CAT 6015 6015FS Hydraulic Shovel Operation & Maintenance Manual 3847019 – PDF DOWNLOAD
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CAT 6015 6015FS Hydraulic Shovel Operation & Maintenance Manual 3847019 – PDF DOWNLOAD
Language : English
Pages : 254
Downloadable : Yes
File Type : PDF
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CAT 6015 6015FS Hydraulic Shovel Operation & Maintenance Manual 3847019 – PDF DOWNLOAD
PREFACE:
- These Operation and Maintenance Manual are designed to familiarize the operator with the
ma- chine and its designated use. - The Operation and Maintenance Manual contain important information on how to operate the
ma- chine safely, properly and with maximum effi- ciency. Observing these instructions
helps to pre- vent 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 environ- mental 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
▪ operation, including setting-up, troubleshoot- ing in the course of work, care,
evacuation of production waste and disposal of fuels and consumables,
▪ maintenance (inspection, servicing, repair) and / or
▪ transport.
- In addition to the Operation and Maintenance Manual and the mandatory rules and
regulations for accident prevention and environmental protec- tion in the user’s country and
at the place where the machine is to be used, the generally recog- nized technical
rules for safe and proper working must be observed ¹ - The Operation and Maintenance Manual are di- rected to the mining-machine specialist. They
can- not provide basic know-how. This can be acquired, for example, in several days’ instruction by
a quali- fied 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 Mainte- nance Manual. - All CGM HMS GmbH operating manuals are is- sued 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.
TABLE OF CONTENTS:
CAT 6015 6015FS Hydraulic Shovel Operation & Maintenance Manual 3847019 – 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 6-1
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