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Cat 6015, 6015 FS Hydraulic Excavator Operation and Maintenance Manual BI651395 – PDF DOWNLOAD
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Cat 6015, 6015 FS Hydraulic Excavator Operation and Maintenance Manual BI651395 – PDF DOWNLOAD
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Description
Cat 6015, 6015 FS Hydraulic Excavator Operation and Maintenance Manual BI651395 – PDF DOWNLOAD
FILE DETAILS:
Cat 6015, 6015 FS Hydraulic Excavator Operation and Maintenance Manual BI651395 – PDF DOWNLOAD
Language : English
Pages : 241
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Cat 6015, 6015 FS Hydraulic Excavator Operation and Maintenance Manual BI651395 – PDF DOWNLOAD
PREFACE
About this Operating Instructions
- These operating instructions are designed to familiarize the operator with the machine and its designated use. The operating instructions 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 operating instructions must be supplemented by the respective national rules and regulations for accident prevention and environmental protection.
- The operating instructions must always be available in the driver’s cab of the machine. The operating instructions must be read and put into practice by any person in charge of carrying out work with or on the machine, such as
operation, including setting-up, 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
- The Operation and Maintenance Manual is 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 Caterpillar Global Mining Hydraulic Mining Shovels GmbH (CGM 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 Operation and Maintenance Manual are not work instructions for carrying out major repairs. Such work is willingly done for you by the CGM HMS after-sales service
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Cat 6015, 6015 FS Hydraulic Excavator Operation and Maintenance Manual BI651395 – PDF DOWNLOAD
TITLEPAGE..................................................................................................................................................................... 1 1 INTRODUCTION................................................................................................................................................................ 11 PREFACE .................................................................................................................................................................. 13 Further machine documentation ........................................................................................................................................ 13 WARRANTY ................................................................................................................................................................. 14 FUNDAMENTAL SAFETY INSTRUCTIONS .......................................................................................................................................... 15 Warnings and symbols ................................................................................................................................................. 15 DESIGNATED USE ........................................................................................................................................................... 16 ORGANIZATIONAL MEASURES .................................................................................................................................................. 17 Selection and qualification of personnel; basic responsibilities ..................................................................................................... 18 Safety instructions governing specific operational phases ............................................................................................................ 18 Special work in conjunction with utilization of the machine and maintenance and repairs as well as troubleshooting during work; disposal of parts and consumables .... 19 Warning of special dangers............................................................................................................................................ 20 Transporting and recommissioning ..................................................................................................................................... 21 INTRDUCTION, FIRE AND EXPLOSION HAZARD ................................................................................................................................... 22 2 OPERATION................................................................................................................................................................... 23 OPERATION - SAFETY INSTRUCTIONS .......................................................................................................................................... 25 INTRDUCTION, FIRE AND EXPLOSION HAZARD ................................................................................................................................... 27 DESCRIPTION OF THE EXCAVATOR ............................................................................................................................................. 28 Excavator layout ..................................................................................................................................................... 29 Undercarriage ........................................................................................................................................................ 30 Superstructure ....................................................................................................................................................... 30 Drive ................................................................................................................................................................ 30 Hydraulic system ..................................................................................................................................................... 30 Pump Managing System (PMS)............................................................................................................................................ 30 Demand control / Zero-flow regulation ................................................................................................................................ 30 Automatic engine speed reduction ..................................................................................................................................... 30 Electrical system .................................................................................................................................................... 30 Signs ................................................................................................................................................................ 33 Fire-extinguisher .................................................................................................................................................... 34 DRIVER'S CAB ............................................................................................................................................................. 35 Entering and leaving the machine - Safety instructions ............................................................................................................... 35 Driver's seat ........................................................................................................................................................ 36 Adjusting the control consoles ....................................................................................................................................... 37 Trainer's / instructor's seat ........................................................................................................................................ 38 Cab interior lamp .................................................................................................................................................... 39 Windscreen washer .................................................................................................................................................... 39 MONITORING, WARNING AND CONTROL ELEMENTS ................................................................................................................................. 40 PUTTING THE MACHINE INTO OPERATION ................................................................................................................................... 59 Refuelling ........................................................................................................................................................... 59 Service Station (optional equipment) ................................................................................................................................. 61 Switching the electrical system on and off ........................................................................................................................... 62 Battery main switch .................................................................................................................................................. 63 Preheating system for engine and hydraulic oil (optional) ............................................................................................................ 64 Fuel preheating system (optional) .................................................................................................................................... 65 STARTING AND STOPPING THE ENGINES ........................................................................................................................................ 66 Starting the engines ................................................................................................................................................. 66 Shutting off the engine ............................................................................................................................................. 67 Emergency stop, engine................................................................................................................................................ 67 VENTILATION AND HEATING .................................................................................................................................................. 68 Air conditioner (optional) ........................................................................................................................................... 68 Auxiliary heating (optional) ......................................................................................................................................... 68 MAXIMUM MACHINE INCLINATIONS, INFORMATION ................................................................................................................................ 69 TRAVELLING, SAFETY INSTRUCTIONS .......................................................................................................................................... 70 Running-in specifications for components of the crawler tracks........................................................................................................ 70 Superstructure basic position ........................................................................................................................................ 71 Travelling forwards/backwards ........................................................................................................................................ 71 Regulating the travelling speed ...................................................................................................................................... 72 Travelling uphill and downhill ....................................................................................................................................... 72 Cornering ............................................................................................................................................................ 72 Turning .............................................................................................................................................................. 72 Travelling over long distances ....................................................................................................................................... 74 Locking the superstructure ........................................................................................................................................... 75 Track parking brake .................................................................................................................................................. 75 TRANSPORTING THE MACHINE ................................................................................................................................................. 76 Transport - Safety instructions ...................................................................................................................................... 76 WORKING OPERATION ........................................................................................................................................................ 78 Safety Instructions .................................................................................................................................................. 78 Before starting work ................................................................................................................................................. 80 Slewing and braking the superstructure ............................................................................................................................... 81 Working .............................................................................................................................................................. 82 After daily operation ................................................................................................................................................ 83 ASSEMBLING WORKING EQUIPMENT - SAFETY INSTRUCTIONS ....................................................................................................................... 84 Securing the machine ................................................................................................................................................. 86 CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS) ........................................................................................................... 87 LIFTING OPERATIONS ....................................................................................................................................................... 88 Safety instructions .................................................................................................................................................. 88 Load-hooks on backhoe buckets ........................................................................................................................................ 89 Speed reduction function ............................................................................................................................................. 91 Hydraulic hammer ..................................................................................................................................................... 92 NOTES .................................................................................................................................................................... 93 3 INSPECTION AND SERVICING.................................................................................................................................................... 95 INSPECTION AND SERVICING - SAFETY INSTRUCTIONS ........................................................................................................................... 97 INSPECTION AND SERVICING, FIRE AND EXPLOSION HAZARD.......................................................................................................................103 ENVIRONMENTALLY COMPATIBLE HYDRAULIC FLUID ...............................................................................................................................104 Environmentally compatible hydraulic fluid - operating instructions ..................................................................................................104 Environmentally compatible hydraulic fluid, conversion ...............................................................................................................104 Environmentally compatible hydraulic fluid - Sampling ................................................................................................................105 ENVIRONMENT-FRIENDLY LUBRICANTS AND GEARBOX OILS .........................................................................................................................106 Lubricants for bearings ..............................................................................................................................................106 Gearbox oils .........................................................................................................................................................106 INSPECTION AND SERVICING PLANS - INSTRUCTIONS ............................................................................................................................107 Intervals ............................................................................................................................................................107 Change of engine oil l................................................................................................................................................107 Oils / Greases .......................................................................................................................................................107 Cleaning jobs ........................................................................................................................................................107 Components ...........................................................................................................................................................107 Plan V ...............................................................................................................................................................109 Plan N ...............................................................................................................................................................111 Plan T and W .........................................................................................................................................................113 Plan A – E ...........................................................................................................................................................115 LUBRICATING CHART – GREASE ...............................................................................................................................................120 Lubricating chart – Grease (legend) ..................................................................................................................................121 Filling quantities - Grease...........................................................................................................................................121 INSPECTION PLAN - OIL ....................................................................................................................................................122 Inspection plan – Oil (legend) .......................................................................................................................................123 Filling quantities - oil .............................................................................................................................................124 Filling quantities - other............................................................................................................................................124 LUBRICANTS ...............................................................................................................................................................125 Notes on the selection of oils and greases ...........................................................................................................................125 Avoid mixing of different hydraulic fluids ...........................................................................................................................125 I. Oil for combustion engines ........................................................................................................................................126 II. Oils for hydraulic system (selection) ............................................................................................................................127 III.a Oils for pump transfer gearbox and travel gearbox ..............................................................................................................128 III.b Oils for swing gearbox .........................................................................................................................................129 V. Greases for bearings and swing rings (Central lubrication system) .................................................................................................130 Grease for idlers, track rollers and support rollers (Lifetime lubrication) ..........................................................................................131 Coolant for use on all combustion engines ............................................................................................................................132 SERVICING WORK ...........................................................................................................................................................133 Hose line for oil and cooling liquid changes .........................................................................................................................133 ENGINE ...................................................................................................................................................................134 Engine - Safety instructions .........................................................................................................................................134 Checking the engine oil level / Topping up ..........................................................................................................................134 Changing the engine oil ..............................................................................................................................................135 Replacing the engine oil filter ......................................................................................................................................136 Centrifuge (optional) ................................................................................................................................................137 Cold-starting fluid (ether) - Replacing the pressure vessel ..........................................................................................................138 COOLING SYSTEM ...........................................................................................................................................................139 Radiators ............................................................................................................................................................139 Topping up cooling liquid ............................................................................................................................................139 Cooling liquid change ................................................................................................................................................140 Water filter replace .................................................................................................................................................141 AIR-INTAKE SYSTEM ........................................................................................................................................................142 Main filter element ..................................................................................................................................................142 Safety filter element ................................................................................................................................................144 Air-intake lines .....................................................................................................................................................144 Dust collection ......................................................................................................................................................144 FUEL SYSTEM ..............................................................................................................................................................145 Fuel system - Safety instructions ....................................................................................................................................145 Replacing the fuel filter ............................................................................................................................................146 Venting the fuel system ..............................................................................................................................................146 Cleaning the fuel tank ...............................................................................................................................................147 Refuelling station (optional) ........................................................................................................................................147 Water trap (option) ..................................................................................................................................................148 ELECTRICAL SYSTEM .......................................................................................................................................................150 Electrical system - Safety instructions ..............................................................................................................................150 Alternator - Instructions ............................................................................................................................................150 Battery main switch / Main fuse ......................................................................................................................................151 Battery ..............................................................................................................................................................151 Floodlight projector, safety instructions ...........................................................................................................................154 Floodlight projector, replacing a defective xenon bulb ...............................................................................................................155 Lighting systems in LED technonogy, instructions .....................................................................................................................156 HYDRAULIC SYSTEM .........................................................................................................................................................157 Hydraulic system - Safety instructions ...............................................................................................................................157 Depressurizing the hydraulic system ..................................................................................................................................157 Checking the hydraulic oil level .....................................................................................................................................158 Topping up with hydraulic oil ........................................................................................................................................158 Changing the hydraulic oil return-flow (hydraulic oil reservoir) .....................................................................................................159 Bypass valves (working circuit) ......................................................................................................................................160 Bypass valves (cooling circuit) ......................................................................................................................................161 Breather filter ......................................................................................................................................................162 High-pressure filter for working hydraulics ..........................................................................................................................163 High-pressure filters for the servo circuit and the feeding circuit of the slewing pump ..............................................................................164 Changing the hydraulic oil ...........................................................................................................................................165 Avoid mixing of different hydraulic fluids ...........................................................................................................................165 Venting the hydraulic system..........................................................................................................................................168 Cleaning the hydraulic oil cooler.....................................................................................................................................169 Pressure accumulator .................................................................................................................................................170 PUMP TRANSFER GEARBOX PUMP TRANSFER GEARBOX ..............................................................................................................................171 Checking the gearbox oil level / Topping up with oil .................................................................................................................171 Changing the gearbox oil .............................................................................................................................................172 SLEWING GEARBOX ..........................................................................................................................................................174 Gearbox - Checking the oil level / Topping up with oil ...............................................................................................................174 Changing the gearbox oil .............................................................................................................................................174 Gearbox venting ......................................................................................................................................................175 Output pinion ........................................................................................................................................................175 TRAVEL GAERBOX ...........................................................................................................................................................176 Gearbox - Checking the oil level / Topping up with oil ...............................................................................................................176 Travel gearbox - Changing the oil ....................................................................................................................................176 Gearbox venting ......................................................................................................................................................176 CRAWLER TRACKS ...........................................................................................................................................................177 Track rollers, support rollers, track pads ...........................................................................................................................177 Track tensioner ......................................................................................................................................................179 Idlers ...............................................................................................................................................................179 Pressure-accumulator inspection regulations ..........................................................................................................................180 Checking the gas charging pressure in the pressure accumulator........................................................................................................180 SLEWING RING .............................................................................................................................................................181 Slewing ring – Instructions ..........................................................................................................................................181 Bearing races.........................................................................................................................................................181 CENTRAL LUBRICATING ......................................................................................................................................................183 Design and function ..................................................................................................................................................183 Greasing cycle ......................................................................................................................................................185 Venting the grease pump ..............................................................................................................................................187 Venting the grease lines .............................................................................................................................................187 Unblocking a grease line .............................................................................................................................................187 Cleaning the grease sieves ...........................................................................................................................................188 Lubricating the grease distributor of the working equipment ..........................................................................................................188 PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING ...............................................................................................................189 Putting the excavator out of operation ...............................................................................................................................189 Battery storage ......................................................................................................................................................189 Recommissioning ......................................................................................................................................................190 NOTES ....................................................................................................................................................................191 4 REPAIR WORK.................................................................................................................................................................193 REPAIR WORK - SAFETY INSTRUCTIONS.........................................................................................................................................195 REPAIR WORK, FIRE AND EXPLOSION HAZARD ...................................................................................................................................197 REPAIR WORK, ENGINE.......................................................................................................................................................198 ELECTRICAL SYSTEM ........................................................................................................................................................199 Assisted starting (with jumper cables) – Safety instructions .........................................................................................................199 Assisted starting (with jumper cables)................................................................................................................................199 Starting the engine with jumper cables (external batteries ...........................................................................................................199 HYDRAULIC SYSTEM..........................................................................................................................................................201 Repair – Instructions ................................................................................................................................................201 Hydraulic hoses – Instructions .......................................................................................................................................201 PRESSURE ACCUMULATORS - SAFETY INSTRUCTIONS...............................................................................................................................202 WELDING AND FLAME CUTTING WORKS - SAFETY INSTRUCTIONS ....................................................................................................................203 DISPOSAL AT THE END OF THE SERVICE LIFE ..................................................................................................................................206 Dismantling and removal instructions .................................................................................................................................206 Risk of deflagrations ................................................................................................................................................206 Risk of fire .........................................................................................................................................................206 Disposing of the machine without polluting the environment ...........................................................................................................206 Further hazardous substances .........................................................................................................................................207 Appropriate disposal of batteries ....................................................................................................................................208 NOTES ....................................................................................................................................................................209 5 ANNEX.......................................................................................................................................................................211 TROUBLESHOOTING ..........................................................................................................................................................213 Instructions on troubleshooting ......................................................................................................................................213 Layout of the fault table ............................................................................................................................................213 Possible causes ......................................................................................................................................................213 Measures .............................................................................................................................................................213 Section ..............................................................................................................................................................213 FAULT TABLES .............................................................................................................................................................214 Combustion engine - Fault table ......................................................................................................................................214 Working hydraulics – Fault table .....................................................................................................................................215 Track drive – Fault table ............................................................................................................................................216 Slewing mechnism – Fault table .......................................................................................................................................217 Central lubricating system – Fault table .............................................................................................................................218 HYDRAULIC CIRCUIT DIAGRAM ................................................................................................................................................219 ABBREVIATIONS ............................................................................................................................................................221 TECHNICAL DATA ...........................................................................................................................................................223 Product Specification Sheet...........................................................................................................................................225 NOTES ...............................................................................................................................................................234 6 INDEX.......................................................................................................................................................................236
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