Cat 6015, 6015FS Hydraulic Shovel Operation and Maintenance Manual BI015768 – PDF DOWNLOAD
FILE DETAILS:
Cat 6015, 6015FS Hydraulic Shovel Operation and Maintenance Manual BI015768 – PDF DOWNLOAD
Language : English
Pages : 254
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Cat 6015, 6015FS Hydraulic Shovel Operation and Maintenance Manual BI015768 – PDF DOWNLOAD
PREFACE
About this Operation and Maintenance Manual
- These Operation and Maintenance Manual are designed to familiarize the operator with the machine and its designated use.
- The Operation and Maintenance Manual contain important information on how to operate the machine safely, properly and with maximum efficiency. Observing these instructions helps to prevent hazardous situations, to reduce repair costs and downtimes and to increase the reliability and service life of the machine.
- The 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 be observed 1 The Operation and Maintenance Manual are directed to the mining-machine specialist. They cannot provide basic know-how.
- This can be acquired, for example, in several days’ instruction by a qualified CGM HMS GmbH (Caterpillar Global Mining Hydraulic Mining Shovels GmbH) mechanic or by attending an CGM HMS GmbH training course for operators or maintenance personnel.
- The CGM HMS GmbH after-sales service will be pleased to deal with any queries you may have after reading through the Operation and Maintenance Manual.
- All CGM HMS GmbH Operation and Maintenance Manuals are issued in German and then translated. Even a good translation may give rise to questions which CGM HMS GmbH will be pleased to answer
- The Operation and Maintenance Manual are not work instructions for carrying out major repairs. Such work is willingly done for you by the CGM HMS GmbH after-sales service
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Cat 6015, 6015FS Hydraulic Shovel Operation and Maintenance Manual BI015768 – PDF DOWNLOAD
1 INTRODUCTION _ 1-1
PREFACE __ 1-1
Further machine documentation 1-1
WARRANTY 1-2
FUNDAMENTAL SAFETY INSTRUCTIONS 1-3
Warnings and symbols _____ 1-3
Contents of the Declaration of Conformity _ 1-3
DESIGNATED USE, UNAUTHORIZED USE 1-4
Noise emission information _ 1-5
Vibration information ______ 1-5
ORGANIZATIONAL MEASURES _ 1-6
Personal protective equipment and the working clothing 1-6
Selection and qualification of personnel; basic responsibilities__ 1-7
Safety instructions governing specific operational phases __ 1-7
Special work in conjunction with utilization of the machine and maintenance and repairs as well as
troubleshooting during work; disposal of parts and consumables 1-8
Warning of special dangers _ 1-9
Transporting and recommissioning 1-10
FIRE AND EXPLOSION HAZARD __ 1-11
NOTES 1-13
2 OPERATION 2-1
OPERATION – SAFETY INSTRUCTIONS 2-3
Operation and Maintenance Manual, where to store it in the operator’s cab 2-4
FIRE AND EXPLOSION HAZARD 2-5
DESCRIPTION OF THE EXCAVATOR __ 2-6
Excavator layout 2-7
Undercarriage __ 2-8
Superstructure _ 2-8
Drive __ 2-8
Hydraulic system _ 2-8
Pump Managing System (PMS) _ 2-8
Programmable Logic Controller (PLC) __ 2-8
Demand control / Zero-flow regulation __ 2-9
Automatic engine speed reduction __ 2-9
Electrical system 2-9
Signs _ 2-11
OPERATOR’S CAB ______ 2-12
Entering and leaving the machine – Safety instructions_ 2-12
Windscreen washer ______ 2-13
Operator’s seat 2-14
Adjusting the control consoles _ 2-15
Trainer’s / instructor’s seat _ 2-16
Fire-extinguisher _ 2-17
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MONITORING, WARNING AND CONTROL ELEMENTS 2-18
PUTTING THE MACHINE INTO OPERATION _____ 2-37
Reducing the operator’s exposure to noise _______ 2-37
Refuelling 2-37
Switching the electrical system on and off 2-40
Battery main switch ______ 2-41
Preheating system for engine and hydraulic oil (optional)__ 2-42
Fuel preheating system (optional) _ 2-43
STARTING AND STOPPING THE ENGINE _______ 2-44
VENTILATION AND HEATING __ 2-46
Air conditioner (optional) __ 2-46
Auxiliary heating (optional) _ 2-46
MAXIMUM MACHINE INCLINATIONS, INFORMATION_ 2-47
TRAVELLING, SAFETY INSTRUCTIONS _ 2-48
Running-in specifications for components of the crawler tracks 2-48
TRAVELLING __ 2-49
Locking the superstructure _ 2-53
Track parking brake ______ 2-53
TRANSPORTING THE MACHINE __ 2-54
Transport – Safety instructions _ 2-54
WORKING OPERATION ___ 2-56
SAFETY INSTRUCTIONS _ 2-56
Before starting work ______ 2-58
Swinging and braking the superstructure _ 2-59
Working operations _______ 2-60
After daily operation ______ 2-61
ASSEMBLING WORKING EQUIPMENT – SAFETY INSTRUCTIONS ___ 2-62
Securing the machine _____ 2-63
CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS) 2-64
LIFTING OPERATIONS ____ 2-65
Safety instructions _______ 2-65
Load-hooks on backhoe buckets. __ 2-66
NOTES 2-71
3 INSPECTION AND SERVICING __ 3-1
INSPECTION AND SERVICING – SAFETY INSTRUCTIONS_ 3-3
INSPECTION AND SERVICING WORK, FIRE AND EXPLOSION HAZARD _ 3-7
ENVIRONMENTALLY COMPATIBLE HYDRAULIC FLUID 3-8
Environmentally compatible hydraulic fluid – Operation and Maintenance Manual ___ 3-8
Environmentally compatible hydraulic fluid, conversion _ 3-8
Environmentally compatible hydraulic fluid – Sampling__ 3-9
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ENVIRONMENT-FRIENDLY LUBRICANTS AND GEARBOX OILS _____ 3-10
Lubricants for bearings ____ 3-10
Gearbox oils __ 3-10
INSPECTION AND SERVICING PLANS – INSTRUCTIONS_ 3-11
Plan V 3-13
Plan N 3-15
Plan T and W _ 3-17
Plan A – E 3-19
LUBRICATING CHART – GREASE _ 3-24
Lubricating chart – Grease (legend) 3-25
Filling quantities – Grease __ 3-25
INSPECTION PLAN – OIL ___ 3-26
Inspection plan – Oil (legend) __ 3-27
Filling quantities – oil ______ 3-28
Filling quantities – other ___ 3-28
LUBRICANTS / CONSUMABLES 3-29
Notes on the selection of oils and greases 3-29
Avoid mixing of different hydraulic fluids _ 3-29
I. Oils for combustion engine 3-30
II. Fluid for hydraulic system __ 3-31
III.a Oils for pump distribution gearbox and travel gearbox 3-32
III.b Oils for swing gearbox 3-33
V Greases for bearings and swing rings (Central lubrication system) 3-34
Grease for idlers, track rollers and support rollers (Lifetime lubrication) _ 3-35
Coolant for use on all combustion engines _______ 3-36
SERVICING WORK _______ 3-37
Hose line for oil and cooling liquid changes_______ 3-37
ENGINE 3-38
Engine – Safety instructions 3-38
Checking the engine oil level / Topping up _______ 3-38
Changing the engine oil ___ 3-39
Replacing the engine oil filters _ 3-40
Cold-starting fluid (ether) – Replacing the pressure vessel _ 3-41
COOLING SYSTEM _______ 3-42
Temperature __ 3-42
Cooler and cooling liquid __ 3-42
Topping up with coolant ___ 3-43
Changing the coolant _____ 3-43
AIR-INTAKE SYSTEM _____ 3-45
Dust trap, cleaning _______ 3-45
Main filter elements ______ 3-46
Secondary filter element __ 3-48
Air-intake lines 3-48
FUEL SYSTEM _ 3-49
Fuel system – Safety instructions __ 3-49
Fuel pre-filter, Draining off water __ 3-49
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Fuel pre-filter, replace ____ 3-50
Secondary fuel filter, replace __ 3-51
Fuel tank – Venting _______ 3-52
Cleaning the fuel tank _____ 3-52
Refuelling station (optional) 3-53
Water trap (option) _______ 3-54
ELECTRICAL SYSTEM ____ 3-56
Electrical system – Safety instructions _ 3-56
Alternator – Instructions ___ 3-56
Electrical circuit diagrams _ 3-56
Electrical system switch-cabinets __ 3-56
Replacing lamps and bulbs 3-56
Floodlight projector, safety instructions 3-57
Lighting systems in LED technonogy, instructions__ 3-59
Battery __ 3-60
Charging batteries inside the machine, safety instructions _ 3-61
Removing and installing the battery 3-62
HYDRAULIC SYSTEM _____ 3-63
Hydraulic system – Safety instructions _ 3-63
Depressurizing the hydraulic system __ 3-63
Checking the hydraulic oil level 3-64
Topping up with hydraulic oil __ 3-64
Changing the hydraulic oil return-flow (hydraulic oil reservoir) _ 3-65
Bypass valves (working circuit) 3-66
Bypass valves (cooling circuit) _ 3-67
Breather filter _ 3-68
High-pressure filter for working hydraulics 3-69
High-pressure filter for the servo circuit, replace___ 3-70
Filter for swing circuit, replace _ 3-71
Changing the hydraulic oil _ 3-72
Avoid mixing of different hydraulic fluids _ 3-72
Venting the hydraulic system __ 3-75
Cleaning the hydraulic oil cooler __ 3-76
Pressure accumulator _____ 3-77
PUMP DRIVE GEARBOX ___ 3-78
Pump drive gearbox – Checking the oil level / Topping up with oil _____ 3-78
Pump drive gearbox – Changing the gearbox oil ___ 3-79
Pump drive gearbox breather, replace _ 3-80
Pump drive gearbox oil filter, replace _ 3-81
Pump drive gearbox – take an oil sample 3-82
SWING GEARBOX 3-84
Swing gearbox, checking the oil level / topping up with oil _ 3-84
Swing gearbox, changing the gearbox oil 3-84
Swing gearbox, clean / replace breather _ 3-85
Swing gearbox output pinion, lubricate 3-85
TRAVEL GEARBOX (P/N 3712319, 3749594)______ 3-86
Travel gearbox, checking the oil level / topping up with oil _ 3-86
Travel gearbox, changing the oil __ 3-86
Travel gearbox, clean / replace breather _ 3-86
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TRAVEL GEARBOX (P/N 3709660) _ 3-87
Travel gearbox, checking the oil level / topping up with oil _ 3-87
Travel gearbox, changing the oil __ 3-87
Travel gearbox, clean / replace breather _ 3-87
UNDERCARRIAGE 3-88
Tracks, cleaning _ 3-88
Track rollers, support rollers, track pads _ 3-89
Track tensioner 3-90
Pressure-accumulator inspection regulations _____ 3-91
Checking the gas charging pressure in the pressure accumulator _____ 3-91
SWING RING __ 3-92
Swing ring – Instructions ___ 3-92
Swing ring, bearing races __ 3-92
CENTRAL LUBRICATING __ 3-94
Design and function ______ 3-94
Greasing cycle 3-96
Venting the grease pump __ 3-98
Venting the grease lines ___ 3-98
Unblocking a grease line __ 3-98
Cleaning the grease sieves 3-99
Lubricating the grease distributor of the working equipment 3-99
OTHER MAINTENANCE ___ 3-100
Heating and air conditioning __ 3-100
PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING __ 3-101
Putting the excavator out of operation 3-101
Battery storage _ 3-101
Recommissioning _______ 3-101
NOTES __ 3-103
4 REPAIR WORK __ 4-1
REPAIR WORK – SAFETY INSTRUCTIONS 4-3
REPAIR WORK, FIRE AND EXPLOSION HAZARD __ 4-4
REPAIR WORK, ENGINE ____ 4-5
HYDRAULIC SYSTEM ______ 4-6
Repair instructions 4-6
Hydraulic hoses – Instructions __ 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
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PRESSURE ACCUMULATORS – SAFETY INSTRUCTIONS _ 4-9
WELDING AND FLAME CUTTING WORKS – SAFETY INSTRUCTIONS 4-10
DISPOSAL AT THE END OF THE SERVICE LIFE __ 4-13
Dismantling and removal instructions _ 4-13
Risk of deflagrations ______ 4-13
Risk of fire 4-13
Disposing of the machine without polluting the environment __ 4-13
Further hazardous substances _ 4-14
Appropriate disposal of batteries __ 4-15
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 5-4
Working hydraulics – Fault table 5-5
Track drive – Fault table ____ 5-6
Swinging mechnism – Fault table __ 5-7
Central lubricating system – Fault table _ 5-8
HYDRAULIC CIRCUIT DIAGRAM 5-9
ABBREVIATIONS _ 5-11
PRODUCT SPECIFICATION SHEET 5-13
NOTES 5-15
6 INDEX __ 6-
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