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CAT 6018, 6018FS Hydraulic Shovel Operation & Maintenance Manual BI015693 – PDF DOWNLOAD
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Description
CAT 6018, 6018FS Hydraulic Shovel Operation & Maintenance Manual BI015693 – PDF DOWNLOAD
FILE DETAILS:
CAT 6018, 6018FS Hydraulic Shovel Operation & Maintenance Manual BI015693 – PDF DOWNLOAD
Language : English
Pages : 286
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
CAT 6018, 6018FS Hydraulic Shovel Operation & Maintenance Manual BI015693 – PDF DOWNLOAD
PREFACE:
About this Operation and Maintenance Manual:
- These Operation and Maintenance Manual are designed to familiarize the operator with the
machine and its designated use. - The Operation and Maintenance Manual contain important information on how to operate the
machine safely, properly and with maximum effi- ciency. Observing these instructions
helps to pre- vent hazardous situations, to reduce repair costs and downtimes and to
increase the reliability and service life of the machine. - The Operation and Maintenance Manual must be supplemented by the respective national rules
and regulations for accident prevention and environ- mental protection. - The Operation and Maintenance Manual must always be available in the 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, 6018FS Hydraulic Shovel Operation & Maintenance Manual BI015693 – PDF DOWNLOAD
TITLEPAGE.................................................................................................................................................................... 1 1 INTRODUCTION............................................................................................................................................................... 11 PREFACE ................................................................................................................................................................. 13 About this Operation and Maintenance Manual ......................................................................................................................... 13 Further machine documentation ....................................................................................................................................... 13 WARRANTY ................................................................................................................................................................ 14 FUNDAMENTAL SAFETY INSTRUCTIONS.......................................................................................................................................... 15 Warnings and symbols ................................................................................................................................................ 15 DESIGNATED USE .......................................................................................................................................................... 16 ORGANIZATIONAL MEASURES.................................................................................................................................................. 17 Personal protective equipment and the working clothing............................................................................................................... 17 Selection and qualification of personnel; basic responsibilities..................................................................................................... 18 Safety instructions governing specific operational phases............................................................................................................ 18 Standard operation............................................................................................................................................... 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 Electric energy.................................................................................................................................................. 20 High-voltage system.............................................................................................................................................. 20 Battery ......................................................................................................................................................... 20 Gas, dust, steam and smoke........................................................................................................................................... 21 Hydraulic equipment.................................................................................................................................................. 21 Noise............................................................................................................................................................ 21 Oil, grease and other chemical substances........................................................................................................................ 21 Ether............................................................................................................................................................ 21 Transporting and recommissioning................................................................................................................................. 21 INTRODUCTION, FIRE AND EXPLOSION HAZARD.................................................................................................................................. 22 NOTES ................................................................................................................................................................... 23 2 OPERATION.................................................................................................................................................................. 25 OPERATION - SAFETY INSTRUCTIONS ......................................................................................................................................... 27 Operating instructions............................................................................................................................................... 27 Pay special attention to: ........................................................................................................................................... 27 Operating personnel.................................................................................................................................................. 27 Personal protective gear and working clothing........................................................................................................................ 27 Safety belt.......................................................................................................................................................... 27 State of the machine................................................................................................................................................. 27 Entering and leaving the machine..................................................................................................................................... 27 Hazard range......................................................................................................................................................... 28 Persons within the hazard zone....................................................................................................................................... 28 Operating Instructions, where to store it in the driver’s cab ....................................................................................................... 28 OPERATION, FIRE AND EXPLOSION HAZARD .................................................................................................................................... 29 DESCRIPTION OF THE EXCAVATOR ............................................................................................................................................ 30 Excavator layout .................................................................................................................................................... 31 Undercarriage.................................................................................................................................................... 31 Superstructure................................................................................................................................................... 31 Loading bucket................................................................................................................................................... 31 Backhoe bucket................................................................................................................................................... 31 Undercarriage ....................................................................................................................................................... 32 Superstructure ...................................................................................................................................................... 32 Drive ............................................................................................................................................................... 32 Hydraulic system .................................................................................................................................................... 32 Pump Managing System (PMS) .......................................................................................................................................... 32 Stored Program Control (SPC) ........................................................................................................................................ 32 Central Management System (CMS) ..................................................................................................................................... 32 Demand control / Zero-flow regulation ............................................................................................................................... 33 Automatic engine speed reduction .................................................................................................................................... 33 Board-Control-System (BCS) .......................................................................................................................................... 33 Electrical system ................................................................................................................................................... 33 Signs and labels .................................................................................................................................................... 34 Warning and instruction signs.................................................................................................................................... 34 Machine number................................................................................................................................................... 40 Engine number.................................................................................................................................................... 40 Component numbers................................................................................................................................................ 40 Entering and leaving the machine, Safety instructions ............................................................................................................... 41 Access ladder lighting .............................................................................................................................................. 41 Swinging ladder ..................................................................................................................................................... 42 Switching the cab interior lighting on and off ...................................................................................................................... 43 Switching the servicing lighting on and off ......................................................................................................................... 44 EMERGENCY STOP switch ............................................................................................................................................... 45 Driver’s seat ...................................................................................................................................................... 46 Trainer's / instructor's seat ....................................................................................................................................... 48 Windscreen washer ................................................................................................................................................... 48 Fire extinguisher ................................................................................................................................................... 49 Extinguishing agent ............................................................................................................................................. 49 Handling......................................................................................................................................................... 49 Inspection....................................................................................................................................................... 49 Automatic fire-extinguishing system (optional) ...................................................................................................................... 50 Inspection....................................................................................................................................................... 50 Manual activation ............................................................................................................................................... 50 Harness (optional) .................................................................................................................................................. 51 Elements of the harness.......................................................................................................................................... 51 Important hints.................................................................................................................................................. 51 Taking on harness................................................................................................................................................ 52 MONITORING, WARNING AND CONTROL ELEMENTS ................................................................................................................................ 54 PUTTING THE MACHINE INTO OPERATION ...................................................................................................................................... 86 Refuelling .......................................................................................................................................................... 86 Refuelling - Safety instructions ................................................................................................................................ 86 Filling in fuel ................................................................................................................................................. 86 Service station (tanklift) .......................................................................................................................................... 87 Lowering the service station .................................................................................................................................... 88 Raising the service station ..................................................................................................................................... 88 Refilling and draining .......................................................................................................................................... 88 Switching the electrical system on and off .......................................................................................................................... 93 Battery main switch ............................................................................................................................................. 93 Preheating system for engine and hydraulic oil (optional) ........................................................................................................... 94 Preheating system for engine and hydraulic oil, function ........................................................................................................ 94 Switching the preheating system for engine and hydraulic oil on and off ......................................................................................... 94 Fuel preheating system (optional) ................................................................................................................................... 95 Fuel preheating system, function................................................................................................................................. 95 Switching the fuel preheating system on and off.................................................................................................................. 95 STARTING AND STOPPING THE ENGINES ....................................................................................................................................... 96 Starting the engines ................................................................................................................................................ 96 Starting the engines at low temperatures ............................................................................................................................ 97 Shutting off the engines ........................................................................................................................................ 98 Emergency - stop ................................................................................................................................................ 98 AIR CONDITIONER (OPTION)................................................................................................................................................. 99 Ventilation / Heating ............................................................................................................................................... 99 Control panel (Sigma) single......................................................................................................................................... 99 Back-up heating (option) ............................................................................................................................................100 Control panel (Eberspächer) .....................................................................................................................................100 Control panel ...................................................................................................................................................101 MAXIMUM MACHINE INCLINATIONS, INFORMATION ...............................................................................................................................102 Maximum machine inclinations during working operations:..............................................................................................................102 Maximum machine inclinations during travelling:......................................................................................................................102 Maximum machine inclinations during maintenance operations:..........................................................................................................102 TRAVELLING, SAFETY INSTRUCTIONS .........................................................................................................................................103 TRAVELLING ..............................................................................................................................................................104 Superstructure basic position .......................................................................................................................................104 Travelling forwards/backwards .......................................................................................................................................104 Regulating the travelling speed .................................................................................................................................105 Travelling uphill and downhill ..................................................................................................................................105 Cornering .......................................................................................................................................................106 Turning .........................................................................................................................................................106 Note.............................................................................................................................................................106 Travelling over long distances ..................................................................................................................................107 Locking the superstructure ..........................................................................................................................................108 Track parking brake .................................................................................................................................................108 TRANSPORTING THE MACHINE ................................................................................................................................................109 Transport - Safety instructions .....................................................................................................................................109 Transport .......................................................................................................................................................109 WORKING OPERATION - SAFETY INSTRUCTIONS .................................................................................................................................110 Running-in instructions for hydraulic cylinders .....................................................................................................................110 Warming-up phase for the hydraulic system ...........................................................................................................................110 Avoid extreme positions of the working equipment ....................................................................................................................111 WORKING OPERATION .......................................................................................................................................................112 Before starting work ................................................................................................................................................112 Switching on the electronic excavator control .......................................................................................................................112 Swinging the superstructure .........................................................................................................................................113 Braking the superstructure ..........................................................................................................................................113 Working movements ...................................................................................................................................................114 Raising and lowering the boom ...................................................................................................................................114 Extending and retracting the bucket or backhoe bucket stick .....................................................................................................114 Filling and emptying the bucket or the backhoe ..................................................................................................................114 Opening and closing the bottom-dump bucket ......................................................................................................................114 After daily operation ...............................................................................................................................................115 Parking the machine .............................................................................................................................................115 ASSEMBLING WORKING EQUIPMENT - SAFETY INSTRUCTIONS ......................................................................................................................116 Personel.............................................................................................................................................................116 Personal protective gear and working clothes.........................................................................................................................116 Tools and auxiliaries................................................................................................................................................116 Securing the working equipment.......................................................................................................................................116 Securing the machine.................................................................................................................................................117 Selecting the attachments............................................................................................................................................117 Protective roof against falling objects..............................................................................................................................117 Securing the machine ................................................................................................................................................118 CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS) ..........................................................................................................119 Application of GLEITMO 815...........................................................................................................................................119 NOTES ...................................................................................................................................................................121 3 INSPECTION AND SERVICING...................................................................................................................................................123 INSPECTION AND SERVICING - SAFETY INSTRUCTIONS ..........................................................................................................................125 Operating manual.....................................................................................................................................................125 Inspection and servicing personnel...................................................................................................................................125 Securing the working equipment.......................................................................................................................................125 Climbing onto and off the machine....................................................................................................................................125 Checking the state of tools..........................................................................................................................................125 Cleaning jobs........................................................................................................................................................126 Handling flammable liquids...........................................................................................................................................126 Fastening and securing elements......................................................................................................................................126 Spare parts..........................................................................................................................................................126 Handling oils and greases............................................................................................................................................126 Visisble oil losses..................................................................................................................................................126 Relieving residual pressure in the hydraulic system..................................................................................................................127 Screwed connections, piping, hydraulic hoses.........................................................................................................................127 Non-polluting disposal...............................................................................................................................................128 Seals................................................................................................................................................................128 Handling batteries...................................................................................................................................................129 Handling of cold-starting fluid (ether)..............................................................................................................................129 Selecting oils and greases...........................................................................................................................................130 Filters..............................................................................................................................................................130 Sealing elements.....................................................................................................................................................130 Oil-level check and oil change.......................................................................................................................................130 Lubricating..........................................................................................................................................................130 After servicing......................................................................................................................................................130 INSPECTION AND SERVICING WORK, FIRE AND EXPLOSION HAZARD ................................................................................................................131 INSPECTION AND SERVICING PLANS - INSTRUCTIONS ...........................................................................................................................133 Intervals ...........................................................................................................................................................133 Change of engine oil ................................................................................................................................................133 Air-intake system ...................................................................................................................................................133 Oils / Greases ......................................................................................................................................................133 Cleaning jobs .......................................................................................................................................................133 Components ..........................................................................................................................................................133 Plan V ..............................................................................................................................................................135 Plan N ..............................................................................................................................................................137 Plan T and W ........................................................................................................................................................139 Plan A – E ..........................................................................................................................................................141 LUBRICATING CHART – GREASE ..............................................................................................................................................148 Lubricating chart – Grease (legend) .................................................................................................................................149 Filling quantities - Grease..........................................................................................................................................149 INSPECTION PLAN - OIL ...................................................................................................................................................150 Inspection plan – Oil (legend) ......................................................................................................................................151 Filling quantities - oil ............................................................................................................................................152 Filling quantities – other ..........................................................................................................................................152 LUBRICANTS, CONSUMABLES..................................................................................................................................................153 Notes on the selection of oils and greases ..........................................................................................................................153 Original CGM HMS oils and greases................................................................................................................................153 Alternative oils and greases.....................................................................................................................................153 Avoid mixing of different hydraulic fluids ..........................................................................................................................153 I. Oils for combustion engines ......................................................................................................................................154 II. Fluid for hydraulic system ......................................................................................................................................155 III.a Oils for pump distribution gearboxes and travel gearboxes .....................................................................................................156 III.b Oils for swing gearboxes ......................................................................................................................................157 V. Grease for bearings, swing rings and track system (Central lubrication system) ...................................................................................158 Greases for idlers, track rollers and support rollers (Lifetime lubrication) ........................................................................................159 Coolant for use on all combustion engines ...........................................................................................................................160 SERVICING WORK ..........................................................................................................................................................161 Hose line for oil and cooling liquid changes ........................................................................................................................161 ENGINE ..................................................................................................................................................................162 Engine - Safety instructions ........................................................................................................................................162 Before cleaning the engines......................................................................................................................................162 Checking the engine oil level / Topping up .........................................................................................................................163 Changing the engine oil .............................................................................................................................................164 Drawing off engine oil with the service station..................................................................................................................164 Filling in engine oil ...........................................................................................................................................165 Filling in engine oil through the service station................................................................................................................165 Replacing the oil filters ...........................................................................................................................................166 Oil filters......................................................................................................................................................166 Cold-starting fluid (ether) - Replacing the pressure vessel .........................................................................................................167 COOLING SYSTEM ..........................................................................................................................................................168 Temperature .........................................................................................................................................................168 Radiators ...........................................................................................................................................................168 Cooling-liquid level ............................................................................................................................................168 Topping up cooling liquid........................................................................................................................................169 Checking the SCA concentration(Only when used at this machine)...................................................................................................169 Cooling liquid change ...............................................................................................................................................170 Draining off cooling liquid .....................................................................................................................................170 Filling in cooling liquid .......................................................................................................................................170 Testing the cooling liquid composition ..........................................................................................................................170 AIR-INTAKE SYSTEM .......................................................................................................................................................171 Dust trap, cleaning ................................................................................................................................................171 Main filter elements ................................................................................................................................................172 Removal and installation ........................................................................................................................................172 Checking and cleaning the main filter element ...................................................................................................................173 Safety filter element ...............................................................................................................................................174 Removal and installation ........................................................................................................................................174 Air-intake lines ....................................................................................................................................................174 FUEL SYSTEM .............................................................................................................................................................175 Fuel system - Safety instructions ...................................................................................................................................175 Replacing the fuel filter ...........................................................................................................................................175 Venting the fuel system .............................................................................................................................................176 Cleaning the fuel tanks .............................................................................................................................................176 Water trap (option)..................................................................................................................................................178 Servicing .......................................................................................................................................................178 ELECTRICAL SYSTEM ......................................................................................................................................................180 Electrical system - Safety instructions .............................................................................................................................180 Alternator - Instructions ...........................................................................................................................................180 Battery .............................................................................................................................................................181 Checking the battery fluid level ................................................................................................................................181 Checking charge condition .......................................................................................................................................181 Removing and installing the battery .............................................................................................................................182 Switchgear cabinet, filter element ..................................................................................................................................183 Breather filter .................................................................................................................................................183 Emptying dust trap ..............................................................................................................................................183 Emptying the dust collector .....................................................................................................................................183 Filter element ..................................................................................................................................................183 Checking and cleaning the filter element ........................................................................................................................184 Floodlight projector, replacing the lamp ............................................................................................................................185 Safety instructions..............................................................................................................................................185 Further instructions.............................................................................................................................................185 Replacing a defective Xenon-lamp.................................................................................................................................186 Lighting systems in LED technonogy, instructions ....................................................................................................................187 HYDRAULIC SYSTEM ........................................................................................................................................................188 Hydraulic system - Safety instructions ..............................................................................................................................188 Depressurizing the hydraulic system .................................................................................................................................188 Checking the hydraulic oil level ....................................................................................................................................189 Changing the hydraulic oil return-flow (hydraulic oil reservoir) ....................................................................................................191 Bypass valves (hydraulic oil reservoir) .............................................................................................................................193 Cleaning the filter screens .....................................................................................................................................193 Replacing the bypass valves and sealing rings....................................................................................................................193 Breather filter .....................................................................................................................................................194 Replacing the filter elements ...................................................................................................................................194 High-pressure filter for working hydraulics .........................................................................................................................195 Replacing the filter elements....................................................................................................................................195 High-pressure filters for the servo circuit .........................................................................................................................196 Replacing the filter elements....................................................................................................................................196 Filter (control circuit) ............................................................................................................................................197 Replacing the filter element.....................................................................................................................................197 Changing the hydraulic oil ..........................................................................................................................................198 Avoid mixing of different hydraulic fluids ..........................................................................................................................198 Drawing off hydaulic oil ........................................................................................................................................199 Drawing off hydaulic oil by means of the service station.........................................................................................................199 Cleaning the hydraulic oil reservoir ............................................................................................................................200 Filling in hydraulic oil ........................................................................................................................................201 Venting the hydraulic system.........................................................................................................................................202 Venting the hydraulic components.................................................................................................................................202 Cleaning the hydraulic oil cooler....................................................................................................................................203 Cleaning.........................................................................................................................................................203 Electronic excavator control.........................................................................................................................................204 Joystick ........................................................................................................................................................204 Pedal............................................................................................................................................................204 Pressure accumulator - Emergency lowering............................................................................................................................205 Pressure-accumulator inspection regulations .....................................................................................................................205 Extract from the German regulations..............................................................................................................................205 Extract from the German acceptance regulations...................................................................................................................205 Checking the gas charging pressure in the pressure accumulator...................................................................................................205 PUMP DRIVE GEARBOX ......................................................................................................................................................206 Pump drive gearbox - Checking the oil level / Topping up with oil ...................................................................................................206 Pump drive gearbox - Changing the gearbox oil .......................................................................................................................207 Drawing off gearbox oil..........................................................................................................................................207 Filling in gearbox oil ..........................................................................................................................................207 Pump drive gearbox breather – replace ...............................................................................................................................208 Pump drive gearbox oil filter – replace .............................................................................................................................209 Pump drive gearbox – take an oil sample .............................................................................................................................210 SWING GEARBOX ...........................................................................................................................................................211 Gearbox - Checking the oil level / Topping up with oil ..............................................................................................................211 Changing the gearbox oil ............................................................................................................................................211 Draining off oil ................................................................................................................................................211 Filling in new oil / Topping up .................................................................................................................................212 Gearbox venting .....................................................................................................................................................212 TRAVEL GEARBOX ..........................................................................................................................................................213 Travel gearbox - Checking the oil level / Topping up with oil .......................................................................................................213 Travel gearbox - Changing oil .......................................................................................................................................214 Draining off oil.................................................................................................................................................214 Filling in oil...................................................................................................................................................214 Travel gearbox, breather filter .....................................................................................................................................214 CRAWLER TRACKS ..........................................................................................................................................................215 Cleaning ............................................................................................................................................................215 Track roller, Support roller ........................................................................................................................................216 Track roller fastening ..........................................................................................................................................216 Support roller fastening ........................................................................................................................................216 Track pads fastening ............................................................................................................................................216 Track tensioner .....................................................................................................................................................217 Design ..........................................................................................................................................................217 Techncal data ...................................................................................................................................................217 Function ........................................................................................................................................................217 Pressure-accumulator inspection regulations .........................................................................................................................218 Extract from the German regulations..............................................................................................................................218 Extract from the German acceptance regulations...................................................................................................................218 Checking the gas charging pressure in the pressure accumulator.......................................................................................................218 SWING RING ..............................................................................................................................................................219 Swing ring - Instructions............................................................................................................................................219 Bearing races .......................................................................................................................................................219 Internal gearing.................................................................................................................................................219 Swing ring - Checking the grease filling.........................................................................................................................220 Swing ring - Filling in grease...................................................................................................................................220 Swing ring - Checking the bolts for tightness....................................................................................................................220 CENTRAL LUBRICATING SYSTEM, STANDARD ....................................................................................................................................221 Design ..............................................................................................................................................................221 Function ............................................................................................................................................................222 Replacing the grease container ......................................................................................................................................223 Filling up the grease container .....................................................................................................................................223 Checking the greasing pressure ......................................................................................................................................224 Unblocking a grease line ............................................................................................................................................224 Cleaning ........................................................................................................................................................224 Oilfilter (hydraulic circuit grease pump) )..........................................................................................................................225 Replacing the filter element.....................................................................................................................................225 Grease filter (Filling the grease container) .......................................................................................................................226 Checking the filter element......................................................................................................................................226 Replacing the filter element.....................................................................................................................................226 Grease filter (Grease lines) ........................................................................................................................................227 Checking the filter element......................................................................................................................................227 Replacing the filter element.....................................................................................................................................227 OTHER MAINTENANCE .......................................................................................................................................................228 Engine ..............................................................................................................................................................228 Cleaning ........................................................................................................................................................228 Before cleaning the engines......................................................................................................................................228 Means of fastening ..............................................................................................................................................228 Cooling system ..................................................................................................................................................228 Exhaust system ..................................................................................................................................................228 Heating and air conditioning ........................................................................................................................................228 HYDRAULIC LADDER ........................................................................................................................................................229 Pressure-accumulator inspection regulations ........................................................................................................................230 Extract from the German regulations..............................................................................................................................230 Extract from the German acceptance regulations...................................................................................................................230 Checking the gas charging pressure in the pressure accumulator...................................................................................................230 PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING ..............................................................................................................231 Putting the excavator out of operation ..............................................................................................................................231 Battery storage .....................................................................................................................................................231 Recommissioning .....................................................................................................................................................231 NOTES ...................................................................................................................................................................233 4 REPAIR WORK................................................................................................................................................................235 REPAIR WORK - SAFETY INSTRUCTIONS........................................................................................................................................237 Operating instructions...............................................................................................................................................237 Repair personnel.....................................................................................................................................................237 Working in greater heights...........................................................................................................................................237 Prestressed units....................................................................................................................................................237 Dismantling components...............................................................................................................................................237 Never remove lead seals..............................................................................................................................................238 After the repair work................................................................................................................................................238 REPAIR WORK, FIRE AND EXPLOSION HAZARD ..................................................................................................................................239 ENGINE, REPAIR WORK .....................................................................................................................................................240 Before cleaning the engines..........................................................................................................................................240 ELECTRICAL SYSTEM .......................................................................................................................................................241 Assisted starting (with jumper cables) – Safety instructions ........................................................................................................241 Assisted starting (with jumper cables)...............................................................................................................................241 Prior to assisted starting ......................................................................................................................................241 Starting the engine with jumper cables (external batteries ..........................................................................................................241 Connecting the jumper cables ....................................................................................................................................242 Starting up the engine ..........................................................................................................................................242 Disconnecting the jumper cables .................................................................................................................................242 HYDRAULIC SYSTEM ........................................................................................................................................................243 Repair instructions .................................................................................................................................................243 Hydraulic hoses – Instructions .....................................................................................................................................243 PRESSURE ACCUMULATORS - SAFETY INSTRUCTIONS .............................................................................................................................244 WELDING AND FLAME CUTTING WORKS - SAFETY INSTRUCTIONS ...................................................................................................................245 Welding work by qualified personnel only.............................................................................................................................245 Increased risk of fire during welding work...........................................................................................................................245 Health hazards.......................................................................................................................................................245 Tanks, pressure vessels and pressure accumulators....................................................................................................................246 Slewing rings and articulated joints.................................................................................................................................246 Information relating to the electrical system and to electronic modules..............................................................................................246 Welding on the counterweight.........................................................................................................................................247 Welding on components of the working equipment and on other fully or partly closed steel structures..................................................................247 Welding on the cab...................................................................................................................................................247 Further information..................................................................................................................................................247 DISPOSAL AT THE END OF THE SERVICE LIFE .................................................................................................................................248 Dismantling and removal instructions ................................................................................................................................248 Risk of deflagrations ...............................................................................................................................................248 Risk of fire ........................................................................................................................................................248 Disposing of the machine without polluting the environment ..........................................................................................................248 Further hazardous substances ........................................................................................................................................249 Appropriate disposal of batteries ...................................................................................................................................249 NOTES ...................................................................................................................................................................251 5 ANNEX......................................................................................................................................................................253 TROUBLESHOOTING .........................................................................................................................................................255 Instructions on troubleshooting .....................................................................................................................................255 Layout of the fault table ...........................................................................................................................................255 Fault............................................................................................................................................................255 Possible causes .................................................................................................................................................255 Measures ........................................................................................................................................................255 Section..........................................................................................................................................................255 FAULT TABLES ............................................................................................................................................................256 Combustion engine - Fault table .....................................................................................................................................256 Working hydraulics – Fault table ....................................................................................................................................257 Track drive – Fault table ...........................................................................................................................................258 Swing mechnism – Fault table ........................................................................................................................................259 Central lubricating system – Fault table ............................................................................................................................260 HYDRAULIC CIRCUIT DIAGRAM ...............................................................................................................................................261 ABBREVIATIONS ...........................................................................................................................................................262 ABBREVIATIONS........................................................................................................................................................263 PRODUCT SPECIFICATION SHEET .............................................................................................................................................265 6018-6018FS-MediumSpecalog_AEHQ7076-00.pdf...........................................................................................................................267 6018/6018 FS Hydraulic Shovel....................................................................................................................................267 Features.....................................................................................................................................................267 Specifications...............................................................................................................................................268 General Data.............................................................................................................................................268 Features.................................................................................................................................................268 Operating Weight.........................................................................................................................................268 Diesel Engines...........................................................................................................................................268 Electric Motor – 6018 AC/6018 AC FS......................................................................................................................268 Electrical System (diesel drive).........................................................................................................................268 Hydraulic System with Pump Managing System...............................................................................................................269 Hydraulic Oil Cooling....................................................................................................................................269 Swing System.............................................................................................................................................269 Retractable Service Station..............................................................................................................................269 Operator’s Cab...........................................................................................................................................270 Undercarriage............................................................................................................................................270 Automatic Lubrication System.............................................................................................................................270 Attachments..............................................................................................................................................270 Dimensions...............................................................................................................................................271 Working Range – TriPower Face Shovel Attachment (FS).....................................................................................................272 Working Range – Backhoe Attachment (BH)..................................................................................................................273 General Packing List.....................................................................................................................................274 TriPower Shovel Attachment...............................................................................................................................276 Backhoe Attachment.......................................................................................................................................277 Optional Equipment...........................................................................................................................................278 NOTES ...................................................................................................................................................................279 6 INDEX......................................................................................................................................................................281
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