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CAT 6018, 6018 FS Hydraulic Shovel Operation & Maintenance Manual BI015192 – PDF DOWNLOAD
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CAT 6018, 6018 FS Hydraulic Shovel Operation & Maintenance Manual BI015192 – PDF DOWNLOAD
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Description
CAT 6018, 6018 FS Hydraulic Shovel Operation & Maintenance Manual BI015192 – PDF DOWNLOAD
FILE DETAILS:
CAT 6018, 6018 FS Hydraulic Shovel Operation & Maintenance Manual BI015192 – PDF DOWNLOAD
Language : English
Pages : 328
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
CAT 6018, 6018 FS Hydraulic Shovel Operation & Maintenance Manual BI015192 – PDF DOWNLOAD
PREFACE:
About this Operation and Mainte- nance Manual:
- 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 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 environ- mental 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, 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 Man- ual 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 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 Operation and Maintenance Manuals are issued in German and then trans-
lated. 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 6018, 6018 FS Hydraulic Shovel Operation & Maintenance Manual BI015192 – PDF DOWNLOAD
BA RH90C(3 847 017.00)-EN.pdf.................................................................................................................................................... 0 TITLEPAGE.................................................................................................................................................................... 3 1 INTRODUCTION............................................................................................................................................................... 13 PREFACE ................................................................................................................................................................. 15 About this Operation and Maintenance Manual ......................................................................................................................... 15 Further machine documentation ....................................................................................................................................... 15 WARRANTY ................................................................................................................................................................ 16 FUNDAMENTAL SAFETY INSTRUCTIONS.......................................................................................................................................... 17 Warnings and symbols ................................................................................................................................................ 17 DESIGNATED USE .......................................................................................................................................................... 18 ORGANIZATIONAL MEASURES.................................................................................................................................................. 19 Selection and qualification of personnel; basic responsibilities..................................................................................................... 20 Safety instructions governing specific operational phases............................................................................................................ 20 Special work in conjunction with utilization of the machine and maintenance and repairs as well as troubleshooting during work; disposal of parts and consumables.... 21 Warning of special dangers........................................................................................................................................... 22 Gas, dust, steam and smoke........................................................................................................................................... 23 Hydraulic equipment.................................................................................................................................................. 23 INTRODUCTION, FIRE AND EXPLOSION HAZARD.................................................................................................................................. 24 NOTES ................................................................................................................................................................... 25 2 OPERATION.................................................................................................................................................................. 27 OPERATION - SAFETY INSTRUCTIONS ......................................................................................................................................... 29 Operating Instructions, where to store it in the driver’s cab ....................................................................................................... 30 OPERATION, FIRE AND EXPLOSION HAZARD .................................................................................................................................... 31 DESCRIPTION OF THE EXCAVATOR ............................................................................................................................................ 32 Excavator layout .................................................................................................................................................... 33 Undercarriage ....................................................................................................................................................... 34 Superstructure ...................................................................................................................................................... 34 Drive ............................................................................................................................................................... 34 Hydraulic system .................................................................................................................................................... 34 Pump Managing System (PMS) .......................................................................................................................................... 34 Stored Program Control (SPC) ........................................................................................................................................ 34 Central Management System (CMS) ..................................................................................................................................... 34 Demand control / Zero-flow regulation ............................................................................................................................... 35 Automatic engine speed reduction .................................................................................................................................... 35 Board-Control-System (BCS) .......................................................................................................................................... 35 Electrical system ................................................................................................................................................... 35 Signs and labels .................................................................................................................................................... 36 Entering and leaving the machine, Safety instructions ............................................................................................................... 43 Access ladder lighting .............................................................................................................................................. 43 Swinging ladder ..................................................................................................................................................... 44 Switching the cab interior lighting on and off ...................................................................................................................... 45 Switching the servicing lighting on and off ......................................................................................................................... 46 EMERGENCY STOP switch ............................................................................................................................................... 47 Driver’s seat ...................................................................................................................................................... 48 Trainer's / instructor's seat ....................................................................................................................................... 50 Windscreen washer ................................................................................................................................................... 50 Fire extinguisher ................................................................................................................................................... 51 Automatic fire-extinguishing system (optional) ...................................................................................................................... 52 Harness (optional) .................................................................................................................................................. 53 MONITORING, WARNING AND CONTROL ELEMENTS ................................................................................................................................ 56 PUTTING THE MACHINE INTO OPERATION ...................................................................................................................................... 88 Refuelling .......................................................................................................................................................... 88 Service station (tanklift) .......................................................................................................................................... 89 Switching the electrical system on and off .......................................................................................................................... 95 Preheating system for engine and hydraulic oil (optional) ........................................................................................................... 96 Fuel preheating system (optional) ................................................................................................................................... 97 STARTING AND STOPPING THE ENGINES ....................................................................................................................................... 98 Starting the engines ................................................................................................................................................ 98 Starting the engines at low temperatures ............................................................................................................................ 99 AIR CONDITIONER (OPTION).................................................................................................................................................101 Back-up heating (option) ............................................................................................................................................102 MAXIMUM MACHINE INCLINATIONS, INFORMATION ...............................................................................................................................104 DRIVING, SAFETY INSTRUCTIONS ............................................................................................................................................105 TRAVELLING ..............................................................................................................................................................106 Superstructure basic position .......................................................................................................................................106 Travelling forwards/backwards .......................................................................................................................................106 Locking the superstructure ..........................................................................................................................................110 Track parking brake .................................................................................................................................................110 TRANSPORTING THE MACHINE ................................................................................................................................................111 Transport - Safety instructions .....................................................................................................................................111 WORKING OPERATION - SAFETY INSTRUCTIONS .................................................................................................................................112 Running-in instructions for hydraulic cylinders .....................................................................................................................112 Warming-up phase for the hydraulic system ...........................................................................................................................112 Avoid extreme positions of the working equipment ....................................................................................................................113 WORKING OPERATION .......................................................................................................................................................114 Before starting work ................................................................................................................................................114 Switching on the electronic excavator control .......................................................................................................................114 Swinging the superstructure .........................................................................................................................................115 Braking the superstructure ..........................................................................................................................................115 Working movements ...................................................................................................................................................116 After daily operation ...............................................................................................................................................117 ASSEMBLING WORKING EQUIPMENT - SAFETY INSTRUCTIONS ......................................................................................................................118 Securing the machine ................................................................................................................................................120 CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS) ..........................................................................................................121 NOTES ...................................................................................................................................................................123 3 INSPECTION AND SERVICING...................................................................................................................................................125 INSPECTION AND SERVICING - SAFETY INSTRUCTIONS ..........................................................................................................................127 INSPECTION AND SERVICING WORK, FIRE AND EXPLOSION HAZARD ................................................................................................................133 INSPECTION AND SERVICING PLANS - INSTRUCTIONS ...........................................................................................................................135 Plan V ..............................................................................................................................................................137 Plan N ..............................................................................................................................................................139 Plan T and W ........................................................................................................................................................141 Plan A – E ..........................................................................................................................................................143 LUBRICATING CHART – GREASE ..............................................................................................................................................150 Lubricating chart – Grease (legend) .................................................................................................................................151 Filling quantities - Grease..........................................................................................................................................151 INSPECTION PLAN - OIL ...................................................................................................................................................152 Inspection plan – Oil (legend) ......................................................................................................................................153 Filling quantities - oil ............................................................................................................................................154 Filling quantities - other...........................................................................................................................................154 LUBRICANTS, CONSUMABLES..................................................................................................................................................155 Notes on the selection of oils and greases ..........................................................................................................................155 Avoid mixing of different hydraulic fluids ..........................................................................................................................155 I. Oils for combustion engines ......................................................................................................................................156 II. Fluid for hydraulic system ......................................................................................................................................157 III.a Oils for pump distribution gearboxes and travel gearboxes .....................................................................................................158 III.b Oils for swing gearboxes ......................................................................................................................................159 V. Grease for bearings, swing rings and track system (Central lubrication system) ...................................................................................160 Greases for idlers, track rollers and support rollers (Lifetime lubrication) ........................................................................................161 Coolant for use on all combustion engines ...........................................................................................................................162 SERVICING WORK ..........................................................................................................................................................163 Hose line for oil and cooling liquid changes ........................................................................................................................163 ENGINE ..................................................................................................................................................................164 Engine - Safety instructions ........................................................................................................................................164 Checking the engine oil level / Topping up .........................................................................................................................165 Changing the engine oil .............................................................................................................................................166 Replacing the oil filters ...........................................................................................................................................168 Cold-starting fluid (ether) - Replacing the pressure vessel .........................................................................................................169 COOLING SYSTEM ..........................................................................................................................................................170 Radiators ...........................................................................................................................................................170 Cooling liquid change ...............................................................................................................................................172 AIR-INTAKE SYSTEM .......................................................................................................................................................173 Dust trap, cleaning ................................................................................................................................................173 Main filter elements ................................................................................................................................................174 Safety filter element ...............................................................................................................................................176 Air-intake lines ....................................................................................................................................................176 FUEL SYSTEM .............................................................................................................................................................177 Fuel system - Safety instructions ...................................................................................................................................177 Replacing the fuel filter ...........................................................................................................................................177 Venting the fuel system .............................................................................................................................................178 Cleaning the fuel tanks .............................................................................................................................................178 Water trap (option)..................................................................................................................................................180 ELECTRICAL SYSTEM ......................................................................................................................................................182 Electrical system - Safety instructions .............................................................................................................................182 Alternator - Instructions ...........................................................................................................................................182 Battery .............................................................................................................................................................183 Switchgear cabinet, filter element ..................................................................................................................................185 Floodlight projector, replacing the lamp ............................................................................................................................187 Lighting systems in LED technonogy, instructions ....................................................................................................................189 HYDRAULIC SYSTEM ........................................................................................................................................................190 Hydraulic system - Safety instructions ..............................................................................................................................190 Depressurizing the hydraulic system .................................................................................................................................190 Checking the hydraulic oil level ....................................................................................................................................191 Changing the hydraulic oil return-flow (hydraulic oil reservoir) ....................................................................................................193 Bypass valves (hydraulic oil reservoir) .............................................................................................................................195 Breather filter .....................................................................................................................................................196 High-pressure filter for working hydraulics .........................................................................................................................197 High-pressure filters for the servo circuit .........................................................................................................................198 Filter (control circuit) ............................................................................................................................................199 Changing the hydraulic oil ..........................................................................................................................................200 Venting the hydraulic system.........................................................................................................................................203 Cleaning the hydraulic oil cooler....................................................................................................................................204 Electronic excavator control.........................................................................................................................................205 Pressure accumulator - Emergency lowering............................................................................................................................206 PUMP GEARBOX ............................................................................................................................................................207 Checking the gearbox oil level / Topping up with oil ................................................................................................................207 Changing the gearbox oil ............................................................................................................................................207 Gearbox venting .....................................................................................................................................................209 SWING GEARBOX ...........................................................................................................................................................210 Gearbox - Checking the oil level / Topping up with oil ..............................................................................................................210 Changing the gearbox oil ............................................................................................................................................210 Gearbox venting .....................................................................................................................................................211 TRAVEL GEARBOX ..........................................................................................................................................................212 Travel gearbox - Checking the oil level / Topping up with oil .......................................................................................................212 Travel gearbox - Changing oil .......................................................................................................................................213 Travel gearbox, breather filter .....................................................................................................................................213 CRAWLER TRACKS ..........................................................................................................................................................214 Track roller, Support roller ........................................................................................................................................215 Track tensioner .....................................................................................................................................................216 Pressure-accumulator inspection regulations .........................................................................................................................217 Checking the gas charging pressure in the pressure accumulator.......................................................................................................217 SWING RING ..............................................................................................................................................................218 Swing ring - Instructions............................................................................................................................................218 Bearing races .......................................................................................................................................................218 CENTRAL LUBRICATING SYSTEM, STANDARD ....................................................................................................................................220 Design ..............................................................................................................................................................220 Function ............................................................................................................................................................221 Replacing the grease container ......................................................................................................................................222 Filling up the grease container .....................................................................................................................................222 Checking the greasing pressure ......................................................................................................................................223 Unblocking a grease line ............................................................................................................................................223 Oilfilter (hydraulic circuit grease pump) )..........................................................................................................................224 Grease filter (Filling the grease container) .......................................................................................................................225 Grease filter (Grease lines) ........................................................................................................................................226 OTHER MAINTENANCE .......................................................................................................................................................227 Engine ..............................................................................................................................................................227 Heating and air conditioning ........................................................................................................................................227 HYDRAULIC LADDER ........................................................................................................................................................228 Pressure-accumulator inspection regulations ........................................................................................................................229 PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING ..............................................................................................................230 Putting the excavator out of operation ..............................................................................................................................230 Battery storage .....................................................................................................................................................230 Recommissioning .....................................................................................................................................................230 NOTES ...................................................................................................................................................................231 4 REPAIR WORK................................................................................................................................................................233 REPAIR WORK - SAFETY INSTRUCTIONS........................................................................................................................................235 REPAIR WORK, FIRE AND EXPLOSION HAZARD ..................................................................................................................................237 ENGINE, REPAIR WORK .....................................................................................................................................................238 ELECTRICAL SYSTEM .......................................................................................................................................................239 Assisted starting (with jumper cables) – Safety instructions ........................................................................................................239 Assisted starting (with jumper cables)...............................................................................................................................239 Starting the engine with jumper cables (external batteries ..........................................................................................................239 HYDRAULIC SYSTEM ........................................................................................................................................................241 Repair instructions .................................................................................................................................................241 Hydraulic hoses – Instructions .....................................................................................................................................241 PRESSURE ACCUMULATORS - SAFETY INSTRUCTIONS .............................................................................................................................242 WELDING AND FLAME CUTTING WORKS - SAFETY INSTRUCTIONS ...................................................................................................................243 DISPOSAL AT THE END OF THE SERVICE LIFE .................................................................................................................................246 Appropriate disposal of batteries ...................................................................................................................................247 NOTES ...................................................................................................................................................................249 5 ANNEX......................................................................................................................................................................251 TROUBLESHOOTING .........................................................................................................................................................253 Instructions on troubleshooting .....................................................................................................................................253 Layout of the fault table ...........................................................................................................................................253 FAULT TABLES ............................................................................................................................................................254 Combustion engine - Fault table .....................................................................................................................................254 Working hydraulics – Fault table ....................................................................................................................................255 Track drive – Fault table ...........................................................................................................................................256 Swing mechnism – Fault table ........................................................................................................................................257 Central lubricating system – Fault table ............................................................................................................................258 HYDRAULIC CIRCUIT DIAGRAM ...............................................................................................................................................259 ABBREVIATIONS ...........................................................................................................................................................260 ABBREVIATIONS........................................................................................................................................................261 TECHNICAL DATA ..........................................................................................................................................................263 Product Specification Sheet..........................................................................................................................................265 NOTES ...................................................................................................................................................................275 6 INDEX......................................................................................................................................................................277 BA_BCS_6018_3847018_en.pdf....................................................................................................................................................... 0 TITLEPAGE....................................................................................................................................................................283 DESCRIPTION .............................................................................................................................................................287 Functions ...........................................................................................................................................................287 Components ..........................................................................................................................................................287 DISPLAYS : USING BCS.....................................................................................................................................................288 Display and keyboard ................................................................................................................................................290 Indicator lights ................................................................................................................................................291 Buttons .........................................................................................................................................................291 Instruments .........................................................................................................................................................292 Service menu ........................................................................................................................................................292 Program 1: Oil change ...........................................................................................................................................293 Program 2 to 6 ..................................................................................................................................................293 The programs (Fig. 15)...........................................................................................................................................293 Program 2: Service ..............................................................................................................................................293 Program 3: Engine ...............................................................................................................................................294 Program 4: Hydraulics (Fig. 19)..................................................................................................................................294 Program 5: Excavator ...........................................................................................................................................295 Program 6: Operating hours ......................................................................................................................................295 HOLD function ...................................................................................................................................................296 Program 7: Setting date and time ................................................................................................................................297 Program 8: Complete fault list ..................................................................................................................................298 Program 9: Service CGM HMS GmbH .................................................................................................................................298 Fault reports .......................................................................................................................................................299 Service data & fault storage: print-out or transfer into Buffer .....................................................................................................300 APPENDIX ................................................................................................................................................................301 Print-out ...........................................................................................................................................................301 21_3847003en.pdf................................................................................................................................................................. 0 DECK-EN......................................................................................................................................................................305 Inhalt-en....................................................................................................................................................................307 Text-EN......................................................................................................................................................................309 Safety instructions .....................................................................................................................................................309 Notes on the selection of oils and greases ..............................................................................................................................309 Caterpillar Global Mining HMS oils and greases...........................................................................................................................309 Alternative oils and greases.............................................................................................................................................309 Why carry out oil analyses? .............................................................................................................................................310 Oil samples are taken at the following places:.......................................................................................................................310 Prerequisites for valid oil samples .....................................................................................................................................311 Analyses-Sets........................................................................................................................................................311 Taking oil samples ......................................................................................................................................................312 Sampling from assemblies equipped with sampling valve................................................................................................................312 Sampling from assemblies without sampling valve .....................................................................................................................313 Interpreting the results of the oil analysis ............................................................................................................................314 A typical laboratory report .........................................................................................................................................314 Typical laboratory report ...........................................................................................................................................315 Typical wear limits .....................................................................................................................................................316 For hydraulic oil in the 6015, 6018, 6030, 6040 machines ............................................................................................................317 For hydraulic oil in 6050, 6060, 6090 machines ......................................................................................................................318 For oil in the pump transfer gearboxes of the 6015, 6018, 6030 ......................................................................................................319 For oil in the pump transfer gearboxes of the 6040, 6050, 6060 ......................................................................................................320 For oil in the pump transfer gearboxes of the 6090 ..................................................................................................................321 For oil in the swing gearboxes of the 6015 - 6090 ...................................................................................................................322 For oil in the travel gearboxes of the 6015, 6018 ..................................................................................................................323 For oil in the travel gearboxes of the 6030, 6040, 6060 .............................................................................................................324 For oil in the travel gearboxes of the 6050, 6090 ...................................................................................................................325 Notes ...................................................................................................................................................................326 rueckseite_mit_cat_logo_en...................................................................................................................................................328
Need help? Contact: [email protected]
PLEASE NOTE:
- This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
- Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.
S.V
