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CAT 6060 AC 6060 AC FS Hydraulic Shovel Operation & Maintenance Manual BI015416 – PDF DOWNLOAD
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CAT 6060 AC 6060 AC FS Hydraulic Shovel Operation & Maintenance Manual BI015416 – PDF DOWNLOAD
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Description
CAT 6060 AC 6060 AC FS Hydraulic Shovel Operation & Maintenance Manual BI015416 – PDF DOWNLOAD
FILE DETAILS:
CAT 6060 AC 6060 AC FS Hydraulic Shovel Operation & Maintenance Manual BI015416 – PDF DOWNLOAD
Language : English
Pages : 270
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
CAT 6060 AC 6060 AC FS Hydraulic Shovel Operation & Maintenance Manual BI015416 – PDF DOWNLOAD
PREFACE:
- This Operation and Maintenance Manual is de- signed to familiarize the operator with the
machine and its designated use. - The Operation and Maintenance Manual contain important information on how to operate the
machine safely, properly and with maximum efficiency. Observing these instructions helps to
prevent haz- ardous situations, to reduce repair costs and down- times 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 al- ways be available in the operator’s cab of the
machine.
The Operation and Maintenance Manual must be read and put into practice by any person in
charge of carrying out work with or on the machine, such as
▪ operation, including setting-up, troubleshooting in the course of work, care,
evacuation of pro- duction waste and disposal of fuels and con- sumables,
▪ 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 ma- chine is to be used, the generally recognized tech- nical 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 Maintenance Manual. - All CGM HMS GmbH Operation and Maintenance Manuals are issued in German and then translated.
Even a good translation may give rise to questions which CGM HMS GmbH will be pleased to answer. - The Operation and Maintenance Manual are not work instructions for carrying out major
repairs. Such work is willingly done fo you by the CGM
HMS GmbH after-sales service.
TABLE OF CONTENTS:
CAT 6060 AC 6060 AC FS Hydraulic Shovel Operation & Maintenance Manual BI015416 – PDF DOWNLOAD
TITLEPAGE..................................................................................................................................................................... 1 1 INTRODUCTION................................................................................................................................................................ 11 PREFACE .................................................................................................................................................................. 13 Further machine documentation ........................................................................................................................................ 13 WARRANTY ................................................................................................................................................................. 14 FUNDAMENTAL SAFETY INSTRUCTIONS........................................................................................................................................... 15 Warnings and symbols.................................................................................................................................................. 15 DESIGNATED USE............................................................................................................................................................ 16 ORGANIZATIONAL MEASURES .................................................................................................................................................. 17 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 / pneumatc equipment ....................................................................................................................................... 21 Noise ................................................................................................................................................................ 21 Oil, grease and other chemical substances ............................................................................................................................ 21 Transporting and recommissioning ..................................................................................................................................... 21 ACCIDENT PREVENTION REGULATIONS FOR ELECTRICALLY POWERED EXCAVATORS ...................................................................................................... 22 Safety instructions for excavators with electric motor ............................................................................................................... 23 In the transformer station........................................................................................................................................ 23 On the excavator.................................................................................................................................................. 23 FIRE AND EXPLOSION HAZARD ................................................................................................................................................ 24 NOTES .................................................................................................................................................................... 25 2 OPERATION................................................................................................................................................................... 27 OPERATION - SAFETY INSTRUCTIONS .......................................................................................................................................... 29 Operation and Maintenance Manual...................................................................................................................................... 29 Operating personnel................................................................................................................................................... 29 Personal protective gear and working clothing......................................................................................................................... 29 Safety belt........................................................................................................................................................... 29 State of the machine.................................................................................................................................................. 29 Entering and leaving the machine...................................................................................................................................... 29 Hazard range.......................................................................................................................................................... 29 Persons within the hazard zone........................................................................................................................................ 30 Marshallers........................................................................................................................................................... 30 Securing the machine.................................................................................................................................................. 30 Operation and Maintenance Manual, where to store it in the operator’s cab ............................................................................................ 30 FIRE AND EXPLOSION HAZARD ................................................................................................................................................ 31 DESCRIPTION OF THE EXCAVATOR.............................................................................................................................................. 32 Excavator layout ..................................................................................................................................................... 33 Undercarriage..................................................................................................................................................... 33 Superstructure.................................................................................................................................................... 33 Loading bucket.................................................................................................................................................... 33 Undercarriage ........................................................................................................................................................ 34 Superstructure ....................................................................................................................................................... 34 Drive ................................................................................................................................................................ 34 Hydraulic system ..................................................................................................................................................... 34 Control and Monitoring Platform (CAMP) ............................................................................................................................... 34 Demand control / Zero-flow regulation ................................................................................................................................ 35 Automatic reset to idling............................................................................................................................................. 35 Board-Control-System (BCS) ........................................................................................................................................... 35 Electrical system .................................................................................................................................................... 35 Power supply ......................................................................................................................................................... 36 Operation with cable reel (optional) ................................................................................................................................. 37 Automatic operation............................................................................................................................................... 37 Manual operation.................................................................................................................................................. 37 Signs ................................................................................................................................................................ 38 Warning and instruction signs..................................................................................................................................... 38 Machine number.................................................................................................................................................... 46 Motor number...................................................................................................................................................... 46 Component numbers................................................................................................................................................. 46 Entering and leaving the machine Safety instructions ................................................................................................................. 47 Access ladder lighting ............................................................................................................................................... 47 Folding ladder ....................................................................................................................................................... 48 Swinging ladder (optional) ........................................................................................................................................... 49 Emergency exit in operator’s cab and escape ladder ................................................................................................................... 50 Switching the cab interior lighting on and off ....................................................................................................................... 51 Switching the maintenance lights on and off .......................................................................................................................... 52 EMERGENCY STOP switch ................................................................................................................................................ 53 Servicing switch ..................................................................................................................................................... 54 Windscreen washer .................................................................................................................................................... 54 Operator's seat ..................................................................................................................................................... 55 Fire extinguisher .................................................................................................................................................... 57 Extinguishing agent .............................................................................................................................................. 57 Handling.......................................................................................................................................................... 57 Inspection........................................................................................................................................................ 57 Automatic fire-extinguishing system (optional) ....................................................................................................................... 58 Inspection........................................................................................................................................................ 58 Trainer's / instructor's seat ........................................................................................................................................ 58 Emergency escape device (optional) ................................................................................................................................... 59 Elements of the harness........................................................................................................................................... 59 Important hints................................................................................................................................................... 59 Taking on harness................................................................................................................................................. 60 MONITORING, WARNING AND CONTROL ELEMENTS ................................................................................................................................. 62 Optional equipment: Air conditioning.................................................................................................................................. 79 PUTTING THE MACHINE INTO OPERATION ....................................................................................................................................... 80 Service station (tanklift) ........................................................................................................................................... 80 Lowering the service station ..................................................................................................................................... 80 Raising the service station ...................................................................................................................................... 80 Refilling and draining ........................................................................................................................................... 80 Battery main switch, switching on and off ............................................................................................................................ 83 Switching the battery main switch on.............................................................................................................................. 83 Switching the battery main switch off............................................................................................................................. 83 Electrical system (24V), switching on and off ........................................................................................................................ 83 Switching the electrical system (24V) on.......................................................................................................................... 83 Switching the electrical system (24V) off......................................................................................................................... 83 Switching the electric motor on and off .............................................................................................................................. 84 Before switching on the electric motor............................................................................................................................ 84 Switching the electric motor on................................................................................................................................... 84 Switching the electric motor off.................................................................................................................................. 85 Time-out before restart .............................................................................................................................................. 85 Electric motor can not be switched on ................................................................................................................................ 86 In case of failure ................................................................................................................................................... 86 Circuit breaker, switching on and off ................................................................................................................................ 87 Motor protection relay, functions .................................................................................................................................... 88 Front panel control and monitoring elements ...................................................................................................................... 89 Air conditioner (optional) ........................................................................................................................................... 90 Ventilation / Heating ............................................................................................................................................ 90 Control panel (SIGMA) ............................................................................................................................................ 90 Back-up heating operator’s cab (optional) ............................................................................................................................ 90 TRAVELLING, SAFETY INSTRUCTIONS .......................................................................................................................................... 91 Trailing cable........................................................................................................................................................ 91 TRAVELLING ............................................................................................................................................................... 92 Superstructure basic position ........................................................................................................................................ 92 Travelling forwards/backwards ........................................................................................................................................ 92 Regulating the travelling speed .................................................................................................................................. 93 Travelling uphill and downhill ................................................................................................................................... 93 Cornering ........................................................................................................................................................ 94 Turning .......................................................................................................................................................... 94 Note.............................................................................................................................................................. 94 Travelling over long distances ................................................................................................................................... 95 Superstructure holding brake ......................................................................................................................................... 96 Track parking brake .................................................................................................................................................. 96 TRANSPORTING THE MACHINE ................................................................................................................................................. 97 Transport - Safety instructions ...................................................................................................................................... 97 Transport ........................................................................................................................................................ 97 WORKING OPERATION - SAFETY INSTRUCTIONS .................................................................................................................................. 98 Running-in instructions for hydraulic cylinders....................................................................................................................... 98 Avoid extreme positions of the attachment............................................................................................................................. 99 WORKING OPERATION ........................................................................................................................................................100 Before starting work .................................................................................................................................................100 Warming up........................................................................................................................................................100 Activating the electronic servo control ..............................................................................................................................100 Swinging the superstructure ..........................................................................................................................................101 Braking the superstructure ...........................................................................................................................................101 Working ..............................................................................................................................................................102 Extending and retracting the bucket or backhoe bucket stick ......................................................................................................102 Opening and closing the bottom-dump bucket .......................................................................................................................102 Raising and lowering the boom ....................................................................................................................................102 Filling and emptying the bucket or the backhoe ...................................................................................................................102 Emergency lowering of the working equipment ..........................................................................................................................103 After daily operation ................................................................................................................................................104 Parking the machine ..............................................................................................................................................104 ASSEMBLING WORKING EQUIPMENT – SAFETY INSTRUCTIONS .......................................................................................................................105 Personel..............................................................................................................................................................105 Personal protective gear and working clothes..........................................................................................................................105 Tools and auxiliaries.................................................................................................................................................105 Securing the working equipment........................................................................................................................................105 Securing the machine..................................................................................................................................................105 Selecting the attachments.............................................................................................................................................105 Protective roof against falling objects...............................................................................................................................105 Securing the machine .................................................................................................................................................106 Risk of injury....................................................................................................................................................106 CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS) ...........................................................................................................107 Application of GLEITMO 815............................................................................................................................................107 ON-BOARD CRANE (OPTIONAL) ................................................................................................................................................108 Personel..............................................................................................................................................................108 On-board crane, monitoring, warning and control elements .............................................................................................................108 On-board crane, putting into operation ...............................................................................................................................109 On-board crane, drive unit ...........................................................................................................................................109 On-Board crane, – blocking the boom in position of rest ..............................................................................................................110 On-board crane, checking .............................................................................................................................................110 Extract from the inspection and testing regulations...............................................................................................................110 Monitoring cameras ...................................................................................................................................................111 NOTES ...................................................................................................................................................................113 3 INSPECTION AND SERVICING....................................................................................................................................................115 SAFETY INSTRUCTIONS FOR EXCAVATORS WITH ELECTRIC MOTOR ...................................................................................................................117 In the transformer station............................................................................................................................................117 On the excavator......................................................................................................................................................117 In the transformer station............................................................................................................................................117 On the hydraulic excavator............................................................................................................................................117 On the hydraulic excavator............................................................................................................................................117 INSPECTION AND SERVICING – SAFETY INSTRUCTIONS ...........................................................................................................................118 Operating manual......................................................................................................................................................118 Inspection and servicing personnel....................................................................................................................................118 Personal protective equipment and working clothing....................................................................................................................118 Securing the working equipment........................................................................................................................................118 Securing the machine..................................................................................................................................................118 Climbing onto and off the machine.....................................................................................................................................118 Checking the state of tools...........................................................................................................................................118 Cleaning jobs.........................................................................................................................................................118 Handling flammable liquids............................................................................................................................................119 Fastening and securing elements.......................................................................................................................................119 Spare parts...........................................................................................................................................................119 Handling oils and greases.............................................................................................................................................119 Visisble oil losses...................................................................................................................................................119 Relieving residual pressure in the hydraulic system...................................................................................................................119 Screwed connections, piping, hydraulic hoses..........................................................................................................................119 Non-polluting disposal................................................................................................................................................120 Seals.................................................................................................................................................................120 Handling batteries....................................................................................................................................................120 Before working on the electrical system...............................................................................................................................120 Selecting oils and greases............................................................................................................................................121 Filters...............................................................................................................................................................121 Sealing elements......................................................................................................................................................121 Oil-level check and oil change........................................................................................................................................121 Lubricating...........................................................................................................................................................121 After servicing.......................................................................................................................................................121 FIRE AND EXPLOSION HAZARD ................................................................................................................................................122 INSPECTION AND SERVICING PLANS – INSTRUCTIONS ............................................................................................................................123 Servicing Intervals ..................................................................................................................................................123 Oils / Greases .......................................................................................................................................................123 Cleaning jobs ........................................................................................................................................................123 Components ...........................................................................................................................................................123 Plan V ...............................................................................................................................................................125 Plan N ...............................................................................................................................................................127 Plan T and W .........................................................................................................................................................129 Plan A – E ...........................................................................................................................................................131 LUBRICATING CHART – GREASE ...............................................................................................................................................138 Lubricating chart – Grease (legend) ..................................................................................................................................139 Filling quantities – Grease ..........................................................................................................................................139 INSPECTION PLAN - OIL ....................................................................................................................................................140 Inspection plan – Oil (legend) .......................................................................................................................................141 Filling quantities - oil .............................................................................................................................................142 Filling quantities - other............................................................................................................................................142 LUBRICANTS ...............................................................................................................................................................143 Notes on the selection of oils and greases ...........................................................................................................................143 Original CGM HMS GmbH oils and greases............................................................................................................................143 Alternative oils and greases......................................................................................................................................143 Avoid mixing of different hydraulic fluids ...........................................................................................................................143 LUBRICANTS / CONSUMABLES .................................................................................................................................................144 I. Oil for combustion engines (On-Board Crane, option) ...............................................................................................................144 II. Oil for hydraulic system (selection) .............................................................................................................................145 III.a Oil for pump gearboxes and travel gearboxes ....................................................................................................................146 III.b Oil for swing gearboxes ........................................................................................................................................147 V. Grease for bearings, swing rings and track system (Central lubrication system) ....................................................................................148 Greases for idlers, track rollers and support rollers (Lifetime lubrication) .........................................................................................149 SERVICING WORK ...........................................................................................................................................................150 Hose line for oil changes ............................................................................................................................................150 ELECTRIC MOTOR ...........................................................................................................................................................151 Electric motor - Safety instructions .................................................................................................................................151 Cleaning the electric motor .........................................................................................................................................151 Electric motor, greasing .............................................................................................................................................152 Additional servicing work.........................................................................................................................................152 ELECTRICAL SYSTEM .......................................................................................................................................................153 Electrical system - Safety instructions ..............................................................................................................................153 Battery, checking state of charge ....................................................................................................................................154 Checking the battery fluid level .................................................................................................................................154 Checking charge of the battery ...................................................................................................................................154 Charging the batteries............................................................................................................................................155 Removing and installing the battery ..............................................................................................................................155 Electrical system, control cabinets ..................................................................................................................................156 Breather filter ..................................................................................................................................................156 Emptying the dust trap ...........................................................................................................................................156 Emptying the dust collector.......................................................................................................................................156 Filter element, clean / replace...................................................................................................................................156 Checking and cleaning the filter element .........................................................................................................................157 Replacing filter mats.............................................................................................................................................157 Draining water from the switchgear cabinet........................................................................................................................157 Slip ring assembly, servicing work ...................................................................................................................................158 Electrical circuit diagrams ..........................................................................................................................................158 Replacing fuses ......................................................................................................................................................158 Replacing lamps and bulbs ............................................................................................................................................158 Xenon floodlight projector (optional), replacing the lamp ............................................................................................................159 Safety instructions...............................................................................................................................................159 Further instructions..............................................................................................................................................159 Replacing a defective Xenon-lamp..................................................................................................................................160 Lighting systems in LED technonogy, instructions .....................................................................................................................161 HYDRAULIC SYSTEM .........................................................................................................................................................162 Hydraulic system - Safety instructions ...............................................................................................................................162 Depressurizing the hydraulic system ..................................................................................................................................162 Checking the hydraulic oil level .....................................................................................................................................163 Hydraulic oil return-flow filters, replace ...........................................................................................................................165 Remove return flow filter elements................................................................................................................................165 Install return flow filter elements...............................................................................................................................166 Remove filter-basket, inspect / clean.............................................................................................................................166 Hydraulic oil return-flow filters, replace (from machine no. 340169) .................................................................................................167 Remove return flow filter elements................................................................................................................................167 Install return flow filter elements...............................................................................................................................168 Remove filter-basket, inspect / clean.............................................................................................................................168 Bypass valves, clean / replace .......................................................................................................................................169 Cleaning the filter screens.......................................................................................................................................169 Replacing the bypass valves and sealing rings ....................................................................................................................169 Hydraulic oil tank breather filters, replace .........................................................................................................................170 Replacing the filter elements ....................................................................................................................................170 Filter (servo control circuit), replace ..............................................................................................................................171 Replacing the filter element......................................................................................................................................171 High-pressure filter for working hydraulics, replace .................................................................................................................172 Replacing the filter elements ....................................................................................................................................172 Filters for swing charge pump, replace ...............................................................................................................................173 Replacing the filter elements.....................................................................................................................................173 Changing the hydraulic oil ...........................................................................................................................................174 Avoid mixing of different hydraulic fluids ...........................................................................................................................174 Draining off hydaulic oil using the Service Station (tanklift)....................................................................................................175 Cleaning the hydraulic oil reservoir .............................................................................................................................175 Filling in hydraulic oil using the service station................................................................................................................176 Filling in hydraulic oil through the return-flow filters..........................................................................................................177 Venting the hydraulic system..........................................................................................................................................178 Venting the hydraulic components..................................................................................................................................178 Cleaning the hydraulic oil cooler.....................................................................................................................................179 Cleaning..........................................................................................................................................................179 Electronic excavator control..........................................................................................................................................180 Joystick .........................................................................................................................................................180 Pedal.............................................................................................................................................................180 Pressure accumulator - Emergency lowering.............................................................................................................................181 Pressure-accumulator inspection regulations ......................................................................................................................181 Extract from the German regulations...............................................................................................................................181 Extract from the German acceptance regulations....................................................................................................................181 PUMP DRIVE GEARBOX .......................................................................................................................................................182 Pump drive gearbox, checking oil level / Topping up with oil .........................................................................................................182 Topping up with oil...............................................................................................................................................183 Pump drive gearbox, changing oil .....................................................................................................................................184 Drawing off gearbox oil...........................................................................................................................................184 Filling in gearbox oil ...........................................................................................................................................184 Pump drive gearbox, pre-chamber ......................................................................................................................................185 Checking oil level, topping up with oil...........................................................................................................................185 Pump drive gearbox, venting ..........................................................................................................................................185 Pre-chambers working pumps, draining oil, changing oil ...............................................................................................................186 Pre-chambers swing pumps, draining oil, changing oil .................................................................................................................186 Pump gearbox, oil filter .............................................................................................................................................187 Check the gear oil filter.........................................................................................................................................187 Changing filter element...........................................................................................................................................187 SWING GEARBOX ............................................................................................................................................................188 Swing gearbox - Checking the oil level / Topping up with oil .........................................................................................................188 Changing the gearbox oil .............................................................................................................................................188 Draining off oil .................................................................................................................................................188 Filling in new oil / Topping up ..................................................................................................................................189 Swing gearbox, venting ,..............................................................................................................................................189 TRAVEL GEARBOX (GEARBOX P/N 3683483) ....................................................................................................................................190 Travel gearbox - Checking the oil level / Topping up with oil ........................................................................................................190 Spur gear section - Checking the oil level / Topping up with oil .................................................................................................190 Brake housing - Checking the oil level / Topping up with oil .....................................................................................................190 Travel gearbox - Changing oil ........................................................................................................................................191 Draining off oil..................................................................................................................................................191 Filling in oil ...................................................................................................................................................191 Spur gear section - Changing the oil / Draining off oil...........................................................................................................191 Filling in oil ...................................................................................................................................................191 Brake housing - Changing oil .....................................................................................................................................192 Draining off oil..................................................................................................................................................192 Filling in oil ...................................................................................................................................................192 Travel gearbox - Breather filter .....................................................................................................................................192 TRAVEL GEARBOX(GEARBOX P/N 3683496) .....................................................................................................................................193 Travel gearbox - Checking the oil level / Topping up with oil ........................................................................................................193 Alternatively:....................................................................................................................................................193 Hydraulic motor chamber / Brake housing - Checking the oil level / Topping up with oil ...........................................................................194 Travel gearbox - Changing oil ........................................................................................................................................195 Draining off oil .................................................................................................................................................195 Filling in oil ...................................................................................................................................................195 Hydraulic motor chamber / Brake housing - Changing oil ...........................................................................................................196 Draining off oil..................................................................................................................................................196 Filling in oil ...................................................................................................................................................196 Travel gearbox -Breather filter ......................................................................................................................................196 TRAVEL GEARBOX(GEARBOX P/N 3749598) .....................................................................................................................................197 Travel gearbox - Checking the oil level / Topping up with oil ........................................................................................................197 Alternatively:....................................................................................................................................................197 Travel gearbox - Changing oil ........................................................................................................................................199 Draining off oil .................................................................................................................................................199 Filling in oil ...................................................................................................................................................199 Hydraulicmotor chamber - Brake housing - Changing oil ............................................................................................................200 Draining off oil..................................................................................................................................................200 Filling in oil ...................................................................................................................................................200 Travel gearbox - Breather filter .....................................................................................................................................200 CRAWLER TRACKS ...........................................................................................................................................................201 Cleaning .............................................................................................................................................................201 Track rollers ........................................................................................................................................................202 Track roller fastening ...........................................................................................................................................202 Support roller fastening .........................................................................................................................................202 Track tensioner ......................................................................................................................................................203 Function .........................................................................................................................................................203 Pressure-accumulator inspection regulations ..........................................................................................................................204 Extract from the German regulations...............................................................................................................................204 Extract from the German acceptance regulations....................................................................................................................204 Checking the gas charging pressure in the pressure accumulator........................................................................................................204 SWING RING ...............................................................................................................................................................205 Swing ring - Instructions.............................................................................................................................................205 Bearing races.........................................................................................................................................................205 Internal gearing..................................................................................................................................................205 Swing ring - Checking the grease filling..........................................................................................................................206 Swing ring - Filling in grease....................................................................................................................................206 Swing ring - Checking the bolts for tightness.....................................................................................................................206 CENTRAL LUBRICATING ......................................................................................................................................................207 Design and function ..................................................................................................................................................207 Function .............................................................................................................................................................208 Filling up the grease container ......................................................................................................................................209 Breather filter ......................................................................................................................................................209 Checking the greasing pressure .......................................................................................................................................210 Checking the greasing pressure .......................................................................................................................................211 Unblocking a grease line..............................................................................................................................................212 Cleaning .........................................................................................................................................................212 Unblocking a grease line..............................................................................................................................................212 Cleaning .........................................................................................................................................................212 Oilfilter (hydraulic circuit grease pump) )...........................................................................................................................213 Replacing the filter element......................................................................................................................................213 Grease filter (Filling the grease container) .........................................................................................................................214 Checking the filter element.......................................................................................................................................214 Replacing the filter element......................................................................................................................................214 Grease filter (Grease lines) .........................................................................................................................................215 Checking the filter element.......................................................................................................................................215 Replacing the filter element......................................................................................................................................215 OTHER MAINTENANCE ........................................................................................................................................................216 Heating and air conditioning .........................................................................................................................................216 Equipment, check for cracks ..........................................................................................................................................216 Reservoirs for used grease at the A-frame, emptying ..................................................................................................................217 Hydraulic ladder, pressure accumulator ...............................................................................................................................217 Pressure-accumulator inspection regulations ..........................................................................................................................218 Extract from the regulations..........................................................................................................................................218 Extract from the German acceptance regulations....................................................................................................................218 Checking the gas charging pressure in the pressure accumulator........................................................................................................218 ON-BOARD CRANE, DRIVE UNIT ...............................................................................................................................................219 Crane engine..........................................................................................................................................................219 Hydraulic system......................................................................................................................................................219 On-board crane, lubricating ..........................................................................................................................................220 Servicing work....................................................................................................................................................220 On-Board crane, checking tightness of fastening bolts ................................................................................................................220 PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING ...............................................................................................................221 Putting the excavator out of operation................................................................................................................................221 Battery storage.......................................................................................................................................................221 Recommissioning ......................................................................................................................................................221 NOTES ....................................................................................................................................................................222 4 REPAIR WORK.................................................................................................................................................................223 SAFETY INSTRUCTIONS FOR EXCAVATORS WITH ELECTRIC MOTOR ...................................................................................................................225 In the transformer station............................................................................................................................................225 On the excavator......................................................................................................................................................225 In the transformer station............................................................................................................................................225 On the hydraulic excavator............................................................................................................................................225 REPAIR WORK - SAFETY INSTRUCTIONS.........................................................................................................................................226 Operation and Maintenance Manual......................................................................................................................................226 Repair personnel......................................................................................................................................................226 Working in greater heights............................................................................................................................................226 Prestressed units.....................................................................................................................................................226 Dismantling components................................................................................................................................................226 Never remove lead seals...............................................................................................................................................226 After the repair work.................................................................................................................................................226 FIRE AND EXPLOSION HAZARD ................................................................................................................................................227 HYDRAULIC SYSTEM..........................................................................................................................................................228 Repair ...............................................................................................................................................................228 Hydraulic hoses – Instructions ......................................................................................................................................228 PRESSURE ACCUMULATORS - SAFETY INSTRUCTIONS...............................................................................................................................229 WELDING AND FLAME CUTTING WORKS - SAFETY INSTRUCTIONS ....................................................................................................................230 Welding work by qualified personnel only..............................................................................................................................230 Increased risk of fire during welding work............................................................................................................................230 Health hazards........................................................................................................................................................230 Tanks, pressure vessels and pressure accumulators.....................................................................................................................231 Slewing rings and articulated joints..................................................................................................................................231 Information relating to the electrical system and to electronic modules...............................................................................................231 Welding on the counterweight..........................................................................................................................................232 Welding on components of the working equipment and on other fully or partly closed steel structures...................................................................232 Welding on the cab....................................................................................................................................................232 Further information...................................................................................................................................................232 DISPOSAL AT THE END OF THE SERVICE LIFE ..................................................................................................................................233 Dismantling and removal instructions .................................................................................................................................233 Risk of deflagrations ................................................................................................................................................233 Risk of fire .........................................................................................................................................................233 Disposing of the machine without polluting the environment ...........................................................................................................233 Further hazardous substances .........................................................................................................................................234 Appropriate disposal of batteries ....................................................................................................................................234 NOTES ....................................................................................................................................................................235 5 ANNEX.......................................................................................................................................................................237 TROUBLESHOOTING ..........................................................................................................................................................239 Instructions on troubleshooting ......................................................................................................................................239 Layout of the fault table ............................................................................................................................................239 Fault.............................................................................................................................................................239 Possible causes ......................................................................................................................................................239 Measures .............................................................................................................................................................239 Section ..............................................................................................................................................................239 FAULT TABLES .............................................................................................................................................................240 Working hydraulics – Fault table .....................................................................................................................................240 Track drive – Fault table ............................................................................................................................................241 Swing mechnism – Fault table .........................................................................................................................................242 Central lubricating system – Fault table .............................................................................................................................243 HYDRAULIC CIRCUIT DIAGRAM ................................................................................................................................................244 ABBREVIATIONS ............................................................................................................................................................245 ABBREVIATIONS.........................................................................................................................................................246 NOISE AND VIBRATION INFORMATION .........................................................................................................................................247 Noise emission information ...........................................................................................................................................247 Vibration information ................................................................................................................................................247 PRODUCT SPECIFICATION SHEET ..............................................................................................................................................249 NOTES ...................................................................................................................................................................263 6 INDEX.......................................................................................................................................................................265
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