such a position that the screw plugs (1, 2 and 3, Fig. 3-124:) are in the displayed position.  Place a collecting recipient for used oil under the travel gearbox.

Choose the required capacity in accordance with the "Refilling quantities - Oil" table.  Unscrew drain plug (2) and drain off the oil completely.

Slackening plug (3) allows the oil to run out more readily.  Clean screw plugs (2 and 3)  Screw screw plug (2) back in place.

 Place a collecting recipient for used oil under the pre-stage.

Choose the required capacity in accordance with the "Refilling quantities - Oil" table.  Unscrew drain plug (3, Fig. 3-125:) and drain off the oil completely.

Slackening plug (4) allows the oil to run out more readily.  Clean screw plugs (3 and 4)  Screw screw plug (3) back in place.

Filling in oil  Unscrew screw plug (2).  Fill in oil through opening in plug (4) until the oil level reaches the center of inspection glas (2).  Screw plug (4) back in place.

Filling in oil  Unscrew screw plugs (1 and 3).  Fill in oil through opening in plug (3) until it flows out of opening in plug (1).  Screw plugs (1 and 3) back in place.

Fig. 3-125:

Fig. 3-124:

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing Brake chambers - Changing oil

Breather filters, clean / replace

Draining off oil

 Unscrew breather filters (1 and 5, Fig. 3-127:) and clean in white spirit or parafin.

 Place a collecting recipient for used oil under the brake-chambers.

Choose the required capacity in accordance with the "Refilling quantities - Oil" table.  Unscrew drain plugs (7, Fig. 3-126:) and drain off the oil completely.

Slackening breather filter (5) allows the oil to run out more readily.  Clean screw plugs (7).  Screw screw plugs (7) back in place.

Filling in oil (Oil grade see: „LUBRICANTS“).  Unscrew screw plugs (6).

Fig. 3-127:

 Fill in oil through opening of breather filter (5) until it flows out of the bore of plugs (6).  Screw plugs (6) and breather filters (5) back in place.

Fig. 3-126:

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing CRAWLER TRACKS Cleaning Clean tracks, track and support rollers, sprockets and idlers regularly and whenever required. Cleaning is especially important in winter to prevent:  the tracks from being thrown off, 

oil from leaking out of track and support rollers, sprockets and idlers,



excessive wear,



the track from breaking.

To clean the tracks:  raise one side of the excavator with the working equipment and allow track to turn;  clean the side member supporting the track;  clean track and support rollers (1 and 2,Fig. 3-128:) thoroughly;  clean the sliding planes on the idler guides.

Fig. 3-128:

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing Track roller, Support roller

Track roller fastening

The track rollers and support rollers (1 and 2, Fig. 3-130:) are supported with grease by means of the automatic undercarriage greasing system.

Check fastening screws (4, Fig. 3-130:) regularly for tightness:  Tighten screws with a torque wrench to the prescribed tightening torque (see: "Technical Handbook").

Optional they could have a permanent grease filling. In this case it is necessary to press in grease filling at regular intervals.

It is necessary to be sure that there is always sufficient grease in the roller bearings.

Inspect all track and support rollers visually for leaks and free movement at regular intervals.

Fig. 3-130:

Support roller fastening Check fastening screws (3, Fig. 3-130:) regularly for tightness Tighten screws with a torque wrench to the prescribed tightening torque (see: "Technical Handbook").

Fig. 3-129:

 Unscrew plug (6, Fig. 3-129:) from breather line.  Remove dust cap (1) from coupling (2).  Remove dust cap (4) from plug (5).  Connect grease hose (3) to couling (2).  Press in grease as long as used grease emerges from breather line.  Screw on plug (6) to breather line.  Disconnect the grease hose (3).  Fix dust caps (1 and 4) back in place.

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing Track tensioner Design The tracks are tensioned with the help of the hydraulic pressure created during travelling. Fig. 3-131:and Fig. 3-132: show parts of the tracks and the tensioner:

Techncal data Track tensioning pressure ca. 70 bars / 1015 psi Pressure limiting valve 330 bars / 4786 psi Gas pressure in pressure accumulator (nitrogen 50 bars / 725 psi filling pressure)

Function The tensioning system is under permanent pressure of ca. 70 bars / 1015 psi which keeps both tracks permanently tensioned. Pressure losses are compensated as soon as the engines have been started. Retensioning is not required.

For cleaning and servicing work, the tracks can be slackened.

To do so:  stop the engines.

Fig. 3-131:

1 2 3 4 5 6 7 8 9 10

Crawler track Idler Drive sprocket Support roller Pressure accumulator Pressure cylinder Pressure limiting valve Track roller Mini- measuring port Stop cock

 open both pressure limiting valves (7, Fig. 3-132:) to slacken the tracks.  After the work, screw down the pressure limiting valves (7) to the limit stop.

Fig. 3-132:

The pressure-limiting valves (7) are preset to a pressure of 330 bars / 4786 psi and sealed in this position. The lead seal must not be removed and the pressure setting of 330 bars / 4786 psi must not be changed.

The track tensioners are maintenance-free.

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing Pressure-accumulator inspection regulations

Checking the gas charging pressure in the pressure accumulator

The following regulations are applicable only in Germany. Please observe the relevant regulations in force in your own country.

After commissioning (new installation or repair), the gas charging pressure in the pressure vessel must be checked at least once during the first week. If no pressure loss is detected, the second pressure test must be performed after ca. 3 months. If no pressure loss is detected in this test either, the testing interval can be fixed at once pressure test each year.

Extract from the German regulations The accumulator vessel must not be subjected to welding, soldering or any other mechanical work.

Work on systems containing accumulators (repairs, connection of pressure gauges or similar work) may be carried out only when the fluid pressure has been relieved.

Extract from the German acceptance regulations Hydraulic accumulators are pressure vessels and are therefore subject to the "Druckbehälterverordnung (DruckbehV)" [Pressure Vessel Regulations].

Their installation, equipment and operation are governed by the "Technische Regeln Druckbehälter (TRB)" [Technical Rules for Pressure Vessels]. The pressure vessels of hydraulic accumulators are classified by the admissible operating pressure p in bars, the capacity l in liters and the product of pressure and capacity p x l. Depending on the class to which the accumulator belongs, the following inspections are mandatory:

The above-mentioned pressure tests are required to ensure the functioning of the track tensioner.

They are no substitute for the inspections as required by the "Pressure Vessel Regulations".

Before checking the gas charging pressure (nitrogen filling pressure) in the pressure accumulator, the track must first be slackened, i.e. the hydraulic part of the tensioning system must be depressurized. See: "Function".

Tab. 3-1

Group IV p ≥ l bar p·x l ≥ 1000

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Inspections prior to commissioning at the factory at the place of use Preliminary inspection by an Acceptance inspection by an expert expert Prototype and pressure test certified by the manufacturer (type approval) or the expert

Regular inspections Internal inspection: every 10 years for noncorrosive fluids; otherwise pressure testing every 5 years: every 10 years by an expert

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing SWING RING Read and observe: "Inspection and servicing - Safety instructions.

Internal gearing The internal gearing (1, Fig. 3-134:) and the pinion (2) are enclosed in a housing (3, Fig. 3-135:). The housing forms a grease-filled trough in which the pinion of the swing mechanism moves.

Shut off the engines.

Wear protective gloves and firm protective clothing.

Swing ring – Instructions The grease filling must be replaced:  when repairs have been carried out on the swing ring, the swing ring seals or the swing ring housing.

Remove old grease completely before filling in new grease.

If greater losses are detected, locate cause immediately to prevent damage to the swing ring.

Greases and greasy cleaning rags must not be allowed to pollute the environment. Discard grease and greasy cleaning rags separately from other waste without polluting the environment.

Bearing races The central lubricating system supplies grease continuously to the two roller bearing races and the internal gearing .

Fig. 3-134:

The grease is pumped to the greasing port of the grease trough by the distributor (Fig. 3-133:). The amount of grease used up during operation is replenished by the central lubricating system.

The housings have a check opening which is closed with a cover (2, Fig. 3-135:). For checking, the cover must be removed.

The grease is pumped to the greasing points of the bearing races by a distributor (Fig. 3-133:).

Fig. 3-135:

Fig. 3-133:

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing Swing ring - Checking the grease filling Read and observe: "Inspection and servicing - Safety instructions.

Swing ring - Filling in grease Prior to initial commissioning, the grease trough of the internal gearing must be filled with grease.

Add grease when  the housing has been replaced,

Shut off the engines.

Wear protective gloves and firm protective clothing.

At regular intervals:  check internal gearing and teeth of swing mechanism pinion for condition



old grease has been removed in the course of other work.

Always fill in fresh grease by hand.

Risk of accidents. Never swing the superstructure when refilling grease.

 check that the grease filling is sufficient.

The housing must always contain enough grease for the gearing - measured from its lower edge - to run in at least 20 mm / 0.78“ of grease over its whole circumference (Fig. 3-136:).

In the event of greater grease losses, eliminate cause immediately and add grease to prevent the internal gearing and the pinion from being damaged by continued swing movements.

Swing ring - Checking the screws for tightness The fastening screws of the swing ring in the superstructure and the undercarriage are tightened with their respective check (see: "Technical Handbook").

When these values are reached, the fastening screws are perfectly tight.

Loosen slack screws before tightening them with a torque wrench to the prescribed (see: "Technical Handbook")..

Fig. 3-136:

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing CENTRAL LUBRICATING Design The excavator is equipped with an automatic central lubricating system which provides grease regularly to all greasing points except those mentioned in the "Lubricating chart - Grease".

The central lubricating system is activated when the electrical system is switched on with the keyswitch and the engines are running. All greasing points connected to the system are greased at regular intervals.

The automatic greasing is interrupted when the engines are stopped with the idle timers.

The central lubricating system is controlled electrohydraulically by the PLC (Programmable logical controller).

The PLC is located in a switch box underneath the cab.

Fig. 3-138:

If a fault occurs, BCS gives a warning on the screen (Fig. 3-138:). Actuat the "Reset" button (73, Fig. 3-137:) to eleminate the fault. Is this is not possible, call in servicing personal.

For further information on the function and setting refer to the Technical Handbook „PLC (Programmable logical controller“).

Fig. 3-137:

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing Function The control elements of the lubricating system areinstalled on the panel (3).

The grease is. pumped by the pumps (1 and 3, Fig. 3-139:) via greasing lines from the grease container to the main distributors on the superstructure and on the undercarriage.

Fig. 3-140:

As soon as the grease container is empty, the BCS (Fig. 3-141:) gives a warning signal. In the event of a fault, the "dumping" function is switched off automatically after 15 min.

Fig. 3-139:

Work can be continued when the grease container is filled with grease.

The control elements of the lubricating system are installed on the panels (3 and 21, Fig. 3-140:).

Fig. 3-141:

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing Filling up the grease container

Breather filter

Fill up the grease container through the service station (Fig. 3-142:).

Check/change the breather filter at regular intervals.  Unscrew wing nut (10, Fig. 3-143:).

The use of the hose is described in the chapter "Hose line for oil and cooling liquid changes".  Switch on the indicator system with toggle switch (23, Fig. 3-142:), indicator lamp (22) lights up.  Unscrew the cap of the express coupling (11).

 Withdraw cover (7, Fig. 3-144:) and filter element (8).  Check filter element. Replace if necessary.  Re-install breather filter.

 Connect the filling hose of the service vehicle.  When the grease container is full, the indicator lamp (34) lights up.  Switch off the indicator system with toggle switch (23), indicator lamp (22) is off.  Remove the flexible hose.

The express coupling closes automatically.  Refit the protective cap.

Fig. 3-143:

Fig. 3-142:

Fig. 3-144:

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing Checking the greasing pressure Check every week, whether the oil pressure indicated by pressure gauge (4, Fig. 3-145:) is 60 bars / 870 psi (the pressure is depending on temperature and viscosity of the oil and may vary).

The necessary greasing pressure of 320 bar / 4641 psi for the superstructure and 180 bar / 2611 psi for the lower carriage is generated by means of a pressure translator.

The greasing pressure is indicated by pressure gauge (9).

In the event of deviating pressure values, shut off the engines and check the central greasing system.

Lower oil pressure means that not all of the greasing points are supplied with grease.

Higher oil pressure may cause bursting of a greasing line.

Lower oil pressure means that not all of the greasing points are supplied with grease.

Fig. 3-145:

This oil pressure is reduced so that the pressure indicated by pressure gauge (2, Fig. 3-146:) is 35 – 40 bars / 507 – 580 psi and by pressure gauge (4) is 49 – 51 bar / 711 – 740 psi.

Always refill the grease container in time to avoid air from penetrating into the greasing system. Air in the greasing may cause malfunctions.

Fig. 3-146:

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing Unblocking a grease line.

Put the excavator back into operation only after the lubricating system works properly and after having actuated the unloaded working equipment for abt.

5 minutes. This is necessary in order to supply sufficient amounts of grease to the cylinder bearings.

Check the grease sieve regularly for contamination and clean, if required. The grease sieve must also be cleaned after an obstruction in one of the grease lines.

Cleaning  Loosen nut (6, Fig. 3-147:).  Withdraw sieve and clean with white spirit or paraffin oil.  Re-insert sieve and fasten with nut (6).

Fig. 3-147:

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing Oilfilter (hydraulic circuit grease pump)

Replacing the filter element Change filter element regulary and when the BCS indicates a contamination.

Read and observe the "Inspection and servicing - Safety instructions" chapter.

Shut off the engines.

Risk of scalding caused by hot hydraulic oil.

The filter housings may also be hot.

Avoid skin contact.

Skin contact with hydraulic oil may cause skin injury.

Wear protective gloves and firm working clothing.

For filtering of the hydraulic oil, high pressure filter (11, Fig. 3-148:).is installed in the pumping line.

Fig. 3-149:

 Unscrew filter housing (5, Fig. 3-149:).  Withdraw filter element (6) from filter housing (5).  Clean filter housing (5) and the sealing face at the filter head (9) with white spirit or paraffin oil.  Check seals (10 and 14) and replace, if required.  Insert new filter element into filter housing (5) and refit to the filter head with new, lightly oiled sealing ring (8).

Fig. 3-148:

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 Check for leaks after putting the filter into operation.

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing Grease filter (Filling the grease container) Read and observe the "Inspection and servicing –Safety instructions" chapter.

Shut off the engines.

Grease filter (13, Fig. 3-150:) is installed in the greasing line to the grease container.

Checking the filter element  Unscrew filter housing (32, Fig. 3-151:).  Withdraw filter element (33) from housing (32).  Remove the grease.  Clean filter housing and contact faces at the filter head with white spirit or paraffin oil.  Insert filter element into housing (32) and attach to the filter head with a new, slightly oiled sealing ring (36).  Check the high-pressure filter for leaks after the system has been put into operation.

Fig. 3-150:

Fig. 3-151:

Replacing the filter element  Remove filter element as described under "Checking the filter element".  Insert new filter element and reassemble.  Check high-pressure filter for leaks after the system has been put into operation.

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing Grease filter (Grease lines) Read and observe the "Inspection and servicing –Safety instructions" chapter.

Checking the filter element  Unscrew filter housing (42, Fig. 3-153:).  Withdraw filter element (43) from housing (42).  Remove the grease.

Shut off the engines.

Grease filter (12, Fig. 3-152:) is installed in the greasing line to the grease container.

 Clean filter housing and contact faces at the filter head with white spirit or paraffin oil.  Insert filter element into housing (42) and attach to the filter head with a new, slightly oiled sealing ring (46).  Check the high-pressure filter for leaks after the system has been put into operation.

Fig. 3-152:

Fig. 3-153:

Replacing the filter element  Remove filter element as described under "Checking the filter element".  Insert new filter element and reassemble.  Check high-pressure filter for leaks after the system has been put into operation.

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing OTHER MAINTENANCE Engine

Heating and air conditioning

Information about maintenance can be found in the engine operating instructions.

The filter mats are located in the air conditioner housing (Fig. 3-154:) below the roof of the cab.

Further servicing works not described are carried out by the Bucyrus HEX Service or the engine manufacturer.

 Open housing of air conditioner.

Cleaning

 Close housing.

Clean or replace the filter mats in the air suction regulary.

 Clean or replace filter mats.

Check the engines regularly.  If the engine is cleaned with a steam-jet cleaner, make sure that the jet is not directed towards electrical components. 

If no steam-jet cleaner is available, the engines must be cleaned with suitable cleaning agents (cold cleaners).

Before cleaning the engines Exhaust pipes and turbo chargers in the engine compartments are covered with special heat-insulating material.

This material must not be spraywashed with steam-jet cleaners or high-pressure cleaners. It will be damaged. Therefore cover all the insulating material with plastic foils before using steam-jet cleaners or highpressure cleaners inside the engine compartments.

Fig. 3-154:

Means of fastening  Check fastening bolts regularly for tightness.

The seating planes of the bolts must be free from paint, dirt and rust.

Exhaust system Check the fastening bolts regularly for tightness when the exhaust system is cold.

Cooling system Check the radiators regularly.  Shut off the engines.  Remove any accumulated dirt.  Clean the fan blades.  Remove guard grid and clean.  Clean the radiators with a jet of water or compressed-air from the outside.  Dry up coolers.

Do not clean radiators with a wire brush or similar hard objects. In case of firmly adhering dirt, remove radiator and clean.

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing Equipment, checking

Hydraulic ladder (optional)

Check the welded joins of the working equipment regulary.

To allow the ramp-type ladder (Fig. 3-157: or Fig. 3-158:) to be lowered in an emergency, the ladder mechanism is equipped with a pressure accumulator (1, Fig. 3-159:).

Inspections must be carried out acc. to the "Structural Inspection Reports" every 500 OH and every 5000 OH. "Structural Inspection Report" forms for those inspections can be downloaded from the Bucyrus HEX website, section "Support, Warranty".

The inside located joins are accessible through the man-holes in stick (arrow, Fig. 3-155:) and boom (arrow, Fig. 3-156:).

Fig. 3-157:

Fig. 3-155:

Fig. 3-158:

The pressure accumulator (1) is located in the superstructure and is accessible from the ground.

Fig. 3-156:

Fig. 3-159:

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing Pressure-accumulator inspection regulations The following regulations are applicable only in Germany. Please observe the relevant regulations in force in your own country.

Extract from the German regulations

Checking the gas charging pressure in the pressure accumulator After commissioning (new installation or repair), the gas charging pressure in the pressure vessel must be checked at least once during the first week. If no pressure loss is detected, the second pressure test must be performed after ca. 3 months. If no pressure loss is detected in this test either, the testing interval can be fixed at once pressure test each year.

The accumulator vessel must not be subjected to welding, soldering or any other mechanical work.

Work on systems containing accumulators (repairs, connection of pressure gauges or similar work) may be carried out only when the fluid pressure has been relieved.

Extract from the German acceptance regulations Hydraulic accumulators are pressure vessels and are therefore subject to the "Druckbehälterverordnung (DruckbehV)" [Pressure Vessel Regulations].

Their installation, equipment and operation are governed by the "Technische Regeln Druckbehälter (TRB)" [Technical Rules for Pressure Vessels]. The pressure vessels of hydraulic accumulators are classified by the admissible operating pressure p in bars, the capacity l in liters and the product of pressure and capacity p x l. Depending on the class to which the accumulator belongs, the following inspections are mandatory: Group III p ≥ l bar and p·x l ≥ 200 bars p·x l ≤ 1000 bars

Inspections prior to commissioning at the factory at the place of use Preliminary inspection by an Acceptance inspection by an expert expert Prototype and pressure test certified by the manufacturer (type approval) or the expert

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Regular inspections Inspection schedule to be drawn up by end user, based on experience with type of operation and operating fluids.

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing ON-BOARD CRANE, DRIVE UNIT The drive unit supplies the crane with hydraulic power. The drive unit comprises the diesel engine, fuel tank, starter batteries and the hydraulic system.

Crane engine More and detailed information about the diesel engine can be found in the Operating and Maintenance Manual for the crane engine.  Before each shift check engine oil level. If necessary top up with engine oil through opening of dipstick (3, Fig. 3-160:).  After each shift fill up fuel tank (1).  Regularly check batteries (4) and cable connections.  Regularly, at least once a year: - change engine oil, - replace engine oil filter, - check / replace air filter (2), - replace fuel filter.

Do not start engine with air filter (2) removed.

Fig. 3-160:

Hydraulic system For more and detailed information, see crane operating instructions.  Prior to each deployment, check the hydraulic oil level at the inspection glass (1, Fig. 3-161:); top up with hydraulic oil if necessary.  Check contamination of hydraulic oil filter regularly at contamination indicator (4).

Fig. 3-161:

 Regularly, but at least once a year replace the hydraulic oil filter (3) and the breather filter (2).

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing On-board crane, lubricating Servicing work  Lubricate all bearings regularly and as required, and spray swing ring with a graphite spray (Fig. 3-162:) 4 lube points 1 - bearing 2 - joint (column/boom) 2 lube points 3 - cylinder bearing 5 lube points 4 - swing ring Graphite spray

On-Board crane, checking tightness of fastening bolts The hydraulic driven on-board crane (Optional) is fixed on the uppercarriage of the machine by means of 16 fastening bolts. The upper and lower fastening bolts (Fig. 3-163:) are important and safety relevant components, they carry all loads and forces of the crane.

Check tightness of all fastening bolts: 

in regular intervals according to the maintenance plans and



before every start of the on-board crane.

Check tightness of the fastening bolts by means of a torque wrench. The tightening torque for fastening bolts M20, quality 10.9, lightly oiled is: 557 Nm.

Fig. 3-162:

Fig. 3-163:

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING Putting the excavator out of operation

Battery storage

 Park the excavator on firm and level ground.

 Check the acid density and the electrolyte level of the battery every two weeks.

 Set the working equipment down on the ground, retracting the piston rods of the hydraulic cylinders as far as possible.  Set all control element to "0".  Clean the machine.

During prolonged machine downtimes, remove the batteries and store in a dry room at an ambient temperature of ca. 20°C / 68°F. Observe the following points with regard to maintenance:  Clean the batteries.

 Recharge the batteries at the latest, when the acid density has dropped to 1.23 kg/dm³.  Keep the batteries clean and dry on the outside.

 Carry out a visual inspection of the excavator.  Remove coarse dirt, snow and ice from the fins and fan wheel of the hydraulic oil cooler.  Carry out engines preservation.  Protect all bright metal parts (e.g. piston rods) from rust and dirt.  Check anti-freeze concentration of the cooling liquid to avoid freezing during the cold season.  Fill up the fuel tanks.  Remove the batteries; see: "Battery storage".  Secure the machine against unauthorized starting by: withdrawing the key from the key-switch locking the cab door securing all lockable hatches.  Cover up all openings.

Recommissioning  Remove the covers.  Degrease / clean all protected components.  Remove engines preservation in acc. with the engine operationg anstructions.  Check the fuel level in tanks.  Check track tension (visual inspection).  Check level and condition of the cooling liquid in the cooling system.  Check grease filling in grease container.  Oil level

- drive engines, - swing gearboxes, - pump transfer gearboxes, - travel gearboxes.

 Check oil level in hydraulic oil reservoir.  Check battery acid density and level.  Install batteries and reconnect.  Function checks:

- superstructure holding, brake, - track brake, - lighting system, - signalling equipment.

 Vent the hydraulic system.

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OPERATING INSTRUCTIONS 6050 / 6050FS Inspection and servicing NOTES .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. ..............................................................................................................................................................................

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OPERATING INSTRUCTIONS 6050 / 6050FS Repair work 4 REPAIR WORK Operating instructions

Target group

Part 1 INTRODUCTION FUNDAMENTAL SAFETY INSTRUCTIONS

Operating personnel + Inspection and servicing personnel + Repair personnel

Part 2 OPERATION

Operating personnel The operating personnel must have knowhow relevant to the operation and the application of this or comparable machines.

Part 3 INSPECTION AND SERVICING Part 4 REPAIR WORK

Inspection and servicing personnel The inspection and servicing personnel must have know-how relevant to the inspection and servicing of this or comparable machines.

Repair personnel The repair personnel must have know-how and experience relevant to the repair of this or comparable machines.

Part 5 ANNEX

Part 6 INDEX

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Operating personnel + Inspection and servicing personnel + Repair personnel Operating personnel + Inspection and servicing personnel + Repair personnel

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OPERATING INSTRUCTIONS 6050 / 6050FS Repair work

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OPERATING INSTRUCTIONS 6050 / 6050FS Repair work REPAIR WORK - SAFETY INSTRUCTIONS Operating instructions Never carry out repair work without having read and understood the operating instructions.

Pay special attention to: "Fundamental Safety Instructions", "Inspection and servicing - safety instructions" and all warnings and safety instructions attached to the machine.

The descriptions of job sequences provide only experienced personnel with the necessary instructions.

The operating manual must be kept with the machine at all times.

Prestressed units Never open defective prestressed units but replace them as an entirety.

In exceptional cases, open only when the system and the operating sequence are precisely known and any special tools required are available.

The operating manual contains no information on this point.

Dismantling components Never do dismantling while the machine is at operating temperature.

Oils, greases, or coolants may have a high temperature and result in burning or scalding.

Leave time for the machine to cool down.

Repair personnel Repair personnel must have know-how and experience relevant to repairing this or comparable machines.

In the absence of such know-how, meticulous training must be given by experienced repair personnel, e.g. from Bucyrus HEX.

Working in greater heights Always wear safety harnesses when working at greater heights.

Wear an approved safety harness; it must be equipped with fall arresters and safety cables.

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Before starting work, depressurize piping and hoses, cylinders, radiator, hydraulic tank and other systems or units.

Replace defective components in good time to prevent major damage.

Clean the defective component carefully before dismantling it.

Mark the dismantled parts in the correct sequence to faciliate re-assembly.

When dismantling the component, close off exposed hose and piping connections, exposed drill holes and housings carefully to prevent any dirt from penetrating.

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OPERATING INSTRUCTIONS 6050 / 6050FS Repair work Never remove lead seals Never change rated pressure of pressure relief valves without the explicit authorization of Bucyrus HEX. Never remove lead seals from pressure relief valves and accumulators.

After the repair work To prevent corrosion, coat all bright metal machine parts with a grease film.

On completing the work, re-assemble all protective devices, covers and noise- and vibrationinsulation material.

Never start up the drive engines while work is being done on the machine.

Check the repaired components and all machine functions in a trial run.

Never release the machine for recommissioning until it is fully functioning.

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OPERATING INSTRUCTIONS 6050 / 6050FS Repair work REPAIR WORK, FIRE AND EXPLOSION HAZARD Safety instructions Prior to commencing work, obtain informationon the national and corporate rules for the prevention of accidents and avoiding fires.

Pay particular attention to hazards caused by combustible and easily flammable substances.

Obtain information on the safe handling of the fire extinguishers to be used.

Avoid smoking and open fire on, next to and below the excavator.

Even battery gases can ignite in open flames or fire.

Combustible and easily or highly inflammable substances or liquids increase the risk of fire and explosion. This is also valid for pressure vessels containing flammable substances as, for instance, spray oil or cold-starting fluid (ether). They are heat-sensitive and can explode even if exposed only to intensive sunlight.

These substance can also ignite themselves if they come close to hot units or objects as, for instance, a turbocharger.

Do not store these substances on the excavator. If combustible, easily or highly flammable substances or liquids were used during maintenance operations, they must be completely removed from the excavator at the end of the work.

Avoid parking the excavator in places where  combustible substances such as coal dust or tar are present. 

Place suitable fire guardings (fire barriers) if open fire or flying sparks cannot be avoided during repair work.

If necessary, also cover the ground with fireprotective blankets.

Apply special protection to cables, cable ducts as well as to hose and pipe lines.

Have all your welding, flame cutting and grinding work approved before starting work.

The engine compartment can be equipped with pressure vessels containing cold-starting fluid (ether). Ether is toxic and highly flammable; the vessels are under pressure. These pressure vessels can explode if exposed to high temperatures (above 49°C / 120°F) or in the event of damage.

Protect the pressure vessels against damage before beginning to work in or close to the engine compartment.

Ensure sufficient ventilation.

Do not keep any fire extinguishers that are not suitable or have not been tested.

Do not extinguish flammable liquids with water.

Use:  dry-powder, carbon-dioxide or foam extinguishing compounds.

When getting into contact with burning substances, the fire-fighting water would abruptly evaporate and distribute the substance such as oil over a wide area. Water causes short-circuits in the electrical system thus possibly entailing new hazards.

Call the fire brigade.

Clean the excavator carefully after the maintenance, if oil, grease, fuel, detergents or coldstarting fluid have been spilt over the machine. If possible, use a steam-jet cleaner for cleaning.

open or smouldering fire may occur.

Remove the excavator from such an area where combustible or easily flammable liquids have spilled from the excavator onto the ground.

Flying sparks (caused by welding, flame cutting, grinding, electrical short-circuit) may cause fire on the ground that can spread to the excavator.

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OPERATING INSTRUCTIONS 6050 / 6050FS Repair work REPAIR WORK, ENGINE Read and observe the "Repair - Safety instructions" chapter and the engine operating instructions before working on the engine.

The engine compartment can be equipped with pressure vessels containing cold-starting fluid (ether).

Ether is toxic and highly flammable; the vessels are under pressure. These pressure vessels can explode if exposed to high temperatures (above 49°C / 120°F) or in the event of damage. Protect the pressure vessels against damage before beginning to work in or close to the engine compartment.

Risk of injury caused by rotating or hot parts of the engine.

Shut off the engine and allow to cool down.

Carry out repair work only if the machine has been secured as described in the "Securing the machine" section of these operating instructions.

Check and replace V-belts only when the engine is stationary.

Before cleaning the engines Exhaust pipes and turbo chargers in the engine compartments are covered with special heat-insulating material.

This material must not be spraywashed with steam-jet cleaners or high-pressure cleaners. It will be damaged. Therefore cover all the insulating material with plastic foils before using steam-jet cleaners or highpressure cleaners inside the engine compartments.

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OPERATING INSTRUCTIONS 6050 / 6050FS Repair work ELECTRICAL SYSTEM Assisted starting (with jumper cables) – Safety instructions Keep any potential ignition sources, such as unshielded lights or burning cigarettes, away from the batteries.

Battery gases are highly flammable.

Explosion hazard.

Do not lean over the batteries when starting the machine from another vehicle.

Risk of injury from acid splashes and battery gases.

Never use assisted starting when the batteries are defective or frozen.

Never connect batteries (battery assemblies) unless they have the same voltage.

Use only tested jumper cables with insulated terminal clips and an adequate lead diameter.

Ensure that the bodies of the supplying and receiving machines are not in contact. Otherwise a current flow could result from connecting the positive poles. Risk of short-circuiting.

Never use welding generators or welding transformers as a source of current.

Position the jumper cables in such a way that they cannot be caught by rotating engine components.

Read and observe: "Inspection and servicing – Safety instructions", paying particular attention to the section "Handling batteries".

Assisted starting (with jumper cables) Prior to assisted starting Read and observe the section: "Assisted starting – Safety instructions".

Starting the engine with jumper cables (external batteries Before connecting the jumper cables (external bateries) check the own batteries for proper operation. Checking is done by switching on the excavator's electrical system.

Do not switch on electrical consumers (e.g. floodlamps) when checking the batteries. In case of doubt, remove the batteries and have them tested.

Assisted starting with batteries installed  Connect first the positive terminal of the jumper cable to the batteries and then to the supplying unit.  Connect the negative terminals in the same order.  After starting, disconnect the jumper cable in reverse order, i.e. first the negative terminal and then the positive terminal.

Assisted starting without batteries installed (only for engine trial run) Do not disconnect the starting aid when the engine is running.

After disconnecting, the alternator runs without batteries.  Connect the jumper cable in the above- described order and disconnect after starting.  Switch off all consumers at the receiving machine and turn the key-operated switch to "0"  Switch off all consumers at the supplying machine (charged batteries) and shut off the engine.

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OPERATING INSTRUCTIONS 6050 / 6050FS Repair work Connecting the jumper cables  Connect the red jumper cable to the positive pole of the empty battery (1,Fig. 4-1:), then to the positive pole of the charged battery (2).

Starting up the engine

 Connect the black jumper cable first to the negative pole of the charged battery (3), then to the negative pole of the empty battery (4).

 Start up the engine of the receiving machine.

If the engine fails to start up after 15 seconds, wait for one minute and thenstart again.

Explosion hazard When the negative terminal is connected to ground, a strong current flows through the jumper cable.

The sparks produced in the contact area can ignite the gases emanating from the discharged battery.

The negative terminal must therefore be connected to ground at a place as far away from the discarged batteríes as possible.

 Start up the engines of the supplying machine and run at high speed.

 When the engine has started up, continue running both machines in no-load operation for about two or three minutes with the jumper cables still connected.

Disconnecting the jumper cables  Negative pole at the receiving machine (4)  Negative pole at the supplying machine (3)  Positive pole at the supplying machine (2)  Positive pole at the receiving machine (1)  For machines with electronic modules: - Run engine for about half an jour at low speed. The batteries are partially charged.

- Shut off engine - Make all electrical connections to the modules.

- Start up engine without jumper cables.

Fig. 4-1:

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OPERATING INSTRUCTIONS 6050 / 6050FS Repair work HYDRAULIC SYSTEM Repair instructions Always depressurize the hydraulic system before disconnecting any hydraulic hoses or pipes.

Read and observe also the chapters "Inspection and servicing - Safety instructions" and "Repair - Safety instructions".

Replace damaged and leaking hydraulic hoses and pipes as soon as possible by new ones.

Use original spare parts from Bucyrus HEX. They are adapted to the respective function.

Do not re-use old hoses.

Never repair damaged hoses.

Discard escaped oil and oily wastes without polluting the environment. These substances must not be allowed to penetrate into the soil.

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Hydraulic hoses – Instructions Even hoses that have been properly stored or used are subject to natural ageing. Their useful life is therefore limited.

Hydraulic hoses must replaced after a service life of six years (including a storage time of 2 years).

Check the date of manufacture on the hose or on the hose fitting regularly.

The recommended interval after which hydraulic hoses - and especially those used in harsh conditions - must be replaced depends on the number of operating hours and on pressure loading.

The use of hoses close to their recommended load limit shortens the replacement interval (e.g. high temperatures, frequent working cycles, extremely high pulse frequencies as well as multi-shift operation and round-the-clock work).

Hydraulic hoses must be replaced, if one of the following defects is detected during a visual inspection:  Damage to the outer fibre reinforcement layer reaching down to the inner layer (cuts, chafe marks, cracks). 

Embrittlement of the outer fibre reinforcement layer (cracks in the hose material).



Changes in the ususal shape of the hose under pressure or in pressureless condition in bends or curves such as detachment of fibre layers, formation of bubbles or bulges.



Leaks.



Non-observance of fitting requirements.



Damage to or deformation of hose fittings that may result in a reduction of the strength of the screwed union.



Detachment of the hose from the fitting.



Corrosion in fittings reducing the strength of the function of the fitting.

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OPERATING INSTRUCTIONS 6050 / 6050FS Repair work PRESSURE ACCUMULATORS SAFETY INSTRUCTIONS The hydraulic system is equipped with pressure accumulators containing nitrogen under high initial pressure.

Even when the hydraulic pressure in the system is reduced, the nitrogen in the accumulator will remain under pressure.

The accumulators are completely safe in operation. If incorrectly handled, however, there is a risk of explosion.

So:  Never handle accumulators never weld or solder.

mechanically,

 Testing and servicing work must be carried out by experts only.  Prior to any testing and servicing work, depressurize the hydraulic part of the system.  To dismantle the accumulator, always wear goggles and working gloves.  Fill accumulator with nitrogen only, never with compressed air or oxygen.  Report any defects or damage to the machine owner without delay.  Prior to recommissioning, an inspection by a specialist or expert is essential if the accumulator was damaged or if the admissible operating temperature or operating pressure was exceeded.

Never remove or paint over warning and information plates, rating plates or type identification markings. Replace illegible or damaged plates immediately

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OPERATING INSTRUCTIONS 6050 / 6050FS Repair work WELDING AND FLAME CUTTING WORKS - SAFETY INSTRUCTIONS The present safety instructions are valid for both types of work. For easier reading, the text only uses the terms "welding work", "welding" or simply "work". These terms do however always refer to both types of work, i.e. "welding and flame-cutting work".

Read these safety instructions before starting any welding or flame-cutting operations.

Welding work by qualified personnel only Carry out welding work only if you have received special training and if you have been ordered to perform such work.

Always bear in mind that you are performing welding work on heavily loaded components. The quality of your welding work can be decisive for the operational capability of the machine and also for the health and life of persons.

Observe the health protection and accident prevention laws and regulations as well as the fire protection regulations in force in your country.

Observe all warning and instruction signs attached to the machine.

Increased risk of fire during welding work Always bear in mind that the heat, the sparks or dripping red-hot metal or slag produced in the process constitute a considerable risk of fire.

The present safety instructions provide information on how to minimize the risk of fire.

Remove all combustible materials close to the welding location or cover them up with noncombustible materials.

If works in the vicinity of combustible materials cannot be avoided, further persons with firefighting equipment must be present on site as fireguards.

Observe the instructions of the machine owner and of the mine.

Health hazards Welding operations produce harmful gases. Do not inhale the fumes and gases and make sure the surroundings of the welding location are well ventilated or equipped with an exhaust system.

Remove all kinds of paint and all coatings as well as all residues of oils and greases from the weld area.

Do not wind the welding cables round your body or parts of your body. The electromagnetic fields produced may damage your health.

Wear the prescribed personal protective equipment such as:  protective clothing,  protective gloves,  protective mask and,  a fall-arrest system for persons working at height.

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OPERATING INSTRUCTIONS 6050 / 6050FS Repair work Tanks, pressure vessels and pressure accumulators Any work on vessels containing or having contained  combustible or combustion-accelerating substances,  potentially explosive substances or  substances susceptible to develop harmful gases, fumes, mists or dusts during welding may only be carried out under expert supervision and only by experienced personnel especially assigned to such work.

This prescription applies, for instance, to all tanks and reservoirs for hydraulic fluid, engine oil, diesel fuel or lubricating grease.

Welding work on pressure vessels and pressure accumulators is forbidden.

Pressure vessels containing cold-starting fluid (ether) may be installed in or near the engine compartment.

Ether is toxic and highly flammable; the vessels are under pressure. These pressure vessels can explode if exposed to high temperatures (above 49°C / 120°F) or in the event of damage.

Protect the vessels against damage and high temperatures.

Do not perform welding work in the vicinity of these pressure vessels before they have been covered up safely against accidental contact or flying sparks. Have the pressure vessels removed from the machine, if safe protection cannot be ensured.

Inform yourself about the locations in the machine where the pressure accumulators of the hydraulic system are installed. Do not perform welding work in the vicinity of these pressure accumulators before they have been covered up safely against accidental contact or flying sparks. Have the pressure accumulators removed from the machine, if safe protection cannot be ensured.

Slewing rings and articulated joints The welding current must not flow through ballbearing or roller-bearing slewings rings, through bolted connections or articulated joints or through hydraulic cylinders.

An electric current flowing through an air gap (e.g. in the bearing or in the articulation) produces a spark which damages the metallic surface.

The welding clamps must therefore always be connected very close to the weld area (max. 2 - 3 m away (6.6-9.8 ft)).

Information relating to the electrical system and to electronic modules Electric arc welding produces electromagnetic fields, electrostatic charges and voltage spikes which can cause damage to electronic modules.

Although the electronic modules of the machine are carefully protected against these influences, it is nevertheless necessary to take additional precautions in order to prevent such damage to the greatest possible extent.

•

Switch off the electrical system ("ignition OFF").

•

Open the battery main switch (or disconnect the starter batteries from the machine).

•

Lay the welding cables as far away from electric lines as possible.

If it is not possible to implement all of the abovementioned precautions, all connectors must be removed from the electronic modules before beginning any welding work.

•

Protect withdrawn terminals and connectors from short circuits and soiling. Cover up terminals and connectors with foils or adhesive tape.

•

Never touch the enclosures of electrical and electronic modules with the welding electrode.

•

Protect electric lines against the heat emanating from the weld area.

•

Restore all electrical connections when the welding operations are terminated.

Never connect the ground clamp of the welding cable to the enclosures of electric or electronic modules.

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OPERATING INSTRUCTIONS 6050 / 6050FS Repair work Welding on the counterweight

Welding on the cab

Counterweights may contain a build-up of flammable gases. Before starting to work, counterweights must be flushed for at least 20 minutes with compressed air in order to remove these build-ups of gas. To permit flushing, the counterweight has two bores in its upper part: a threaded bore M18x1.5 for the compressed-air line and another unthreaded bore to let the air out.

The driver's cab is designed in such a way that it meets the FOPS (Falling Objects Protective Structure) requirements in accordance with DIN EN ISO 3449.

Detailed information / instructions on this subject can be found in Service Information 2006-33 which is available on the CGM HMS website under Maintenance & Service.

Welding on components of the working equipment and on other fully or partly closed steel structures Components may be equipped with pipelines routed inside. These lines can contain combustible substances such as hydraulic oil or lubricating grease which may be set on fire by welding operations.

•

Check whether pipes or hosepipes are connected to the steel component.

•

Depressurize these lines.

•

Open the screwed connections and empty the lines routed inside the component.

•

Start welding only after these operations have been carried out.

Welding and other mechanical work is forbidden as there is a risk of reducing the structural stability of the cab.

Further information More detailed information concerning the state-ofthe-art execution of welding operations can be found in the Service Manual "Welding for maintenance and repair".

For problems or queries please contact the competent service personnel.

If parts of the machine have to be removed or dismantled, please read and observe the chapters: "Assembly of working equipment, safety instructions", "Inspection and servicing, safety instructions", "Repair, safety instructions".

Electric lines may also be be laid inside partly open steel structures in order to protect them against damage. They are not always visible from each viewing direction. Electric lines may catch fire as a result of the heat produced during welding.

•

Therefore check carefully whether electric lines are laid in the vicinity of the weld area.

•

Protect electric lines against the heat produced at the weld area or have them removed before starting the welding operations.

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OPERATING INSTRUCTIONS 6050 / 6050FS Repair work DISPOSAL AT THE END OF THE SERVICE LIFE Dismantling and removal instructions Before beginning work, think about the risks involved, e.g.: 



Most of the machine components have considerable mass. Therefore use only lifting gear and slings of sufficient bearing capacity.

Risk of residual pressures still in the hydraulic system. Be very careful when opening hydraulic lines.

Read the following text attentively and observe the instructions given. Respecting the instructions will help you to protect yourself against health hazards and injuries and to prevent avoidable environment pollution.

4-14

Risk of deflagrations In the course of time, flammable gases may have formed or accumulated in the hollow spaces of welded constructions, e.g. the counterweight. To remove these flammable gases, the hollow spaces must be purged carefully with compressed air before work with hand grinders, flame cutters or other sparking tools is being undertaken.

Risk of fire Remainders of fuel or oils may lead to the formation of flammable gases in tanks or other hollow spaces. When these tanks or hollow bodies are cut into pieces, the gases may ignite or even explode.

For this reason, remove all fuel or oil remainders from these components and purge them carefully with compressed air in order to eliminate flammable gases (other efficient methods of removing flammable gases can also be applied) before work with hand grinders, flame cutters or other sparking tools is being undertaken.

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OPERATING INSTRUCTIONS 6050 / 6050FS Repair work Disposing of the machine without polluting the environment

Further hazardous substances 

Batteries contain lead and acid.

Before stripping down the machine at the end of its service life observe the following instructions:



Electronic modules are located in switch cabinets of the cab module, the engine module, the control column.



Pressure accumulators contain nitrogen under high pressure and possibly remainders of hydraulic oil.



Lamps of Xenon working lights contain mercury.

The required electronic control circuits are integrated in the housings of the working lights.



The fluorescent lamps of the maintenance lighting (discharge types) contain mercury.



Insulating material of cables can contain PVC.



The fire extinguishing system (if installed) contains trigger charges (ATTENTION, explosion risk) on the extinguishing agent containers.

Pressure accumulators, extinguishing gas and extinguishing powder.

For more detailed information please refer to the manufacturer's safety datasheets.

The assemblies of the machine contain various operating fluids or lubricants. These substances may pollute the environment (so-called hazardous substances) and must therefore be disposed of properly.

Observe the national laws and regulations governing the non-polluting disposal of these substances.

Remove all operating fluids from the systems, remove all lubricants and dispose of these substances properly. 

Fuel system: fuel tanks, fuel filters, fuel lines, filling station.

Auxiliary attachment and units, such as an onboard crane or an auxiliary heater have their own fuel tanks with the correpsonding line systems.



Hydraulic oil: hydraulic oil reservoir, hydraulic cylinders, hydraulic motors, hosepipes, piping, hydraulic pumps, hydraulic valves, hydraulic oil filter, filling station.



Engine coolant: engine, radiator, expansion reservoir, piping and hosepipes, filling station.



Gearbox oil in swing, travelling and transfer gearbox systems, expansion tanks, piping and hosepipes, filling station; idlers, support and track rollers.



Have the refrigerant (R134A) sucked out of the air conditioner system.



Grease from the central lubricating system, grease drum, piping and hosepipes, distributors, filling station; grease accumulations in bearings of the working equipment, grease filling in the swing ring, grease filling in track and support rollers as well as in idlers.

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OPERATING INSTRUCTIONS 6050 / 6050FS Repair work Appropriate disposal of batteries The machine is equipped with batteries containing lead and other harmful and polluting substances.

Damaged or used batteries must therefore not be disposed of in the environment. They must be disposed of properly and separately from other waste.

The batteries are marked with the corresponding symbols (Fig. 4-2:).

Since batteries contain also reusable materials, they are taken back free of charge by the manufacturer, dealer or by other specialized companies.

In the European Community, the final consumer is obliged by law to to dispose of used batteries in designated waste collections centers.

Observe the current regulations and laws of your country with regard to the handling of damaged or used batteries.

4-16

Fig. 4-2:

The symbols in Fig. 4-2: have the following meaning: 

Crossed-out waste bin= Do not dispose of batteries with normal household waste.



Pb……= Chemical symbol for lead.

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OPERATING INSTRUCTIONS 6050 / 6050FS Repair work NOTES .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. ..............................................................................................................................................................................

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OPERATING INSTRUCTIONS 6050 / 6050FS Repair work

4-18

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OPERATING INSTRUCTIONS 6050 / 6050FS Annex 5 ANNEX Operating instructions

Target group

Part 1 INTRODUCTION FUNDAMENTAL SAFETY INSTRUCTIONS

Operating personnel + Inspection and servicing personnel + Repair personnel

Part 2 OPERATION

Operating personnel The operating personnel must have knowhow relevant to the operation and the application of this or comparable machines.

Part 3 INSPECTION AND SERVICING Part 4 REPAIR WORK

Inspection and servicing personnel The inspection and servicing personnel must have know-how relevant to the inspection and servicing of this or comparable machines.

Repair personnel The repair personnel must have know-how and experience relevant to the repair of this or comparable machines.

Part 5 ANNEX

Operating personnel + Inspection and servicing personnel + Repair personnel

Part 6 INDEX

Operating personnel + Inspection and servicing personnel + Repair personnel

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OPERATING INSTRUCTIONS 6050 / 6050FS Annex

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OPERATING INSTRUCTIONS 6050 / 6050FS Annex TROUBLESHOOTING Instructions on troubleshooting

Layout of the fault table

Faults are often due to the machine not being correctly operated or serviced.

Fault

For this reason, it is vital to read through the relevant section of the operating instructions once again before rectifying any faults.

The fault is described here as the outcome of an observation or a previous activity.

Therefore make careful observations.

If you are unable to detect the cause of the fault or to rectify it, apply to the Bucyrus HEX after-sales service.

Study the problem carefully. First think, then act.

Describe the fault and all accompanying circumstances as precisely as possible when calling on the Bucyrus HEX after-sales service. Exact data allow for fast troubleshooting.



What repair and servicing work was carried out previously?



Has this defect already occurred?

Never do any jobs for which you are not qualified.



The fault table lists all faults which have been reported to date and outlines their possible causes and rectifying measures. In exceptional cases, a described fault may also have a different cause.

Is it one or several simultaneously occurring faults?

Possible causes

Ask yourself the following questions:  Which warning signals preceded the fault?

The possible causes of the observed fault are outlined in this group. They are arranged in order of probability, i.e. the possible cause occurring in most cases heads the list.

Measures This describes the troubleshooting procedure.

Section This specifies where information on troubleshooting is given in the operating instructions. If there is no entry, the Bucyrus HEX after-sales service should be consulted

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OPERATING INSTRUCTIONS 6050 / 6050FS Annex FAULT TABLES Combustion engine - Fault table Fault Engine fails to start or starts only with difficulty Engine does not turn Engine starts, but runs enevenly or intermittently Engine gets too hot, temperature warning activated Engine not working at full power Engine not working on full cylinder papacity Engine without oil pressure or oil pressure too low Engine oil comsumption too high Engine emits blue smoke Engine emits white smoke Engine emits black smoke Engine cannot be stopped Engine throttled down strongly Cause Oil level too low •

• • •

• • • • •

• •

•

•

•

•

• •

A

Oil level too high

Engine oil level

S

Engine inclination too big

Engine Op. P Instr.

Lubricants W

Fuel quality not corresponding to specification •

Air filter contaminated / turbo-charger defective

Engine Op. W Instr.

Air intake syst. P

Fuel filter contaminated

Fuel filter

•

Charge-air line leaking

• • •

1) Contact the Bucyrus HEX Service

Chapter ref.

Engine oil level

Engine oil of wrong SAE-class

•

Remedial action Check P Adjust E Replace W Top up A Reduce S Clean R

P/W P

•

Radiator / cooling fins contaminated

Cooler cleaning R

•

Cooling fan or water pump defective or loose

Engine Instr.

•

Cooling air gets too hot / heat buid-up

Op. P/W P

•

Battery defective or discharged

•

Cable connections in starter circuit loose or corroded

•

Starter defective or pinion not in mesh

P

Shut-off relay jamming

1)

•

•

•

• • • •

•

•

•

• • • •

•

• • • •

Injection valve defective Combustion engine blocked on output side

• •

•

• •

• PMS malfunction • Celect coding lamp flashing/lit Celect defective (software error)

P P

Engine Instr.

Injection line leaking

•

5-4

Incorrect valve setting

Battery

Op. E P

Engine Instr.

Op. P/W 1) 1) 1) 1)

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OPERATING INSTRUCTIONS 6050 / 6050FS Annex Working hydraulics – Fault table Fault

Remedial action

Working and swing functions not operational No boom function No bucket function No backhoe function No stick function Working movements too slow Power loss in working hydraulics Uncontrolled working movements Cause Electronic excavator control not activated/defective

•

Check Adjust Replace Top up Reduce Clean

P E W A S R

1) Contact the Bucyrus HEX Service Abschnitt Working P

•••••

•

Malfunction of pressure-relief valve

1)

•

•

Servo system pump defective

1)

••••• • •

ECO-power switch in 80%-position

•

Fuel filter contaminated

•

Insufficient engine power

• •

• •

• Malfunction of primary / sencondary pressure-relief valves Engine speed too low

1) P P Fuel filter

P/W

Engine mal- 1) function Hydraulic oil temperatur too high (warning lamp lit, PMS fault indicator Hydraulic oil P/R lamp lit) oil cooler contaminated cooler cleaning Engine coolant temperature too high (warning lamp lit and PMS fault 1) indicator lamp flashing) 1) • Malfunction of solenoid valves 1) • Malfunction of control spool Engine coupling defective

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OPERATING INSTRUCTIONS 6050 / 6050FS Annex Track drive – Fault table Fault

Remedial action

No forward travel and no reversing travel Maximum travel speed cannot be reached Insufficient traction power

•

•

•

• •

• • • • • •

• •

• •

5-6

•

Cause Malfunction of pressure-relief valves

Check Adjust Replace Top up Reduce Clean

P E W A S R

1) Contact the Bucyrus HEX Service Chapter ref.

1)

Servo system pump defective Malfunction of travel valve (pedal) Engine nominal speed too low Malfunction of control spool ECO-power switch in 80%-position Insufficient engine power

1) 1) 1) 1) Travelling P Engine mal- 1) fuction Hydraulic oil temperatur too high (warning lamp lit, PMS fault indi- Hydraulic oil P/R cator lamp lit) oil cooler contaminated cooler cleaning Engine coolant temperature too high (warning lamp lit and PMS 1) fault indicator lamp flashing)

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OPERATING INSTRUCTIONS 6050 / 6050FS Annex Swing mechnism – Fault table Fault

Remedial action

No swing possible No righthand or lefthand swinging Slewing performance insufficient Uncontrolled swinging movement

Cause Electronic excavator control not activated / defective

• • • • • •

•

• •

• • • • •

Limiting switch optional, ramp-type ladder not complete retracted Superstructure holding brake applied Pressure-relief valve adjusted too low level / defective Servo system pump defective Malfunction in feed-pressure circuit of swing pump Malfunction in high-pressure circuit of swing system Malfuction of moment-regulating valve Malfunction in swing pump displacement cylinder Excessive leakage in swing motor

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Check Adjust Replace Top up Reduce Clean 1) Contact the Bucyrus HEX Service Chapter ref.

Working

P E W A S R

Operation

P P 1) 1) 1) 1) 1) 1) 1)

P

5-7

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OPERATING INSTRUCTIONS 6050 / 6050FS Annex Central lubricating system – Fault table Fault

Remedial action

Grease pump not working, the BCS does not indicate a warning Automatic circuit breaker on Grease pump not working, pilot lamp lit Grease pump working, no grease delivered Greasing pressure too high or too low

• • • •

Cause Timer defective

• • •

•

• • •

• • • • •

5-8

Lines between timer and hydraulic motor defective Hydraulikmotor defektive Grease pump defective Grease sieve clogged Distributor defective Grease container empty Grease pump does not suck grease Leaky lines Non-return valve defective Pressure switch defective

Check P Adjust E Replace W Top up A Reduce S Clean R Vent L 1) Contact the Bucyrus HEX Service Chapter ref.

P/W P/W P/W P/W P/R P/W P/A P/L P/L P/W E

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OPERATING INSTRUCTIONS 6050 / 6050FS Annex Engine electronic unit, displaying stored fault codes Engine electronics, displaying faults The CENTRY-system can display and record detectable fault conditions within the CENTRY system and circuits.

The fault lamps (43, Fig. 5-1:) for the left engine and (46, Fig. 5-2:) for the right engine will light up for approx. two seconds after switching on the electrical system of the machine using key switch (32). They will go out when no faults are being detected.

While a fault condition is being detected, the fault lamp will turn “ON“ or “ON FLASHING”.

CENTRY will turn the lamp „ON“ for warning faults, and „ON FLASHING“ for more severe faults that can affect engine operation and need immediate attention. Active fault conditions MUST be corrected as soon as possible.

Engine electronic, displaying faults in memory

Fig. 5-1:

To determine an active CENTRY fault code, the CENTRY system must be switched into diagnostic mode. To do so: •

Shut off engine.

•

Turn key switch electrical system (32) in position „ON“, don’t start the engine.

•

Push momentary switch „DIAGNOSTIC ON/OFF“ (55 or 65) for one or two seconds to the left.

If there are no active faults in the memory, fault lamps (43 or 46) will light up only while momentary switch (55 or 65) is pushed.

However, if an active fault does exist, the warning lamp will begin flashing out the three digit diagnostic code.

Example: Two flashes with short pause between = 2; Short pause; Three flashes with short pause between = 3; Short pause; Four flashes with short pause between = 4; Longer pause, then repeating the same code.

Fig. 5-2:

The fault code is = 234.

Pushing momentary switch (55 or 65) will advance to the next fault code.

In the „Operation and Maintenance Manual CENTRY-System“ you can find a table listing all the fault codes with information about reason and effect.

To quit the diagnostic mode, turn key switch electrical system (32) in position “OFF” or start the engine.

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OPERATING INSTRUCTIONS 6050 / 6050FS Annex HYDRAULIC CIRCUIT DIAGRAM Detailled information can be found in the „Technical Handbook“ chapter 8 or contact Bucyrus HEX Service.

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OPERATING INSTRUCTIONS 6050 / 6050FS Annex ABBREVIATIONS A abt. acc.

Ah API approx.

Ampere (SI base unit of electric current) about according to Ampere hours (SI base unit of quantity of electricity) American Petroleum Institute approximately

BA bar Bh

= OI = Operating instructions unit of pressure, 1 bar = 14.5 psi = OH = Operating hour

CE

Communauté Européenne = European community Committee for european Construction Equipment (Defines a measure for bucket, grab or scoop filling) European Standardization Committee centimeter (= 1/100 m) Cubic centimeters per revolution counterclockwise clockwise

CECE

CEN cm cm3/rev CCW CW

dia.

DIN

Decibel (sound intensity according to measuring method A) Diameter German Industrial Standard

ECM eff. e.g. etc.

Electronic Control Module on engines Effective for example Etcetera

Fig. FMI

Figure, serial number of illustration Failure Mode Identifier, description of malfunctions according to SAE J1939 Falling objects protective structures Rock shovel (working equipment) foot (unit of distance), 1 ft = 0.30 meter

dB(A)

FOPS FS ft gal GLR

HD Hydr.

gallon (unit of volume), 1 gal = 3.78 liters Full-load controller (electronic module for PMS) Heavy duty Hydraulic, Hydraulics

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i i.e.

IFN

Transmission ratio id est = that is ISO service rating, blocked

incl.

including, inclusive of

ISO

International Standardization Organization

kg kg/dm3

Kilogram (unit of weight), 1 kg = 2.2 lb Kilograms per cubic decimeter (= unit of specific density) Kilometers per hour KiloNewtons per meter (1 kNm = 1000 Nm) = unit of torque Kilowatt (1 kW = 1.36 hp)

km/h kNm kW l lb Lb/in² LC LED l/min LpA LwA

Liter (unit of volume), 1 liter = 0.26 gal pound (unit of mass), 1 lb = 0.45 kg Pounds per square inch (= psi) Long crawler Light-emitting diode Liters per minute Sound pressure at workplace Sound power level of the machine in stationary operation

m MA mA max. min. min-1 mm

Meter (unit of distance), 1 m = 3.28 ft Tightening torque Milliampere (=1/1000 A) maximal, maximum minimal, minimum Revolutions per minute Millimeter (=1/1000 m)

N N, kN NLGI NLGI-Klasse Nm No.

Normal, standard version Newton, kiloNewton (unit of force) National Lubricating Grease Institute (USA) Consistency - lubricant classification acc. to DIN 51 818 Newtonmeter (unit of torque) Number

OH op.inst.

OW

Operating hour Operating instructions Superstructure

oz

ounce (unit of volume) 1 oz = 0.03 liter

5-11

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OPERATING INSTRUCTIONS 6050 / 6050FS Annex ABBREVIATIONS

PLC

Pump Managing System Part number (Bucyrus HEX) Part number (Bucyrus HEX) Metric horsepower (1 PS = 0.74 kW) pund per sqare inch (unit of pressure), 1 psi = 0.069 bar Programmable logic controller

Qty.

Quantity

R, r resp.

RH ROPS rpm RTF

Radius Respectively Crawler hydraulics (excavator) Roll-over protective structures Revolutions per minute (= min-1) Rich Text File, textbased file format

SAE sec./s.

SN SPN

Society of Aotomotive Engineers (USA) Second Sachnummer = Bucyrus HEX partnumber Suspect Parameter Number, description of malfunctions according to SAE J1939 Width across flats

PMS P/No. PN PS psi

SW t THB TL tm typ.

U/min USB UW V VDMA

Metric ton (= 1000 kg) Technical Handbook Backhoe dipper (attachment) Tons by meters (obsolescent unit of swing torque) Typical Revolutions per minute Universal Serial Bus, interface for fast data exchange Undercarriage Volt (unit of electric voltage) Association of German Machinery and Systems Manufacturers

W

Watt (unit of electric power)

°C °F > <

Degrees Celsius (temperature) Degrees Fahrenheit (temperature) greater than less than

5-12

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OPERATING INSTRUCTIONS 6050 / 6050FS Annex TECHNICAL DATA

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Cat®

6050 Hydraulic Shovel

Specifications Electrical System (diesel drive) System voltage Batteries in series / parallel installation Alternators Working spot lights

24 V 6 x 210 Ah - 12 V each 630 AH - 24 V in total 2 x 175 A each 8 x high-brightness Xenon lights

• Battery isolation relays • Emergency stop switches accessible from ground level, in engine module and in operator’s cab

Hydraulic Oil Cooling Oil flow of cooling pumps Diesel version 4 x 488 l/min (4x 129 US gal/min) Electric version 4 x 491 l/min (4x 130 US gal/min) Diameter of fans 4 x 1 170 mm (4 x 46 in) • Cooling system is fully independent of all main circuits, i.e. controlled cooling capacity is available whenever engine is running • Gear-type cooling pumps supplying high-volume, lowpressure oil to fans and aluminium coolers • Fan speed and flow of oil to the coolers are thermostatically controlled • Extremely high cooling efficiency to ensure optimum oil temperature

Electric Motor (optional) Type Output Voltage

Squirrel cage induction motor 1 600 kW 6.6 kV +/- 10% (other on request) Rated Current IN 166 A (at 6.6 kV) Frequency 50 Hz (60 Hz optional) Revolutions 1,500 min-1 (1,800 min-1 optional) Starting current 700 A (525 A optional) • Custom-made electric motor with increased gap between rotor and stator to withstand severe mining conditions • Power limit control by Pump Management System

Diesel Engines Engine Features Fuel tank capacity 10 700 l (2,820 US gal) • Hydraulically driven radiator fan with electronically controlled fan speed • Microprocessed engine control • Automatic rev. reduction • Heavy-duty air filters, STRATA 1 with automatic dust evacuation • Two-stage fuel filter incl. water separator • Additional high-capacity water separator • Pre-lube starting system • Eliminator with centrifuge for engine oil filtration

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Hydraulic Shovel—6050

7 580 mm (24 ft 10 in) 7 350 mm (24 ft 1 in)

8 730 mm (26 ft 7 in) 7 000 mm (23 ft)

8 760 mm (28 ft 9 in)

7 600 mm (24 ft 11 in)

6 460 mm (21 ft 3 in)

2 480 mm (8 ft 2 in)

6 400 mm (21 ft) 8 540 mm (28 ft)

2 780 mm (9 ft 1 in)

1,120 mm (3 ft 8 in) 1 400 mm (4 ft 7 in)

7 000 mm (23 ft )

General Data

Operating Weight

Operating Weight Face Shovel Backhoe

525 tonnes (579 tons) 534 tonnes (589 tons)

Engine Output SAE J 1995 Cummins® K1500E Cummins® QSK38

1 880 kW 2,520 HP 1 880 kW 2,520 HP

Shovel Standard track pads 1 400 mm (4 ft 7 in) Operating weight 525 000 kg (1,157,420 lb) Ground Pressure 25.7 N/cm2 (37.3 psi) Additional track pads available on request

Standard Bucket Capacity Face Shovel (SAE 2:1) Backhoe (SAE 1:1)

26.0 m3 34.0 yd3 28.0 m3 36.6 yd3

Features • TriPower shovel attachment • Independent oil cooling system • Spacious walk-through machine house • 5-circuit hydraulic system • Electronic-hydraulic servo control • Board Control System (BCS) • Torque control in closed-loop swing circuit • Automatic central lubrication system • Xenon working lights

Backhoe 1 400 mm (4 ft 7 in) Standard track pads Operating weight 534 000 kg (1,177,260 lb) Ground Pressure 25.7 N/cm2 (37.3 psi) Additional track pads available on request

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Hydraulic Shovel—6050 Diesel Engines Version 1 - Cummins K1500E Tier 1 Make and model 2 x Cummins K1500E Total rated net power ISO 3046/1 1 880 kW (2,520 HP) 1,800 min-1 Total rated net power SAE J1349 1 880 kW (2,520 HP) 1,800 min-1 Total rated gross power SAE J1995 1 880 kW (2,520 HP) 1,800 min-1 No. of cylinders (each engine) 12 Bore 159 mm (6.25 in) Stroke 159 mm (6.25 in) Displacement 37.8 l (2,300 in3) Aspiration Turbocharged and aftercooled Max. altitude without deration 2 438 m (8,000 ft) a.s.l. ®

Version 2 - Cummins QSK38 Tier 2 Make and model 2 x Cummins QSK38 Total rated net power ISO 3046/1 1 880 kW (2,520 HP) 1,800 min-1 Total rated net power SAE J1349 1 880 kW (2,520 HP) 1,800 min-1 Total rated gross power SAE J1995 1 880 kW (2,520 HP) 1,800 min-1 No. of cylinders (each engine) 12 Bore 159 mm (6.25 in) Stroke 159 mm (6.25 in) Displacement 37.8 l (2,300 in3) Aspiration Turbocharged and aftercooled Max. altitude without deration Emission certification

3 300 m (10,800 ft) a.s.l.

US EPA Tier 4i

Hydraulic System with Pump Managing System Main pumps 4 x variable flow axial piston pumps (Diesel and electric versions) Max. oil flow Diesel version 4 x 912 l/min (4 x 241 US gal/min) Electric version 4 x 933 l/min (4 x 246 US gal/min) Max. pressure, attachment 30 MPa = 300 bar (4,350 psi) Max. pressure, travel 37 MPa = 370 bar (5,370 psi) Swing pumps Diesel version 4 x reversible swash plate pumps Electric version 3 x reversible swash plate pumps Max. oil flow Diesel version 4 x 351 l/min (4 x 93 US gal/min) Electric version 3 x 491 l/min (3 x 131 US gal/min) Max. pressure, swing system Diesel version 32 MPa = 320 bar (4,640 psi) Electric version 35 MPa = 350 bar (5,080 psi)

Total volume of hydraulic oil Diesel version Approx. 7 800 I (2,060 US gal) Electric version Approx. 7 300 I (1,930 US gal) Hydraulic tank capacity Diesel version Approx. 5 500 l (1,450 US gal) Electric version Approx. 5 000 l (1,320 US gal) • Pump Managing System contains: - Electronic load limit control - Flow on demand from main pumps depending on joystick position - Automatic regulation of main pumps to zero flow without demand - Automatic rpm reduction of engine speed during working breaks - Reduced oil flow of main pumps at high hydraulic oil temperature or high engine temperature • Pressure cut-off for main pumps • Cooling of pump transmission gear oil • Filters: - Full-flow high-pressure filters (100 μm) for the main pumps, installed directly behind each pump - High pressure filters (100 μm) for the closed swing circuit - Full-flow filters (10 μm) for the complete return circuit - Pressure filters (40 μm and 6 μm) for servo circuit - Pressure filters (40 μm) for the feed pumps of the closed swing circuit - Transmission oil filters (40 μm)

Undercarriage Travel speeds (2 stages) 1st stage Max. 1.6 km/h (0.99 mph) 2nd stage Max. 2.3 km/h (1.44 mph) Max. tractive force 2 576 kN (578,900 lb) Gradability of travel drives Max. 50 % Track pads (each side) 39 Bottom rollers (each side) 6 Support rollers (each side) 2 plus a skid plate in between Travel drives (each side) 1 planetary transmission with

2 two-stage axial piston motors Parking brakes Wet multiple disc brake, spring-applied/hydraulically released • Cast double-grouser combined pad links with bushings connected by hardened full floating pins • All running surfaces of sprockets, idlers, rollers and pad links, as well as teeth contact areas of sprocket and pad links, are hardened • Fully hydraulic, self-adjusting track tensioning system with membrane accumulator • Automatic hydraulic retarder valve to prevent over-speed on downhill travel • Acoustic travel alarm

Hydraulic Shovel—6050 Operator’s Cab Operator’s eye level Internal dimensions

approx. 7.6 m (24 ft 11 in) Length 2 200 mm (7 ft 3 in) Width 1 600 mm (5 ft 3 in) Height 2 150 mm (7 ft 1 in) • Pneumatically cushioned and multi-adjustable comfort seat with lumbar support, seat heating, safety belt, headand armrests • Switch in seat cushion to automatically neutralize the hydraulic controls when operator leaves the seat • Joystick controls integrated in independently adjustable seat consoles • Fold-away auxiliary seat with safety belt • FOPS (rock guard; approved acc. to DIN ISO 3449) integrated into cab structure • All-round safety glass, armored windshield and sliding side window • Windshield with parallel intermittent wiper / washer • Roller blind at windshield • Robust instrument panel incl. large colored BCS screen with transflective technology • Board Control System (BCS) electronic monitoring and data logging system for vital signs and service data of engines, hydraulic systems and lubrication systems • Machine access via retractable boarding ladder, hydraulically operated • Sliding emergency ladder (kick-down type) with ladder cage

Swing System Swing Drives

4 compact planetary transmissions with axial piston motors Parking Brakes Wet multiple disc brake, spring-loaded / hydraulically released Max. swing speed Diesel version 3.8 rpm Electric version 4.0 rpm Swing ring Triple-race roller bearing with sealed internal gearing • Closed-loop swing circuit with torque control • Hydraulic braking of the swing motion by counteracting control • All raceways of swing ring, as well as grease bath for internal gearing, supplied by automatic central lubrication system

Automatic Lubrication System Capacity of grease container 1 000 l (264 US gal) • Dual-circuit system with hydraulically driven heavy-duty pump and electronic time relay control to adjust the pause / lube times • Connected to the lubrication system are the swing roller bearing with internal gearing and all pivot points of attachment, bucket and cylinders • System failures displayed by Board Control System • Grease filters (200 μm) between service station and container, as well as directly behind grease pump

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Retractable Service Station Retractable service station installed underneath the engine module and easily accessible from ground.

Equipped with: • Quick couplings for: - Diesel fuel - Engine coolant - left / right - Pump transmission gear oil - left / right - Engine oil (oil pan) - left / right - Engine oil (additional tank - optional) - left / right - Hydraulic oil tank - Grease container • Cat jump-start socket • Indicator lights for fuel tanks left/right full and grease container full

Attachments • Booms and sticks are torsion-resistant, welded box design of high tensile steel with massive steel castings at pivot areas • Welding procedures allow for internal counter-welding (double prep weld) wherever possible • Booms and sticks are stress-relieved after welding • Inspection hole in booms • Catwalks with rails at booms • Pressure-free lowering of boom (FS and BH) and stick (FS) by means of a float valve • Shovel attachment with unique TriPower kinematics ensuring the following main features: - Horizontal automatic constant-angle bucket guidance - Vertical automatic constant-angle bucket guidance - Automatic roll-back limiter to prevent material spillage - Kinematic assistance to hydraulic forces - Constant boom momentum throughout the entire lift arc - Crowd force assistance • All buckets (FS and BH) are equipped with a universal wear package suitable for all standard applications, which consists of: -S pecial liner material covering main wear areas inside and outside of bucket - Lip shrouds between teeth - Wing shrouds on side walls - Heel shrouds at bottom edges • Special wear packages for highly abrasive materials on request

EM027997-0

Hydraulic Shovel—6050 TriPower Face Shovel Attachment (FS) Working Diagram - Boom 8.0 m (26 ft 2 in) - Stick 5.1 m (16 ft 9 in)

Working Range Max. digging height Max. digging reach Max. digging depth Max. dumping height

Crowd distance on level

50 ft 2 in 53 ft 2 in 7 ft 10 in 38 ft 9 in

Digging Forces Max. crowd force Max. crowd force at ground level Max. breakout force

Heavy rock shovel ESCO S130

Heavy rock shovel ESCO S130

Standard rock shovel Light rock shovel ESCO S130 ESCO S130

24.5 m³ (32.0 yd³)

26.5 m³ (34.7 yd³)

30.5 m³ (39.9 yd³)

32.3 m³ (42.2 yd³)

21.0 m³ (27.5 yd³) 4 800 mm (15 ft 9 in) 4 300 mm (14 ft 1 in) 2 500 mm (8 ft 2 in) 6

23.0 m³ (30.1 yd³) 4 800 mm (15 ft 9 in) 4 300 mm (14 ft 1 in) 2 500 mm (8 ft 2 in) 6

26.0 m³ (34.0 yd³) 4 800 mm (15 ft 9 in) 4 300 mm (14 ft 1 in) 2 500 mm (8 ft 2 in) 6

28.0 m³ (36.6 yd³) 4 800 mm (15 ft 9 in) 4 300 mm (14 ft 1 in) 2 500 mm (8 ft 2 in) 6

42 400 kg (93,480 lb)

41 800 kg (92,150 lb)

42 900 kg (94,580 lb)

43 100 kg (95,020 lb)

2.2 t/m³ (3,710 lb/yd³)

2.0 t/m³ (3,370 lb/yd³)

1.8 t/m³ (3,030 lb/yd³) 1.65 t/m³ (2,780 lb/yd³)

15.3 m 16.2 m 2.4 m 11.8 m 5.5 m

Face Shovels Type Iron ore shovel Tooth system ESCO S130 Capacity SAE / PCSA 1:1 21.0 m³ (27.5 yd³) Capacity SAE / CECE 2:1 18.0 m³ (23.5 yd³) Total width 4 800 mm (15 ft 9 in) Inner width 4 300 mm (14 ft 1 in) Opening width 2 250 mm (8 ft 2 in) No. of teeth 6 Weight including wear kit 40 400 kg (89,070 lb) Max. material density (loose) 2.6 t/m³ (4,380 lb/yd³)

1 890 kN 424,740 lb 1 650 kN 370,800 lb 1 500 kN 337,100 lb

19 ft

EM027997-0

Hydraulic Shovel—6050 Backhoe Attachment (BH) Working Diagram - Boom 10.5 m (34 ft 5 in) - Stick 5.5 m (18 ft 1 in)

Working Range Max. digging depth Max. digging reach Max. digging height Backhoes Type Tooth system Capacity SAE 1:1 Capacity CECE 2:1 Capacity struck Total width Inner width No. of teeth Weight incl. universal wear kit Max. material density (loose)

9.2 m 30 ft 2 in 19.5 m 64 ft 16.8 m 55 ft 1 in

Digging Forces Max. crowd force Max. breakout force

1 200 kN 269,680 lb 1 200 kN 269,680 lb

Standard rock bucket (Other buckets on request) ESCO size 110 28.0 m³ (36.6 yd³) 24.6 m³ (32.2 yd³) 21.2 m³ (27.7 yd³) 4 440 mm (14 ft 7 in) 4 040 mm (13 ft 3 in) 6 32 300 kg (72,210 lb) 1.8 t/m³ (3,030 lb/yd³)

2 100 2 100 mm mm 2 100 mm (6 ft (611 ft 11 in)in) (6 ft 11 in)

2 750 2 750 mm mm 2 750 mm (7 ft (75ftin) 5 in) (7 ft 5 in)

2 100 mm (6 ft 11 in)

2 100 mm 2 100 mm (6 ft 11 in) (6 ft 11 in)

Crawler side frame (2 units) 400 mm (27 ft 7weight in) Width 2 200 mm (7 ft 38 in) Gross 44 600 kg (98,330 lb)

6 750 mm (22 ft 2 in) 6 750 mm (22 ft 2 in)

3 820 mm (12 ft 6 in)

2 360 mm 3 750 mm (12 ft 4 in)

(7 ft 9 in)

1 550 mm (5 ft 1 in)

1 580 mm (5 ft 2 in)

Gross Weight

2 900 kg (6,390 lb)

2 500 mm (8 ft 2 in)

5 570 mm (18 ft 3 in)

1 300 mm (4 ft 3 in) 1 270 mm (4 ft 2 in)

1 700 kg (3,750 lb)

1 100 mm (3 ft 7 in) 2 000 mm (6 ft 7 in)

740 kg (1,630 lb)

1 300 mm (4 ft 3 in) 2 700 mm (8 ft 10 in) 1 900 kg (4,190 lb)

Above values are approximate. Details may vary depending on scope of supply and destination.

Exact data subject to selected machine configuration and final packing list.

Length

Length

Length

Height

Barrels (hydraulic oil)

3 500 mm (11 ft 6 in) Barrels (hydraulic3oil; 500 grease) mm (11 ft 6 in) 2 500 mm (8 ft 2 in)

Length

1 300 mm (4 ft 3 in) 2 100 mm (6 ft 11 in) 1 470 kg (3,240 lb) Length Height

1 700 mm (5 ft 7 in)

2 750 mm 2 360 mm (7 ft 9 in)

1 550 mm (5 ft 1 in)

1 550 mm (5 ft 1 in) Height

Length

3 300 mm (10 ft 10 in) 1 600 mm (5 ft 3 in) 1 780 mm (5 ft 10 in) 1 620 kg (3,570 lb)

3 500 mm (11 ft 6 in)

Grease container with pump

Retractable ladder

mm (5 ft 2 in) ft 6 in) 1 300 mm (4 ft 33 500 in)mm1(11030 mmmm (3(5ftft512580 in) 390 kg (860 1 550 mm lb) (5 ft 1 in) 1 580 in)

Height Height

3 070 mm (10 ft 1 in)

Swing ring bolts, access ladder, etc. 3 300 mm (10 ft 10 in) 1 600 mm (5 ft 3 in) 1 260 mm (4 ft 2 in)

Mufflers and covers

1 580 mm (5 ft 2 in)

1 580 mm (5 ft 2 in) 1 950 mm (6 ft 5Length in) 1 320 mm (4 ftLength 4 in) 2 460 kg (5,4201 550 lb) mm (5 ft 1 in)

4 800 kg (10,580 lb)

2 200 mm (7 ft 3 in)

2 360 mm 2 360 mm (7 ft 9 in) (7 ft 9 in)

1 750 mm (5 ft 9 in)

Height

Height

1 550 mm (5 ft 1 in) 1 550 mm (5 ft 1 in)

1 580 mm (5 ft 2 in) 1 580 mm (5 ft 2 in)

1 350 mm (4 ft 5 in) 2 100 mmLength (6 ft 7 in)

Swing ring cover

4 000 mm (13 ft 1 in)

4 000 1 580 2 mm in)1 in)(13 ft 1 in)1 550 mm (5 ft 1 in) 1 550(5 (5 ft 4 000 mmmm (13 ftmm 1ftin)

1 580 mm (5 ft 2 in)

Width

3 750 mm (12 ft 4 in)

3 750 mm (12 ft 4 in)

1 550 mm (5 ft 1 in)

2 360 2 360 mm mm 2 360 mm (7 ft (79ftin) 9 in) (7 ft 9 in)

3 450 mm (11 ft 4 in)

3 750 mm (12 ft 4 in)

4 000 mm (13 ft 1 in)

3 820 mm (12 ft 6 in)

3 820 mm (12 ft 6 in)

3 820 mm (12 ft 6 in)

3 820 mm (12 ft 6 in)

3 750 mm (12 ft 4 in)

3 700 mm (12 ft 2 in)

1 750 1 750 mm mm 1 750 mm (5 ft (59ftin) 9 in) (5 ft 9 in)

1 750 mm (5 ft 9 in)

1 750 mm (5 ft 9 in)

1 750 mm (5 ft 9 in)

7 000 mm (23 ft) 7 000 mm (23 ft)

4 000 mm (13 ft 1 in)

Gross weight 36 000 kg (79,370 lb) 19 300 kg (42,550 lb)

2 360 mm Height (7 ft 9 in)

2 700 mm (8 ft 10 in)

4 000 mm (13 ft 1 in) 4Width 000 mm (13 ft 1 in)

Height

Four swing gears

3 500 mm (11 ft 6 in) mm (4 ft 5 in) 3 500 mm 1 (11350 ft 6 in)

Two radiators with fan

Length

3 070 mm (10 ft 1 in)

Content

1 580 mm (5 ft 2 in)

1 750 mm

3 500 mm (11 ft 6 in)

3 500 mm (11 ft 6 in)

3 720 mm (12 ft 2 in)

(5 ft 9 in)

Crates

070ft mm 31 070 in)mm mm (103(10 ft 070 1ftin) mm 1 in)(10 ft 1 in) 3 070 mm 3(10 1 in)(10 3ft070

3 500 mm (11 ft 6 in) 3 500 mm (11 ft 6 in)

3 070 mm (10 ft 1 in)

3 070 mm (10 ft 1 in)

3 720 mm (12 ft 2 in) 3 720 mm (12 ft 2 in)

4 000 mm (13 ft 14in) 000 mm (13 ft 1 in)

Lower part Upper part

6 750 mm (22 ft 2 in)

Gross weight 9 750 kg (21,490 lb)

4 000 mm (13 ft 1 in) 4 000 mm (13 ft 1 in)

Counterweights 4 000 mm (13 ft 1 in)

4 000 mm (13 ft 1 in)

Crate with cabin and FOPS Width 2 610 mm (8 ft 7 in) Gross weight 3 500 kg (7,720 lb) 3 720 mm (12 ft 2 in)

4 000 mm (13 ft 1 in)

10 200 mm (33 ft 6 in)

Height

3 700 mm (12 ft 2 in)

3 720 mm (12 ft 2 in) 3 720 mm (12 ft 2 in)

4 000 mm (13 ft 1 4 in)000 mm (13 ft 1 in)

1 750 3 070 mmmm (10 ft(5 1 in) ft 9 in)

700ft mm 32 700 in)mm mm (123(12 ft 700 2ftin) mm 2 in)(12 ft 2 in) 3 700 mm 3(12 2 in)(12 3ft700

3 700 mm (12 ft 2 in) 3 700 mm (12 ft 2 in)

3 700 mm (12 ft 2 in)

3 720 mm (12 ft 23in) 720 mm (12 ft 2 in)

4 000 mm (13 ft 1 in)

Oil cooler module 4 000 mm (13 ft 1 in) Width 2 000 mm (6 ft 47000 in)mm (13 ft 1 in) 4 000 mm (13 ft 1 in)

Cab pedestal module 10 200 mm (33 ft 6 in) 10 200 mm (33 ft 6 in) Width 2 500 mm (8 ft 2 in) Gross weight 7 100 kg (15,650 lb)

3 720 mmmm (12(12ftft22in) 3 720 in)

330 mm (1 ft 1 in)

1 750 mm (5 ft 9 in)

10 200 mm (33 ft 6 in)

200 mm (33 ft 6 in) 10 200 mm (33 ft10 6 in)

3 450 mm (11 ft 4 in)

10 10 200 mm (33 ft 6 in) 200 mm (33 ft 6 in) 10 200 mm (33 ft 6 in)

3 450 mm (11 ft 4 in)

3 450 mm (11 ft 4 in)

Superstructure Center Frame 6 400 mm (23 ft) 10 200 mm (33 ft 6 in) Width 3 600 mm (11 ft 10 in) Gross weight 62 000 kg (136,690 lb)

2 360 mm (7 ft 9 in)

3 450 mm (11 ft 4 in)

450 43 in) 450 mm mm (113(11 ft450 4ftin) 4mm in) (11 ft 4 in) 3 450 mm 3(11 ft 4mm in) (11 3ft450

mm (23 ft) 6 tracks consisting of 136 400pad links each 330 mm (1 ft 1 in) 8 400 mm (27 ft 7 in) Width 1 400 mm (4 ft6 400 7 in) Gross weight (each) 10 700 kg mm (23 ft) 330 mm (1 ft 1 in)(23,590 lb) 8 400 mm (27 ft 7 in)

6 400 mm (23 ft)

6 750 mm (22 ft 2 in)

750 mm 2 in) (22 ft 2 in) 6 (22 750ft mm Engine 6module with diesel engines Width 7 000 mm (23 ft) Gross weight 42 000 kg 6 750 mm (22 ft 2 in) (92,590 lb)

2 360 mm (7 ft 9 in)

330 mm (1 ft 1 in)

330 mm (1 ft 1 in) 6 400 mm (23 ft) 330 mm (1 ft 1 in) 6 400 mm (23 ft) 330 mm (1 ft 1 in) 6 400 mm (23 ft)

2 750 mm (7 ft 5 in)

6 750 mm (22 ft 2 in)

2 750 mm (7 ft 5 in)

2 100 mm (6 ft 11 in)

6 400 mm (23 ft) 8 400 mm (27 ft 7 in) 400 (23 (27 ft) ft 7 in) 8 400 mm6(27 ft8mm 7400 in)mm

6 750 mm (22 ft 2 in)

330 mm (1 ft 1 in) 330 mm (1 ft 1 in)

2 100 mm (6 ft 11 in)

2 100 mm (6 ft 11 in)

8 400 mm 6 400 mm (23 ft)(27 ft 7 in) 8 400 mm (27 ft 7 in)

2 100 mm (6 ft 11 in)

330 mm (1 ft 1 in)

2 750 mm (7 ft 5 in)

2 750 mm (7 ft 5 in)

8 400 mm (27 ft 7 in)

2 750 mm 2 750 mm (7 ft 5 in) (7 ft 5 in)

Undercarriage center frame with swing roller bearing Width 3 800 mm (12 6ft750 6 mm in)(22 ft 2 in) Gross weight 42 300 kg (93,250 lb)

820 63 in) mm (123(12 ft820 6ftin) 820 mm 6mm in) (12 ft 6 in) 3 820 mm 3(12 ft 6mm in) (12 3ft820

8 400 mm (27 ft 7 in)

Height

General Packing List

EM027997-0

750 43 in) 750 mm mm (123(12 ft750 4ftin) 4mm in) (12 ft 4 in) 3 750 mm 3(12 ft 4mm in) (12 3ft750

Hydraulic Shovel—6050

Length

EM027997-0

Hydraulic Shovel—6050 TriPower Shovel Attachment

4 500 mm (14 ft 9 in)

6 250 mm (20 6mm in) 6 250 (20 6ft250 mm (20ftft66in) in)

4 500 mm (14 ft 9 in)

4 500 mm (14 ft 9 in)

900 mm (2 ft 11 in)

900 mm (2 ft 11 in) 900 mm (2 ft 11 in)

2 000 mm (6 ft 7 in) 2 000 mm (6 ft 7 in)

2 000 mm (6 ft 7 in)

2 000 mm (6 ft 7 in)

Height Height

Height

Height

Height 2 000 mm (6 ft 7 in)

Height

Height

2 750 mm (9 ft)

2 750 mm (9 ft)

2 750 2 750 mmmm (9 ft) (9 ft)

2 750 mm (9 ft)

2 750 mm (9 ft) 2 750 mm (9 ft)

3 200 mm (10 ft 6 in)

Length

Length Length Length Length

Height Height

Gross weight Length Length 5 000 kg (11,020 lb) Length 3 260 kg (7,190 lb) Length 3 400 kg (7,500 lb)

Height

Height

7 700 mm (25 ft 3 in)

Height Height

Crates with main valve block, catwalks, railings & other parts 7 700 mm (25 ft 3 in) Length Width Height 7 700 mm (25 ft 3 in) 3 650 mm (12 ft) 2 170 mm (7 ft 1 in) 1 520 mm (5 ft) 4 300 mm (14 ft 1 in) 1 900 mm (6 ft 3 in) 1 700 mm (5 ft 7 in) 4 960 mm (16 ft 3 in) 1 900 mm (6 ft 3 in) 1 900 mm (6 ft 3 in)

Length

Length

2 pallets with stick cylinders each 860 (2 ft mm 10 in)(2 ft 10 in) mm (2 ft 10 in) Width 800 860mm (2 860 ft mm 7860 in) Gross weight 4 200 kg (9,260 lb) mm (2 ft 10 in) Length

860 mm (2 ft 10 in)

900 mm (2 ft511 5ft200 (17 ft 860 1 in) 5 200 (17 ft 1 in) 200in) mm (17 1 mm in) mm mm (2 ft 10 in)

860 mm (2 ft 10 in)

900 mm (2 ft 11 in)

900 mm (2 ft 11 in) 5 200 mm (17 ft 1 in) 5900 200 mm mm (17 in)in) 6 250 mm (20 ft 6 in) 6 250900 (2 ftft111 mm (20 ft 6 (2 in) ft 11 in) mm 6 250 mm (20 ft 6 in) 6 250 mm (20 ft 6 in) 900 mm (2 ft 11 in) 6 250 mm (20 ft 6 in)

6 250 mm (20 6ft250 6 in) mm (20 ft 6 in)

Above values are approximate. Details may vary depending on scope of supply and destination.

900 mm (2 ft 11 in) Exact data subject to selected 6machine configuration and final packing list.

250 mm (20 ft 6 in) 6 250 mm (20 ft 6 in)

7 700 mm (25 ft 3 in)(25 ft 3 in) 7 700 mm

Height Height

3 750 mm (12 ft 4 in)

2 pallets with boom cylinders each 4 500 mm (14 ft 9 in) Width 800 mm (2 ft 7 in) Gross weight 7ft 180 kg (15,830 lb) 900 mm 11 900(2 mm (2 ftin) 11 in) 4 500 mm (14 ft 9 in)

7 700 mm (25 ft 3 in) 7 700 mm (25 ft 3 in)

7 700 mm (25 ft 3 in)

7 700 mm (25 ft 3 in)

750mm mm 33750 (12(12 ft 4 ft in)4 in)

4 500 mm (14 ft 9 in)

4 500 mm (14 ft 9 in)

3 750 mm (12 ft 4 in)

3 750 3 750 mmmm (12 (12 ft 4ftin)4 in)

3 750 mm (12 ft 4 in)

3 750 mm (12 ft 4 in)

3 750 mm 3 750 (12mm ft 4 in) (12 ft 4 in)

3 7503mm 4 in)ft 4 in) 750(12 mmft(12

11 500 mm (37 ft 9 in)

4 5004mm (14 mm ft 9 in)(14 ft 9 in) 500

7 700 mm (25 ft 3 in) 7 700 mm (25 ft 3 in)

700 mm (2 ft 4 in)

Height

11 500 mm (37 ft 9 in) Backhoe bucket incl. pins for stick and linkage 11 500 mm (37 ft 9 in) Capacity (2:1) Width Gross Weight 11 500 mm (37 ft 9 in) 28 m³ (36.6 yd³) 4 440 mm (14 ft 7 in) 34 500 kg (76,060 lb)

4 500 4 500 mm (14 ftmm 9 in)(14 ft 9 in)

4 400 mm (14 ft 5 in)

7 700 mm (25 ft 3 in)

11 500 mm 9 in) 11(37 500 ft mm (37 ft 9 in)

4 500 mm (14 ft 9 in)

700 mm (2 ft 4 in)

4 400 mm (14 ft 5 in)

3 200 mm (10 ft 6 in)

11 500 mm (37 ft 9 in)

2 000 mm (6 ft 7 in)

2 000 mm (6 ft 7 in) 2 000 mm (6 ft 7 in)

3 200 3 200 mmmm (10 (10 ft 6ftin)6 in)

4 400 mm (14 ft 5 in)

200 mm ft 6 in) 3 3200 mm (10 (10 ft 6 in)

3 200 mm 3 200 (10mm ft 6 in) (10 ft 6 in)

11 500 mm (37 ft 9 in)

11 500 mm (37 ft11 9 in) 500 mm (37 ft 9 in)

3 200 mm (10 ft 6 in)

11 500 mm (37 ft 9 in)

3 200 mm (10 ft 6 in)

5 100 mm (16 ft 9 in)

700 mm (2 ft 4 in)

Length

Stick with linkage and bucket cylinder 700 mm (2 ft 4 in) Width 2 300 mm (7 ft 7 in) Gross weight 28 000 kg (61,730 lb)

Monoboom without main valve block 5 100 mm (16 ft 9 in) 4 400 mm (14 ft 5 in) 700 mm (2 ft 4 in) Width 5 000 mm (16 ft 5 in) Gross weight 46 000 kg (101,410 lb)700 mm (2 ft 4 in)

11 500 mm (37 ft 9 in)

4 400 mm (14 ft 5 in)

4Length 400 mm (14 ft 5 in)

5 100 mm (16 ft 9 in)

5 100 mm (16 ft 9 in)

HeightHeight Height

700 mm (2 ft 4 in)

700 mm (2 ft 4 in)

700 mm (2 ft 4 in)

700 mm (2 ft 4 in)

700 mm (2 ft 4 in)

4 400 mm (14 ft 5 in)

Length

4 400 mm (14 ft 5 in)

700 mm (2 ft 4 in) Length

700 mm (2 ft 4 in) 4 400 mm (14 ft 5 in)

4 400 mm (14 ft 5 in)

2 750 mm (9 ft)

5 100 mm (16 ft 9 in)

4 400 mm (14 ft 5 in)

3 200 3mm ft 6(10 in)ft 6 in) 200(10 mm

5 100 mm (16 ft 9 in)

4 400 mm (14 ft 5 in) in) 4 400700 mmmm (14(2ftft54in)

4 400 mm (14 ft 5 in)

700 mm (2 ft 4 in)

700 mm (2 ft 4 in)

4 400 mm (14 ft 5 in)

6 000 mm (19 ft 8 in)

700 mmLength (2 ft 4 in)

Length

3 900 mm (12 ft 10 in)

5 100 mm (16 ft 9 in)

Backhoe Attachment

700 mm (2 ft 4 in)

4 400 mm (14 ft 5 in)

700 mm (2 ft 4 in) 5 100 mm (16 ft 9 in)

Length

Height Height

3 900 mm 3 900 (12mm ft 10(12 in)ft 10 in)

5 100 mm (16 ft 9 in)

2 000 mm 2 000 (6 ftmm 7 in) (6 ft 7 in)

3 600 mm (11 ft 10)

2 Bundles with 2 stick cylinders and 2 bucket cylinders each Width 1 200 mm (3 ft 11 in) Gross weight 200 700 mm 5 (2 ft 4 in) kg (11,460 lb)

Bundle with 2 boom cylinders 4 400 mm (14 ft 5 in) Width 1 200 mm (3 ft 11 in) 5 100 mm Gross (16 ft 9 in)weight 7 100 kg (15,650 lb) 4 400 mm (14 ft 5 in) mm (2 ft 4 in) 5 100 mm (16 ft59 100 in) mm (16 ft 700 9 in)

Length

6 000 mm (19 ft 8 in)

Height Height

8 900 mm (29 ft 2 in)

700 mm (2 ft 4 in) 700 mm (2 ft 4 in) 700 mm (2 ft 4 in)

Length

Length Length

2 750 mm 2 750 (9 ft) mm (9 ft)

4 400 mm (14 ft 5 in)

Length

6 000 mm (19 ft 8 in)

3 900 mm (12 ft 10 in)

8 900 mm (29 ft 2 in)

6 000 mm (19 ft 8 in)

Height

3 900 mm (12 ft 10 in)

4 400 mm (14 ft 5 in)

4 400 mm (14 ft 5 in)

3 900 mm (12 ft 10 in)

3 600 mm 3 600 (11mm ft 10) (11 ft 10)

3 900 mm (12 ft 10 in)

8 900 mm (29 ft 2 in)

6 000 mm (19 ft 8 in)

6 000 mm (19 ft 8 in)

8 900 mm (29 ft 2 in)

4 400 mm (14 ft 5 in) 4 400 mm (14 ft 5 in)

4 400 mm (14 ft 5 in)

3 900 3 900 mmmm (12 (12 ft3 600 10 ft in) 10 in) mm (11 ft 10)

8 900 mm (29 ft 2 in)

3 900 mm (12 ft 10 in)

8 900 mm (29 ft 2 in)

3 900 mm (12mm ft 10 in)ft 10 in) 3 900 (12

8 900 mm (29 ft 2 in)

3 600 mm (11 ft 10)

8 900 mm (29 ft 2 in)

Face shovel incl. pin for stick Capacity (2:1) Width Gross Weight 26.0 m³ (34.0 yd³) 4 800 mm (15 ft 9 in) 43 900 kg (96,780 lb)

6 000 mm (19 ft 8 in) 6 000 mm (19 ft 8 in) Crates with catwalks, railings and other parts 6 000 mm (19 ft 8 in) 6 000 mm (19 ft 8Width in) Length Height Gross weight 4 270 mm 1 900 mm 1 700 mm 3 400 kg (14 ft) (6 ft 3 in) (5 ft 7 in) (7,500 lb)

2 750 mm (9 ft) 2 750 mm (9 ft)

3 600 3 600 mmmm (11 (11 ft 10) ft 10)

8 900 mm (29 ft 2 in)

6 000 mm (19 ft 8 in) 6 000 mm (19 ft 8 in)

3 600 mm (11 ft 10)

8 900 mm (29 ft 2 in)

3 600 mm (11 ft 10)

8 900 mm (29 ft 2 in) 8 900 mm (29 ft 2 in)

3 600 mm (11 ft 10)

3 600 mm (11mm ft 10) 3 600 (11 ft 10)

Boom with main valve block, TriPower linkages and rods Width 3 050 mm (10 ft) Gross weight 46 800 kg (103,180 lb)

2 000 2 000 mmmm (6 ft(67ftin)7 in)

Stick Width 2 400 mm (7 ft 10 in) Gross weight 17 300 kg (38,140 lb)

5 200 mm (17(17ftft11in) 5 200 mm in)

5 200 mm (17 ft 1 in) 5 200 mm (17 ft 1 in) 5 200 mm (17 ft 1 in)

860 mm (2 ft 10 in) mm ft 10 in) 860 mm860 (2 ft 10(2in) 860 mm (2 ft 10 in)

860 mm (2 ft 10 in) 5 200 mm (17 ft 1 in)

5 200 mm (17 ft 1 in)

EM027997-0

Hydraulic Shovel—6050 Component Accessibility on Superstructure 1. Diesel Engines 4. Oil coolers 2. Gearboxes with hydraulic pumps 5. Hydraulic tank 3. Engine radiators with hydraulically driven fan 6. Swing drives

4

7. Rotary distributor 8. Travel valves 9. Switch cabinet and battery box

10. Operator’s seat 11. BCS tower 12. Auxilliary seat

4 2 8

6

3

1

5 7

9

2

3

1

11 10

12

Anti-slip catwalks Anti-slip walking areas

Optional Equipment General

Cab

• Export crating • Finishing as per end user´s corporate colors • Customizing of logos as per customer’s specification

• Various heating and air-conditioning systems • Roller blinds at all windows • Rear windscreen wiper • Additional instrumentation

Superstructure • Hydraulic service crane on superstructure with auxilliary engine • Mesabi radiators instead of standard radiators • Oil change interval extension for engine oil up to 1,000 hrs • Folding access stairway, stairway angle approx. 45° • Round container with a standard 200 l grease barrel (instead of 1,000 l grease container) • Lubricated pinion for greasing of internal gearing of swing ring • Various cold-weather packages

Additional optional equipment available on request

Undercarriage • Track pad width 1 600 mm (5 ft 3 in) or 1,800 mm (5 ft 11 in) • Automatic lubrication of rollers by central lube system • Cover plate under carbody (belly plate)

Attachment • Guards for shovel cylinders of FS-attachment • Xenon lighting on boom • Special wear packages

For more complete information on Cat products, dealer services, and industry solutions, visit us on the web at mining.cat.com and www.cat.com © 2011 Caterpillar Inc. All rights reserved CAT, CATERPILLAR, their respective logos, “Caterpillar Yellow” and the “Power Edge” trade dress, as well as corporate and product identity used herein, are trademarks of Caterpillar and may not be used without permission.

AEHQ6525

EM027997-0

OPERATING INSTRUCTIONS 6050 / 6050FS Annex

5-16

BA RH200(3 847 006.00)-EN

EM027997-0

OPERATING INSTRUCTIONS 6050 / 6050FS Annex NOTES .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. 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BA RH200(3 847 006.00)-EN

5-15

EM027997-0

OPERATING INSTRUCTIONS 6050 / 6050FS Annex

5-16

BA RH200(3 847 006.00)-EN

EM027997-0

OPERATING INSTRUCTIONS 6050 / 6050FS Index 6 INDEX Operating instructions

Target group

Part 1 INTRODUCTION FUNDAMENTAL SAFETY INSTRUCTIONS

Operating personnel + Inspection and servicing personnel + Repair personnel

Part 2 OPERATION

Operating personnel The operating personnel must have knowhow relevant to the operation and the application of this or comparable machines.

Part 3 INSPECTION AND SERVICING Part 4 REPAIR WORK

Inspection and servicing personnel The inspection and servicing personnel must have know-how relevant to the inspection and servicing of this or comparable machines.

Repair personnel The repair personnel must have know-how and experience relevant to the repair of this or comparable machines.

Part 5 ANNEX

Operating personnel + Inspection and servicing personnel + Repair personnel

Part 6 INDEX

Operating personnel + Inspection and servicing personnel + Repair personnel

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OPERATING INSTRUCTIONS 6050 / 6050FS Index

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OPERATING INSTRUCTIONS 6050 / 6050FS Index

A ABBREVIATIONS........................................... 5-11 About this Operating Instructions ..................... 1-3 Access lighting................................................ 2-18 After daily operation........................................ 2-91 Air conditioner (option) ................................... 2-74 Air-intake lines .............................................. 3-161 Air-intake system .......................................... 3-109 AIR-INTAKE SYSTEM.................................. 3-157 Alternator - Instructions ................................ 3-167 ASSEMBLING WORKING EQUIPMENT SAFETY INSTRUCTIONS .......................... 2-92 Assisted starting (with jumper cables).............. 4-7 Assisted starting (with jumper cables) – Safety instructions .................................................... 4-7 Automatic engine speed reduction ................... 2-9 Automatic fire-extinguishing system (optional)2-29 Avoid mixing of different hydraulic fluids . 3-131, 3186

B Back-up heating (option) ................................ 2-75 Battery .......................................................... 3-168 Battery storage ............................................. 3-226 Bearing races................................................ 3-211 Before starting work........................................ 2-89 Board-Control-System (BCS) ........................... 2-9 Brake chambers - Changing oil .................... 3-206 Braking the superstructure ............................. 2-89 Breather filter ..................................... 3-180, 3-215 Breather filters, clean / replace.......... 3-203, 3-206 Bypass valves (hydraulic oil reservoir) ......... 3-179

C Cab interior lamp ............................................ 2-21 CENTRAL LUBRICATING............................ 3-213 Central lubricating system – Fault table ........... 5-8 Central Management System (CMS) ............... 2-8 Change of engine oil..................................... 3-109 Changing the gearbox oil................... 3-195, 3-199 Changing the hydraulic oil ............................ 3-186 Changing the hydraulic oil return-flow filters (hydraulic oil reservoir .................................... 3-177 Checking the gas charging pressure in the pressure accumulator ........................... 3-210, 3-223 Checking the gearbox oil level / Topping up with oil............................................................... 3-194 Checking the greasing pressure................... 3-216 Checking the hydraulic oil level .................... 3-175 Cleaning jobs ................................................ 3-109 Cleaning the fuel tanks ................................. 3-163 Cleaning the hydraulic oil cooler .................. 3-191 Cold-starting fluid (ether) – Replacing the pressure vessel ................................................ 3-150 BA RH200(3 847 006.00)-EN

Combustion engine - Fault table....................... 5-4 Components.................................................. 3-109 Coolant for use on all combustion engines... 3-138 Cooling liquid, change .................................. 3-154 COOLING SYSTEM ..................................... 3-151 Corrosion protection for pins and bearings (bushings and hubs)............................................. 2-94 CRAWLER TRACKS .................................... 3-207

D Demand control / Zero-flow regulation ............. 2-9 Depressurizing the hydraulic system............ 3-174 DESCRIPTION OF THE EXCAVATOR............ 2-6 Design........................................................... 3-213 Designated use, unauthorized use ................... 1-6 Drive.................................................................. 2-8 Driver's seat .................................................... 2-26 Dust collection............................................... 3-161

E Electrical system ............................................... 2-9 ELECTRICAL SYSTEM......................... 3-167, 4-7 Electrical system - Safety instructions .......... 3-167 Electronic excavator control.......................... 3-192 Eliminator filter and centrifuge ...................... 3-148 Emergency machine drive .............................. 2-83 EMERGENCY STOP switch........................... 2-23 Engine........................................................... 3-221 ENGINE ........................................................ 3-140 Engine - Safety instructions .......................... 3-140 Engine electronic unit, displaying stored fault codes............................................................. 5-9 Engine oil reservoir (optional), draining the oil off ................................................................... 3-145 Engine oil reservoir, checking the oil level / topping up....................................................... 3-142 Engine oil, change ........................................ 3-143 Engine oil, checking the level / topping up ... 3-141 Entering and leaving the machine, Safety instructions ............................................................. 2-18 Equipment, checking .................................... 3-222 Escape ladder ................................................. 2-24 Excavator layout ............................................... 2-7 Extract from the German regulations............ 3-223

F FAULT TABLES................................................ 5-4 Filling quantities - Grease ............................. 3-127 Filling quantities - oil ..................................... 3-130 Filling quantities - other................................. 3-130 Filling up the grease container ..................... 3-215 Filter (control circuit) ..................................... 3-181 Fire and explosion hazard .............................. 1-12 Fire extinguisher ............................................. 2-28 Floodlight projector, replacing the lamp........ 3-172 6-3

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OPERATING INSTRUCTIONS 6050 / 6050FS Index Folding ladder (optional)................................. 2-19 Fuel filter, replace ......................................... 3-162 FUEL SYSTEM............................................. 3-162 Fuel system, Safety instructions................... 3-162 Fuel system, venting..................................... 3-163 Function ........................................................ 3-214 FUNDAMENTAL SAFETY INSTRUCTIONS ... 1-5 Further machine documentation....................... 1-3

G Gearbox - Checking the oil level / Topping up with oil............................................................... 3-199 Gearbox venting ........................................... 3-200 Gearbox, breather valve ............................... 3-196 Grease filter (Filling the grease container) ... 3-219 Grease filter (Grease lines) .......................... 3-220 Grease for idlers, track rollers and support rollers (Lifetime lubrication).................................. 3-137 Greases for bearings, swing rings and track system (Central lubrication system ................ 3-136

H Harness (optional ........................................... 2-30 High-pressure filter for working hydraulics ... 3-182 High-pressure filters for feeding circuits and slewing pumps.................................................. 3-184 High-pressure filters for slewing circuit......... 3-185 High-pressure filters for the servo circuit...... 3-183 Hose line for oil and cooling liquid changes . 3-139 HYDRAULIC CIRCUIT DIAGRAM ................. 5-10 Hydraulic hoses – Instructions ......................... 4-9 Hydraulic ladder (optional)............................ 3-222 Hydraulic system .............................................. 2-8 HYDRAULIC SYSTEM ................................. 3-174 HYDRAULIC SYSTEM ..................................... 4-9 Hydraulic system - Safety instructions ......... 3-174

I Illuminating the control column ....................... 2-22 Inspection and servicing - Safety instructions .... 3103 Inspection and Servicing plans - Instructions3-109 inspection and servicing work, Fire and Explosion Hazard....................................................... 3-108 INSPECTION PLAN - OIL ............................ 3-128 Inspection plan – Oil (legend)....................... 3-129 Instructions on troubleshooting ........................ 5-3 Intervals ........................................................ 3-109

L Layout of the fault table .................................... 5-3 LUBRICANTS ............................................... 3-131 LUBRICATING CHART – GREASE ............. 3-126 Lubricating chart – Grease (legend)............. 3-127

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M Main filter elements, checking and cleaning. 3-159 Main filter elements, removal and installation..... 3158 Maximum machine inclinations, information... 2-77 Measures .......................................................... 5-3 MONITORING, WARNING AND CONTROL ELEMENTS ................................................. 2-34

N Notes.............................................1-13, 2-99, 5-15 NoteS ............................................................ 3-228 NOTES............................................................ 4-13 Notes on the selection of oils and greases... 3-131

O Oil change prolongation system, replacing the oil filter............................................................ 3-147 Oilfilter (hydraulic circuit grease pump) ........ 3-218 Oils / Greases ............................................... 3-109 Oils for combustion engines ......................... 3-132 Oils for hydraulic system............................... 3-133 Oils for pump gearboxes and travel gearboxes.. 3134 Oils for swing gearboxes .............................. 3-135 ON-BOARD CRANE (OPTIONAL) ................. 2-95 On-Board crane, – blocking the boom in position of rest .......................................................... 2-97 On-board crane, checking .............................. 2-97 On-Board crane, checking tightness of fastening bolts ........................................................... 3-225 On-board crane, drive unit ............................ 3-224 On-board crane, drive unit .............................. 2-96 On-board crane, lubricating .......................... 3-225 On-board crane, monitoring, warning and control elements...................................................... 2-95 On-board crane, putting into operation........... 2-96 Operating Instructions, where to store it in the driver’s cab .................................................... 2-4 Operation - Safety instructions ......................... 2-3 OPERATION, Fire and explosion hazard ......... 2-5 Optional equipment......................................... 2-98 Organizational measures.................................. 1-7 OTHER MAINTENANCE .............................. 3-221

P Plan A - E...................................................... 3-117 Plan N ........................................................... 3-113 Plan T............................................................ 3-115 Plan V ........................................................... 3-111 Possible causes................................................ 5-3 Pre-chamber, breather valve ........................ 3-197 Preface.............................................................. 1-3 Pressure accumulator - Emergency lowering..... 3193 BA RH200(3 847 006.00)-EN

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OPERATING INSTRUCTIONS 6050 / 6050FS Index PRESSURE ACCUMULATORS - SAFETY INSTRUCTIONS............................................. 4-10 Pressure-accumulator inspection regulations .... 3210 Pressure-accumulator inspection regulations .... 3223 Pre-stage - Changing the oil......................... 3-205 Pump Managing System (PMS) ....................... 2-8 PUMP TRANSFER GEARBOX .................... 3-194 Pump transfer gearbox lube oil filters........... 3-198 Putting the excavator out of operation.......... 3-226 PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING............. 3-226 PUTTING THE MACHINE INTO OPERATION .. 264

R Recommissioning ......................................... 3-226 Refuelling........................................................ 2-64 Repair instructions............................................ 4-9 Repair work - Safety instructions...................... 4-3 repair work, ENGINE ........................................ 4-6 repair work, Fire and Explosion Hazard ........... 4-5 Replacing the bypass valves and sealing rings . 3179

S Safety filter element, replace ........................ 3-160 Safety instructions governing specific operational phases........................................................... 1-8 Section.............................................................. 5-3 Securing the machine..................................... 2-93 Selection and qualification of personnel; basic responsibilities............................................... 1-8 Service station (tanklift) .................................. 2-64 Servicing lighting............................................. 2-22 SERVICING WORK...................................... 3-139 Shutting off the engines.................................. 2-73 Signs ............................................................... 2-10 Special work in conjunction with utilization of the machine and maintenance and repairs as well as troubleshooting during work; disposal of parts and consumables................................. 1-9 Starting and stopping the engines .................. 2-71 Starting the engine with jumper cables (external batteries ........................................................ 4-7 Starting the engines........................................ 2-71 Starting the engines at low temperatures....... 2-72 Stored Program Control (SPC)......................... 2-8 Superstructure .................................................. 2-8 Superstructure basic position ......................... 2-79 Superstructure holding brakes ....................... 2-85

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SWING GEARBOX ....................................... 3-199 Swing mechnism – Fault table.......................... 5-7 SWING RING................................................ 3-211 Swing ring - Instructions ............................... 3-211 Swing the superstructure ................................ 2-89 Swinging ladder (optional) .............................. 2-20 Switchgear cabinet ....................................... 3-170 Switching the electrical system on and off...... 2-70

T TECHNICAL DATA......................................... 5-13 Track drive – Fault table ................................... 5-6 Track parking brake ........................................ 2-85 Track roller, Support roller ............................ 3-208 Track tensioner ............................................. 3-209 Trainer's / instructor's seat.............................. 2-25 Transport - Safety instructions........................ 2-86 Transporting the machine ............................... 2-86 Travel forwards/backwards............................. 2-79 Travel gearbox - Changing oil............3-202, 3-205 Travel gearbox - Checking the oil level / Topping up with oil .......................................3-201, 3-204 TRAVEL GEARBOX (valid for gearbox PN 2763214) ................................................... 3-204 TRAVEL GEARBOX (valid for gearbox PN 3673978) ................................................... 3-201 TravellING, SAFETY INSTRUCTIONS .......... 2-78 TROUBLESHOOTING...................................... 5-3

U Unblocking a grease line .............................. 3-217 Undercarriage ................................................... 2-8

V Venting the hydraulic system........................ 3-190

W Warning of special dangers ............................ 1-10 Warnings and symbols ..................................... 1-5 Warranty ........................................................... 1-4 Water filter, change....................................... 3-156 Water trap (option)........................................ 3-165 Welding operations - Safety instructions ........ 4-11 Windscreen washer ........................................ 2-25 Working hydraulics – Fault table ...................... 5-5 Working movements ....................................... 2-90 WORKING OPERATION ................................ 2-89 Working operation - Safety instructions.......... 2-87

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OPERATING INSTRUCTIONS 6050, 6050FS Board-Control-System

Board-Control-System

6050, 6050FS

No.

Caterpillar Global Mining HMS GmbH



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OPERATING INSTRUCTIONS 6050, 6050FS Board-Control-System

______________________________________________________________________________________ Published by:

Caterpillar Global Mining HMS GmbH Department Technical Publications D-44149 Dortmund, Karl-Funke-Straße 36 Tel. 49 (0) 231 922-4340 Fax 49 (0) 231 922-5005 Email: documentation.HEX@cat.com https://mining.cat.com www.bucyrus-hex.com

© Copyright Caterpillar Global Mining Hydraulic Mining Shovels GmbH 2012. The reproduction, distribution and utilization of this manual / file as well as the communication of its content to others without express authorization is prohibited. Offenders will be held liable for the payment of damages. All rights reserved in the event of the grant of a patent, utility model or design.

Printed in Germany

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OPERATING INSTRUCTIONS 6050, 6050FS Board-Control-System CONTENTS DESCRIPTION ________________________________________________________________________ 1 FUNCTIONS ________________________________________________________________________ 1 COMPONENTS _____________________________________________________________________ 1 DISPLAYS : USING BCS ________________________________________________________________ 2 DISPLAY AND KEYBOARD ____________________________________________________________ 4 Indicator lights _____________________________________________________________________ 5 Buttons __________________________________________________________________________ 5 INSTRUMENTS _____________________________________________________________________ 6 SERVICE MENU _____________________________________________________________________ 6 Program 1: Oil change ______________________________________________________________ 7 Program 2 to 6_____________________________________________________________________ 7 The programs (Fig. 15) ______________________________________________________________ 7 Program 2: Service _________________________________________________________________ 7 Program 3: Engine _________________________________________________________________ 8 Program 4: Hydraulics (Fig. 19) _______________________________________________________ 8 Program 5: Excavator _______________________________________________________________ 9 Program 6: Operating hours __________________________________________________________ 9 HOLD function____________________________________________________________________ 10 Program 7: Setting date and time _____________________________________________________ 11 Program 8: Complete fault list ________________________________________________________ 12 Program 9: Service Bucyrus HEX _____________________________________________________ 12 FAULT REPORTS___________________________________________________________________ 13 SERVICE DATA & FAULT STORAGE: PRINT-OUT OR TRANSFER INTO BUFFER ______________ 14 APPENDIX __________________________________________________________________________ 15 PRINT-OUT________________________________________________________________________ 15 DATA ACQUISITION COMPUTER DER 1__________________________________________________ 17 SENSOR ANALOGUE INPUTS ________________________________________________________ 17 DATA ACQUISITION COMPUTER DER 1__________________________________________________ 18 SENSOR DIGITAL INPUTS ___________________________________________________________ 18 DATA ACQUISITION COMPUTER DER 2__________________________________________________ 19 SENSOR ANALOGUE INPUTS ________________________________________________________ 19 DATA ACQUISITION COMPUTER DER 2__________________________________________________ 20 SENSOR DIGITAL INPUTS ___________________________________________________________ 20 DATA ACQUISITION COMPUTER DER 3__________________________________________________ 21 SENSOR ANALOGUE INPUTS ________________________________________________________ 21 DATA ACQUISITION COMPUTER DER 3__________________________________________________ 22 SENSOR DIGITAL INPUTS ___________________________________________________________ 22

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OPERATING INSTRUCTIONS 6050, 6050FS Board-Control-System

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OPERATING INSTRUCTIONS 6050, 6050FS Board-Control-System DESCRIPTION

Components

Functions

Fig. 1 shows BCS and various modules. The main parts of the BCS are:

The Board Control System, abbreviated to BCS, monitors essential functions of the excavator and its components. It releases an appropriate signal if any maximum value is exceeded and also sends a report to be archived in the memory bank. If a normal operating status can be reached by temporarily reducing the excavator's output, then this is monitored by BCS and done by PMS. If it is necessary for the operator to take certain action, e.g. to stop one of the engines a relevant command is sent to the BCS display screen.

Pos. 1 2 3

Function Computer and Display Keyboard Printer Data acquisition computers, sensors and switches are mounted on several positions on the machine.

BCS also gives information on sevicing and trouble- shooting.

Sensors installed at various points on the excavator constantly transmit their readings to the BCS computer. All essential pieces of operating data are displayed on the screen in the form of simulated instruments. Other values, e.g. the number of hours operated by the excavator, its engines or, its travel or swing gears, are archived and can be called up as and when required.

The data shown in the figures are examples. The instruments on the screen indicate the actual operating conditions.

Fig. 1

Because BCS automatically warns of any abnormal conditions that require a corrective action, the operator can concentrate fully on the work in hand, and is not distracted by constantly having to keep an eye on many instruments or by having to decide upon appropriate actions to be taken in case of limit values being exceeded.

The operator and the servicing crew also have the means of calling up particular background information from the BCS archive.

This Technical Handbook (THB) has been compiled to provide the necessary information for working with the BCS.

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OPERATING INSTRUCTIONS 6050, 6050FS Board-Control-System DISPLAYS : USING BCS BCS contains several sub-programs:  "Instrument" display.

The basic display (Fig. 2) appears automatically. Three further displays (Figs. 3, 4 & 5) can be called up when required.

Fig. 4

Fig. 2

Fig. 5

Fig. 3

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OPERATING INSTRUCTIONS 6050, 6050FS Board-Control-System  Instructions when BCS discovers a fault.

Instructions appear automatically in block (2, Fig. 6). These instructions are to be carried out immediately. Status reports.

If an operating status requires a cut-back in excavator functions, a relevant report is displayed in block (2, Fig. 6).

Fig. 6

 Service menu.

The programs listed in (Fig. 7), or the program "Service - Bucyrus HEX GmbH " can be called up as needed.  Instructions for trouble-shooting (HELP blocks).

Information can be called up to help in localizing and remedying a particular fault.

Fig. 7

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OPERATING INSTRUCTIONS 6050, 6050FS Board-Control-System Display and keyboard (Fig. 8)

The top display line always shows the same "instruments" (Fig. 9 - 12).

The display screen is divided into 3 blocks.

Oil pressure and coolant temperatures for, LH & RH engines.

1. Graphic display

The "instruments" in the bottom line are:

- Graphics - Fault reports - HELP blocks for trouble-shooting

In the basic graphic (Fig. 9): Hydraulic oil temperature, battery charge, rev. settings for LH & RH engines.

2. Status block Indicators lights (11 - 22) The buttons (31 - 40) are arranged underneath the display.

Fig. 9

Fig. 8

Fig. 10

In alternative 1 (Fig. 10): Pump gearbox temperature and fuel levels for LH & RH engines.

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OPERATING INSTRUCTIONS 6050, 6050FS Board-Control-System Indicator lights (Fig. 13) Pos. 11 12 13 14 15 16 17 18 19 20 21 22

Function Battery charge monitoring Cooling liquid temperature Engine oil pressure Idle Timer Cooling liquid min.

Battery charge monitoring Cooling liquid temperature Engine oil pressure Idle Timer Cooling liquid min.

Lubrication ON Electronic excavator control ON

Fig. 11

In alternative 2 (Fig. 11): Lube system grease pressure; Fuel system pressure

Fig. 13

Buttons

Fig. 12

In alternative 3 (Fig. 12): main pumps pressure P1+P4, P2+P3; battery charge, ambient temperature.

Scroll through alternatives with Return to basic graphic (Fig. 9) with

UP/DOWN BACK

(Fig. 13) Pos. Function 31 UP, select BCS program, positions the cursor select BCS program, 32 DOWN, positions the cursor confirms a program; 33 ENTER, activates a desired program 34 BACK, recalls the service program 35 HOLD, freezes actual service data 36 PRINT, recalls the Print Menue 37 SERV. recalls the Service Menue 38 HELP, recalls the Help Menue 39 BL+, adjusts BCS monitor background lighting (bright) 40 BL-, adjusts BCS monitor background lighting (dark)

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OPERATING INSTRUCTIONS 6050, 6050FS Board-Control-System Instruments

Service menu

As soon as the electrics are switched on, the basic graphic (Fig. 14) appears in the display.

The service menu contains various sub-programs and the menu "Service - Bucyrus HEX ".

This graphic shows the most important operational values in analog and digital form.

Call up service menu with Return to basic graphic with

Three further displays (Figs. 10, 11 & 12) can be called up when required.

The top display line always shows the same "instruments".

The service menu (Fig. 15) lists 8 programs.

Program 9 is reserved for Bucyrus HEX GmbH service personnel.

SERVICE BACK

Fig. 15 Fig. 14

Select a program with

UP/DOWN

The cursor > indicates the program to be called up.

Enter the required program with Return to service menu with

ENTER BACK

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OPERATING INSTRUCTIONS 6050, 6050FS Board-Control-System Program 1: Oil change

Program 2 to 6

(Fig. 16)

The programs (Fig. 15)

The display shows the number of hours operated by each engine and the number of operating hours to the next oil change.

Return to service menu with

BACK

2. Service 3. Engine 4. Hydraulics 5. Excavator 6. Operating hours can be used to call up important system data.

Program 2: Service (Fig. 17) Shows important data for the service Return to service menu with

BACK

Fig. 16

Fig. 17

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OPERATING INSTRUCTIONS 6050, 6050FS Board-Control-System Program 3: Engine

Program 4: Hydraulics (Fig. 19)

(Fig. 18)

The program displays important values for the hydraulic system. Also hyd. oil temperature, swing circuit temperature and ambient temperature.

In addition to important data for both engines and pump transfer gearboxes, this program also shows the total hours operated and the number of hours at rated load (LOAD). It also shows the compressed air pressure and the ambient temperature.

Return to main menu with

Return to main menu with

BACK

BACK

Fig. 19

Fig. 19

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OPERATING INSTRUCTIONS 6050, 6050FS Board-Control-System Program 5: Excavator

Program 6: Operating hours

(Fig. 20)

(Fig. 21)

The screen shows the number of reported cases of contamination in the main, swing and charge pumps and in the pump transfer gearboxes since commissioning. It also shows fuel levels for LH and RH engines, the number of hours to the next oil change, the board voltage and the ambient temperature.

The screen displays following operating hours/load ratings:

Return to main menu with

Hours operated at work = hours run by the hydraulics at work, swingl or travel

BACK

Total hours operated

= engines running

Hours operated under load

= engines running time at rated load

Engines utilization % = hours operated under load total hours operated Hydraulic utilization (%) = hours operated at work total hours operated.

The number of hours spent travelling or swinging the superstructure are indicated separately.

Return to main menu with

BACK

Fig. 20

Fig. 21

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OPERATING INSTRUCTIONS 6050, 6050FS Board-Control-System HOLD function

IMPORTANT

Any of the values on display in programs 2 - 6 (Figs. 17 - 21) can be "frozen" and then printed out (Fig. 22).

The printer must be connected beforehand.

The screen otherwise displays "Printer not connected". See directions in printer manual.

The print-out contains only the "frozen" values from menus 2, 3, 4, 5 or 6 (Fig. 23).

Return to main menu with

BACK

Fig. 22

"Freeze" the display with

HOLD

The values frozen with the HOLD button are stored (archived) until

Fig. 23

 the function if cancelled by pressing HOLD again  the basic graphic is recalled with the BACK button  the print-out is finished No fresh data or faults are displayed while the screen is "frozen".

Start print-out with

PRINT

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OPERATING INSTRUCTIONS 6050, 6050FS Board-Control-System Program 7: Setting date and time (Fig. 24 und 25) The date and time are shown in each of the displays.

Program 7 can be used to set / correct the date and the time.

Select line to be altered with Alter value with

ENTER UP / DOWN

After leaving the program a window appears on the screen with the question "Take over data" Take over data Return without change

ENTER BACK

Fig. 25

Fig. 24

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OPERATING INSTRUCTIONS 6050, 6050FS Board-Control-System Program 8: Complete fault list

Program 9: Service Bucyrus HEX

(Fig. 26 und 27)

(Fig. 28)

The fault storage archive contains all reported faults.

The archive contains a maximum of 125 fault reports. If a fault occurs when the archive is full, thescreen diplays “fault storage archive is full“

Scroll through archive with

This menu is reserved for Bucyrus HEX GmbH Service. It is only accessible after a Code No. has been entered. It is therefore not described here.

UP/DOWN

Change from fault list to fault description ENTER

Fig. 28

Fig. 26

Fig. 27

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OPERATING INSTRUCTIONS 6050, 6050FS Board-Control-System Fault reports

Examples: Stop engine and/or Engine output reduced

Any faults occurring during operation are shown in the lower part of the graphic display (Fig. 29).

If more than 125 faults are present, information on action to be taken concerning less-important faults can only appear on the display when faults with higher priorities have been remedied (or action taken).

IMPORTANT Programs or menus can be changed even if a fault is being indicated.

The fault reports are always listed in their respective order or priority. The most important fault appears in the top line.

If a fault occurs in one of the components which has an "instrument", then the instrument also appears at the left of the display (Fig. 30).

If several faults are present, the cursor indicates the fault to which the instrument belongs.

Information on remedying faults can be called up with the HELP button.

Any fault (even if only 1 is listed) can be selected with the cursor and HELP information called up (Fig. 29).

HELP information appears in the upper sector of the display (Fig. 30).

Select fault with

UP/DOWN

Call up information with

HELP

Cancel HELP information with

BACK

Fig. 29

The bottom sector of the display lists the action to be taken by the operator, or the action that has been taken automatically by the BCS system.

Fig. 30

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OPERATING INSTRUCTIONS 6050, 6050FS Board-Control-System Service data & fault storage: print-out or transfer into Buffer Necessary are:  Select basic graphic with: (press several times if necessary)

BACK

 Connect printer. Otherwise BCS reports: "Printer not connected" Print with

PRINT

Select a desired program shown on the display (Fig. 31).

Fig. 31

Select sub-menu with cursor > Start print-out with Back to the basic menu with

UP/DOWN ENTER BACK

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OPERATING INSTRUCTIONS 6050, 6050FS Board-Control-System APPENDIX Print-out Fault storage print-out Bucyrus HEX GmbH >>> BOARD CONTROL SYSTEM RH 200 <<< Serial No.:

200122

Print out no.. 5 Last print out

22.09.09 19.09.09

13.42 18.41

Hours operated:

LH engine :

835

RH engine

848

Contamination:

MAIN PUMP MAIN PUMP MAIN PUMP MAIN PUMP

1 2 2 2 3 2 4 2

GEARBOX GEARBOX

1 1 2 0

SWING PUMP SWING PUMP

1 0 2 0

Fault storage

No. 1 of 5 LH engine, oil pressure too low First occurence : 22.09.09 Last occurence : 22.09.09 Cases : Metered value : Speed :

13.13 13.28 2 2,0 bar 1800 rpm

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OPERATING INSTRUCTIONS 6050, 6050FS Board-Control-System

Fig. 1

DATA ACQUISITION COMPUTER DER 1 Sensor analogue inputs Item 1 2 3 4 5 6 7 8 9 10 11 12

Terminal no.

5 7 9 11 13 15 17 19 21 23 25 26

Diagram ident.

B 40.1 B 39.1 B 17 B1 B 29 B 107.1 B4 B2 B3 R1

Function

Sensor type

Oil pressure engine LH Oil temperature engine LH not in use Oil temperature gearbox LH PMS regulator pressure LH PMS regulator pressure RH Fuel pressure LH Pressure servo control system Oil pressure main pumps 1 + 3 Oil pressure main pumps 2 + 4 Fuel tank LH

4 – 20 mA 4 – 20 mA 4 – 20 mA 4 – 20 mA 4 – 20 mA 4 – 20 mA 4 – 20 mA 4 – 20 mA 4 – 20 mA 0 – 90 

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OPERATING INSTRUCTIONS 6050, 6050FS Board-Control-System

Fig. 2

DATA ACQUISITION COMPUTER DER 1 Sensor digital inputs Item 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36

Terminal no.

27 29 31 33 35 37 39 41 43 45 47 49 51 53 55 57

Diagram ident.

B 12 S 177 S 178 S 65 S 60 B 14.1 S 110 S 76 S 62 S 61 S 59 S 77 S 64 S 63 S 56 SPS

Function

Sensor type

Min. coolant level engin LH Contamination slewing motor 1 Contamination slewing motor 2 Contamination gearbox LH Housing temperature slewing pump 1 Min. hydraulic oil level Pressure gearbox LH Contamination feed pump 2 Contamination slewing pump 1 Housing temperature slewing pump 2 Contamination slewing pump 2 Contamination feed pump 1 Contamination main pump 1 Contamination main pump 2 Hydraulic oil filter Grease line A activated

GND GND GND GND GND GND GND GND GND GND GND GND GND GND + 27 V + 27 V

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OPERATING INSTRUCTIONS 6050, 6050FS Board-Control-System

Fig. 3

DATA ACQUISITION COMPUTER DER 2 Sensor analogue inputs Item 41 42 43 44 45 46 47 48 49 50 51 52

Terminal no.

5 7 9 11 13 15 17 19 21 23 25 26

Diagram ident.

B 40.2 B 39.2 B 22 B 38.1 B 37.1 B 38.2 B 37.2 B5 B 107.2 R2

Function

Sensor type

Oil pressure engine RH Oil temperature engine RH

4 – 20 mA 4 – 20 mA

Oil temperature gearbox RH Pressure slewing motor 1 Temperature slewing circuit 1 Pressure slewing motor 2 Temperarure swing circuit 2 Outside temperature Fuel pressure RH Fuel tank RH not used

4 – 20 mA 4 – 20 mA 4 – 20 mA 4 – 20 mA 4 – 20 mA 4 – 20 mA 4 – 20 mA 0 – 90  0- 30 V

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OPERATING INSTRUCTIONS 6050, 6050FS Board-Control-System

Fig. 4

DATA ACQUISITION COMPUTER DER 2 Sensor digital inputs Item 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76

Terminal no.

27 29 31 33 35 37 39 41 43 45 47 49 51 53 55 57

Diagram ident.

B 20 S 179 S 180 S 75 S 70 S 11 S 68 S 72 S 69 S 71 S 66 S 74 S 73 S 94 SPS

Function

Sensor type

Min. coolant level engin RH Contamination slewing motor 3 Contamination slewing motor 4 Contamination gearbox RH Housing temperature slewing pump 3 not used Pressure gearbox RH Contamination feed pump 4 Contamination slewing pump 3 Housing temperature slewing pump 4 Contamination slewing pump 4 Contamination feed pump 3 Contamination main pump 3 Contamination main pump 4 Pressure swing circuit Grease line B activated

GND GND GND GND GND GND GND GND GND GND GND GND GND + 27 V + 27 V

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OPERATING INSTRUCTIONS 6050, 6050FS Board-Control-System

Fig. 5

DATA ACQUISITION COMPUTER DER 3 Sensor analogue inputs Item 81 82 83 84 85 86 87 88 89 90 91 92

Terminal no.

5 7 9 11 13 15 17 19 21 23 25 26

Diagram ident.

B 125 B 36

S 212

Function

Sensor type

Grease drum level - drum full Greasing pressure

4 – 20 mA 4 – 20 mA 4 – 20 mA

not used not used not used not used Shutoff valve closed V)

(dig.

4 – 20 mA 4 – 20 mA 4 – 20 mA 0 – 90  +27 0- 30 V

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OPERATING INSTRUCTIONS 6050, 6050FS Board-Control-System

Fig. 6

DATA ACQUISITION COMPUTER DER 3 Sensor digital inputs Item 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116

Terminal no.

27 29 31 33 35 37 39 41 43 45 47 49 51 53 55 57

Diagram ident.

SPS S 193 SPS SPS S 57 CMS S 26 SPS Relais Relais S 216.1 S 216.2 K 137 S 67 SPS SPS

Function

Sensor type

Pressure lub. system, lower carriage (opt.) not used Greasing ON Greasing malfunction Air filter engine LH Travel 2nd stage Superstructure brake Parking brake Relay contact engine LH Relay contact engine RH Dumper counter Dumper reset Electronic excavator control (seat contact) Air filter engine RH Idle timer engine LH Idle timer engine RH

GND GND GND GND GND GND GND GND GND GND GND GND GND GND + 27 V + 27 V

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OPERATING INSTRUCTIONS 6050, 6050FS Board-Control-System INDEX Instruments .......................................................... 6

A Appendix.............................................................15

P

Fault reports........................................................13 Functions ..............................................................1

Print-out ............................................................. 15 Program 1 Oil change........................................................ 7 Program 2 Service ............................................................. 7 Program 2 to 6 ..................................................... 7 Program 3 Engine.............................................................. 8 Program 5 Excavator ......................................................... 9 Program 6 Operating hours ............................................... 9 Program 7 Setting date and time ..................................... 11 Program 8 Complete fault list, ......................................... 12 Program 9 Service Bucyrus HEX .................................... 12

H

S

HOLD function ....................................................10

Service data & fault storage print-out or transfer into buffer ....................... 14 Service menu ....................................................... 6

B Buttons..................................................................5

C Components .........................................................1

D DESCRIPTION .....................................................1 Display and keyboard ...........................................4

F

I Indicator lights.......................................................5

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