Cat 6015, 6015FS Hydraulic Shovel Operation and Maintenance Manual BI651380 – PDF DOWNLOAD
FILE DETAILS:
Cat 6015, 6015FS Hydraulic Shovel Operation and Maintenance Manual BI651380 – PDF DOWNLOAD
Language : English
Pages : 254
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Cat 6015, 6015FS Hydraulic Shovel Operation and Maintenance Manual BI651380 – PDF DOWNLOAD
PREFACE
- 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 operator’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
- 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 operating 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 BI651380 – 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
BA 6015(3 847 019.01)-EN
TABLE OF CONTENTS
vi
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
BA 6015(3 847 019.01)-EN
TABLE OF CONTENTS
vii
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
BA 6015(3 847 019.01)-EN
TABLE OF CONTENTS
viii
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
BA 6015(3 847 019.01)-EN
TABLE OF CONTENTS
ix
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
BA 6015(3 847 019.01)-EN
TABLE OF CONTENTS
x
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 __ 6-1
VIDEO PREVIEW OF THE MANUAL:
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