CAT 6015 6015FS Hydraulic Shovel Operation & Maintenance Manual 3847019 - PDF DOWNLOAD

BA 6015(3 847 019.01)-EN 08 / 2013

Operation and Maintenance Manual 6015, 6015FS Hydraulic Shovel

No.

BA 6015(3 847 019.01)-EN

Published by:

Caterpillar Global Mining HMS GmbH Dept. Technical Publications D-44149 Dortmund, Karl-Funke-Straße 36 Tel. 49 (0) 231 922-4340 Fax 49 (0) 231 922-5005 E-Mail dokumentation-HEX@cat.com https://mining.cat.com www.bucyrus-hex.de

© Copyright Caterpillar Global Mining Hydraulic Mining Shovels GmbH 2013. The reproduction, distribution and utilization of this manual / file as well as the communication of its content to others without express authorization is prohibited. Offenders will be held liable for the payment of damages. All rights reserved in the event of the grant of a patent, utility model or design.

Printed in Germany

ii

BA 6015(3 847 019.01)-EN

The Operation and Maintenance Manual is in 6 sections; the sections are designed for different target groups: Operation and Maintenance Manual

Target group

Part 1 INTRODUCTION FUNDAMENTAL SAFETY INSTRUCTIONS

Operating personnel + Inspection and servicing personnel + Repair personnel

Part 2 OPERATION

Operating personnel The operating personnel must have knowhow relevant to the operation and the application of this or comparable machines.

Part 3 INSPECTION AND SERVICING Part 4 REPAIR WORK

Inspection and servicing personnel The inspection and servicing personnel must have know-how relevant to the inspection and servicing of this or comparable machines.

Repair personnel The repair personnel must have know-how and experience relevant to the repair of this or comparable machines.

Part 5 ANNEX

Part 6 INDEX

Operating personnel + Inspection and servicing personnel + Repair personnel Operating personnel + Inspection and servicing personnel + Repair personnel

iii

BA 6015(3 847 019.01)-EN

iv

BA 6015(3 847 019.01)-EN

TABLE OF CONTENTS TABLE OF CONTENTS 1 INTRODUCTION___________________________________________________________________ 1-1 PREFACE ________________________________________________________________________ 1-1 Further machine documentation _____________________________________________________ 1-1 WARRANTY ______________________________________________________________________ 1-2 FUNDAMENTAL SAFETY INSTRUCTIONS _____________________________________________ 1-3 Warnings and symbols _____________________________________________________________ 1-3 Contents of the Declaration of Conformity______________________________________________ 1-3 DESIGNATED USE, UNAUTHORIZED USE _____________________________________________ 1-4 Noise emission information _________________________________________________________ 1-5 Vibration information ______________________________________________________________ 1-5 ORGANIZATIONAL MEASURES ______________________________________________________ 1-6 Personal protective equipment and the working clothing __________________________________ 1-6 Selection and qualification of personnel; basic responsibilities______________________________ 1-7 Safety instructions governing specific operational phases _________________________________ 1-7 Special work in conjunction with utilization of the machine and maintenance and repairs as well as troubleshooting during work; disposal of parts and consumables ____________________________ 1-8 Warning of special dangers _________________________________________________________ 1-9 Transporting and recommissioning __________________________________________________ 1-10 FIRE AND EXPLOSION HAZARD ____________________________________________________ 1-11 NOTES _________________________________________________________________________ 1-13 2 OPERATION ______________________________________________________________________ 2-1 OPERATION - SAFETY INSTRUCTIONS _______________________________________________ 2-3 Operation and Maintenance Manual, where to store it in the operator’s cab ___________________ 2-4 FIRE AND EXPLOSION HAZARD _____________________________________________________ 2-5 DESCRIPTION OF THE EXCAVATOR _________________________________________________ 2-6 Excavator layout__________________________________________________________________ 2-7 Undercarriage ____________________________________________________________________ 2-8 Superstructure ___________________________________________________________________ 2-8 Drive ___________________________________________________________________________ 2-8 Hydraulic system _________________________________________________________________ 2-8 Pump Managing System (PMS)______________________________________________________ 2-8 Programmable Logic Controller (PLC)_________________________________________________ 2-8 Demand control / Zero-flow regulation_________________________________________________ 2-9 Automatic engine speed reduction ____________________________________________________ 2-9 Electrical system__________________________________________________________________ 2-9 Signs__________________________________________________________________________ 2-11 OPERATOR'S CAB ______________________________________________________________ 2-12 Entering and leaving the machine - Safety instructions___________________________________ 2-12 Windscreen washer ______________________________________________________________ 2-13 Operator's seat __________________________________________________________________ 2-14 Adjusting the control consoles ______________________________________________________ 2-15 Trainer's / instructor's seat _________________________________________________________ 2-16 Fire-extinguisher_________________________________________________________________ 2-17 v

BA 6015(3 847 019.01)-EN

TABLE OF CONTENTS MONITORING, WARNING AND CONTROL ELEMENTS__________________________________ 2-18 PUTTING THE MACHINE INTO OPERATION __________________________________________ 2-37 Reducing the operator's exposure to noise ____________________________________________ 2-37 Refuelling ______________________________________________________________________ 2-37 Switching the electrical system on and off _____________________________________________ 2-40 Battery main switch ______________________________________________________________ 2-41 Preheating system for engine and hydraulic oil (optional)_________________________________ 2-42 Fuel preheating system (optional) ___________________________________________________ 2-43 STARTING AND STOPPING THE ENGINE ____________________________________________ 2-44 VENTILATION AND HEATING _______________________________________________________ 2-46 Air conditioner (optional) __________________________________________________________ 2-46 Auxiliary heating (optional)_________________________________________________________ 2-46 MAXIMUM MACHINE INCLINATIONS, INFORMATION ___________________________________ 2-47 TRAVELLING, SAFETY INSTRUCTIONS ______________________________________________ 2-48 Running-in specifications for components of the crawler tracks ____________________________ 2-48 TRAVELLING ____________________________________________________________________ 2-49 Locking the superstructure _________________________________________________________ 2-53 Track parking brake ______________________________________________________________ 2-53 TRANSPORTING THE MACHINE ____________________________________________________ 2-54 Transport - Safety instructions ______________________________________________________ 2-54 WORKING OPERATION ___________________________________________________________ 2-56 SAFETY INSTRUCTIONS _________________________________________________________ 2-56 Before starting work ______________________________________________________________ 2-58 Swinging and braking the superstructure ______________________________________________ 2-59 Working operations_______________________________________________________________ 2-60 After daily operation ______________________________________________________________ 2-61 ASSEMBLING WORKING EQUIPMENT - SAFETY INSTRUCTIONS ________________________ 2-62 Securing the machine_____________________________________________________________ 2-63 CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS) ___________ 2-64 LIFTING OPERATIONS ____________________________________________________________ 2-65 Safety instructions _______________________________________________________________ 2-65 Load-hooks on backhoe buckets. ____________________________________________________ 2-66 NOTES _________________________________________________________________________ 2-71 3 INSPECTION AND SERVICING_______________________________________________________ 3-1 INSPECTION AND SERVICING - SAFETY INSTRUCTIONS________________________________ 3-3 INSPECTION AND SERVICING WORK, FIRE AND EXPLOSION HAZARD____________________ 3-7 ENVIRONMENTALLY COMPATIBLE HYDRAULIC FLUID__________________________________ 3-8 Environmentally compatible hydraulic fluid - Operation and Maintenance Manual ______________ 3-8 Environmentally compatible hydraulic fluid, conversion ___________________________________ 3-8 Environmentally compatible hydraulic fluid - Sampling____________________________________ 3-9

vi

BA 6015(3 847 019.01)-EN

TABLE OF CONTENTS ENVIRONMENT-FRIENDLY LUBRICANTS AND GEARBOX OILS __________________________ 3-10 Lubricants for bearings ____________________________________________________________ 3-10 Gearbox oils ____________________________________________________________________ 3-10 INSPECTION AND SERVICING PLANS - INSTRUCTIONS ________________________________ 3-11 Plan V _________________________________________________________________________ 3-13 Plan N _________________________________________________________________________ 3-15 Plan T and W ___________________________________________________________________ 3-17 Plan A – E______________________________________________________________________ 3-19 LUBRICATING CHART – GREASE ___________________________________________________ 3-24 Lubricating chart – Grease (legend)__________________________________________________ 3-25 Filling quantities - Grease__________________________________________________________ 3-25 INSPECTION PLAN - OIL___________________________________________________________ 3-26 Inspection plan – Oil (legend)_______________________________________________________ 3-27 Filling quantities - oil______________________________________________________________ 3-28 Filling quantities – other ___________________________________________________________ 3-28 LUBRICANTS / CONSUMABLES_____________________________________________________ 3-29 Notes on the selection of oils and greases_____________________________________________ 3-29 Avoid mixing of different hydraulic fluids______________________________________________ 3-29 I. Oils for combustion engine _____________________________________________________ 3-30 II. Fluid for hydraulic system ____________________________________________________ 3-31 III.a Oils for pump distribution gearbox and travel gearbox ____________________________ 3-32 III.b Oils for swing gearbox _____________________________________________________ 3-33 V Greases for bearings and swing rings (Central lubrication system)_____________________ 3-34 Grease for idlers, track rollers and support rollers (Lifetime lubrication)______________________ 3-35 Coolant for use on all combustion engines ____________________________________________ 3-36 SERVICING WORK _______________________________________________________________ 3-37 Hose line for oil and cooling liquid changes____________________________________________ 3-37 ENGINE_________________________________________________________________________ 3-38 Engine - Safety instructions ________________________________________________________ 3-38 Checking the engine oil level / Topping up ____________________________________________ 3-38 Changing the engine oil ___________________________________________________________ 3-39 Replacing the engine oil filters ______________________________________________________ 3-40 Cold-starting fluid (ether) - Replacing the pressure vessel ________________________________ 3-41 COOLING SYSTEM _______________________________________________________________ 3-42 Temperature ____________________________________________________________________ 3-42 Cooler and cooling liquid __________________________________________________________ 3-42 Topping up with coolant ___________________________________________________________ 3-43 Changing the coolant _____________________________________________________________ 3-43 AIR-INTAKE SYSTEM _____________________________________________________________ 3-45 Dust trap, cleaning _______________________________________________________________ 3-45 Main filter elements ______________________________________________________________ 3-46 Secondary filter element __________________________________________________________ 3-48 Air-intake lines __________________________________________________________________ 3-48 FUEL SYSTEM ___________________________________________________________________ 3-49 Fuel system - Safety instructions ____________________________________________________ 3-49 Fuel pre-filter, Draining off water ____________________________________________________ 3-49

vii

BA 6015(3 847 019.01)-EN

TABLE OF CONTENTS Fuel pre-filter, replace ____________________________________________________________ 3-50 Secondary fuel filter, replace _______________________________________________________ 3-51 Fuel tank - Venting _______________________________________________________________ 3-52 Cleaning the fuel tank_____________________________________________________________ 3-52 Refuelling station (optional) ________________________________________________________ 3-53 Water trap (option) _______________________________________________________________ 3-54 ELECTRICAL SYSTEM ____________________________________________________________ 3-56 Electrical system - Safety instructions ________________________________________________ 3-56 Alternator - Instructions ___________________________________________________________ 3-56 Electrical circuit diagrams _________________________________________________________ 3-56 Electrical system switch-cabinets____________________________________________________ 3-56 Replacing lamps and bulbs ________________________________________________________ 3-56 Floodlight projector, safety instructions _______________________________________________ 3-57 Lighting systems in LED technonogy, instructions_______________________________________ 3-59 Battery ________________________________________________________________________ 3-60 Charging batteries inside the machine, safety instructions ________________________________ 3-61 Removing and installing the battery__________________________________________________ 3-62 HYDRAULIC SYSTEM _____________________________________________________________ 3-63 Hydraulic system - Safety instructions ________________________________________________ 3-63 Depressurizing the hydraulic system _________________________________________________ 3-63 Checking the hydraulic oil level _____________________________________________________ 3-64 Topping up with hydraulic oil _______________________________________________________ 3-64 Changing the hydraulic oil return-flow (hydraulic oil reservoir) _____________________________ 3-65 Bypass valves (working circuit) _____________________________________________________ 3-66 Bypass valves (cooling circuit)______________________________________________________ 3-67 Breather filter ___________________________________________________________________ 3-68 High-pressure filter for working hydraulics_____________________________________________ 3-69 High-pressure filter for the servo circuit, replace ________________________________________ 3-70 Filter for swing circuit, replace ______________________________________________________ 3-71 Changing the hydraulic oil _________________________________________________________ 3-72 Avoid mixing of different hydraulic fluids______________________________________________ 3-72 Venting the hydraulic system _______________________________________________________ 3-75 Cleaning the hydraulic oil cooler ____________________________________________________ 3-76 Pressure accumulator_____________________________________________________________ 3-77 PUMP DRIVE GEARBOX ___________________________________________________________ 3-78 Pump drive gearbox - Checking the oil level / Topping up with oil __________________________ 3-78 Pump drive gearbox - Changing the gearbox oil ________________________________________ 3-79 Pump drive gearbox breather, replace________________________________________________ 3-80 Pump drive gearbox oil filter, replace ________________________________________________ 3-81 Pump drive gearbox – take an oil sample _____________________________________________ 3-82 SWING GEARBOX ________________________________________________________________ 3-84 Swing gearbox, checking the oil level / topping up with oil ________________________________ 3-84 Swing gearbox, changing the gearbox oil _____________________________________________ 3-84 Swing gearbox, clean / replace breather ______________________________________________ 3-85 Swing gearbox output pinion, lubricate _______________________________________________ 3-85 TRAVEL GEARBOX (P/N 3712319, 3749594) ___________________________________________ 3-86 Travel gearbox, checking the oil level / topping up with oil ________________________________ 3-86 Travel gearbox, changing the oil ____________________________________________________ 3-86 Travel gearbox, clean / replace breather ______________________________________________ 3-86 viii

BA 6015(3 847 019.01)-EN

TABLE OF CONTENTS TRAVEL GEARBOX (P/N 3709660) ___________________________________________________ 3-87 Travel gearbox, checking the oil level / topping up with oil ________________________________ 3-87 Travel gearbox, changing the oil ____________________________________________________ 3-87 Travel gearbox, clean / replace breather ______________________________________________ 3-87 UNDERCARRIAGE ________________________________________________________________ 3-88 Tracks, cleaning _________________________________________________________________ 3-88 Track rollers, support rollers, track pads ______________________________________________ 3-89 Track tensioner __________________________________________________________________ 3-90 Pressure-accumulator inspection regulations __________________________________________ 3-91 Checking the gas charging pressure in the pressure accumulator __________________________ 3-91 SWING RING ____________________________________________________________________ 3-92 Swing ring - Instructions ___________________________________________________________ 3-92 Swing ring, bearing races __________________________________________________________ 3-92 CENTRAL LUBRICATING __________________________________________________________ 3-94 Design and function ______________________________________________________________ 3-94 Greasing cycle __________________________________________________________________ 3-96 Venting the grease pump __________________________________________________________ 3-98 Venting the grease lines ___________________________________________________________ 3-98 Unblocking a grease line __________________________________________________________ 3-98 Cleaning the grease sieves ________________________________________________________ 3-99 Lubricating the grease distributor of the working equipment _______________________________ 3-99 OTHER MAINTENANCE___________________________________________________________ 3-100 Heating and air conditioning_______________________________________________________ 3-100 PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING _____________ 3-101 Putting the excavator out of operation _______________________________________________ 3-101 Battery storage _________________________________________________________________ 3-101 Recommissioning _______________________________________________________________ 3-101 NOTES ________________________________________________________________________ 3-103 4 REPAIR WORK____________________________________________________________________ 4-1 REPAIR WORK - SAFETY INSTRUCTIONS_____________________________________________ 4-3 REPAIR WORK, FIRE AND EXPLOSION HAZARD _______________________________________ 4-4 REPAIR WORK, ENGINE____________________________________________________________ 4-5 HYDRAULIC SYSTEM ______________________________________________________________ 4-6 Repair instructions ________________________________________________________________ 4-6 Hydraulic hoses – Instructions _______________________________________________________ 4-6 ELECTRICAL SYSTEM _____________________________________________________________ 4-7 Assisted starting (with jumper cables) – Safety instructions ________________________________ 4-7 Assisted starting (with jumper cables) _________________________________________________ 4-7 Starting the engine with jumper cables (external batteries _________________________________ 4-7

ix

BA 6015(3 847 019.01)-EN

TABLE OF CONTENTS PRESSURE ACCUMULATORS - SAFETY INSTRUCTIONS ________________________________ 4-9 WELDING AND FLAME CUTTING WORKS - SAFETY INSTRUCTIONS _____________________ 4-10 DISPOSAL AT THE END OF THE SERVICE LIFE _______________________________________ 4-13 Dismantling and removal instructions ________________________________________________ 4-13 Risk of deflagrations______________________________________________________________ 4-13 Risk of fire______________________________________________________________________ 4-13 Disposing of the machine without polluting the environment ______________________________ 4-13 Further hazardous substances ______________________________________________________ 4-14 Appropriate disposal of batteries ____________________________________________________ 4-15 NOTES _________________________________________________________________________ 4-17 5 ANNEX __________________________________________________________________________ 5-1 TROUBLESHOOTING ______________________________________________________________ 5-3 Instructions on troubleshooting_______________________________________________________ 5-3 Layout of the fault table ____________________________________________________________ 5-3 Possible causes __________________________________________________________________ 5-3 Measures _______________________________________________________________________ 5-3 Section _________________________________________________________________________ 5-3 FAULT TABLES ___________________________________________________________________ 5-4 Combustion engine - Fault table _____________________________________________________ 5-4 ,Working hydraulics – Fault table_____________________________________________________ 5-4 Working hydraulics – Fault table _____________________________________________________ 5-5 Track drive – Fault table____________________________________________________________ 5-6 Swinging mechnism – Fault table ____________________________________________________ 5-7 Central lubricating system – Fault table________________________________________________ 5-8 HYDRAULIC CIRCUIT DIAGRAM _____________________________________________________ 5-9 ABBREVIATIONS _________________________________________________________________ 5-11 PRODUCT SPECIFICATION SHEET__________________________________________________ 5-13 NOTES _________________________________________________________________________ 5-15 6 INDEX ___________________________________________________________________________ 6-1

x

BA 6015(3 847 019.01)-EN

Introduction 1 INTRODUCTION Operation and Maintenance Manual

Target group

Part 1 INTRODUCTION FUNDAMENTAL SAFETY INSTRUCTIONS

Operating personnel + Inspection and servicing personnel + Repair personnel

Part 2 OPERATION

Operating personnel The operating personnel must have knowhow relevant to the operation and the application of this or comparable machines.

Part 3 INSPECTION AND SERVICING Part 4 REPAIR WORK

Inspection and servicing personnel The inspection and servicing personnel must have know-how relevant to the inspection and servicing of this or comparable machines.

Repair personnel The repair personnel must have know-how and experience relevant to the repair of this or comparable machines.

Part 5 ANNEX

Part 6 INDEX

Operating personnel + Inspection and servicing personnel + Repair personnel Operating personnel + Inspection and servicing personnel + Repair personnel

1-1

BA 6015(3 847 019.01)-EN

Introduction

1-2

BA 6015(3 847 019.01)-EN

Introduction PREFACE 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 efficiency. Observing these instructions helps to prevent hazardous situations, to reduce repair costs and downtimes and to increase the reliability and service life of the machine.

The Operation and Maintenance Manual must be supplemented by the respective national rules and regulations for accident prevention and environmental protection.

The Operation and Maintenance Manual must always be available in the operator's cab of the machine.

The Operation and Maintenance Manual must be read and put into practice by any person in charge of carrying out work with or on the machine, such as 

operation, including setting-up, troubleshooting in the course of work, care, evacuation of production waste and disposal of fuels and consumables,

All CGM HMS GmbH operating 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 for you by the CGM HMS GmbH after-sales service.

Further machine documentation The documentation relating to the machine is listed according to scope, quantity and language in the shipping note of the machine or in the covering letter if supplied separately. The Operation and Maintenance Manual, the spare-parts list and the Service Manuals are marked with the serial number of the machine.

The documentation supplied with your machine is rather comprehensive. Therefore, it has been split up in several volumes: Volume 1: the present Operation and Maintenance Manual, Volume 2:

spare-parts list of the machine,

Volume 3:

electrical circuit diagram and key,

Volume 4:

documentation of the engine and of other components,



maintenance (inspection, servicing, repair) and / or

Volume 5:

Service Manual Part 1



transport.

Volume 6:

Service Manual Part 2

In addition to the Operation and Maintenance Manual and the mandatory rules and regulations for accident prevention and environmental protection in the user's country and at the place where the machine is to be used, the generally recognized technical rules for safe and proper working 1 must be observed The Operation and Maintenance Manual are directed to the mining-machine specialist. They cannot provide basic know-how. This can be acquired, for example, in several days' instruction by a qualified 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.

Depending on the size of your machine, the documentation can also consist of more volumes.

If you cannot find the information you are looking for in the present Operation and Maintenance Manual please check also the other volumes of the documentation.

The Service Manual Part 1 also provides information on how to assemble the machine, on functions of the hydraulic system, on hydraulic circuit diagrams etc.

On taking receipt of the consignment, please check that the documentation is complete and in the language requested by you.

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.

1

Complies with VDMA recommendation "Operating instructions" 1-1

BA 6015(3 847 019.01)-EN

Introduction WARRANTY The warranty of CGM HMS GmbH presupposes among other things that the servicing works as described in the Operation and Maintenance Manual have been performed: 

in a workshop authorized in writing by your Caterpillar dealer or by CGM HMS GmbH,

and 



by your Caterpillar dealer or by the CGM HMS GmbH Service

or 

Do not operate the machine  when components / assemblies are defective or missing,

by using the original spare parts of CGM HMS GmbH.

The proper execution of the servicing works must be documented on the CGM HMS GmbH Service checklists.

if one or several of such components of which more than one are installed in the machine have been removed.

In cases of doubt seek advice from the CGM HMS GmbH Service.

CGM HMS GmbH refuses to assume the guaranteee for damage and consequential damage caused by an abusive utilization of the machine.

Therefore: Do not operate the machine,  when several track rollers or support rollers have been removed; 

when one or several swinging gearboxes have failed or been removed;



when one or several teeth on the backhoe or on the shovel are worn or missing;



when parts of the hardfacing layer on the backhoe or on the shovel are worn or missing.

Working under these circumstances results in heavy wear and possibly in severe damage and thus in high repair costs.

Such circumstances are considered by CGM HMS GmbH as "abusive utilization".

Why? The machines have been designed and built on the basis of detailed calculations and so that all of the components installed absorb the occurring forces and are thus loaded to an equal extent.

Example: If the machine is used for working with, for instance, one or even several track rollers removed, the forces must be absorbed by the remaining track rollers. These are then overloaded or loaded to a greater extent than calculated.

The consequences are higher wear and consequential damage to the track rollers, but also to other components of the machine: chassis, travel gearbox and crawler track.

1-2

BA 6015(3 847 019.01)-EN

Introduction FUNDAMENTAL SAFETY INSTRUCTIONS Complies with VDMA recommendation "Operation and Maintenance Manual"

Warnings and symbols The following signs are used in the Operation and Maintenance Manual to designate instructions of particular importance: Precautionary rules and measures designed to protect the machine operator and other persons from lifethreatening danger or injuries and to prevent extensive damage.

Information and precautionary measures designed to prevent damage to the machine or other property.

Contents of the Declaration of Conformity Manufacturers: CGM HMS GmbH GmbH Karl-Funke-Strasse 36 44149 Dortmund Federal Republic of Germany Fon: 49 (0) 231-922-3 Fax: 40 (0) 231-922-5300 EC Declaration of Conformity in acc. with EC Machine Directive 2006/42/EC The manufacturer declares that the following machine: Hydraulic Mining Shovel 6015, 6015FS conforms to EC Directive 2006/42/EC. (Reference: EC Official Journal of the European Union L157/24 of 09.06.2006) Persons authorized for the composition of technical documents: Mr Uwe Friedhoff (Design dept.).

Signed by: Head of Design Department and Head of Quality Assurance Department.

1-3

BA 6015(3 847 019.01)-EN

Introduction DESIGNATED USE, UNAUTHORIZED USE The machine has been built in accordance with state-of-art standards and the recognized safety rules. Nevertheless, its use may constitute a risk to life and limb for the user or third parties or cause damage to the machine and to other material property (acceptable risk) An acceptable risk is present, e.g.: loose material or material to be loaded may drop out of the bukket or backhoe while the working equipment is being swivelled.

The machine must be used only in technically perfect condition in accordance with its designated use and the instructions set out in the Operation and Maintenance Manual, and only by safetyconscious persons who are fully aware of the risks involved in operating the machine. Any functional disorders, especially those affecting the safety of the machine, should therefore be rectified immediately.

With attached shovel equipment, the machine is to be used solely for loosening and loading of:  sand, oil sand,  gravel,  blasted rock,  ore,

Using the hydraulic shovel or its attachments for purposes other than or extending beyond those stated above, e.g.:  for lifting or transporting persons, 

as a working platform,



for lifting crane loads without the equipment being approved for this purpose,



for driving in posts, sheetpiles supports, etc. without the equipment being approved for this purpose,



for moving material to the side (sweeping),



for breaking down rocks by beating with the shovel or the backhoe,



for fitting or reparing of other machínes

is contrary to its designated use and considered as "unauthorized use".

Lifting eyes on the lower carriage -

are settled for transporting with a crane only.

-

must not be used for towing a machine.

 coal, and other raw materials.

With attached backhoe equipment, the machine can additionally also be used for excavating and loading of excavatable soils and other raw materials.

Operating the machine within the limits of the desigated use also involves observing the instructions set out in the Operation and Maintenance Manual and complying with the inspection and maintenance directives.

1-4

Improper use may involve a life-threatening risk for operators or other personnel or may cause injury or extensive damage.

The manufacturer/supplier cannot be held liable for any damage resulting from other than the designated use. The risk involved in such misuse lies with the user.

BA 6015(3 847 019.01)-EN

Introduction Noise emission information

Vibration information

Noise emission data are specified in acc. with EC Machine Directive 2006/42/EC, Annex I, Section 1.7.4.2.u)

On the condition that the excavator is used within the limits of its designated use, the installation of seats for operators in conformity with ISO 7096 ensures that the weighted vibration accelerations awz (measured in compliance with ISO 2631 Part I) fulfil the requirements with respect to the protection against whole-body vibrations in acc. with EC Vibration Directive 2002/44/EG.

Sound power level: LWA = 116,9 dB(A).

Sound pressure level at operator's seat: LpA = 79,4 dB(A).

The vibrations transferred are indicated in acc. with EC Machine Directive 2006/42/EG, Annex I; Section 3.6.3.1, resp. with the "Regulations for noise and vibration at the place of work", Section 4, as of 18.12.2008.

The effective value of the weighted acceleration to which the wole body is exposed, does not exceed 2 0.5 m/s .

The measurement uncertainty is ±3% (tolerance of the measuring instruments).

1-5

BA 6015(3 847 019.01)-EN

Introduction ORGANIZATIONAL MEASURES The Operation and Maintenance Manual must always be at hand at the place of use of the machine, e.g. by stowing them in the place provided for such purpose.

In addition to the Operation and Maintenance Manual, observe and instruct the user in all other generally applicable legal and other mandatory regulations relevant to accident prevention and environmental protection.

These compulsory regulations may also deal with the handling of hazardous substances, issuing and/or wearing of personal protective equipment or traffic regulations.

The Operation and Maintenance Manual must be supplemented by instructions covering the duties involved in supervising and notifying special organizational features, such as job organization, working sequences or the personnel entrusted with the work.

Personnel entrusted with work on the machine must have read the Operation and Maintenance Manual and in particular the chapter on safety before beginning work. Reading the Operation and Maintenance Manual after work has begun is too late. This applies especially to persons working only occasionally on the machine, e.g. during setting up or maintenance.

Check - at least from time to time - whether the personnel is carrying out the work in compliance with the Operation and Maintenance Manual and paying attention to risks and safety factors.

For reasons of security, long hair must be tied back or otherwise secured, garments must be close-fitting and no jewellery, such as rings, may be worn. Injury may result from being caught up in the machinery or from rings catching on moving parts.

Use protective equipment wherever required by the circumstances or by law.

Personal protective equipment and the working clothing Depending on the cleaning, servicing and/or repair activities to be performed, the personal protective equipment and the working clothing may consist of the following items:  fall arresters,  protective suit,  helmet,  goggles - e. g. for cleaning work - or for welding work  protective gloves - e.g. for work on hot units - for grinding and welding work  protective working gloves - e.g. for fitting work - for grinding and welding work  ear protectors.

Observe all safety instructions and warnings attached to the machine.

See to it that safety instructions and warnings attached to the machine are always complete and perfectly legible.

In the event of safety-relevant modifications or changes in the behaviour of the machine during operation, stop the machine immediately and report the malfunction to the competent authority/person.

Never make any modifications, additions or conversions which might affect safety without the supplier's approval. This also applies to the installation and adjustment of safety devices and valves as well as to welding work on load-bearing elements.

Use only the original sparts parts of CGM HMS GmbH. They are the only ones to fulfill the technical specifications of the machine.

Replace hydraulic hoses within stipulated and appropriate intervals, even if no safety-relevant defects have been detected.

Adhere to prescribed intervals or those specified in the Operation and Maintenance Manual for routine checks and inspections.

For the execution of maintenance work, tools and workshop equipment adapted to the task on hand are absolutely indispensable.

The personnel must be familiar with the location and operation of fire extinguishers.

Observe all fire-warning and fire-fighting procedures.

1-6

BA 6015(3 847 019.01)-EN

Introduction Selection and qualification of personnel; basic responsibilities

Safety instructions governing specific operational phases

Any work on and with the machine must be executed by reliable personnel only. Statutory minimum age limits must be observed.

Standard operation

Employ only trained or instructed staff and set out clearly the individual responsibilities of the personnel for operation, set-up, maintenance and repair.

Make sure that only authorized personnel works on or with the machine.

Define the machine operator's responsibilities giving the operator the authority to refuse instructions by third parties that are contrary to safety.

Do not allow persons to be trained or instructed or persons taking part in a general training course to work on or with the machine without being permanently supervised by an experienced person.

Work on the electrical system and equipment of the machine must be carried out only by a skilled electrician or by instructed persons under the supervision and guidance of a skilled electrician and in accordance with electrical engineering rules and regulations.

Work on chassis and brake systems must be performed by skilled personnel only, which has been specially trained for such work.

Work on hydraulic systems must be carried out only by personnel with special knowledge and experience of hydraulic equipment.

Avoid any operational mode that might be prejudicial to safety.

Before beginning work, familiarize yourself with the surroundings and circumstances of the site, such as obstacles in the working area and the bearing capacity of the soil.

Take the necessary precautions to ensure that the machine is in a safe and reliable state.

Operate the machine only if all protective and safety-oriented devices, such as removable safety devices, emergency shut-off equipment, soundproofing elements and exhausters, are in place and fully functional.

Check the machine at least once per working shift for obvious damage and defects. Report any changes (incl. changes in the machine's working behaviour) to the competent organization/person immediately. If necessary, stop the machine immediately and lock it.

In the event of malfunction, stop the machine immediately and lock it. Have any defects rectified immediately.

Start the machine from the operator's seat only.

During start-up and shut-down procedures always watch the indicators in accordance with the Operation and Maintenance Manual.

Before setting the machine in motion, make sure that nobody is at risk.

Before starting work or travelling with the machine, check that braking, signalling and lighting systems are fully functional.

Before setting the machine in motion always check that the accessories have been safely stowed away.

1-7

BA 6015(3 847 019.01)-EN

Introduction

In conditions of poor visibility and after dark always switch on the lighting system.

Persons accopanying the operator must be seated on the passenger seat provided for this purpose.

When crossing underpasses and bridges or when passing under overhead lines always make sure that there is sufficient clearance.

Always keep a distance from the working face and from slopes.

Avoid any operation that might be a risk to machine stability.

Never travel across slopes; always keep the working equipment and the load close to the ground, especially when travelling downhill.

On sloping terrain always adapt your travelling speed to the prevailing ground conditions.

Before leaving the operator's seat always secure the machine against inadvertent movement and unauthorized use.

Shut off the engine.

Special work in conjunction with utilization of the machine and maintenance and repairs as well as troubleshooting during work; disposal of parts and consumables Observe the adjusting, maintenance and inspection activities and intervals set out in the Operation and Maintenance Manual, including information on the replacement of parts and equipment. These activities may be executed by skilled personnel only.

Brief operating personnel before beginning special operations and maintenance work, and appoint a person to supervise the activities.

In any work concerning the operation, conversion or adjustment of the machine and its safetyoriented devices or any work related to maintenance, inspection and repair, always observe the start-up and shut-down procedures set out in the Operation and Maintenance Manual and the information on maintenance work.

Ensure that the maintenance area is adequately secured.

If the machine is completely shut down for maintenance and repair work, it must be secured against inadvertent starting by:  removing the ignition key and  attaching a warning sign.

Carry out maintenance and repair work only if the machine is positioned on stable and level ground and has been secured against inadvertent movements.

To avoid the risk of accidents, individual parts and large assemblies being moved for replacement purposes should be carefully attached to lifting tackle and secured. Use only suitable and technically perfect lifting gear and suspension systems with adequate lifting capacity. Never work or stand under suspended loads.

The fastening of loads and the instructing of crane operators should be entrusted to experienced persons only. The marshaller giving the instructions must be within sight or sound of the operator.

For carrying out overhead assembly work always use specially designed or otherwise safetyoriented ladders and working platforms. Never use machine parts as a climbing aid Wear a safety harness when carrying out maintenance work at heights above 1 m.

Wear an approved harness equipped with fall arresters and safety lines.

1-8

BA 6015(3 847 019.01)-EN

Introduction Keep all handles, steps, handrails, platforms, landings and ladders free from dirt, snow and ice.

Clean the machine, especially connections and threaded unions, of any traces of oil, fuel or preservatives before carrying out maintenance/repair.

Never use aggressive detergents. Use lint-free cleaning rags.

Before cleaning the machine with water, steam jet (high-pressure cleaning) or detergents, cover or tape up all openings which - for safety and functional reasons - must be protected against water, steam or detergent penetration. Special care must be taken with electric motors and switch-gear cabinets.

Ensure during cleaning of the machine that the temperature sensors of the fire-warning and firefighting systems do not come into contact with hot cleaning agents as this might activate the firefighting system.

After cleaning remove all covers and tapes applied for that purpose.

After cleaning, examine all fuel, lubricant, brake and hydraulic fluid lines for leaks, loose connections, chafe marks and damage. Any defect found must be rectified without delay.

Always tighten any screwed connections that have been loosened during maintenance and repair.

Any safety devices removed for set-up, maintenance or repair purposes must be refitted and checked immediately upon completion of maintenance and repair work.

Ensure that all consumables and replaced parts are disposed of safely and with minimum environmental impact.

Warning of special dangers Electric energy Use only original fuses with the specified current rating. Switch off the machine immediately if trouble occurs in the electrical system.

When working with the machine, maintain a safe distance from overhead electric lines. If work is to be carried out close to overhead lines, the working equipment must be kept well away from them.

Caution, danger! Check out the prescribed safety distances.

If your machine comes into contact with a live wire  do not leave the machine  drive the machine out of the hazard zone; warn others against approaching and touching the machine  have the live wire de-energized  do not leave the machine until the damaged or contacted line has been safely de-energized.

The electrical equipment of machines is to be inspected and checked at regular intervals. Defects such as loose connections or scorched cables must be rectified immediately.

High-voltage system Floodlamps equipped with gaz discharge lamps require a high-voltage supply (ca. 25 kV).

The high voltage is generated by a ballast unit.

Switch off the electrical system of the excavator before touching the lamp or the ballast unit.

Battery Warning! Battery Posts, terminals and related accessories contain lead and lead compounds, chemicals known to cause cancer and reproductive harm. Wash hands after handling.

1-9

BA 6015(3 847 019.01)-EN

Introduction Gas, dust, steam and smoke

Noise

Always start and operate the engine in a wellvented area;

During operation, all sound baffles of the machine must be closed.

If in an enclosed area, vent the exhaust to the outside.

Always wear the prescribed ear protectors.

Do not modify or tamper with the exhaust system.

Oil, grease and other chemical substances

Diesel engine exhaust and some of its constituents are known to cause cancer, birth defects, and other reproductive harm.

Operate fuel-operated heating systems only on adequately ventilated premises. Before starting the machine on enclosed premises, make sure that there is sufficient ventilation.

Observe the regulations in force at the respective site.

Carry out welding, flame-cutting and grinding work on the machine only if this has been expressly authorized, as there may be a risk of explosion and fire.

Before carrying out welding, flame-cutting and grinding operations, clean the machine and its surroundings from dust and other inflammable substances and make sure that the premises are adequately ventilated (risk of explosion).

CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its con-

When handling oil, grease or other chemical substances, observe the product-related safety regulations (see safety specifications).

Be careful when handling hot consumables (risk of burning or scalding).

Ether The machine can be equipped with pressure vessels for cold-starting fluid (ether) installed in the engine compartment. Ether is toxic and highly flammable; the vessels are under pressure. These pressure vessels can explode if exposed to high temperatures (above 49°C / 120°F) or in the event of damage. Protect the vessels against damage and high temperatures.

Do not store pressure vessels with cold-starting fluid (ether) on the excavator.

stituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

Do not eat, drink or smoke when replacing pressure vessels with cold-starting fluid (ether). Observe the instructions on the pressure vessels.

Provide for sufficient ventilation (see also Part 3 "Inspection and servicing").

Hydraulic equipment

Do not open empty cold-starting fluid pressure vessels (ether). Have the vessels disposed of properly.

Check all lines, hoses and screwed connections regularly for leaks and obvious damage. Repair damage immediately. Splashed oil may cause injury and fire.

Depressurize all system sections and pressure pipes (hydraulic system) to be removed in accordance with the specific instructions for the unit concerned before carrying out any repair work.

Hydraulic lines must be laid and fitted properly.

Ensure that no connections are interchanged. The fittings, lengths and quality of the hoses must comply with the technical requirements.

For further details please refer to the instructions and safety data-sheets of the manufacturer / supplier of pressure vessels with cold starting fluid (ether).

Transporting and recommissioning The machine must be loaded and transported only in accordance with the Operation and Maintenance Manual.

Use only appropriate means of transport and lifting gear of adequate capacity.

The recommisioning procedure must be strictly in accordance with the Operation and Maintenance Manual.

1-10

BA 6015(3 847 019.01)-EN

Introduction FIRE AND EXPLOSION HAZARD Safety instructions Prior to commencing work, obtain informationon the national and corporate rules for the prevention of accidents and avoiding fires.

Pay particular attention to hazards caused by combustible and easily flammable substances.

Obtain information on the safe handling of the fire extinguishers to be used.

Avoid smoking and open fire on, next to and below the hydraulic shovel.

Combustible and easily flammable substances or liquids increase the fire and explosion hazard.

Do not store or transport flammable substances on the hydraulic shovel during the work. This is also valid for pressure vessels containing flammable substances as, for instance, spray oil or coldstarting fluid (ether). They are heat-sensitive and can explode even if exposed only to intensive sunlight.

Clean the hydraulic shovel carefully, if oil, grease, fuel, detergents or cold-starting fluid have been spilt over the machine. If possible, use a steam-jet cleaner for cleaning.

These substance can also ignite themselves if they come close to hot units or objects as, for instance, a turbocharger.

Even battery gases can ignite in open flames or fire.

Place suitable fire guardings (fire barriers) if open fire or flying sparks cannot be avoided during repair work.

Apply special protection to cables, cable ducts as well as to hose and pipe lines.

If necessary, also cover the ground with fireprotective blankets.

The engine compartment can be equipped with pressure vessels containing cold-starting fluid (ether). Ether is toxic and highly flammable; the vessels are under pressure. These pressure vessels can explode if exposed to high temperatures (above 49°C / 120°F) or in the event of damage.

Protect the pressure vessels against damage before beginning to work in or close to the engine compartment.

Ensure sufficient ventilation.

Clean the hydraulic shovel before starting a job.

Do not keep any fire extinguishers that are not suitable or have not been tested.

Do not extinguish flammable liquids with water.

Use: 

dry-powder,



carbon-dioxide or



foam extinguishing compounds.

When getting into contact with burning substances, the fire-fighting water would abruptly evaporate and distribute the substance such as oil over a wide area. Water causes short-circuits in the electrical system thus possibly entailing new hazards.

Call the fire brigade.

Have all your welding, flame cutting and grinding work approved.

Avoid parking the hydraulic shovel in places where 

combustible substances such as coal dust or tar are present.



open or smouldering fire may occur.

Remove the hydraulic shovel from such an area where combustible or easily flammable liquids have spilled from the hydraulic shovel onto the ground.

Flying sparks (caused by welding, flame cutting, grinding, electrical short-circuit) may cause fire on the ground that can spread to the hydraulic shovel.

1-11

BA 6015(3 847 019.01)-EN

Introduction

1-12

BA 6015(3 847 019.01)-EN

Introduction NOTES ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... .......................................................................................................................................................................

1-13

BA 6015(3 847 019.01)-EN

Introduction

1-14

BA 6015(3 847 019.01)-EN

Operation 2 OPERATION Operation and Maintenance Manual

Target group

Part 1 INTRODUCTION FUNDAMENTAL SAFETY INSTRUCTIONS

Operating personnel + Inspection and servicing personnel + Repair personnel

Part 2 OPERATION

Operating personnel The operating personnel must have knowhow relevant to the operation and the application of this or comparable machines.

Part 3 INSPECTION AND SERVICING Part 4 REPAIR WORK

Inspection and servicing personnel The inspection and servicing personnel must have know-how relevant to the inspection and servicing of this or comparable machines.

Repair personnel The repair personnel must have know-how and experience relevant to the repair of this or comparable machines.

Part 5 ANNEX

Part 6 INDEX

Operating personnel + Inspection and servicing personnel + Repair personnel Operating personnel + Inspection and servicing personnel + Repair personnel

2-1

BA 6015(3 847 019.01)-EN

Operation

2-2

BA 6015(3 847 019.01)-EN

Operation OPERATION - SAFETY INSTRUCTIONS Operation and Maintenance Manual Never operate the machine before having read and understood the Operation and Maintenance Manual.

Pay special attention to: the "Fundamental Safety Instructions" and to all warning and instruction signs attached to the machine.

Familiarize yourself with the layout, the functioning and the sense of actuation of the control elements prior to starting up the machine.

Activate the control elements from the operator's seat only.

Keep the Operation and Maintenance Manual with the machine at all times.

Operating personnel The operating personnel must be fully informed of the operation and application of this or comparable machines.

The necessary know-how can be acquired in several days' instruction, e.g. by an CGM HMS GmbH mechanic or by attending an CGM HMS GmbH operator's training course.

Safety belts For machines with safety belts for operating personnel: Check the safety belts attached to the operator's seat as well as at the trainer’s seat. In the event of damage or after an accident, have them replaced immediately.

Apply the safety belts before starting work.

State of the machine Operate the machine only in a safe state and only in accordance with its designated use. Always observe the safety instructions.

Always have inspection and maintenance work carried out on schedule.

Operate the machine only with the equipment and component combinations approved by CGM HMS GmbH. Clear-cut data are given in the technical specification.

Never install and commission other equipment and component combinations without CGM HMS GmbH having first inspected and approved the project.

Before starting work or travelling with the machine, check that the braking, signalling and lighting systems are fully functional.

Poor visibility may result in accidents. Always clean the windows and the glass covers of all lamps before starting the machine.

Personal protective gear and working clothing

Check that all warning and instruction signs attached to the machine are present and legible.

Wear a safety helmet and working footwear with non-slip soles. Smooth soles may slip from steps and pedals resulting in injury or incorrect operation.

Entering and leaving the machine

Wear closely fitting working clothing when operating the machine. Loose, wide garments may result in control levers being inadvertently activated.

Always maintain a three point contact with the steps and grab handles.

Always face the machine when entering or leaving it.

Use only the ladders, steps, platforms and grab handles provided when entering and leaving the machine.

Always keep ladders, steps and platforms in a non-slip, safe state and remove any oil, grease, soil, snow, ice and other foreign matter immediately.

2-3

BA 6015(3 847 019.01)-EN

Operation Hazard range The hazard range is that zone around the machine in which persons are within reach of loads or attachments falling as a result of operational movements by the machine, of its equipment and attachments or of swinging loads.

Persons within the hazard zone

Operation and Maintenance Manual, where to store it in the operator’s cab One copy of the Operation and Maintenance Manual for the machine must be available in the operator’s cab during operation.

The binder with the Operation and Maintenance Manual can be stored in the tray (Fig. 2-1:).

Always use the horn to warn persons in the immediate vicinity of the machine before starting up the machine.

Ensure that no one sets foot in the hazard zone of the machine. Interrupt work until such persons have left the hazard zone.

Marshallers The marshaller must keep outside the hazard zone.

Have a marshaller to assist you: 

when you have no clear overview over the hazard zone of the machine,



when reversing,



when shunting.

Use only those communication signals which you and the marshaller understand, or use aids for communication (e.g. walkie-talkie/camera).

Calls cannot be understood by the marshaller because of the noise made by the machine during operation.

Keep in constant contact with the marshaller.

Stop the machine immediately if you lose contact with the marshaller.

Securing the machine Secure the machine as described under "Securing the machine" before: 

mounting or dismantling the attachment,



parking the machine after daily operation,



carrying out any servicing or repair work.

2-4

Fig. 2-1:

BA 6015(3 847 019.01)-EN

Operation FIRE AND EXPLOSION HAZARD Safety instructions Prior to commencing work, obtain informationon the national and corporate rules for the prevention of accidents and avoiding fires.

Pay particular attention to hazards caused by combustible and easily flammable substances.

Obtain information on the safe handling of the fire extinguishers to be used.

Remove the hydraulic shovel from such an area where combustible or easily flammable liquids have spilled from the hydraulic shovel onto the ground.

Flying sparks (caused by welding, flame cutting, grinding, electrical short-circuit) may cause fire on the ground that can spread to the hydraulic shovel.

Clean the hydraulic shovel before starting work.

Place suitable fire guardings (fire barriers) if open fire or flying sparks cannot be avoided during repair work.

If necessary, also cover the ground with fireprotective blankets.

Avoid smoking and open fire on, next to and below the hydraulic shovel.

Apply special protection to cables, cable ducts as well as to hose and pipe lines.

Combustible and easily or highly inflammable substances or liquids increase the risk of fire and explosion

The engine compartment can be equipped with pressure vessels containing cold-starting fluid (ether). Ether is toxic and highly flammable; the vessels are under pressure. These pressure vessels can explode if exposed to high temperatures (above 49°C / 120°F) or in the event of damage.

Protect the pressure vessels against damage before beginning to work in or close to the engine compartment.

Do not store or transport flammable substances on the hydraulic shovel during the work. This is also valid for pressure vessels containing flammable substances as, for instance, spray oil or coldstarting fluid (ether). They are heat-sensitive and can explode even if exposed only to intensive sunlight.

Ensure sufficient ventilation.

Clean the hydraulic shovel carefully, if oil, grease, fuel, detergents or cold-starting fluid have been spilt over the machine. If possible, use a steam-jet cleaner for cleaning.

Do not keep any fire extinguishers that are not suitable or have not been tested.

These substance can also ignite themselves if they come close to hot units or objects as, for instance, a turbocharger.



Clean rubber or electrical with compressed air only.

When getting into contact with burning substances, the fire-fighting water would abruptly evaporate and distribute the substance such as oil over a wide area. Water causes short-circuits in the electrical system thus possibly entailing new hazards.

Ensure sufficient ventilation.

Even battery gases can ignite in open flames or fire.

Avoid parking the hydraulic shovel in places where 

combustible substances such as coal dust or tar are present.



open or smouldering fire may occur.

Do not extinguish flammable liquids with water.

Use: dry-powder, carbon-dioxide or foam extinguishing compounds.

Call the fire brigade.

Have all your welding, flame cutting and grinding work approved before starting work.

2-5

BA 6015(3 847 019.01)-EN

Operation DESCRIPTION OF THE EXCAVATOR

Fig. 2-2:

2-6

BA 6015(3 847 019.01)-EN

Operation Excavator layout

Loading bucket

Fig. 2-2:

29 – Boom

Undercarriage

30 - TriPower linkage

1 - Track drive 2 – Idler 3 - Track roller 4 - Support roller 5 - Crawler track 6 - Track tensioner 7 - Swinging ring

31 – Stick 32 - Bottom-dump bucket 33 - Boom cylinder 34 - Stick cylinder 35 - Tipping cylinder 36 - Bottom-dump cylinder 42 - Control valves 43 - Bottom-dump control valve

Superstructure 8 – Hydraulic oil reservoir

44 - Quick-action valve

Backhoe bucket

9 – Radiator (engine cooling liquid) 10 - Fuel tank 11 - Engine 12 - Pump transfer gearbox 13 – Hydraulic pumps (main pumps) 14 – Hydraulic pump (fan drive) 15 - Swinging pump 16 – Pilot control pump 17 - Cooling oil pump 18 – Hydraulic oil cooler

31 - Stick 33 - Boom cylinder 34 - Stick cylinder 37 - Monoblock boom 38 - Backhoe bucket 39 - Backhoe cylinder 40 - Toggle link 41 - Toggle lever 42 - Control valves

19 – Swinging gear 20 – Batteries and battery main switch 21 – Operator`s cab with air conditioner 22 – Control panel 23 – Counterweight 24 – Grease container for central lubricating system 25 – Travel control block and rotor 26 – Air-intake system with vacuum-meter 27 – Exhaust system 28 - Ladder

2-7

BA 6015(3 847 019.01)-EN

Operation Undercarriage

Pump Managing System (PMS)

The undercarriage of the hydraulic excavator serves as a stable base and for travelling. The crawler tracks are driven hydraulically with oil motors and travel gearboxes. Undercarriage and superstructure are connected by means of a swinging ring.

The Pump Managing System (PMS) with overlimit regulation ensures optimum utilization of the installed or preset engine power.

Superstructure

The electronic pump demand control prevents the machine from demanding more hydraulic power than the diesel engine can furnish. A microprocessor ensures that the hydraulic output power of the pump is optimally suited to the actual operation conditions.

The superstructure accommodates the drive and part of the hydraulic and electrical equipment.

Drive The drive unit comprises diesel engine, pump transfer gearbox, hydraulic pumps, hydraulic cylinders and hydraulic motors.

Programmable Logic Controller (PLC) The PLC controls the functions:  Engine Start, 

Engine Stop,

Hydraulic system



Engine Idle,

All working and travelling movements are performed hydraulically. The movements are controlled by servovalves. The working commands are initiated by hand and transmitted to the valves via control circuits. The oil supply from the superstructure to the undercarriage is ensured by the rotor. The hydraulic system is overload-protected by pressure-relief valves. The hydraulic pumps are supplied with oil from a hydraulic reservoir.



Central lubricating system and



Further auxiliary functions.

2-8

Further information is given in the Service Manual: “Stored-program control”.

BA 6015(3 847 019.01)-EN

Operation Demand control / Zero-flow regulation

Electrical system The electrical system operates on 24 volts

In the fine-control range, swivelling of the hydraulic pumps, and thus the variation of oil flow, are proportional to control lever and pedal valve travel. This means that during the work, the pumps supply only as much hydraulic oil as required to perform the working movement. In the neutral position of the control levers, the pumps are automatically swivelled to zeroflow.

These special features offer the following advantages:  reduced fuel consumption, 

minimum power losses,



reduced temperature of the hydraulic oil,



greater service life of hydraulic pumps and diesel engine.

Automatic engine speed reduction If the control pedals and control levers and thus the servovalves are not actuated for a period of 10 seconds or more (programable), the speed of the engine is automatically reduced to idling. This function is a further contribution to fuel economy.

2-9

BA 6015(3 847 019.01)-EN

Operation

Fig. 2-3:

2-10

BA 6015(3 847 019.01)-EN

Operation Signs Warning and instruction signs Observe the warning and instruction signs attached to the machine.

Keep the signs legible and clean.

Replace signs immediately if they have become illegible.

New warning and instruction signs can be ordered from the CGM HMS GmbH Spare Parts Service.

The ordering part numbers are set out in the spare-parts list of the machine.

Fig. 2-3: shows the location of warning and instruction signs on the machine.

Fig. 2-5:

Machine number

Engine number

The identification plate with the machine number (Fig. 2-5:) is attached to the front side of the Aframe (arrow, Fig. 2-4:).

The serial number plate (Fig. 2-6:) for the diesel engine is located on the diesel engine.

Fig. 2-6: Fig. 2-4:

Component numbers Other larger units also have identification plates indicating, among other things, their serial number.

On steel components, the CGM HMS GmbH part number or the serial number may be stamped into the metal at a clearly visible place.

2-11

BA 6015(3 847 019.01)-EN

Operation OPERATOR'S CAB Entering and leaving the machine - Safety instructions Clean off oil, grease, soil, mud, snow, ice and other substances from shoes, grab handles and steps.

Keep steps, platforms and grab handles in a non-slippery condition.

Risk of injury due to slipping.

For entering and leaving use only the steps, platforms and grab handles provided (see Fig. 2-7: and Fig. 2-8:).

Always face the machine when entering or leaving it.

Fig. 2-7:

Always maintain a three point contact with the steps and grab handles.

Fig. 2-8:

2-12

BA 6015(3 847 019.01)-EN

Operation Cab interior lamp

Windscreen washer

The interior lamp is switched on and off with switch (1, Fig. 2-9:).

The reservoir of the windscreen washing system (1, Fig. 2-10:) is located in the behind the cover (1, Fig. 2-11:).  Remove cover (1).

For the reservoir (1, Fig. 2-10:) capacity refer to the "Refilling quantities - Other" table.

Fig. 2-9:

Switch position

0 - lamp off, 1 – lamp on.

Fig. 2-10:

The interior lamp can be used even if the electrical system is switched off.

Therefore, switch off the interior lamp when leaving the machine. The batteries may be discharged if the interior lamp is left on for prolonged periods.

Fig. 2-11:

2-13

BA 6015(3 847 019.01)-EN

Operation Operator's seat

Adjusting the lumbar support

The operator's seat (Fig. 2-12:) can be adjusted in inclination, height and fore-and-aft position. The seat suspension can be adapted to the operator's weight.

The backrest is equipped with an upper and a lower air chamber.

Pull knob (7) upwards - the lower chamber is inflated with air

Never adjust the seat while driving.

Concentrate on the road to avoid accidents.

Before carrying out any seat adjustments:

Pull knob (3) upwards - the upper chamber is inflated with air

- stop the machine - set the control lever to "0"

Adjusting the seat cushion

Push knobs (3 and 7) downwards - the air chambers are deflated.

Adjust the inclination of the seat cushion with buttons (1 and 2).

Button (1) – lower frontside of cushion Button (2) – lower backside of cushion Bring the seat cushion into the desired position by moving the body forwards or backwards. Release button (1 or 2).

Adjusting the armrests The armrests can be raised or lowered as required.

To adjust the armrest inclination, turn knobs (6) to the right or left.

Fore-and-aft position The fore-and-aft position of the seat can be adjusted with lever (9).

Fig. 2-12:

Adjusting the backrest Adjust the inclination of the backrest with button (5) verstellen. Lean against the backrest or move your body forwards to bring the backrest into the desired position. Release button (5).

2-14

Pull lever (9) upwards, slide seat to the desired position and allow lever (9) to engage.

Fore-and-aft adjustment of the seat plate The fore-and-aft position is adjusted with lever (8).

Pull lever (8) upwards, slide seat plate to the desired position and allow lever (8) to engage.

BA 6015(3 847 019.01)-EN

Operation Adjusting the control consoles Do not adjust the control consoles during travelling.

Concentrate on the road to avoid accidents.

Do not adjust the control consoles when the hydraulic pilot control is activated.

Risk of moving the control levers inadvertently and of triggering uncontrolled movements of the working equipment.

Before adjusting the consoles:

The control consoles on the right and left of the operator's seat can be shifted parallel to the seat by abt. 16 cm (6.3 in) forwards and backwards so that the operator can select the the position best suited to him for fatigue-free working.

Adjusting the right control console:  Push lever (124) outwards against the pressure of the spring and maintain while shifting the console into the desired position.  Release the lever and check that the console locking mechanism has engaged.

Adjusting the left control console:  Push lever (123) outwards against the pressure of the spring and maintain while shifting the console into the desired position.  Release the lever and check that the console locking mechanism has engaged.

 stop the machine by releasing the travelling pedals (112 and 113, Fig. 2-13:); they will return to 0.  stand working equipment on the ground.  stop the engine.

Fig. 2-13:

2-15

BA 6015(3 847 019.01)-EN

Operation Trainer's / instructor's seat For operator training / instructing purposes it is often required that a trainer / instructor accompanies the operator in the cab.

For the safety of the trainer / instructor during excavator operation the cab is equipped with a second seat. This seat is installed behind the operator's seat (Fig. 2-14:).  Sit down on this seat and do not forget to fasten the seat-belt (if installed).  Do not leave this seat during the training / instruction session and /or as long as the machine is in operation.

Fig. 2-14:

2-16

BA 6015(3 847 019.01)-EN

Operation Fire-extinguisher The excavator cmay be equipped with a fireextinguisher (arrow, Fig. 2-15: and Fig. 2-16:).

Handling  Pull out safety pin (2, Fig. 2-16:).  Press down button (3) firmly and release.  Operate the extinguishing gun.

After fire-fighting, the extinguisher must be refilled Immediately and prepared ready for use.

Inspection Have fire-extinguishers inspected regulary by an expert. This is required by the authorities and the insurance companies, but also for your own safety.

Fig. 2-15:

The excavator operator and the maintenance personnel must inform themselves about how to handle the fire-extinguisher in order to be able to act fast and efficiently in case of beginning fires. Such instruction should be given by a qualified instructor.

Extinguishing agent Each filre-extinguisher is filled with 12 kg (26.4 lb) of Glutex. This extinguishing agent is used for fighting fires of classes A, B and C. Fires are extinguished fast, perfectly and without residues.

Have the fire-extinguisher checked at the prescribed intervals by authorized testing institutes.

Fire extinguishing system (optional) The automatic fire extinguishing system prevents fire from spreading. It is, however, assumed that that the machine be thoroughly cleaned of combustible and easily flammable substances.

Inspection Have the extinguishing system inspected regularly by an expert. This is required by authorities and insurance companies and is in the interests of your own safety.

Have the extinguishing system check at the prescribed intervals by authorized testing institutes.

Fig. 2-16:

2-17

BA 6015(3 847 019.01)-EN

Operation MONITORING, WARNING AND CONTROL ELEMENTS

Fig. 2-17:

2-18

BA 6015(3 847 019.01)-EN

Operation (Fig. 2-17:)

No. 1

Element Monitoring device Engine monitoring

Function Symbol Indicates different parameters on the display (E) Use push buttons (C and D) to scroll through parameter list.

Indicator lamps (A and B) lit when an active fault occurs.

Indicates the oil temperature in the pump transfer gearbox

2

Thermometer

Engine temperature

3

Pressure gauge

Engine oil pressure

Indicates the oil pressure in the diesel engine lubricating system

4

Warning device

Engine monitoring

Gives an acoustic warning signal if a fault is reported  Engine oil pressure too low 

5

Warning lamp

PMS (PUMP MANAGING SYSTEM)

6

Warning lamp

HPI warning

7

Warning lamp

HPI warning

8

Warning lamp

HPI warning

Engine temperature too high

Lower the equipment to the ground and shut off engin immediately if the warning device (4) sounds. The warning device (4) continues to sound until the fault has been retified.

Lamp flashes:  when the electrical system is on (engine stationary)  in the event of a fault (engine running) short-circuit, cable break or defective componenent (magnetic pick-up, termperature probe for load-sensing or proportional valve) Lamp is permanently lit  when the programmed hydraulic oil temperature of 80°C (176°F) is exceeded.

Lamp is lit up in the event of an HPI fault The lamp moreover indicates the fault code.

Contact CGM HMS GmbH after-sales service or engine manufacturer (see switch (52).

Lamp is lit up in the event of an HPI fault The lamp moreover indicates the fault code.

Shut off engine Stop working.

Contact CGM HMS GmbH after-sales service or engine manufacturer (see switch (52).

Lamp is lit up (e. g.):  when the engine oil pressure is too low  when the cooling water temperature is too high Shut off engine

2-19

BA 6015(3 847 019.01)-EN

Operation

Fig. 2-18

2-20

BA 6015(3 847 019.01)-EN

Operation Fig. 2-18

No.

Element

Function

9

Warning lamp

10

Warning lamp

11

Warning lamp

12

Warning lamp

Alternator

Lit when the alternator does not charge the battery.

13

Thermometer

Gearbox temperatur

Indicates the temperature in the pump gearbox

Cooling-liquid level

Symbol

Lit when the cooling-liquid level is too low.

Not in use Not in use

2-21

BA 6015(3 847 019.01)-EN

Operation

Fig. 2-19:

2-22

BA 6015(3 847 019.01)-EN

Operation Fig. 2-19:

No. 14

Element Thermometer

Function Indicates the temperature of the oil in the Hydraulic oil tempehydraulic reservoir. rature

15

Warning lamp

Swinging pump contamination

Lit when the swinging pump is contaminated with metallic particles.

16

Warning lamp

Swinging pump temperature

Lit when the temperature of the swinging pump is too high.

17

Indicator lamp

Preheating, travel motors (optional)

Lit when the preheating system is switched on.

Free for optional equipment.

19

Warning lamp

Min. hydraulic oil level

20

Warning lamp

Minimum fuel

Lit when the hydraulic oil level is below limit value.

Shut off engine Lit when the fuel has been used up, so that there is only the fuel reserve (abt. 115 l) left

21

Indicator lamp

Track parking brake Lit when the parking brake is applied.  The parking brake is automatically applied when the machine is stationary.

18



The parking brake is automatically released when the "Travel" function is active.

22

Warning lamp

Main pump I contamination

Lit when the hydraulic pump I is contaminated with metallic particles

23

Warning lamp

Main pump II contamination

Lit when the hydraulic pump II is contaminated with metallic particles

24

Indicator lamp

Preheating system engine and hydraulic oil (optional)

Lit when the preheating system is switched on (switch pos. 51).

25

Symbol

Free for optional equipment

2-23

BA 6015(3 847 019.01)-EN

Operation

Fig. 2-20:

2-24

BA 6015(3 847 019.01)-EN

Operation Fig. 2-20: No. Element 26 Warning lamp

Hydraulic oil filter

27

Indicator lamp

Idle-Auto

28

Warning lamp

Superstructure holding brake

Symbol Function Lit when the flow resistance in the hydraulic return-flow filters is too high.

Replace filter elements when this warning lamp does not go out with the oil at operating temperature Lit when the automatic speed reduction function is activated (speed reduced to idling when the pilot control valves remain inactivated for abt. 10 seconds).

Lit when the holding brake is applied.  The holding brake is automatically applied when the superstructure is stationary.



29 30

Indicator lamp

Lubrication ON

31

Indicator lamp

32

Warning lamp

Preheating system fuel (optional) Hydraulic reservoir

33

Indicator lamp

Pilot control

34 35

The holding brake is automatically released when the "Swinging" function is active.

Free for optional equipment Lit when the lubricating system is on and in the event of a malfunction (see "Central lubricating system") Lit when the preheating system is switched on (switch 55).

Lit when the shut-off valve at the hydraulic reservoir is closed.

The engine cannot be started when the shut-off valve is closed.

Closing the valve while the engine is running stops the engine.

Lit when the pilot control is active. see also pushbutton (85) Free for optional equipment Free for optional equipment

2-25

BA 6015(3 847 019.01)-EN

Operation

Fig. 2-21:

2-26

BA 6015(3 847 019.01)-EN

Operation Fig. 2-21: No. 36

Element Buzzer

Function Symbol Sounds an acoustic warning when a malfunctionis reported continuous tone together with warning lamps 9,19.

Intermittent tone with warning lamps 15,16,22,23 Shut off the engine immediately and lower the working equipment to the ground when buzzer (36) sounds continuously and when one of the warning lamps indicates a fault. The buzzer continues to sound until the fault has been rectified.

In the event of pump contamination or excessive swinging pump temperature, buzzer (36) sounds intermittently. The corresponding warning lamp lights up. The buzzer continues to sound until the fault has been rectified.

2-27

BA 6015(3 847 019.01)-EN

Operation

Fig. 2-22:

2-28

BA 6015(3 847 019.01)-EN

Operation Fig. 2-22: No. 51

Element Switch

52 53

Momentary contact switch Switch

54

Switch

55

Switch

56 57

Switch Switch

Speed reduction

58

Switch

Greasing system

59 60

Display Rotary switch

Operating hours Fan, air conditioner

Preheating system engine and hydraulic oil (optional) Engine monitor Floodlamps on working equipment (optional) Engine monitor

Preheating system fuel (optional)

Function Switch preheating system for engine and hydraulic oil ON/OFF. When switched on, indicator lamp (24) lits.

Diagnose ON/OFF

Symbol

Floodlamps on the working equipment ON / OFF Listing of fault codes, see warning lamps (6 and 7) (Increment – next fault) (Decrement – previous fault) Switch preheating system for fuel ON/OFF. When switched on, indicator lamp (31) lits.

Free for optional equipment to the left: normal operation of automatic speed reduction of diesel engine; activated during working pauses to the right: automatic speed reduction off Starts an additional greasing intervall.

Length of interval is programmed in the controller.

Not in use 3-stage regulation of air flow.

2-29

BA 6015(3 847 019.01)-EN

Operation

Fig. 2-23:

2-30

BA 6015(3 847 019.01)-EN

Operation Fig. 2-23: No. 61

Element Switch

Windscreen wiper

Function Permanent / intermittent wiping

62

Switch

Floodlamp

Front of superstructure on the right

63

Momentary contact switch Switch

Windscreen washer

Wipe/wash operation

Floodlamp

Counterweight

Momentary contact switch

Holding brakes in finaldrives

Applies the holding brakes of the final drives

64 65

66

Switch

Floodlamp

67

Momentary contact switch

Superstructure holding brake

68

Switch

Floodlamp

Symbol

Actuate the switch only when the machine is stationary. The holding brake is released automatically when the driving function is activated.

Operator's cab, instrument illumination Applies the holding brake of the superstructure Actuate the switch only when the superstructure is stationary. The holding brake is released automatically when the superstructure swinging function is activated.

Operator's cab, rear right

2-31

BA 6015(3 847 019.01)-EN

Operation

Fig. 2-24:

2-32

BA 6015(3 847 019.01)-EN

Operation Fig. 2-24: No. 70

Element Speed control

Potentiometer

Function Controls the engine speed

Symbol

- turn counter-clockwise to the limit stop: idling speed - turn clockwise to the limit stop: full speed Not connected

71 72

Key-switch

73 74 75 76 77 78 79

Pushbutton

80

Pushbutton

Activation /De-activation of electrical system Position 1: function check of indicator and warning lamps and of buzzer Position 3: starting of engine Free for optional equipment Free for optional equipment Free for optional equipment Free for optional equipment Free for optional equipment Free for optional equipment Boom-floating posi- When actuated: tion (only for load- boom cylinders are pressurized when retracted. ing shovel equipment) Depress button (79) only when control lever (88) is in position "0" Sounding of the horn Horn

2-33

BA 6015(3 847 019.01)-EN

Operation

Fig. 2-25:

2-34

BA 6015(3 847 019.01)-EN

Operation Fig. 2-25: No. 81

Element Pedal

87

Travelling, right track Pedal Travelling, left track Pedal Bottom dump (only for loading shovel equipment) Pushbutton inside Pilot control operators seat Control lever

88

Control lever

89

Switch

90

Indicator lamp

91

Lever

93

Radio

94

Control knob

82 83

85

95

Auxiliary heating (optional) Auxiliary heating (optional) Air conditioner (optional)

Function forwards / backwards

Symbol

forwards / backwards Opens/closes the bucket bottom

Activation/de-activation of pilot control Raising and lowering of bucket- or backhoe stick; swinging and braking of the superstructure Raising and lowering of boom; dumping of the bucket or back-tipping of the backhoe bucket Switches auxiliary l heating ON / OFF. Lits when auxiliary heating is switched ON. Controls the amount of warm air.

Optional equipment

Air conditioner

Adjusting the amount of warm air.

Cigarette lighter

97

Socket

PMS diagnosis.

98

Socket

Diagnosis engine electronics.

99

PMS-Box (Loadlimit regulator)

Fault code display with PMS (5) warning lamp.

2-35

BA 6015(3 847 019.01)-EN

Operation

2-36

BA 6015(3 847 019.01)-EN

Operation PUTTING THE MACHINE INTO OPERATION

Refuelling Refuelling - Safety instructions

Before daily start-up, carry out works in accordance with servicing plan T (cf. Part 3 "Inspection and servicing") Prior to your dailiy start-up, make sure the machine has been cleaned of combustible and easily flammable substances.

Otherwise, increased fire and explosion hazard will exist.

Explosion hazard Avoid open flames and stop smoking.

Fuels and fuel gases are inflammable.

Risk of fire.

Fuel may cause skin injury. Wear protective gloves or use a barrier cream.

Stand working equipment on the ground.

Shut off the engine.

Do not spill fuel and do not allow fuel to penetrate into the soil. Fuel pollutes the environment.

Reducing the operator's exposure to noise All noise protection devices of the machine must be in place and fully functional when the machine is in operation. e.g.

Wipe off spilt fuel immediately with cleaning rags or soak up with binding agents.

Fuel and cleaning material must be disposed of without polluting the environment.

Report fuel accidents immediately to the user or his representative.



doors, flaps and vover of the engine compartments must be closed,

Fuel level in the fuel tank



access doors to the compartments of the radiator fans must not be left open,

Fuel level in the fuel reservoir is visible at the inspection glass (6, Fig. 2-26:).



the cab door must be closed,



the exhaust silencer must be checked for holes,



the screwed conections of all components fastend with bolts must be checked for tightness. Loose components tend to vibrate and to rattle, thus increasing the noise level.

Wear ear protectors when leaving the operator's cab with the engine on and running.

Fig. 2-26:

2-37

BA 6015(3 847 019.01)-EN

Operation Filling in fuel  Unscrew cap of filler tube (2, Fig. 2-27:).  Fill in fuel through the filter sieve in the filler tube.

Do not remove the sieve.

Refuelling with the refuelling system (optional) The refuelling system (1, Fig. 2-29:) is installed besides the step-ladder.

Fig. 2-29: Fig. 2-27:

The refuelling system consists of an electrical pump,filling hose, switch box (2, Fig. 2-30:) and key-switch (3).

Quick refuelling (optional) The express coupling (1, Fig. 2-28:) for quick refulling is located behind the step-ladder.

Fig. 2-30:

Fig. 2-28:

 For filling in fuel, unscrew the cap of the express coupling.  Attach express coupling of filling hose from the service vehicle to the express coupling.  Fill in fuel.  When the fuel tank is filled, take off filling hose and refit cap on the express coupling.

2-38

Check before refuelling that the earthing strap (4, Fig. 2-30:) is attached to the chassis. Sparking caused by static or electric charges may set fuel on fire.

BA 6015(3 847 019.01)-EN

Operation When using the refuelling system  Unscrew cap (16, Fig. 2-31:) from express coupling (17).  Attach filling hose (18) to express coupling (17) and introduce into the fuel barrel. The electrical pump of the refuelling system is switched on with key-switch (14).

Switch on electrical pump only after the filling hose with the micro-filter has been immersed into the fuel barrel.

It is recommended to use a micro-filter in the filling line.Fuel should always be filled in through a screen.

Fig. 2-31:

Prior to initial commissioning or after repairs on the refuelling system carry out the following works:  Loosen elbow union (12) and fill pump (11) with fuel.  Retighten elbow union (12).

2-39

BA 6015(3 847 019.01)-EN

Operation Switching the electrical system on and off Key-switch (72, Fig. 2-32:) serves to switch the following functions:

P= 0= 1=

2= 3=

Not connected All electrical consumers without current.

Engine off.

Electrical system on: lamp test.

All monitoring and warning lamps are activated for 5 seconds and buzzer (36, Fig. 2-33:) is activated for 1 second. Thereafter, warning lamps (9, 12, 21,26, 28) are lit. Warning lamp (5) flashes.

Not connected.

Engine start. All warning and monitoring lamps must be off when engine runs.

Fig. 2-32:

Fig. 2-33:

2-40

BA 6015(3 847 019.01)-EN

Operation Battery main switch The battery main switch is located under a lockable hatch (5, Fig. 2-34:) beside the batteries and the tool box. The battery main switch disconnects the whole electrical system from the batteries. In the OFF position, the battery main switch protects  the machine against unauthorized starting of the engine, 

the batteries against inadvertent discharge.

Only the automatic fire-extinguishing system (optional equipment) remains connected to the power supply even when the switch is in the OFF position.

The two switch positions shown in Fig. 2-35: have the following meaning: I = ON II = OFF In the OFF position, the battery main switch handle can be withdrawn.

Never set battery main switch to OFF when the engine is running to avoid destruction of electrical components by voltage peaks.

Fig. 2-34:

Fig. 2-35:

2-41

BA 6015(3 847 019.01)-EN

Operation Preheating system for engine and hydraulic oil (optional) Preheating system for engine and hydraulic oil, function

When the temperatures of the engine oil, engine coolant and the hydraulic oil are below -10°C:  Connect the system to the external power supply.

The preheating system consists of heating elements for engine oil, engine coolant and hydraulic oil.

 Switch on the preheating system with switch (51, Fig. 2-36:).

The pilot lamp (24, Fig. 2-37:) lights up.

At low outside temperatures, the system facilitates starting of the engine and ensures that the hydraulic system reaches its operating temperature faster.

The preheating system is operated electrically with an external supply voltage. This voltage is available at a socket outlet in the frame of the superstructure near the oil cooler.

(The system has been set at the factory for a standard supply of 400 volts, threephase AC. Other voltages are available on request.).

 Switch off the preheating system with switch (51, Fig. 2-36:) when the engine and the hydraulic system have reached a temperature above 0°C. The pilot lamp (24, Fig. 2-37:) goes out.  Switch on the fuel preheating system (see "Fuel preheating system (option)").

Switching the preheating system for engine and hydraulic oil on and off Risk of an electric shock.

Check first: Insulation of the socket outlet on the machine in good condition?

Insulation of the connecting cable in good condition?

Connect the system to the power supply only if the insulation of the components is in perfect condition.

Fig. 2-36:

Observe the national safety regulations to be applied in the presence of electric current.

Fig. 2-37:

2-42

BA 6015(3 847 019.01)-EN

Operation Fuel preheating system (optional) Fuel preheating system, function At temperatures below 0°C, the paraffin particles contained in the diesel fuel begin to clump together. They form flakes which clog up the fuel lines and the filters. Starting of the engine is then no longer possible.

To prevent this, the diesel fuel must be preheated.

Preheating is effeceted by means of two heating elements in the fuel line. The heating elements are attached to the engine.

They are equipped with internal thermostats ensuring an automatic temperature regulation.

Switch on the fuel preheating only after preheating of the engine and of the hydraulic oil is terminated (see "Preheating system for engine and hydraulic oil (option)").

The preheating time is dependent on the outside temperature.

Fig. 2-38:

Switching the fuel preheating system on and off  Switch on the ignition by turning key-switch (72, Fig. 2-38:) to position 1.  At temperatures below 0°C, switch on the fuel preheating with switch (55).

The pilot lamp (31, Fig. 2-39:) lights up.

Fig. 2-39:

 Start up the engine by turning key-switch (72, Fig. 2-38:) to position 3 (see also "Starting and stopping the engine").  Switch off the fuel preheating with switch (55), when the engine has reached its operating temperature.

The pilot lamp (31, Fig. 2-39:) goes out.

2-43

BA 6015(3 847 019.01)-EN

Operation STARTING AND STOPPING THE ENGINE Starting the engine Start and operate combustion engine only on well-ventilated premises.

Stop the engine immediately  if the monitoring device (1, Fig. 2-41:) shows a malfunction of the engine after starting, 

if an acoustik warning sounds from the warning device (4),

and / or the warning lamp  hydraulic system (5) In closed rooms, exhaust gases must be evacuated to the outside.

Do not work on the exhaust system an do not make any modifications to it;



alternator (12) lits up.

Locate cause of the fault and rectify before restarting the engine.

Exhaust gases from diesel engines and some of their constituents may cause cancer, birth defects and other reproductive harm.

Fig. 2-41:

Starting the engine at low temperatures If the machine is used in low temperatures, the engine may be equipped with a cold-starting device.

Fig. 2-40:

 Turn speed control knob (70, Fig. 2-40:) counter-clockwise to the limit stop (idling).  Insert key into key-switch (72) and turn right to position 3.  Release key after the engine has fired.

Allow engine to run at idling for at least 5 minutes before running it at full load.

Repeat the starting procedure if the engine does not fire. Repeat starting procedure not more often than 3 to 4 times. Do not operate the starter for more than 10 seconds.

2-44

The pressure vessel containing the cold-starting fluid (ether) can be installed in or near the engine compartment.

The vessel is screwed into an electro-mechanical metering valve. When the engine is started at temperatures below 0°C (32°F), this valve is activated automatically by the engine electronics and injects a precisely metered amount of cold-starting fluid into the air intake duct of the engine.

Ether is toxic and highly inflammable. Safety instructions and information concerning the handling of pressure vessels for cold-starting fluids (ether) can be found in the following chapters: "Fundamental safety instructions", "Inspection and servicing - Safety instructions", "Cold-starting fluid (ether) - Replacing the pressure vessel".

BA 6015(3 847 019.01)-EN

Operation Shutting off the engine

Emergency stop

During interruptions of the work and after the work, stand working equipment on the ground.

In case of emergency, e.g. if buzzer (36, Fig. 2-43:sounds, the engine can be shut off from full load.  Turn key in key-switch (72, Fig. 2-43:) to position "0" (electrical system without current).

Do not shut off engine before the working equipment rests on the ground.  Turn speed control knob (70, Fig. 2-42:counter-clockwise to the limit stop (idling).

Do not shut off the engine out of full load. The engine should be run at idling for another 5 minutes to allow the lubricating oil and the cooling liquid to dissipate the combustion heat from the combustion chamber and from bearings and shafts.  Turn key in key-switch (72) to position "0" (electrical system without current).

Fig. 2-43:

Fig. 2-42:

2-45

BA 6015(3 847 019.01)-EN

Operation VENTILATION AND HEATING

Air conditioner (optional)

Ventilation (fresh air)

The control elements of the air cond. are installed under the ceiling of the operator's cab (Fig. 2-46).  The desired temperature is adjusted with control knob (1).  The desired blower intensity level / amount of air is selected with control knob (2).

For more information, please refer to the air conditioner manual of the manufacturer.

Fig. 2-44:

 When the engine is stationary, turn keyoperated switch (72, Fig. 2-44:) to position 1  Slide heating control lever (91, Fig. 2-45:) backwards (heating power = 0).  Turn rotary switch (60, Fig. 2-44:) to the desired fan intensity (steps 1 - 3).

Adjusting the heating performance  Slide lever (91, Fig. 2-45:) forwards depending on the heating performance desired. The foremost position gives maximum heating power.  If greater amounts of warm air are needed, switch on the fan with rotary switch (60, Fig. 2-44:).

Fig. 2-45:

2-46

Fig. 2-46

Auxiliary heating (optional) Switch ON / OFF auxiliary heating with switch (89, Fig. 2-47). When switched ON, indicator lamp (90) lits.

Additional information can be found in the manufacturers instruction manual.

Fig. 2-47

BA 6015(3 847 019.01)-EN

Operation MAXIMUM MACHINE INCLINATIONS, INFORMATION The machine must not exceed the inclinations indicated for working, travelling and servicing operations and during downtimes. The values specified in the tables below are valid for all types of working equipment.

If the maximum inclinations are exceeded, there is a risk of severe damage to the engine due to insufficient lubrication. In the event of extreme inclinations the machine can topple over.

The working performance of the machine is especially economical when the machine stands on firm and level ground.

A loss of performance and higher wear must be accepted when the machine works in an inclined position, e.g. when building a ramp or when swinging uphill.

For the building of ramps, the values specified in the table "Maximum inclinations during working operations" may be exceeded. In this case, however, a reduced service life of the components can be expected.

During downtimes, the machine must be parked in such a way that its inclination does not exceed 3° / 5.2 %

Maximum machine inclinations during working operations:

forward inclination

rearward inclination

side inclination

5° / 8.7%

5° / 8.7%

5° / 8.7%

Maximum machine inclinations during travelling: Type

Engine

forward deg / %

rearward deg / %

side deg / %

6015

QSK19

30° / 57.7%

30° / 57.7%

30° / 57.7%

C18

30° / 57.7%

30° / 57.7%

30° / 57.7%

Maximum machine inclinations during maintenance operations:

forward inclination

rearward inclination

side inclination

0° - 2° / 3.4%

0° - 2° / 3.4%

0° - 2° / 3.4%

2-47

BA 6015(3 847 019.01)-EN

Operation TRAVELLING, SAFETY INSTRUCTIONS Have the attachment raised only so far as to permit the machine to be driven under overhead power lines without any risk.

Close the cab door.

If the machine is fitted with a safety belt for the operator, fasten the belt.

If the superstructure is turned by more than 90° from the BASIC POSITION, the excavator travels in the opposite direction to that selected.

If the position of the superstructure in relation to the undercarriage is not exactly known, touch the accelerator.

Lightly to see which direction the machine takes, before initiating the full travelling movement.

Warn persons in the immediate vicinity by sounding the horn before setting off.

Never drive across slopes.

Take the utmost care on slippery, greasy ground.

Sound the horn to warn persons in the immediate vicinity before starting travelling.

Do not exceed the maximum machine inclination (see “Maximum machine inclinations, information” chapter.

Running-in specifications for components of the crawler tracks Prior to initial commissioning and/or after repair work, run in the idlers, track rollers and support rollers as follow:

Fig. 2-49:

 Raise the equipment (Fig. 2-48:and Fig. 2-49:)  Drive the excavator in revers approx. 50 m (164ft).  Drive the excavator in forwards approx. 50 m (164ft).  Stop the excavator and measure the temperature at each idler, track roller and support roller with an infrared thermometer (at a temperature of approx. 100° C (212°F) wait for idlers, track rollers and support rollers to cool down).  Repeat this running-in procedure up to 10x.  Check all idlers, track rollers and support rollers for leaks.

The engine must be at operating temperature before being subjected to full load.

If the machine is to be driven a longer distance, the superstructure must be secured against turning by means of the superstructure holding brake.

Do not exceed the maximum machine inclination (see “Maximum machine inclinations, information” chapter.

Do not travel uphill or downhill with the excavator if the gradient is greater than 20°.

In this case, the engine may be insufficiently lubricated.

Fig. 2-48:

2-48

BA 6015(3 847 019.01)-EN

Operation TRAVELLING

Travelling forwards/backwards

Superstructure basic position

Travelling forwards:  depress pedals (81 and 82) forwardsThe excavator travels in the direction of the idler (2, Fig. 2-50:).

Travel direction and sense of actuation of pedals (81 and 82, Fig. 2-51:) are identical only when the excavator is in its BASIC POSITION (Fig. 2-50:).

Travelling backwards:  depress pedals (81 and 82, Fig. 2-51:) backwardsThe excavator travels in the direction of the drive sprocket (4,Fig. 2-50:).

During travelling, an acoustic warning (Travel Alarm) sounds.

Fig. 2-50:

If the superstructure is swinged out of its basic position by more than 90° (Fig. 2-52:), the excavator moves in a direction opposite to that expected when pedals (81 and 82, Fig. 2-51:) are depressed.

Fig. 2-52:

The pedals return automatically to their "0" positions when released.

Reverse the excavator only over short distances and with the assistance of marshallers because of restricted rear-view conditions.

Do not travel across slopes.

When travelling uphill or downhill, the travel drive must always be at the rear. Travel only in the basic position of the excavator and only forwards.

Be extremely careful on slippery and greasy ground.

Fig. 2-51:

If the operator is not completely sure of the position of the superstructure with regard to the undercarriage, pedals (81 and 82) should be depressed slightly in order to find out which way the excavator moves before initiating the full travelling movement.

Do not exceed the maximum machine inclination (see “Maximum machine inclinations, information” chapter.

All instructions with regard to travelling speed regulation and travel direction control are applicable only as long as the crawler tracks have sufficient grip and do not slip.

2-49

BA 6015(3 847 019.01)-EN

Operation Regulating the travelling speed Travelling on level ground Regulate the travelling speed with  pedals (81 and 82, Fig. 2-53:) and  the engine speed control (70).

Travelling uphill and downhill Read and observe the "Travelling Safety instructions" chapter.

Do not exceed the maximum machine inclination (see “Maximum machine inclinations, information” chapter.  Depress pedals (81 and 82,) fully to the limit stop.  Regulate the travel speed only with the engines speed control (70).

When travelling downhill, the travel retarder valve acts as a speed limiter.

The travel retarder valve works correctly if pedals (81 and 82) are fully depressed down to the limit stop.

Fig. 2-53:

Should the travelling speed become too high when travelling downhill release pedals (81 and 82) to stop the excavator.

Cornering To take a right-hand corner forwards  depress only peda l (82,) forwards.

To take a lefthand corner forwards  depress only pedal (81) forwards.

Turning To turn to the right  depress pedal (82) forwards and pedal (81) backwards.

To turn to the left  depress pedal (81) forwards and pedal (82) backwards.

2-50

BA 6015(3 847 019.01)-EN

Operation Note Change the position of the undercarriage - parallel or perpendicular to the working face - only by cornering forwards/backwards (Fig. 2-54:).

The same procedure should be adopted if the excavator is to be driven out of depressions (Fig. 2-55:): Cornering to the left

from pos. 1 to pos. 2

Cornering to the right from pos. 2 to pos. 3 Never use the working equipment to raise one side of the undercarriage and then turn the undercarriage by initiating the swinging and/or the travelling function.

This way of working is contrary to the excavator'sdesignated use.

There is a risk of accident. Moreover, the tracks, swinging gear, roller bearing swinging ring, backhoe or bucket back-wall and the front part of the bucket are subjected to inadmissibly high stresses.

Fig. 2-54:

Cornering to the left: forwards

from pos. 1 to pos. 2,

backwards

from pos. 2 to pos. 3,

forwards

from pos. 3 to pos. 4.

Fig. 2-55:

2-51

BA 6015(3 847 019.01)-EN

Operation

Travelling over long distances Travel only forwards with the hydraulic shovel in its basic position.

Travelling backwards over longer distances could damage parts of the undercarriage.

Read and observe the "Travelling – Safety instructions" chapter.

Backhoe bucket equipment (Fig. 2-57:):  Fully extend boom cylinder 1.  Retract backhoe cylinder 2.  Retract stick cylinder 3.  Extend backhoe cylinder 2 and stick cylinder (3) to such an extent as to reach the position of the equipment shown in Fig. 2-57:

Do not exceed the maximum machine inclination (see “Maximum machine inclinations, information” chapter.

When travelling, pay attention to sufficient headroom, e. g. under cable bridges and high-tension cables.

Keep the loading or the backhoe bucket close to the ground. For a more uniform loading of the tracks, the equipment must, however, be kept at a steep angle (Fig. 2-56: / Fig. 2-57:).

Fig. 2-57:

Lower the equipment when travelling underneath obstacles.

If the equipment position must be changed:  stop the excavator  change the position  continue to travel.

Fig. 2-56:

Loading bucket equipment (Fig. 2-56:):  Fully extend boom cylinder (1).  Extend bucket cylinder 2.  Extend stick cylinder 3.  Retract bucket cylinder 2 and stick cylinder (3) to such an extent as to reach the position of the equipment (Fig. 2-56:).

2-52

After travelling for 15 minutes without interruption, stop the excavator and check the temperatureof the track rollers.

If the temperature does not exceed ca. 100° C (212°F):  continue travelling.

In case of higher temperatures:  Stop travelling. Resume travelling only after the track rollers have cooled down to ca. 40° C (104°F).

BA 6015(3 847 019.01)-EN

Operation Locking the superstructure The superstructure can only be locked in the BASIC POSITION.

Lock the superstructure and the undercarriage:  when travelling over longer distances (more than 1 km), 

Track parking brake The excavator is equipped with two track brakes integrated in the track drives.

The track brakes are parking brakes which relieve the hydro-static travel drives during working operation and which protect the excavator against rolling forwards and backwards.

during transport.

Locking the superstructure (Fig. 2-58:):  Take locking bar (18) out of the tool box.  Swing superstructure slowly until the hole in superstructure is in alignment with with lugs (16).  Push locking pin (18) and recure with bolts.

After travelling or after transport:  remove locking pin and place back into the tool box.

Fig. 2-59:

The brakes are controlled by means of the travel pedals (81 and 82, Fig. 2-59:). In neutral position of the pedals, the brakes are applied and the excavator is braked. During travelling, the brakes are released.

When the excavator is stationary, the brakes can be applied with switch (65, Fig. 2-60:).

Fig. 2-58:

Fig. 2-60:

2-53

BA 6015(3 847 019.01)-EN

Operation TRANSPORTING THE MACHINE Transport - Safety instructions

The partly dismantled excavator can now be transported on a semi ow-bed trailer (low-bed trailer with front platform) (Fig. 2-61:).

The machine must be loaded and transported only after all safety regulations have been observed and complied with.

Entrust loading and transporting of the machine to a company experienced in the transport of heavy equipment.

The responsability for loading and transporting lies with the transport company or their representative.

Remove oil, grease, soil, mud, snow, ice and other materials from the excavator's crawler tracks and from ramps and loading platforms of the transport vehicle to minimize slipping.

Secure the transport vehicle against rolling away.

Use only tying equipment of sufficient strength (the weights and dimensions of the excavator are set out in the "Technical specifications").

Transport The dimensions and the service weight of the fully assembled excavator do not allow the excavator to be transported in an undismantled state on a lowbed trailer over public roads.

Therefore, the following components and modules must be dismantled beforehand:  counterweight 

operator's cab



excavating tool (loading bucket, backhoe bucket)



stick



boom

Fig. 2-61:

The dismantled components and modules must be transported on vehicles or low-bed trailers of sufficient size and carrying capacity.

Loading the excavator:  Lower the front platform of the low-bed trailer down to the ground.  Uncouple the front part of the low-bed trailer and pull it away with the truck tractor.  Drive the excavator (without counterweight) from the front over the lowered platform with the tracks straddling the low-bed trailer. Align the machine properly in the longitudinal and the transverse direction (Fig. 2-62:).

Fig. 2-62:

2-54

BA 6015(3 847 019.01)-EN

Operation

 Place solid timbers between the low-bed platform and the center part of the undercarriage (Fig. 2-64:).

 Couple the tractor to the low-bed trailer and raise the platform. The excavator is raised at the same time by the supporting timbers, so that the crawler tracks are clear of the ground (Fig. 2-64:).

Fig. 2-63:

Fig. 2-64:

 Lock the superstructure (Fig. 2-63:).

 Secure the excavator with suitable means (chain hoists, wire ropes, chains, turn-buckles) (Fig. 2-64:).

Unload the excavator in reverse order.

Unlock the superstructure before swinging it for the first time.

2-55

BA 6015(3 847 019.01)-EN

Operation WORKING OPERATION SAFETY INSTRUCTIONS Read the sections "Fundamental safety instructions" and "Operation, safety instructions" carefully and observe the instructions given in them.

Do not exceed the maximum machine inclination (see “Maximum machine inclinations, information” chapter.

Inspect the site for underground gas, power and water lines before starting work. Any damage to such lines is a risk to life!

Clean off any earth, mud, snow, ice, grease and oil adhering to your working footwear before operating the machine. There is otherwise a risk of slipping off the pedals and initiating inadvertent movements.

Running-in instructions for hydraulic cylinders Compression of an oil/air compound in a hydraulic cylinder may result in detonations which might damage pistons and sealing rings.

Prior to initial commissioning and/or after repairs, run in the hydraulic cylinders as follows:  Start up the engine and run at low speed.

The pressure-limiting valve in the hydraulic system must not respond 

In the first two working cycles, retract and extend the pistons of the hydraulic cylinders to max. ½ to ¾ (not to the limit stop).

Never change direction suddenly. The waiting time between changes of direction must be at least 4 seconds.



In the next eight working cycles, retract and extend the pistons of the hydraulic cylinders to the limit stop. The waiting time between changes of direction must be at least 4 seconds.



When all hydraulic cylinders have been run in, the excavator can operate at a higher engine speed.

Sound the horn to warn persons in the immediate vicinity before starting work.

Stop work if anyone is in the hazard range of the machine. Make sure they have left the hazard range before resuming work.

Never operate the machine unless it is standing on a reasonably horizontal, flat surface. The stability of the machine is otherwise at risk.

Ensure that the attachment has adequate clearance below overhead power lines and structures.

Trenches and working faces may give way. Keep well clear of them.

Do not operate the machine,  when several track rollers or support rollers have been removed; 

when one or several teeth on the backhoe or on the shovel are worn or missing;



when parts of the hardfacing layer on the backhoe or on the shovel are worn or missing.

Working under these circumstances results in heavy wear and possibly in severe damage and thus in high repair costs.

Such circumstances are considered by CGM HMS GmbH as "abusive utilization".

CGM HMS GmbH refuses to assume the guarantee for damage and consequential damage caused by an abusive utilization of the machine.

2-56

BA 6015(3 847 019.01)-EN

Operation Warming up the hydraulic system At low temperatures, bring the engine down to moderate speed, then activate all hydraulic functions for about 10 minutes (bring to service temperature). For further instructions, see section "Lubricants".

If the warning lamps for engine temperature, engine oilpressure, coolant level, alternator or hydraulic oil filter control (with hydraulic oil at service temperature) light up: Lower the working equipment and shut off engine.

Avoid extreme positions of the working attachment

Fig. 2-67

Parts of the attachment may damage the machine if they are moved into extreme positions (see illustrations Fig. 2-65 - Fig. 2-69).

Work carefully, avoiding extreme positions of this kind.

Fig. 2-68

Fig. 2-65

Fig. 2-69

Fig. 2-66

2-57

BA 6015(3 847 019.01)-EN

Operation Before starting work Prior to initial commissioning and after repairs on the central lubricating system or the hydraulic cylinders, move the unloaded equipment for abt.

5 minutes.

This is required to ensure an adequate supply of grease to the cylinder bearings when the work starts.

Switching on the servo control The servo control is switched on and off with switch (85, Fig. 2-70:) inside the operators seat.

Servo control activated: operator is sitting on his seat.

Servo control deactivated: operator's seat is empty.

Warn persons in the immediate vicinity by sounding the horn before starting work.

Wait until all persons have left the immediate vicinity.

Warming up At low outside temperatures it is necessary to run the hydraulic system up to operating temperature.

The temperatures at which warming up is necessary depend on the type of hydraulic oil used; cf. also "Oils for hydraulic systems".  Run the diesel engine at ca. 2/3 full speed and start to perform no-load working movements for abt. 10 minutes with the excavator.

2-58

Fig. 2-70:

BA 6015(3 847 019.01)-EN

Operation Swinging and braking the superstructure Swinging the superstructure The superstructure can only be swung if the superstructure holding brake is released.  To swing the superstructure to the right: shift control lever (87, Fig. 2-71:) to the right.

Superstructure holding brake The superstructure holding brake can be activated with momentary-contact switch (67, Fig. 2-72:).

The superstructure holding brake is released automatically when the "superstructure swinging" function is activated.

Actuate switch (67) only when the superstructure is stationary.

 To swing the superstructure to the left: shift control lever (87) to the left.

The superstructure holding brake is not suited for braking the swinging movement.

After releasing, the control lever returns automatically to position "0". But the superstructures motion will not be braked automatically then. To bring the superstructure to standstill, shift control lever (115) into the opposite direction of superstructures motion (countering).

Braking the superstructure The superstructures motion will not be braked automatically when releasing control lever (87, Fig. 2-71:).

The superstructure is braked onlywhen control lever (87) is shifted into the direction opposite the swinging movement (countering).

In case of emergency the superstructure holding brake can be activated with switch (67, Fig. 2-72:).

Fig. 2-72:

 To brake a swinging movement to the right: shift control lever (87) to the left.  To brake a swinging movement to the left: shift control lever (87) to the right.

Fig. 2-71:

2-59

BA 6015(3 847 019.01)-EN

Operation Working operations When released, all control levers for working operation return automatically to position "0".

Level a surface only in the bucket's digging direction. Never "beat" or "sweep" with the bucket.

Close bucket completely before beginning to dig. Do not level off a surface with the front shell of the bucket open

Raising and lowering the boom To raise the boom:  pull control lever (88, Fig. 2-73:) backwards.

To lower the boom:  push control lever (88) forwards.

To lower the boom with pressure:  depress button (79) and  push control lever (88) forwards.

Extending and retracting the bucket or backhoe bucket stick To extend the stick:  push control lever (87) forwards.

To retract the stick:  pull control lever (87) backwards.

Fig. 2-73:

Filling and emptying the bucket or the backhoe To fill/tip back the bucket:  shift control lever (88) to the left.

To empty the bucket by dumping / tipping:  shift control lever (88) to the right.

Opening and closing the bottom-dump bucket To open the bucket:  press pedal (83) forwards.

To close the bucket:  press pedal (83) backwards.

2-60

BA 6015(3 847 019.01)-EN

Operation After daily operation Parking the machine  Park the machine on level and stable ground. This is particularly important in winter to avoid freezing of the tracks.  Stand the working equipment on the ground.  Shut off the engine.  Shift both control levers into all directions todepressurize the hydraulic cylinders.  Withdraw the key from the electrical system key-switch.

Escaping oil pollutes the environment.

Repair leaks immediately (or have them repaired).

Report oil accidents to the user of the machine.  Check the superstructure, undercarriage and the working equipment for damage and all steel components for cracks or fractures.

 Close the cab window.

 Report detected damage immediately to the user.

 Lock the cab door and all lockable hatches and covers on the machine.

 Clean off gross dirt, ice and snow from the fins and the fan wheel of the hydraulic oil cooler

 Clean the machine of coarse dirt as well as of combustible and easily flammable substances, if possible with a stream jet (rubber parts and electric components with compressed air - refer to information label) Otherwise, the fire and explosion hazard will exist.  Fill up the fuel tank.  Inspect the engine, the hydraulic system, the track rollers, support rollers, idlers and gearboxes visually for leaks.

2-61

BA 6015(3 847 019.01)-EN

Operation ASSEMBLING WORKING EQUIPMENT - SAFETY INSTRUCTIONS Personel Assembly work may be carried out only by operating or maintenance personnel who have the necessary know-how at their disposal.

If such know-how is lacking, meticulous instruction must be given by experienced personnel, e.g. from CGM HMS GmbH. The operating manual, and in particular the section headed "Fundamental Safety Instructions", must have been read and understood.

Only such persons may start up the machine during assembly work in order to adjust the attachments.

Incorrect operation of the machine or the attachments may give rise to life-threatening situations.

Personal protective gear and working clothes Wear closely fitting working clothing when working on the machine. Loose, wide garments may catch on machine parts and result in injury.

Wear a safety helmet, safety footwear and gloves.

Tools and auxiliaries Tools, hoists, slings, trestles and other devices must be in a reliable, safe state.

Metal splinters may cause injury when accessory bolts are being driven in or out. A brass or copper mandrel should therefore be used for this purpose, and goggles must be worn.

Use only the steps, platforms and handrails when climbing onto or off the machine.

Always keep steps and platforms in a non-slip state. Remove any oil, grease, earth, clay, snow, ice and other foreign matter immediately.

Securing the working equipment Stand working equipment on the ground in such a way that no movements can be made if mechanical or hydraulic connections become detached.

Secure any equipment or component which is to be mounted or dismantled, or whose position is to be changed, with hoists or appropriate slinging/supporting devices to prevent them from moving, slipping or falling inadvertently.

Securing the machine Carry out work on the attachment only if the machine is secured as described in the "Securing the machine" section.

Selecting the attachments The machine can be equipped with various attachments. The components of the attachments are assembled with hydraulic cylinders and connectors. Components can be combined in various ways for optimum adaptation of the attachments to the specific application.

Operate the machine only with the equipment and component combinations expressly approved by CGM HMS GmbH for this type of machine.

Never install and commission other equipment and component combinations without CGM HMS GmbH first having inspected and approved the project in writing.

Protective roof against falling objects The machine is equipped with an integrated cabprotection roof (FOPS).

2-62

BA 6015(3 847 019.01)-EN

Operation Securing the machine Risk of injury.

The machine must not be started by unauthorized persons.

Therefore, secure the machine.

Observe the accident prevention regulations.

Depressurize pipeline systems, on which work is to be carried out, by appropriate measures.

Protective shrouds of moving machine parts may only be opened or removed when the drive unit is stationary and protected against inadvertent starting.

Before carrying out fitting works, the machine and the equipment must be protected against inadvertent starting by placing chocks under the tracks and by standing the working equipment on the ground.

Hydraulic and lubricating systems: Close all open bores, pipe and hose connections with pressureresistant plugs.

Refill collected hydraulic oil back into the hydraulic system only through the return-flow filters. Dispose of non re-usable oils without polluting the environment.

Secure the machine as described below:  before carrying out any fitting and modification work on the working equipment, 

before carrying out any servicing and repair work on the machine.

 Park the machine on level and stable ground.  Lock the superstructure.  Stand the working equipment on the ground.  Shut off the engine.  Depressurize the hydraulic system.  Withdraw the key from the key-switch.  Before carrying out works on the electrical system or before performing welding work on the machine, set battery main switch to position "OFF".  Insulate the connecting terminals and plugs properly.

All components of CGM HMS GmbH machines have been carefully purpose-coordinated. Troublefree operation and a long service life can only be achieved with original CGM HMS GmbH spare parts.

Respect the sequence of working operations when fitting or replacing the attachments. The sequence has been determined and tested by qualified experts.

2-63

BA 6015(3 847 019.01)-EN

Operation CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS) Use "GLEITMO 815" anti-corrosive agent only.

Other agents are not approved by CGM HMS GmbH All pins and bearings (bushings and hubs) of the working equipment or in equipment componenents must be treated with "GLEITMO 815" anticorrosive agent before fitting.

Doing so  permits easy fitting and dismantling 

protects against rust, oxidation and similar wear



prevents seizing and fretting corrosion in nonmoving parts of bearings.

This is achieved by aluminium and copper particles forming a protective layer on the metal. This layer removes surface irregularities and does not sweat, seize or harden.

Part no. for "GLEITMO 815" is 2764305, available from CGM HMS GmbH Spare-Parts Service

2-64

Application of "GLEITMO 815"  Clean off grease, oil, dirt and corrosion protection agents from pins and bearings using white spirit or diesel fuel.

Rust patches must be thoroughly removed, if any.

All parts must present a dry, bright metal surface.  Apply a thin layer of "GLEITMO 815" on pins and all bearings using a brush or a spray can.

Pin shafts and bearings must be completely co-vered by the protective layer.

If the protective layer of a pin already treated with "GLEITMO 815" is damaged, these areas must be touched up before fitting the part.  Fitting and securing of pins.

If the pin is too heavy to be fitted manually, apply "GLEITMO 815" at first only on abt. a quarter of the pin's length.

Then position pin by means of a lifting gearready for fitting.

Apply "GLEITMO 815" on the remaining length of pin shaft, fit pin and secure.

BA 6015(3 847 019.01)-EN

Operation LIFTING OPERATIONS Safety instructions Never use the machine for lifting-gear operation unless it is equipped and approved for this purpose, i.e. the machine must be equipped with an overload warning system and a pipe break protection.

Read the sections "Fundamental safety instructions" and "Operation safety instructions" with care and observe the instructions contained in them.

Switch the overload warning system on. (cf. "Product Specification Sheet").

Room for slingers

Register the weight of the load. Sling only those loads not exceeding the load capacity of the lifting gear and of the machine Sling the load in such a way as to prevent it from slipping or falling while being lifted or transported.

Transporting the load Never move the load above persons. Keep the load as close as possible to the ground. Prevent the load from swinging The machine must never be driven with a slung load unless the road surface is even and the roadway is clearly visible.

Roadway visibility can be improved by adjusting the boom and swinging the superstructure to the right.

The built-in overload warning device cannot totally exclude accidents due to incorrect operation. This applies in particular to:  inadequate hooking of the load or the loadcarrying device,

Slingers must approach the working gear from the side when the load is slung.



During the lifting and transporting of loads, slingers or other assistant personnel must stand in a safe position or go beside the machine to ensure that they are outside the hazard zone.

excessive deceleration or acceleration forces (hard braking or strong swinging with the load to be moved),



loads dropping into the cable,



oblique pull,

Ensure that slingers and other assistant personnel are always in sight.



driving the excavator into an area with steeply sloping ground,



exposure to strong wind.

Slinging loads Use only tested and efficient lifting gear with an adequate load capacity.

Avoid these risks by handling the machine carefully and with discretion.

Hoist the load only from the hooks provided for that purpose.

Never use the the teeth of backhoe buckets, shovels or grabs.

Cable lugs, thimbles or U-bolts may slip from the teeth, putting the load out of control.

2-65

BA 6015(3 847 019.01)-EN

Operation Load-hooks on backhoe buckets.

Lifting capacity of the load hook

In order to be able to use the excavator with backhoe attachment also for short lifting operations, the backhoe buckets are available with welded loadhooks (Fig. 2-74: and Fig. 2-75:) (optional equipment).

The maximum lifting capacity of the load-hook is indicated besides the hook (Fig. 2-74: and Fig. 2-75:).

Read and observe "Lifting-gear operation - Safety instructions".

Lifting capacity of the excavator The admissible lifting capacity as a function of the working range is set out in the load table, see "Product Specification Sheet".

Switch on your overload warning system.

Fig. 2-75:

Fig. 2-74:

2-66

BA 6015(3 847 019.01)-EN

Operation Overload warning system

Checking the overload warning system

Hydraulic excavators that are used as lifting gear or for the transport of loads must be equipped with an overload warning system.

Check the overload warning system for safe operation before beginning to work with the loadhook.

The overload warning system consists mainly of an electro-hydraulic switching unit which gives an optical and an acoustic warning signal before the maximum admissible load moment is reached.

In case of malfunctions have the overload warning system immediately checked and repaired by CGM HMS GmbH.

Do not switch off the overload warning system when the warning signal sounds.

The overload warning system must be on during lifting-gear operation.

Do not make re-adjustments or repairs of the overload warning system.

Re-adjustments or repairs might lead to incorrect operation or failure of the system.

The overload warning system only gives warning signals.

Putting the overload warning system out of operation

It cannot avert the danger of overturning.

Shut off the overload warning system if the machine is to be used exclusively for digging.

When the warning signal sounds: - let the load down immediately - reduce the working radius or the load.

In spite of the overload warning system, the operator must assure himself beforehand that the load to be lifted does not exceed the excavator's lifting capacity.

The admissible load moment is exceeded if too big a load is being lifted with a large working radius of the equipment (lifting capacity cf. the "Lifting capacity of the excavator" section).

2-67

BA 6015(3 847 019.01)-EN

Operation Pipe burst protection

Speed reduction function

The pipe burst protection prevents uncontrolled lowering of the working equipment if a hydraulic line to the boom cylinder bursts.

Do not activate the speed reduction function when the machine is used for lifting operations and during travelling.

The hydraulic port on the rod-side of the boom cylinder is blocked off so that the hydraulic oil in the cylinder can flow out only if the "boom lowering" function is activated.

When a hydraulic line has broken:  Warn persons in the vicinity of the machine by sounding the signal horn.

Stop working.  Secure the area within reach of the working equipment and the attached load.

Persons must be prevented from entering the hazard zone under the working equipment or the suspended load.

The speed reduction function can cause the hydraulic output to drop off suddenly.

The speed reduction sets the drive engine back to idling speed if the working equipment remains inactivated during more than 10 seconds.

 Replace the broken hydraulic line or have it replaced before continuing the work.  Absorb spilt hydraulic oil and dispose of oilsoaked cleaning rags, binding agents, etc. without polluting the environment.

Fig. 2-76:

Switching on the speed reduction:  Set toggle switch to the left (57, Fig. 2-76:) Indicator lamp (27, Fig. 2-77:) lights up when the the speed reduction function is active.

Switching off the speed reduction:  Set toggle switch (57) to the left.

Fig. 2-77:

2-68

BA 6015(3 847 019.01)-EN

Operation Hydraulic hammer Working with the hydraulic hammer - Safety instructions Nobody must stand in the hazard range of the hammer.

Risk of injury by splintering stones.

Stop the work immediately if persons enter the hazard range of the hammer or the machine.

Close the front window of the machine before putting the hammer into operation.

Mount a protective grid as a splinter protection.

Wear ear protectors.

Operate the hammer only when sitting in the operator's seat.

The power of the machine and that of the hydraulic hammer must be adapted to each other. In case of doubt, contact the CGM HMS GmbH Service.

Do not change the setting of the pressure-relief valves without approval and do not remove lead seals.

Observe the Operation and Maintenance Manual of the hammer manufacturer.

Stop the work immediately when oil losse are detected. Collect escaping oil and discard without polluting the environment.

Report oil accidents immediately to the user or his representative.

Repair leaks and damage immediately or have them repaired.

2-69

BA 6015(3 847 019.01)-EN

Operation

2-70

BA 6015(3 847 019.01)-EN

Operation NOTES ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... .......................................................................................................................................................................

2-71

BA 6015(3 847 019.01)-EN

Operation

2-72

BA 6015(3 847 019.01)-EN

Inspection and servicing 3 INSPECTION AND SERVICING

Operation and Maintenance Manual

Target group

Part 1 INTRODUCTION FUNDAMENTAL SAFETY INSTRUCTIONS

Operating personnel + Inspection and servicing personnel + Repair personnel

Part 2 OPERATION

Operating personnel The operating personnel must have knowhow relevant to the operation and the application of this or comparable machines.

Part 3 INSPECTION AND SERVICING Part 4 REPAIR WORK

Inspection and servicing personnel The inspection and servicing personnel must have know-how relevant to the inspection and servicing of this or comparable machines.

Repair personnel The repair personnel must have know-how and experience relevant to the repair of this or comparable machines.

Part 5 ANNEX

Part 6 INDEX

Operating personnel + Inspection and servicing personnel + Repair personnel Operating personnel + Inspection and servicing personnel + Repair personnel

3-1

BA 6015(3 847 019.01)-EN

Inspection and servicing

3-2

BA 6015(3 847 019.01)-EN

Inspection and servicing INSPECTION AND SERVICING SAFETY INSTRUCTIONS

Securing the machine

Operating manual

Carry out servicing work only if the machine is secured as described in the section "Securing the machine".

No inspection and servicing work must be carried out until the operating manual has been read and understood.

Climbing onto and off the machine

Pay special attention to: „Fundamental safety instructions" and all warnings and safety instructions attached to the machine.

Use only the ladders, steps, platforms and handrails provided when climbing onto or off the machine.

The operating manual lists all jobs to be done. The descriptions of job sequences, however, provide only

Always keep ladders, steps, platforms and handrails in a non-slip, safe state and remove any oil, grease, soil, clay, snow, ice and other foreign matter immediately.

Experienced personnel with the necessary instructions.

Always face the machine when climbing on and off.

The operating manual must be kept with the machine at all times.

Inspection and servicing personnel Inspection and servicing personnel must have the necessary know-how on the inspection and servicing of this or comparable machines.

The necessary know-how can be acquired in a several day's instruction, e.g. by an CGM HMS GmbH mechanic or by attending an CGM HMS GmbH training course.

Personal protective equipment and working clothing Wear closely fitting working clothing when working on the machine. Loose, wide garments may catch on machine parts and result in injury.

Wear a safety helmet, safety footwear, gloves and, in the event of high noise levels, ear protectors.

Securing the working equipment Stand working equipment on the ground in such a way that no movements can be made if mechanical or hydraulical connections become detached.

Secure any equipment or component which is to be mounted or dismantled, or whose position is to be changed, with hoists or appropriate slinging / supporting devices to prevent them from moving, slipping or falling inadvertently.

Checking the state of tools Use only fully functional, reliable tools.

Select the right tool for the job.

Wrenches of the wrong size, for example, may slip and cause injury.

Cleaning jobs Prior to commencing work, clean your working area, if necessary and possible, with a stream jet (rubber parts and electric components with compressed air - refer to information label).

Exhaust pipes and turbo chargers in the engine compartments are covered with special heatinsulating material. This material must not be spraywashed with steam-jet cleaners or highpressure cleaners. It will be damaged. Therefore cover all the insulating material with plastic foils before using steam-jet cleaners or high-pressure cleaners inside the engine compartments.

Use only lint-free cleaning rags when working on the hydraulic system or the engines.

Cleaning agents and solvents may give off harmful, readily flammable vapours. Never work with such agents except on well ventilated premises; never inhale the vapours and never smoke.

Prevent solvents and cleaning agents from coming into contact with your skin.

Wear gloves.

Observe the instructions on the packaging.

3-3

BA 6015(3 847 019.01)-EN

Inspection and servicing Handling flammable liquids

Visisble oil losses

When handling flammable liquids:

Have any visible leakage repaired immediately.



never smoke,

Escaping oil is an environmental hazard.



keep away from unshielded light sources and naked flames,

Fuel and other consumables often have low flash points and are readily ignited. Never attempt to extinguish burning liquids with water.

Use: 

dry powder,



carbon dioxide or



foam extinguishers.

Water used for extinguishing purposes would vapourize instantaneously on contact with burning substances and spread burning oil, for example, over a wide area. Water generates short circuits in the electrical system, possibly producing hazards.

Notify the fire brigade.

Fastening and securing elements Check fastening and securing elements, e.g. bolts, nuts, washers, before using them again.

Replace any damaged parts.

Spare parts Use only the original sparts parts of CGM HMS GmbH. They are the only ones to fulfill the technical specifications of the machine.

Soak up any oil that has escaped with a binding agent.

Sweep up binding agent and dispose of it separately from other waste.

Relieving residual pressure in the hydraulic system Only unpressurized hydraulic systems may be opened. Even when a machine is parked on a horizontal surface with ist attachments supported on the ground and its driving motors switched off, there may still be substantial residual pressure in parts of the hydraulic system, e.g. primary pressure from the last hydraulic movements prior to stopping the machine.

Residual pressure is reduced only gradually. If an intervention into the hydraulic system is to be undertaken immediately after stopping, the system must be depressurzized: (do not leave the operator's seat)  Stand working equipment on the ground,  Shut off the engines,  Move all control levers and pedals repeatedly into all ndirections.

Screwed connections, piping, hydraulic hoses Repair any leakage in the piping and hose system immediately.

Handling oils and greases Hot lubricant or hydraulic oil emerging uncontrolled from the system may result in severe burns.

Never set foot withing reach of the emerging oil jet.

Avoid contact with the skin. Wear gloves and firm protective clothing.

Used oil may be harmful to the skin.

Clean soiled skin thoroughly with warm soapy water and apply a barrier cream. Never use fuels or solvents for cleaning the skin.

If you have swallowed any oil, avoid vomiting but consult a doctor immediately.

3-4

A fine, highly pressurized jet of hydraulic oil can penetrate the skin.

Never search for leakages with the fingers, but use a piece of cardboard and always wear goggles.

If oil has penetrated into the skin, consult a doctor immediately.

Never repair damaged piping; always replace them.

Replace hydraulic hoses immediately on detecting any damage or moist areas.

Tighten leaking screw plugs only when the system is depressurized.

Escaping oil is an environmental hazard.

BA 6015(3 847 019.01)-EN

Inspection and servicing

Non-polluting disposal Dispose of oils, greases, cooling liquids, detergents, solvents and oil-containing components, such as filters, cleaning rags, replaced wearing parts and unusable machine parts, without polluting the environment and separately from other waste.

Do not dispose of these substances together with household wastes.

Fill these substances into the containers provided for such purposes.

Like any other oil, also bio-degradable, "environmental-friendly" hydraulic oil must be disposed of separately.

Do not allow oils and oily wastes to penetrate into the soil or into water. They are an environmental hazard.

Engine exhaust gases Start and operate combustion engines only on well-ventilated premises.

In closed rooms, exhaust gases must be evacuated to the outside; Do not work on the exhaust system and do not make any modifications to it.

Exhaust gases from diesel engines and some of their constituents may cause cancer, birth defects and other reproductive harm.

Handling batteries Battery Posts, terminals and related accessories contain lead and lead compounds, chemicals known to cause cancer and reproductive harm.

Wash hands after handling.

Used pressure vessels for cold-starting fluid (ether) must be disposed of properly. Contact the supplier with regard to disposal / return of the vessels.

Batteries give off explosive gases.

Even apparently empty pressure vessels can contain rests of ether and therefore explode if they are damaged or heated up above 49°C / 120°F. They must therefore be handled in the same way as full pressure vessels.

Avoid any contact with the skin, mouth, eyes and clothing. Avoid spilling battery acid or inhaling the vapours.

Never handle batteries close to naked flames and unshielded light sources, never smoke.

Battery acid is toxic and corrosive.

Wear gloves, firm protective clothing and goggles / face protection shield when handling batteries.



Do not keep them on the machine.



Do not damage or open the vessels.

If the skin is splashed with acid, rinse thoroughly with running water and consult a doctor.



Do not expose the vessels to great heat or direct sunlight.



If the eyes are splashed with acid, rinse thoroughly with running water and consult a doctor immediately.

Do not dispose of in fire.



Keep the vessels in a place inaccessible to unauthorized persons.

Never set tools down on the battery. They may induce a short circuit, causing irreparable damage to the battery and injuring persons.



Dispose of the vessels properly.

Seals After replacing parts or after opening housings replace seals. Always use new seals and gaskets.

Clean sealing faces prior to assembly.

Individual spares may contain asbestos. Such spares or their packaging are marked with: Never process spares containing asbestos mechanically. Inhaling asbestos dust is a health hazard.

Clean sealing faces prior to assembly.

Never wear metal necklaces, bracelets or watchstraps when working on the battery. The metal parts may induce a short-circuit resulting in burns.

Dispose of used batteries separately from other waste in the interests of environmental protection.

Before working on the electrical system Before performing work on the electrical system where tools, spare parts, etc. can come into contact with electrical conductors or contacts, the battery must be disconnected.

Disconnect first the negative and then the positive terminal.

After the work: Reconnect first the positive and then the negative terminal.

3-5

BA 6015(3 847 019.01)-EN

Inspection and servicing Handling of cold-starting fluid (ether)

Filters

The engine compartment can be equipped with pressure vessels containing cold-starting fluid (ether).

Replace / clean all filter elements or filter cartridges within the specified periods.

Ether is toxic and highly flammable; the vessels are under pressure. These pressure vessels can explode if exposed to high temperatures (above 49°C / 120°F) or in the event of damage.

Protect the pressure vessels against damage before beginning to work in or close to the engine compartment.

Read and observe the instructions on the pressure vessels.

For further details please refer to the instructions and safety data-sheets of the manufacturer / supplier of pressure vessels with cold starting fluid (ether).

Provide for sufficient ventilation.

Do not eat, drink or smoke when replacing an empty vessel.

Do not inhale the vapours of escaping cold-starting fluid.

In contact with the skin, ether can cause frostbites and irritations. Avoid skin contact.

All filters are coordinated carefully with the equipment. Original CGM HMS GmbH parts must be used to ensure smooth running and a long service life of the engine and the hydraulic units.

Sealing elements When dismantling parts, watch for sealing elements.

Check sealing elements prior to installation and replace any that are even slightly damaged.

When assembling, ensure a perfect fit.

Oil-level check and oil change Position the machine horizontally.

Change the oil when the machine is at operating temperature. Warm oil flows better and carries suspended particles (carbon or abraded matter) better.

Wear suitable protective gloves and goggles.

Even apparently empty pressure vessels can still contain rests of ether and therefore explode if they are damaged or heated up above 49°C. They must therefore be handled in the same way as full pressure vessels. 

Do not keep them on the machine.



Do not damage or open the vessels.



Do not expose the vessels to great heat or direct sunlight.



Do not dispose of in fire.



Keep the vessels in a place inaccessible to unauthorized persons.



Dispose of the vessels properly.

Selecting oils and greases Use the recommended qualities only, matching viscosities with the temperature level.

3-6

Lubricating Clean the lubricating nipple, then lubricate as scheduled.

After servicing To prevent corrosion, coat all bright metal parts with a grease film.

On completing work, re-install all protective devices.

Never start up the drive motors while work is being done on the machine.

Carry out performance tests with the machine.

BA 6015(3 847 019.01)-EN

Inspection and servicing INSPECTION AND SERVICING WORK, FIRE AND EXPLOSION HAZARD Safety instructions Prior to commencing work, obtain informationon the national and corporate rules for the prevention of accidents and avoiding fires.

Pay particular attention to hazards caused by combustible and easily flammable substances.

Obtain information on the safe handling of the fire extinguishers to be used.

Avoid smoking and open fire on, next to and below the hydraulic shovel.

Even battery gases can ignite in open flames or fire.

Combustible and easily or highly inflammable substances or liquids increase the risk of fire and explosion. This is also valid for pressure vessels containing flammable substances as, for instance, spray oil or cold-starting fluid (ether). They are heat-sensitive and can explode even if exposed only to intensive sunlight.

These substance can also ignite themselves if they come close to hot units or objects as, for instance, a turbocharger.

Do not store these substances on the hydraulic shovel. If combustible, easily or highly flammable substances or liquids were used during maintenance operations, they must be completely removed from the hydraulic shovel at the end of the work.

Place suitable fire guardings (fire barriers) if open fire or flying sparks cannot be avoided during repair work.

If necessary, also cover the ground with fireprotective blankets.

Apply special protection to cables, cable ducts as well as to hose and pipe lines.

Have all your welding, flame cutting and grinding work approved before starting work.

The engine compartment can be equipped with pressure vessels containing cold-starting fluid (ether). Ether is toxic and highly flammable; the vessels are under pressure. These pressure vessels can explode if exposed to high temperatures (above 49°C / 120°F) or in the event of damage.

Protect the pressure vessels against damage before beginning to work in or close to the engine compartment.

Ensure sufficient ventilation.

Do not keep any fire extinguishers that are not suitable or have not been tested.

Do not extinguish flammable liquids with water.

Use: 

dry-powder, carbon-dioxide or foam extinguishing compounds.

When getting into contact with burning substances, the fire-fighting water would abruptly evaporate and distribute the substance such as oil over a wide area. Water causes short-circuits in the electrical system thus possibly entailing new hazards.

Call the fire brigade.

Clean the hydraulic shovel carefully after the maintenance, if oil, grease, fuel, detergents or cold-starting fluid have been spilt over the machine. If possible, use a steam-jet cleaner for cleaning.

Avoid parking the hydraulic shovel in places where 

combustible substances such as coal dust or tar are present.



open or smouldering fire may occur.

Remove the hydraulic shovel from such an area where combustible or easily flammable liquids have spilled from the hydraulic shovel onto the ground.

Flying sparks (caused by welding, flame cutting, grinding, electrical short-circuit) may cause fire on the ground that can spread to the hydraulic shovel.

3-7

BA 6015(3 847 019.01)-EN

Inspection and servicing ENVIRONMENTALLY COMPATIBLE HYDRAULIC FLUID Environmentally compatible hydraulic fluid - Operation and Maintenance Manual The hydraulic system of this machine can be filled ex works with environmentally compatible, synthetic hydraulic fluid as an option. In this case, the machine is supplied with stickers containing the corresponding instructions.

For the initial filling, CGM HMS GmbH uses only: PANOLIN HLP SYNTH 68 CGM HMS GmbH (P/N: 2115005).

This synthetic hydraulic fluid has been tested by CGM HMS GmbH and approved for application in CGM HMS GmbH machines.

A change from mineral hydraulic oil to this synthetic hydraulic fluid can, however, be made also at a later date.

Environmentally compatible hydraulic fluid, too, must not be simply poured away but disposed of in the same way as used oil.

If hydraulic fluid seeps into the ground, the machine owner and the competent authorities must be informed. HLP SYNTH 68 is suitable only for hydraulic systems.

Operating equipment and attachments driven with mineral hydraulic oil must not be mounted until thoroughly emptied, cleaned and flushed.

Analysis will show whether the hydraulic fluid can be used beyond the standard changing intervals.

See section: "Environmentally compatible hydraulic fluid, sampling".

Environmentally compatible hydraulic fluid, conversion Read and observe: "Inspection and Servicing - Safety Instructions".

 Bring hydraulic system to operating temperature.  Retract all hydraulic cylinders.  Drain off hydraulic oil (see Operation and Maintenance Manual, section 3 "Inspection and Servicing").  Fill hydraulic oil tank with HLP SYNTH 68 up to halfway mark.  Activate all hydraulic functions including travelling for about 30 minutes. The hydraulic system is being flushed during this time.

As HLP SYNTH 68 is not soluble in water This means that condensate may be deposited in the hydraulic oil tank.

It must therefore be drained off at regular intervals and after lengthy downtimes, then disposed of in the same way as used oil.

Then drain off the hydraulic fluid.

The fluid can be used repeatedly for flushing. Otherwise it must be properly disposed of. In this case, a disposal expert must be consulted as this is a mixture of synthetic hydraulic fluid and mineral hydraulic oil.

Use only HLP SYNTH 68 for changing or topping up the hydraulic fluid.

The hydraulic fluid must not be mixed with hydraulic oils or hydraulic fluids by other manufacturers, as this affects its biodegradability.

 Change all filters in the hydraulic system.

3-8

Fill the hydraulic oil tanks with new HLP SYNTH 68.

BA 6015(3 847 019.01)-EN

Inspection and servicing Fix an instruction sticker (Fig. 3-1:): 

in the cab,



on the hydraulic oil tank and



on hydraulically-operated attachment.

Environmentally compatible hydraulic fluid - Sampling Complete sets are compiled for hydraulic fluid analysis. They contain all necessary parts. 

Sets are available from the CGM HMS GmbH Spare-Parts Service: Part-No. 1 465 077.



Hydraulic fluid analyses are performed by: WEARCHECK GmbH Bahnhofstraße 75 D-83098 Brannenburg

 After 30 - 50 operating hours with environmentally compatible hydraulic fluid, take a sample of the hydraulic fluid.  Send this sample in to the above address for analysis.

Fig. 3-1:

 Start up the machine. Check level in hydraulic tank according to servicing plan.  The hydraulic fluid may dissolve deposits in the hydraulic system.

So change all filters 30 - 50 operating hours after making the change.

Make further filter changes according to servicing plan.  Sample the hydraulic fluid after 30 - 50 operating hours and send in for analysis. (See section: "Environmentally compatible hydraulic fluid, sampling").

The company will then notify you of the result of the analysis.

After this, CGM HMS GmbH recommends sending in a sample for analysis every 1000 operating hours or once a year.

It is essential that the hydraulic fluid should be analysed not later than after 3000 operating hours.

The results of the analysis show whether the hydraulic fluid is still serviceable and the changing interval can be extended.

In case of questions contact the CGM HMS GmbH Service.

3-9

BA 6015(3 847 019.01)-EN

Inspection and servicing ENVIRONMENT-FRIENDLY LUBRICANTS AND GEARBOX OILS Lubricants for bearings The machine can be lubricated with an environment-friendly grease.

Environment-friendly grease can be used in the central lubricating system, in all other bearings and in the roller-bearing swinging ring.

BP Biogrease E2 is approved by CGM HMS GmbH as an environmentfriendly grease.

3-10

Gearbox oils Environment-friendly gearbox oils are not approved by CGM HMS GmbH for use in the travelling, swinging and pump transfers gearboxes.

BA 6015(3 847 019.01)-EN

Inspection and servicing INSPECTION AND SERVICING PLANS - INSTRUCTIONS Intervals The inspection and Servicing plan lists all jobs which have to be done on the machine at regular intervals.

The individual inspection and Servicing plans are marked with letters providing a link between the operating hours (OH) recorded by the hours-run meter of the machine and the inspection and sServicing plans.

Plan V N

Do all jobs .... ...once prior to initial commissioning. ...after initial commissioning and during the running-in period (up to 100 OH). ...every 10 OH or every working shift 1) T 2 ...every 60 OH or weekly .

W ...after every 250 OH. A ...after every 500 OH. B ...after every 1000 OH. C ...after every 5000 OH. D ...after every 10000 OH. E OH = Bh = Operating hours

Air-intake system The air filter must be serviced only if the BCS so indicates. Replace the filter elements after one year at the latest.

Oils / Greases For the specification of oils and greases to be used refer to the „LUBRICANTS / CONSUMABLES“ section.

The numerals mentioned in the "Oil / Grease" column in the inspection and Servicing plans have the following meaning: Oils for combustion engines and comI pressors Oils for hydraulic systems II IIIa, b, c Oils for gearboxes Greases for bearings and swing rings V

Cleaning jobs Cleaning jobs, especially on cooling systems, must be done at shorter intervals if the machine is exposed to severe dust build-up.

Components Change of engine oil The intervals stated for changing the engine oil apply to fuels with a sulphur content of  0.5% and a permanent ambient temperature down to –10° C (14 °F).

In case of higher sulphur content and/or a permanent ambient temperature of below –10° C (14 °F), shorter intervals are required.

The maintenance intervals for components, e.g. engine and gearbox, are listed in the following CGM HMS GmbH maintenance schedules.

It is possible that the manufacturer's documentation for these components states intervals deviating from the above-mentioned intervals.

In such case, only the maintenance intervals specified by CGM HMS GmbH shall apply.

If the engine oil change intervals are not reached within 6 months, the oil must be changed at least after 6 months.

2

Whichever comes first.

3-11

BA 6015(3 847 019.01)-EN

Inspection and servicing

3-12

BA 6015(3 847 019.01)-EN

Inspection and servicing Plan V Plan V - Once prior to initial commissioning Location

Servicing work

Page 1 of 2 Quantity/ No.

Engine

Check oil level

1

Check

1

Battery

Check charge level

2

Lighting

Check operation

Monitoring, warning and control elements

Check function of monitoring, warning and control elements

Cooling system Cooling liquid Electrical system

Fuel system Refuelling station (option) - Earthing strap (equipotential bonding)

Check tightness

Hydraulic system

Check function of working and travelling movement

1

Check pressure (see Service Manual) Hydraulic oil reservoir

Check oil level

1

Hydraulic cylinders

Vent (see chapter “Venting hydraulic system“)

Pump drive gearbox and cooling circuit

Check oil level

1

- Pump mounting flanges, expansion reservoir

Check oil level

1

Swing gearbox

Check oil level

1

Travel gearbox

Check oil level

2x1

Swing ring Internal gearing

Check grease filling

1

Undercarriage Track roller

Check for leaks and free movement

2x8

Support roller

Check for leaks and free movement

2x1

Track

Check pressure (see Service Manual)

2

Idler

Check leaks and free movement

2

3-13

BA 6015(3 847 019.01)-EN

Inspection and servicing Plan V - Once prior to initial commissioning Location

Servicing work

Page 2 of 2 Quantity/ No.

Central lubricating system Grease container

Check filling level (indicator lamp)

1

- Compressor

Check oil level

1

All lines, fittings and connections

Inspect visually for leaks, wearing marks

All articutated joints and hinges

Grease

Air conditioner (optional)

3-14

BA 6015(3 847 019.01)-EN

Inspection and servicing Plan N Plan N – After initial commissioning and during the running-in period (up to 100 OH) Page 1 of 1 Location

Servicing work

Quantity/ No.

Engine (after 100 OH) - Bearing, fastening bolts

Check for tightness (see Service Manual)

- V-belt / Poly-V-belt

Visual check, check for tightness

Cooling system Radiator - Bearing, fastening bolts

Check for tightness (see Service Manual)

Cooling liquid

Carry out analysis of cooling liquid after 500 OH (see: Operation and Maintenance Manual of the engine)

Hydraulic system Oil cooler - Bearing, fastening bolts

Check for tightness (see Service Manual)

Return-flow filter

Replace

4

Magnetic rod

Clean

3

Pressure accumulator – emergency lowering

Check function

1

Pressure accumulator – track tensioner

Check function

2x1

Pump drive gearbox and cooling circuit

Change oil (See chapter „Pump drive gearbox - Changing the gearbox oil“)

1

- Pump mounting flanges, expansion reservoir

Change oil

13

Swing gearbox

Change oil

1

Fastening bolts

Check for tightness (see Service Manual)

Travel gearbox

Change oil

Fastening bolts

Check for tightness (see Service Manual)

3

3

3

2x1

Swing ring Fastening bolts (swing ring, undercarriage and superstructure)

Check for tightness (see Service Manual)

Superstructure Fastening bolts, especially at superstructure / pedestal / operator´s cab

Check for tightness (see Service Manual)

Undercarriage Fastening bolts, track pads

Check for tightness (see: Service Manual)

All lines, fittings and connections

Inspect visually for leaks, wearing marks

3

see: “Refilling quantities – Oil“ table 3-15

BA 6015(3 847 019.01)-EN

Inspection and servicing

This page intentionally left blank.

3-16

BA 6015(3 847 019.01)-EN

Inspection and servicing Plan T and W Plan T - Every 10 OH or every working shift (whichever comes first) Plan W - Every 60 OH or every working week (whichever comes first) Page 1 of 2 Location

Servicing work

Quantity/ No. 1

Plan T 

Plan W 

Engine

Check oil level

Cooling fluid level

Check

1





Radiator

Check / clean

1





Fuel filter

Drain off water

1





Water trap (optional)

Drain off water

1





Vacuum-meter

Check indication

2





Intake and clean-air lines

Check for tightness and leaks

Dust trap

Clean

2x1





Cyclon-Prefilter

Check / clean

2x1









Cooling system

Fuel system

Air-intake system 

Electrical system Lighting

Check operation

Switchgear cabinet 

- Breather filter, dust trap

Check / clean

1

Monitoring, warning and control elements

Check function of monitoring, warning and control elements





Hydraulic system

Check function of working and travelling movement



 

Inspect visually for leaks 



Hydraulic oil reservoir

Check oil level

1

Oil cooler

Check / clean

1

Fan wheel

Check condition

1

Pump drive gearbox and cooling circuit

Check oil level

1

- Pump mounting flanges, expansion reservoir

Check oil level

1

- Gearbox

Check for unusual noises or smells, higher temperatures or vibrations. If in doubt, contact your Caterpillar dealer service.

1



- Gearbox and radiator

Check for excessive dirt and dust, clean to prevent overheating.

1



Swing gearbox

Check oil level

1





Travel gearbox

Check for leaks

2x1





 

 





3-17

BA 6015(3 847 019.01)-EN

Inspection and servicing

Plan T - Every 10 OH or every working shift (whichever comes first) Plan W - Every 60 OH or every working week (whichever comes first) Quantity/ No.

Page 2 of 2 Plan Plan T W

Location

Servicing work

Undercarriage Tracks

Inspect track tension visually

2x1

Track roller

Check for leaks and free movement

2x8



Support roller

Check for leaks and free movement

2x1



Idler

Check for leaks and free movement

2x1



Grease container

Check grease level (warning lamp)

1

Lubricating points

Check for incoming grease

Air conditioner (optional)

(see: “Air Conditioning manual“)

1

Fire extinguisher

Check condition

1





1













Central lubricating system

Automatic fire-extinguishing sys- Check control module tem (optional) All lines, fittings and connections Inspect visually for leaks, wearing marks







 

Operator’s cab - Window panes

Clean





- Mirrors

Clean / adjust





Excavator

Check visually / Overall cleaning

3-18



BA 6015(3 847 019.01)-EN

Inspection and servicing Plan A – E Plan A - after every 250 OH (at 250, 750, 1250 ... OH)

Plan B - after every 500 OH (at 500, 1500, 2500 ... OH)

Plan C - after every 1000 OH (at 1000, 2000, 3000, 4000 ... OH)

Plan D - after every 5000 OH (at 5000, 15000, 25000 ... OH)

Plan E - after every 10000 OH (at 10000, 20000, 30000, ... OH)

Location

Servicing work

Menge / No.

Servicing acc. with W or T

Page 1 of 5 Plan Plan Plan Plan Plan A B C D E     

Engine Inspection and servicing

See: Operation and Mainte-

Oil

Carry out oil analysis

nance Manual of the engine Oil

Change oil

1

4



























Clean 









Check tension











Check condition











Oil filter

Replace

V-belt V-belt

2

- Bearing - Fastening bolts

Check tightness







- Rubber bearing

Check condition







Crankcase breather

Clean

1











Groundscrew engine electronics

Check, clean, fasten

1











Starter

Check









Water pump

Check

Turbo charger

Check









After 3000 OH:

See: Operation and Maintenance Manual of the engine

Crankshaft

Inspect Vibration damper

Electronic Unit Injector

Inspect/Adjust

Engine speed sensors

Check/Clean/Adjust

Engine timing sensors

Check/Clean/Adjust

Engine Valve Lash

Inspect/Adjust

Engine Valve Rotators

Inspect

4

see: “Refilling quantities – Oil“ table

3-19

BA 6015(3 847 019.01)-EN

Inspection and servicing Plan A - after every 250 OH (at 250, 750, 1250 ... OH)

Plan B - after every 500 OH (at 500, 1500, 2500 ... OH)

Plan C - after every 1000 OH (at 1000, 2000, 3000, 4000 ... OH)

Plan D - after every 5000 OH (at 5000, 15000, 25000 ... OH)

Plan E - after every 10000 OH (at 10000, 20000, 30000, ... OH)

Location

Servicing work

Cooling system

Inspect visually for leaks

Page 2 of 5 Plan Plan Plan Plan Plan A B C D E     

Radiator

Clean, check tightness









- Fastening bolts

Check tightness







- Rubber bearing

Check condition







Cooling liquid

Carry out cooling liquid (ELC) analisis (see: Operation and Maintenance Manual of the engine)







Change

Menge / No.





15



Anti-freeze

Check







Lines

Check for leaks







Hose clamps

Check tightness











Fuel system Fuel filter

Replace

1











Fuel prefilter

Replace

1











Tank breather valve

Clean

1





Water trap (optional)

Clean

1







Check / replace

26







7





















Air-intake system Main filter element Secondary filter element

Replace

2

Air-intake line and clean-air line

Check for tightness and leaks

Hoses

Replace

Intercooler

Check / clean











Battery cable connections

Check for tightness











Battery

Check fluid level









Electrical system 2

5

Cooling-liquid (ELC) replacement after 6000 OH at the latest

6

Replacement of the main filter element after one year resp. after 3 cleaning cycles.

7

Replacement of secondary filter element after one year resp. after 3 cleaning cycles of the main filter element at the latest.

3-20

BA 6015(3 847 019.01)-EN

Inspection and servicing

Plan A - after every 250 OH (at 250, 750, 1250 ... OH)

Plan B - after every 500 OH (at 500, 1500, 2500 ... OH)

Plan C - after every 1000 OH (at 1000, 2000, 3000, 4000 ... OH)

Plan D - after every 5000 OH (at 5000, 15000, 25000 ... OH)

Plan E - after every 10000 OH (at 10000, 20000, 30000, ... OH)

Location

Servicing work

Hydraulic system

Check pressure (see: Service Manual)

Menge / No.

Page 3 of 5 Plan Plan Plan Plan Plan A B C D E   

Oil cooler - Bearing, fastening screws

Check for tightness







- Rubber bearing

Check condition







Return-flow filter

Replace

4







High-pressure filter

Replace

2





Magnetic rod

Check / clean

4







Bypass valve (working circuit) Clean valve

2







Bypass valve (cooling circuit) Check / clean filter sieve

2







Replace valve

2





Filter (pilot control circuit)

Replace

1





Filter (swinging mechanism pump feeding-circuit)

Replace

1





Hydraulic oil reservoir

Carry out oil analysis

1







Change oil

8 9







1

Breather filter oil reservoir

Replace

1

Pressure accumulators

Check pressure (see Service Manual)

1

Cylinder (seals and guide rings)

Replace

8



  

see: “Refilling quantities – Oil“ table

9

Unless it is regulary analyzed, the hydraulic oil must be changed every 5000 OH or after 3 years at the latest

3-21

BA 6015(3 847 019.01)-EN

Inspection and servicing

Plan A - after every 250 OH (at 250, 750, 1250 ... OH)

Plan B - after every 500 OH (at 500, 1500, 2500 ... OH)

Plan C - after every 1000 OH (at 1000, 2000, 3000, 4000 ... OH)

Plan D - after every 5000 OH (at 5000, 15000, 25000 ... OH)

Plan E - after every 10000 OH (at 10000, 20000, 30000, ... OH)

Carry out oil analysis

Menge / No. 1

Page 4 of 5 Plan Plan Plan Plan Plan A B C D E    

Change oil

1 10 11







Clean, replace

1







- Pump mounting flanges, expansion reservoir

Change oil

1

10







- Breather filter

Clean, replace

1







Swing gearbox

Carry out oil analysis

1







Change oil

10













Location

Servicing work

Pump drive gearbox and cooling circuit - Breather filter

Fastening bolts

1

 

Check for tightness

Breather filter

Clean

1







Output-pinion bearing

Lubricate

1







Travel gearbox

Carry out oil analysis

2









Check oil level

2









Change oil

2

10





Breather filter

Replace

2





Swing ring

Check grease filling

1

Gearing / pinion

Check condition

Fastening bolts (swinging ring, undercarriage, superstructure)

Check for tightness (see: Service Manual)

Undercarriage

Check wear (see Service Manual)

Diaphragm accumulator

Check pressure (see Service Manual)

2

- diaphragm

Replace

2

Track pad fastening bolts

Check for tightness (see Service Manual)

10

see: “Refilling quantities – Oil“ table

11

In case of using TM Gear oil CLP 220 LT CGM HMS GmbH P/N 6 002 885: Oil analysis after 1000 OH; oil change after 2000 OH

3-22













































BA 6015(3 847 019.01)-EN

Inspection and servicing

Plan A - after every 250 OH (at 250, 750, 1250 ... OH)

Plan B - after every 500 OH (at 500, 1500, 2500 ... OH)

Plan C - after every 1000 OH (at 1000, 2000, 3000, 4000 ... OH)

Plan D - after every 5000 OH (at 5000, 15000, 25000 ... OH)

Plan E - after every 10000 OH (at 10000, 20000, 30000, ... OH) Location

Servicing work

Menge / No.

Central lubricating system

Check function

Grease screen

Check / clean

1

Pump element

Replace

1

Air conditioner resp. heating

(see „Air Conditioner Manual“)

1

- Filter mat air suction (Backside operator`s seat)

Replace

3

Steel components

Visual inspection acc. to "Structural Inspection Report 12 every 500 OH" If any suspect areas have been found additional testing is required: For detailed crack analysis prepare the surface of the relevant area to be inspected and carry out the dye penetrant, magnetic powder or ultrasonic test.

Page 5 of 5 Plan Plan Plan Plan Plan A B C D E     







































Modules - Fastening bolts

Check for tightness (see Service Manual)







All articulated joints and hinges

Lubricate







12

" Structural Inspection Reports" for inspections every 500 OH can be downloaded from the CGM HMS website www.bucyrus-HEX.de, section "Support, Warranty ".

3-23

BA 6015(3 847 019.01)-EN

Inspection and servicing LUBRICATING CHART – GREASE

Fig. 3-2:

3-24

BA 6015(3 847 019.01)-EN

Inspection and servicing

Lubricating chart – Grease (legend) No. Greasing point

Number

Lubricant properties

1

Central lubricating system – grease container

1

V 13

Grease every .... operating hours 10

7

Swing gearbox output pinion

1

V 13

1000

All other greasing points are supplied with grease by the central lubricating system.

Filling quantities - Grease Greasing point Central lubricating system – grease container

Lubricant properties

app. 10

app. 22

app. 20

app. 44

2 x app. 1.1

2 x app. 2.4

CGM HMS GmbH P/No. 16 x app.2.5 2764564

16 x app.5.5

2 x app. 2.5

2 x app. 5.5

app. 50 cm3

app. 1.7 oz

V 13

Internal gearing – Roller-bearing swing ring Idler (permanent grease filling) Track roller (permanent grease filling)

Tribol

Support roller (permanent grease filling) Swing gearbox output pinion

13

Filling quant. in kg lb

V 13

see: "LUBRICANTS / CONSUMABLES" section

3-25

BA 6015(3 847 019.01)-EN

Inspection and servicing INSPECTION PLAN - OIL

Fig. 3-3:

3-26

BA 6015(3 847 019.01)-EN

Inspection and servicing

Inspection plan – Oil (legend) 1

Engine

1

I

Check oil level every ... OH 10

2

Hydraulic system

1

II

10

10000 15

3

Pump drive gearbox

1

III.a

60

1000

3

- pump mounting flanges, expansion reservoir

1

III.a

10

1000

4

Swing gearbox

1

III.b

10

1000

5

Travel gearbox

2

III.a

500

5000

No. Location

Number

Lubricant 14 properties

Change oil every ... OH 250

Bh = OH = Operating Hours

14

see: "LUBRICANTS / CONSUMABLES" section

15

Change hydraulic oil every 5000 OH unless the oil is analyzed at regular intervals, but not later than every 3 years.

3-27

BA 6015(3 847 019.01)-EN

Inspection and servicing

Filling quantities - oil Location

Filling quantities in litres

gal

Drive engine - without filter change

app. 60

app. 15.85

- with filter change

app. 66

app. 17.45

Hydraulic oil system at oil change

app. 1700

app. 449

- oil reservoir

app. 1300

app. 343

Pump drive gearbox

app. 13,5

app. 3.6

- cooling circuit

app. 13,5

app. 3.6

- pump mounting flanges (working pumps)

2 x app. 1.4

2 x app. 0.37

- pump mounting flange (hydraulic pumps)

1 x app. 0.2

1 x app. 0.05

app. 14

app. 3.7

Travel gearbox (P/Ns 3712319, 3749594)

2 x app. 18

2 x app. 4.75

Travel gearbox (P/N 3709660)

2 x app. 13,5

2 x app. 3.56

Swing gearbox

Oil

I I I II II

III.a III.b III.a III.a

Filling quantities – other Location

Filling quantities in litres

gal

Cooling system - engine

app. 115

app. 30.4

Fuel tank

app. 1300

app. 343

Screen washer

app. 13

app. 3.4

3-28

BA 6015(3 847 019.01)-EN

Inspection and servicing LUBRICANTS / CONSUMABLES Notes on the selection of oils and greases Original CGM HMS GmbH oils and greases Besides regular and careful maintenance, the quality of the oils and greases used in the machine has a decisive influence on high performance, reliability and long service life of a machine and of its units and assemblies.

The lubricants tables in the CGM HMS GmbH Operation and Maintenance Manual contain specifications for the oils and greases that are approved for use in CGM HMS GmbH machines. These oils and greases are especially adapted to CGM HMS GmbH machines and their units and assemblies.

Other oils and greases which do not fulfil the requirements of the specifications can be the cause of premature wear or of damage to and failures of machine units and assemblies.

For this reason, CGM HMS GmbH only approves the use of the specified oils and greases.

All other qualities are not approved.

Avoid mixing of different hydraulic fluids The machine has been run in at the factory with BM Long Term Hydraulic Fluid HSS (Part-No. 2482971). CGM HMS GmbH recommends using this high-grade hydraulic fluid also in operation as it has been made especially for use in these machines to which it is also perfectly adapted.

If oil analyses are performed regularly and with positive results, the BM Long Term Hydraulic Fluid can remain in the machine for up to 10 000 operating hours.

If an alternative hydraulic fluid is to be used, it must fulfil the same specifications. Please note that the change interval for alternative fluids is fixed at 5 000 operating hours.

There is an increased risk of damage to hydraulic components, if different hydraulic fluids are mixed during topping up as well as when changing over to a fluid of a different type or from another manufacturer.

For topping up, it is therefore necessary to use only same hydraulic fluid as the one that is already in the hydraulic system.

The oils and greases filled into the machine must meet at least the specifications mentioned in the lubricants tables of the CGM HMS GmbH Operation and Maintenance Manual.

When changing over to an alternative hydraulic fluid, please observe that there is always a small amount of old fluid remaining in the hydraulic system even after the system has been emptied. The mixing of this residual amount of old fluid with the new alternative fluid reduces the properties of the fluid dramatically and can cause damage to components of the hydraulic system in operation.

In the event of damage to the machine or to its units and assemblies caused by the use of alternative oils and greases that are not compatible with CGM HMS GmbH specifications, CGM HMS GmbH does not assume any responsibility and does not accept any warranty claims.

To avoid this result, the change-over to the alternative fluid must be performed in strict compliance with the manufacturer's prescriptions. The manufacturer must confirm that his hydraulic fluid is compatible with the BM Long Term Hydraulic Fluid.

Alternative oils and greases

The remaining amount of old fluid must not exceed 2% of the total volume. This can only be achieved by repeated flushing with the total fluid volume.

If the remaining amount of fluid exceeds 2% of the total volume, the fluid becomes a detrimental "mixed fluid".

The operation of the system with mixed fluids must by all means be avoided.

CGM HMS GmbH assumes no warranty for damage caused as a result of the machine having been operated with consumables of inappropriate specification or with mixed fluids.

3-29

BA 6015(3 847 019.01)-EN

Inspection and servicing

I.

Fig. 3-4:

3-30

Oils for combustion engine

BA 6015(3 847 019.01)-EN

Inspection and servicing

II.

Fluid for hydraulic system

Fig. 3-5:

3-31

BA 6015(3 847 019.01)-EN

Inspection and servicing

III.a Oils for pump distribution gearbox and travel gearbox

Fig. 3-6:

3-32

BA 6015(3 847 019.01)-EN

Inspection and servicing

III.b Oils for swing gearbox

Fig. 3-7:

3-33

BA 6015(3 847 019.01)-EN

Inspection and servicing

V

Fig. 3-8:

3-34

Greases for bearings and swing rings (Central lubrication system)

BA 6015(3 847 019.01)-EN

Inspection and servicing

Grease for idlers, track rollers and support rollers (Lifetime lubrication)

Fig. 3-9:

3-35

BA 6015(3 847 019.01)-EN

Inspection and servicing

Coolant for use on all combustion engines

Fig. 3-10:

3-36

BA 6015(3 847 019.01)-EN

Inspection and servicing SERVICING WORK Hose line for oil and cooling liquid changes Collect escaping oil and cooling liquid and discard without polluting the environment.

Carry out oil changes when the machine is at operating temperature; warm oil drains away more easily.

The engine, hydraulic oil reservoir, swinging gearbox and the engine cooling system are equipped with special oil drain valves (1, Fig. 3-11:).

These valves can be used for changing the oil and the coolant in clean conditions and in a nonpolluting way.

Procede as follows to change the oil or the coolant:  Place a collecting recipient for used oil or coolant under the drain valve (capacity see "Refilling Quantities - Oil", "Refilling Quantities Other"  Take the drain hose out of the the tool-box.  Unscrew the protective cap from the drain valve.  Screw the drain hose (2) on the valve; the valve opens and the oil / coolant drains off.  Remove the drain hose from valve after the oil / coolant has drained off; the valve closes automatically.  Screw the protective cap back in place.

Before cleaning the engine

Fig. 3-11:

Exhaust pipes and turbo chargers in the engine compartments are covered with special heat-insulating material.

This material must not be spraywashed with steam-jet cleaners or high-pressure cleaners. It will be damaged. Therefore cover all the insulating material with plastic foils before using steam-jet cleaners or highpressure cleaners inside the engine compartments.

3-37

BA 6015(3 847 019.01)-EN

Inspection and servicing ENGINE Engine - Safety instructions

Checking the engine oil level / Topping up

Read and observe: "Inspection and Servicing – Safety Instructions" and the engine Operation and Maintenance Manual.

Risk of injury from hot or rotating parts of the engine.

Shut off engine and allow to cool down.

Exhaust gases from diesel engines and some of their constituents may cause cancer, birth defects and other reproductive harm.

Start and operate combustion engines only on well-ventilated premises.

Fig. 3-12:

In closed rooms, exhaust gases must be evacuated to the outside;

 Park the machine on a horizontal surface and protect it against rolling away.

Do not work on the exhaust system an do not make any modifications to it.

 Shut off the engine.

Attention, ether The engine compartment can be equipped with pressure vessels containing cold-starting fluid (ether).

Ether is toxic and highly flammable; the vessels are under pressure. These pressure vessels can explode if exposed to high temperatures (above 49°C / 120°F) or in the event of damage. Protect the pressure vessels against damage before beginning to work in or close to the engine compartment.

 Withdraw dipstick (arrow, Fig. 3-12:).  Wipe dipstick clean with a clean and lintfree cloth and re-insert.  Withdraw oil dipstick once again. The oil level should now lie between the marks (arrows, Fig. 3-13:). If the oil level is at the "min" mark or below, top up with engine oil through the fillertube (arrow, Fig. 3-15:).

Secure the machine as described in the "Securing the machine" section.

Protect the skin from potentially harmful contact with engine oil. Wear protective gloves and firm working clothing.

Checking, retensioning the V-belt tension These and other servicing works are described in the engine manufacturer's Operation and Maintenance Manual.

3-38

Fig. 3-13:

BA 6015(3 847 019.01)-EN

Inspection and servicing Changing the engine oil Read and observe: "Inspection and servicing – Safety instructions".

Risk of scalding from hot engine oil.

The engine may also be hot.

Wear protective gloves and firm working clothing.

Collect escaping oil and discard without polluting the environment.

Draining off engine oil  Bring engine oil to operating temperature.  Park the machine on a horizontal surface and secure.

Fig. 3-15:

 Shut off the engine.

After draining of the oil:  Replace the engine oil filter.  Remove the hose line.

The automatic drain coupling closes automatically.  Screw on protective cap.  Fill in engine oil through the filler tube (arrow, Fig. 3-15:) until the oil level reaches the "max" mark (Fig. 3-16:).  Start the engine and allow to run for abt. 2 minutes at idling.

Fig. 3-14:

 Check oil level and top up with oil up to the "max" mark, if required.

 Drain off engine oil using the oil draining hose (Fig. Fig. 3-14:).

The use of the oil draining hose is described in the "Hose line for oil and cooling liquid changes" chapter.

Fig. 3-16:

3-39

BA 6015(3 847 019.01)-EN

Inspection and servicing Replacing the engine oil filters Read and observe: "Inspection and servicing – Safety instructions".

Risk of scalding from hot engine oil.

The filter housing may also be hot.

Wear protective gloves and firm working clothing.

Collect escaping oil and discard with-out polluting the environment.

Replacing engine oil filters Fig. 3-18:

 Unscrew the filters.  Screw on new filters with a slightly oiled sealing ring and tighten by hand.

After replacing the engine oil filters carry out the engine oil change in compliance with the engine Operation and Maintenance Manual. (when not done).

Fig. 3-17:

 Shut off the engine. Wait until engine has cooled down.

Risk of falling Put on a safety harness before working on the catwalk on the right-hand side of the superstructure (1, Fig. 3-17:). Attach the safety line to the grab handles (3).

 Open the flap of the engine compartment on the right-hand side of the superstructure (2, Fig. 3-17:).

The oil filters (1, Fig. 3-18:) are then accessible.

3-40

 Let the engine run at idling for a short time and check the filters for leaks. Shut off the engine.  Check the oil level after about 10 minutes and top up, if necessary.

BA 6015(3 847 019.01)-EN

Inspection and servicing Cold-starting fluid (ether) - Replacing the pressure vessel

If the machine is used in low temperatures, the engine may be equipped with a cold-starting device.

Read and observe: "Inspection and servicing Safety instructions"

The pressure vessel containing the cold-starting fluid (ether) can be installed in or near the engine compartment.

Risk of injury Cold-starting fluid is composed mainly of ether.

Ether is toxic when the mists and vapours are inhaled. Ether is harmful to the eyes, the skin, the respiratory system and the central nervous system.

Prolonged inhalation of ether can be fatal.

In contact with the skin, ether can cause frostbites and irritations.

Ether is toxic and highly flammable; the vessels are under pressure.

These pressure vessels can explode if exposed to high temperatures (above 49°C/ / 120°F) or in the event of damage.

Before replacing an empty pressure vessel: Read and observe the instructions on the pressure vessels.

For further details please refer to the instructions and safety data-sheets of the manufacturer / supplier of pressure vessels with cold starting fluid (ether).

The vessel is screwed onto an electro-mechanical metering valve.

At temperatures below 0°C (32°F), this valve is activated automatically by the engine electronics and injects a precisely metered amount of cold-starting fluid into the air intake duct of the engine.

Replacing the pressure vessel:  Remove the clamp around the pressure vessel.  Unscrew the pressure vessel carefully from the metering valve.  Remove the used seal from the metering valve.  Insert a new seal into the valve (supplied with the new pressure vessel).  Screw the new pressure vessel onto the metering valve and tighten by hand.  Fasten the clamp round the pressure vessel.

Even apparently empty pressure vessels can contain rests of ether and therefore explode if they are damaged or heated up above 49°C / 120°F. They must therefore be handled in the same way as full pressure vessels. 

Do not keep them on the machine.



Do not damage or open the vessels.

Provide for sufficient ventilation of the surroundings.



Do not expose the vessels to great heat or direct sunlight.

Do not eat, drink or smoke when replacing an empty vessel.



Do not dispose of in fire.

Do not inhale the vapours of escaping cold-starting fluid (ether).



Keep the vessels in a place unaccessible to unauthorized persons.

Avoid skin contact. Wear suitable protective gloves and goggles.



Dispose of the vessels properly.

3-41

BA 6015(3 847 019.01)-EN

Inspection and servicing COOLING SYSTEM

Cooler and cooling liquid Risk of falling

Read and observe: "Inspection and servicing - Safety instructions".

Put on a safety harness before working on the superstructure. Attach the safety line to eyelets or railings (arrows, Fig. 3-19:).

Secure the machine as described in the "Securing the machine" section.

Shut off the engine and allow to cool down.

Risk of scalding from hot cooling liquid.

Collect escaping cooling liquid and discard without polluting the environment.

Protect the skin from contact with cooling liquid.

Skin contact with cooling liquid is a potential health hazard.

Wear protective gloves and firm working clothing.

Temperature The cooling-liquid circuit is controlled by a thermostat. The maximum admissible temperature is ca.

100° C / 212° F. In case of higher temperatures warning lamp on satellite illuminated - locate cause and rectify.

The cooler (1, Fig. 3-19:) is located on the superstructure.  Check the cooler fins for dirt before every workshift and clean, if necessary.  Check the coolant level at the indicator (3, Fig. 3-20:). The coolant level should be between the “FULL” and the “LOW” mark.

An insufficient coolant level is also indicated by means of a warning lamp in the control satellite.  Top up with coolant, if necessary.

Fig. 3-19:

Fig. 3-20:

3-42

BA 6015(3 847 019.01)-EN

Inspection and servicing Topping up with coolant

Changing the coolant Read and observe: Inspection and servicing – Safety instructions.

Risk of scalding from hot cooling liquid.The coolers may also be hot.

Wear protective gloves and firm working clothing.

Collect escaping coolant and discard without polluting the environment.

Change the cooling agent regularly and after 6000 operating hours (OH) at the latest.

Fig. 3-21:

Risk of scalding from hot cooling liquid under pressure. Open radiator cap cautiously.

 Turn the cap (2, Fig. 3-21:) into the first notch to reduce the pressure in the reservoir.  After depressurization turn the cap into the open position and remove.  Fill cooling liquid into the cooling system through the filler tube (2).

Do not add cold coolant when the engine is still at operating temperature.

Let the engine cool down to below 50 °C (122°F) before adding coolant.

 Screw on the cap (2).

For topping up the cooling system use only the cooling agent CAT ELC - CGM HMS GmbH P/N 2482777 - which is specially adapted to these engines. The coolant offers frost protection down to – 37°C (-34.6°F).

After topping up with coolant run the engine for a short time to remove air inclusions before filling the reservoir with coolant up to the mark on indicator (3).

Fig. 3-22:

 Prepare a collecting recipient for used cooling liquid. Choose the required recipient capacity in accordance with the "Refilling quantities Other" table.  Shut off the engine, allow to cool down.

Risk of scalding from hot coolant under pressure. Open the cap of the expansion reservoir carefully.

 Turn the cap (2, Fig. 3-21:) into the first notch to reduce the pressure in the reservoir..  After depressurization turn the cap into the open position and remove.

In the case of significant coolant losses check the entire cooling system for leaks.

Check all lines regularly for leaks and all hose clamps for tightness.

3-43

BA 6015(3 847 019.01)-EN

Inspection and servicing

The drain valve for coolant is accessible under the engine compartment (arrow, Fig. 3-23:).  Drain off the coolant with the drain hose attached to the drain valve. (arrow, Fig. 3-23:).

The use of the cooling liquid draining hose is described in the " Hose line for oil and cooling liquid changes " chapter.  Remove the drain hose from the valve after the oil / coolant has drained off; the valve closes automatically.  Fill the required amount of cooling agent CAT ELC, CGM HMS GmbH P/N 2482777, which is specially adapted to these engines, into the system by pouring it into the expansion reservoir (2, Fig. 3-21:). (see: "Refilling quantities Other" table.).  Check the filling level at indidicator (3, Fig. 3-22:).  After topping up with coolant run the engine for a short time to remove air inclusions before filling the system with coolant up to the mark on indicator (3).

For more information see also: "Operating and servicing instructions for the engine".

Fig. 3-23:

3-44

Testing the cooling liquid composition The „Engine Operation and Maintenance Manual“ contain a detailed description of how to prepare and test the cooling liquid composition. In case of imminent frost check that the factory-adjusted antifreeze concentration is sufficient for the expected temperatures.

Check the cooling liquid in the cooling system regularly to ensure that the mixture is sufficiently concentrated to prevent corrosion under the corresponding operating conditions.

BA 6015(3 847 019.01)-EN

Inspection and servicing AIR-INTAKE SYSTEM Risk of injury when falling down.

Put on your fall protection equipment before entering the superstructure.

Risk of injury caused by hot parts of the engine exhaust system.

Let exhaust cool down.

Dust trap, cleaning The dust trap (arrow, Fig. 3-25:) collects dust and dirt that infiltrates the air filter housing.  To remove dust and dirt, squeeze the flexible part of the dust trap several times. ust and dirt will be detached and come off.

Read and observe the "Engine Safety instructions" chapter.

Do not start the engine when parts of the air-intake system have been detached.

Engine damage may occur if the engine is allowed to draw in unfiltered air.

Secure the machine as described in the "Securing the machine" section.

The air-intake system is equipped with two dry-air filters (Fig. 3-24:) consisting of prefilter, main and secondary filter element.

Fig. 3-25:

Fig. 3-24:

3-45

BA 6015(3 847 019.01)-EN

Inspection and servicing Main filter elements An insufficient air-intake performance, caused by a contaminated main filter element, is indicated by the vacuum-meters (8, Fig. 3-26:).

Clean or replace main filter element only if the vacuum-meter (8, Fig. 3-26:) indication changes to "RED" with the engine running at high speed.

Removal and installation  Loosen clamps (1, Fig. 3-27:) at the air filter housing and remove cover (2).  Withdraw main filter element (3).

Do not remove secondary filter element (4).  Replace or clean main filter element.  Before installing the filter element, clean contact faces at cover (2) and at filter housing.  Put on cover (2) using clamps (1).

New or cleaned main filter elements should always be at hand to shorten excavator downtimes.

Fig. 3-26: Fig. 3-27:

3-46

BA 6015(3 847 019.01)-EN

Inspection and servicing Checking and cleaning the main filter element  Examine the filter paper of the element with a lamp which is introduced into the element (Fig. 3-28:. Any damage is then clearly visible.

Replace damaged or deformed elements immediately.

 Check element seal. When the seal is damaged, the filter element must be replaced, too.

Cleaning with compressed air is suitable if the filter element is to be re-used immediately.  Blow filter element (Fig. 3-29:) clean with dry compressed air from the inside by moving the compressed-air gun up and down.

The pressure at the nozzle must not exceed 3 bars / 43psi.

Cleaning is terminated when all visible dust has been blown out of the filter element.

Fig. 3-28:

Never clean filter element by beating against hard objects.

Replace the main filter element after 1000 operating hours or 3 cleaning cycles; and, after one year of operation at the latest.

Fig. 3-29:

3-47

BA 6015(3 847 019.01)-EN

Inspection and servicing Secondary filter element

Air-intake lines

Removal and installation

At regular intervals:

Replace the secondary filter elements (4, Fig. 3-30:) after 1000 operating hours or 3 cleaning cycles; after one year of operation at the latest.

Never clean the secondary filter element, but always renew.

 Remove main filter element (3, Fig. 3-30:) as described above.  Withdraw secondary filter element (4).  Install the new secondary filter element and a cleaned or a new main filter element.

Fig. 3-30:

3-48

 check intake lines for leaks and hose clamps for tightness;  replace hoses between filter housing and engine when they were damaged.

During all works on the air-intake system ensure proper sealing to prevent unfiltered air from reaching the engine.

BA 6015(3 847 019.01)-EN

Inspection and servicing FUEL SYSTEM Fuel system - Safety instructions

Fuel pre-filter, Draining off water Read and observe the "Inspection and servicing – Safety instructions" chapter.

Read and observe the "Inspection and servicing – Safety instructions" chapter.

Read and observe the "Fuel system – Safety instructions" chapter.

Secure the machine as described in the "Securing the machine" section.

Before working on the fuel system: 

shut off the engine,



keep away naked flames,



do not smoke.

Collect escaping fuel and discard without polluting the environment.

Discard used fuel filters without polluting the environment.

Avoid skin contact with diesel fuel.

Fig. 3-31:

Diesel fuel may cause skin injury.

Wear firm working clothing.

Wear protective gloves or use a barrier cream.

Do not allow dirt to enter the fuel system. Thoroughly clean the area around a fuel component before disconnect it.

It may be necessary to relieve residual fuel pressure from the fuel system before the fuel filter is removed. Wait for one to five minutes until the fuel pressure has lowered.

Fig. 3-32:

 Open the flap of the engine compartment (1, Fig. 3-31:). The fuel filters are now accessible.

The pre-filter (1, Fig. 3-32:) works at the same time also as a water trap:  Open valve (2) and drain off water until fuel emerges from the valve.  Close valve (2).

For further information please refer to the "Engine, Operation and Maintenance Manual".

3-49

BA 6015(3 847 019.01)-EN

Inspection and servicing Fuel pre-filter, replace Read and observe the "Inspection and servicing – Safety instructions" chapter.

Read and observe the "Fuel system – Safety instructions" chapter.

 Unscrew pre-filter (1, Fig. 3-33:) completely.  Pour out fuel and discard it without polluting the environment.  Unsrew the collector (2) from the fuel pre-filter and clean it.  Clean the contact surface at the filter head.  Clean and check the O-Ring of the collector.

Replace the ring, if it damaged. Dip the O-ring into clean diesel fuel.  Screw the collector (2) with the O-ring by hand to the new pre-filter (1), tighten by hand.

Using a tool for tightening of the collectorcan cause irreparable damage to the collector.

 The new pre-filter can be filled with fresh and clean fuel. This helps to prevent rough running of the engine caused by excessive amounts of air in the fuel system.  Lubricate the sealing of the primary fuel filter lightly with clean fuel and screw it onto the filter base by hand. Continue to tighten filter by a further 1/2 to 3/4 turn.

Using a tool for tightening of the filter element can cause cracking or deformation of the filter head.

 Start the engine and let it run for about one minute. Check that the fuel system has no leaks.

For further information please refer to the "Engine operating and servicing instructions".

3-50

Fig. 3-33:

BA 6015(3 847 019.01)-EN

Inspection and servicing Secondary fuel filter, replace Read and observe the "Inspection and servicing – Safety instructions" chapter.

Read and observe the "Fuel system – Safety instructions" chapter.  Open the flap of the engine compartment (1, Fig. 3-34:). The fuel filters are now accessible.  Unsrew the fuel filter (3, Fig. 3-35:).  Clean the contact surface at the filter head.  Do not fill fuel into the new filter. This measure prevents unfiltered fuel from getting into the injection system.

Fig. 3-34:

 Apply a thin layer of clean diesel fuel on the seal of the new filter.  Screw the fuel filter onto the filter base by hand. Use the rotation index marks on the filter as a guide for proper tightening. Tighten the filter according to the instructions that are on the filter.

Using a tool for tightening of the filter element can cause cracking or deformation of the filter head.  Vent the fuel system, see "Engine, Operation and Maintenance Manual".

Fig. 3-35:

3-51

BA 6015(3 847 019.01)-EN

Inspection and servicing Fuel tank - Venting

Cleaning the fuel tank

The fuel tank is vented with a breather valve (4, Fig. 3-36:).

Risk of explosion Read and observe the "Inspection and servicing. Safety instructions" chapter.

Clean breather valve regularly.  Remove breather valve, flush with paraffin oil and blow clean with compressed air.

Do not use white spirit, paraffin oil or other solvents.

For cleaning and flushing use diesel fuel.

Avoid skin contact.

Skin contact with diesel fuel can be a health risk.

Wear firm working clothing.

Wear protective gloves or use a barrier cream.

Do not let fuel penetrate into the soil.

Keep for re-use or discard without polluting the environment.

Fig. 3-36:

Fig. 3-37:

3-52

BA 6015(3 847 019.01)-EN

Inspection and servicing Refuelling station (optional)  Drive the machine until the fuel tank is almost empty.  Check how much fuel is left in the tank and place a recipient of sufficient capacity under the drain plugs of the tank.  Turn out the drain plug (5, Fig. 3-37:) of the fuel tank and drain off the fuel.  Flush the tank with diesel fuel.  Screw the drain plug (5) back into the tank.

Sparking caused by static or electric charges may set fuel on fire.

Check earthing strap (equipotential bonding) (4, Fig. 3-38:) regularly for tightness.

Only a perfectly connected earthing strap can remove static or electric charges and thus avoid the risk of fire during refuelling.

 Fill in fuel through the strainer in the filling nozzle (2).

Fig. 3-38:

3-53

BA 6015(3 847 019.01)-EN

Inspection and servicing Water trap (option)

Draining off water

Water contained in the fuel is removed by the water trap (Fig. 3-39:).

Carry out the following works in accordance with the servicing schedule and at regular intervals.  Loosen venting plug (9, Fig. 3-40:) and leave drain valve (3) open until there is no more water in the diesel fuel flowing out of the valve.

Fig. 3-39:

Fig. 3-40:

Collect escaping liquid in a recipient suitable for diesel fuel and discard without polluting the environment.

The liquid flowing out of the valve flushes and cleans the filter element(6) von from top to bottom.  Close drain valve (3) and tighten venting plug (9).

3-54

BA 6015(3 847 019.01)-EN

Inspection and servicing Checking / cleaning the filter element Replace filter element (6, Fig. 3-41:) only when the suction resistance is too high.  Loosen venting plug (9) and leave drain valve (3) open until the reservoir is completely empty.

Collect escaping liquid in a recipient suitable for diesel fuel and discard without polluting the environment.

 Remove cover (5).  Remove spring holder (7) and filter element (6) from filter housing (4).

Fig. 3-41:

 Check / replace filter element (6)  Clean filter housing (4) using diesel fuel.  Check cover sealing and replace,if necessary.  Insert filter element (6) and spring housing (7) into filter housing (4).  Fasten cover (5) on filter housing (4).

Check for proper sealing.

 Clean recipient (1) and filter housing (4).  Loosen flange (2).  Take off recipient (1) and clean with diesel fuel  Check cover sealing and replace, if necessary.  Attach recipient (1) with flange (2) at filter housing (4).

Check for proper sealing.

3-55

BA 6015(3 847 019.01)-EN

Inspection and servicing ELECTRICAL SYSTEM Electrical system - Safety instructions Risk of injury caused by battery acid and gases.

Read and observe the "Inspection and servicing – Safety instructions" chapter.

Wear goggles, working gloves and firm working clothing.

Carry out voltage and continuity checks only by means of a test lamp or a measuring instrument.

Do not check by "touching ground" with a bare wire. The short-circuit thus produced damages the alternator and the electronic modules of the PMS.

Alternator - Instructions Never disconnect cables from the alternator, regulator and the battery when the engine is running to avoid damage to the alternator and regulator.

Do not interchange the cables when connecting the battery (observe polarity).

Carry out voltage and continuity checks only by means of a test lamp or a measuring instrument.

Do not check by "touching ground" with a bare wire. The short-circuit thus produced damages the alternator and the regulator.

Cables and cable lugs must not get in contact with other metal parts. Replace broken or damaged cables and the respective cable lugs.

Electrical circuit diagrams The electrical circuit diagrams and wiring diagrams are annexed to the spare-parts list. Further information can be found in the CGM HMS GmbH Service Manual "Working with circuit diagrams".

Electrical system switch-cabinets The electrical system switch-cabinets are located in the cab module, in the pump compartment and behind the hydraulic reservoir. The cabinets are described in the spare-parts list (electrical circuit diagram) together with the designation of the electrical components.

Fuses and their function are listed on a sheet inside the switch-cabinets in the cab module.

Replacing lamps and bulbs If a bulb does not work after replacement, the pertaining fuses, connection cables and contacts must be checked.

Xenon-working floodlights are operated with high voltage.

Read and observe the chapter: “Floodlight projector, replacing the lamp”.

Floodlights working with LED-technology do not have replacable lamps / bulbs. The floodlight must be replaced if defective.

3-56

BA 6015(3 847 019.01)-EN

Inspection and servicing Floodlight projector, safety instructions The floodlight projectors use xenon technology.

The lamp is not a usual incandescent lamp, but a gas discharge lamp which is operated with a ballast unit. The ballast unit is integrated in the floodlight projector.

When the projector is turned on, the ballast unit generates a high-voltage pulse of more than 25000 volts to start the xenon lamp.

Warning!

This high-voltage pulse can be a lifethreatening risk, if a person comes into contact with any of the live components. This can be the case, for instance, 

if the lamp is operated improperly,



if the projector housing is opened in an inapropriate way or



by sticking one's hand into an opened or damaged projector.

Protect yourself from potential risks by reading and by observing the following safety instructions.

Always switch off the projector and disconnect it from its power supply before replacing the Xenon lamp.

Allow the xenon lamp to cool off before removing it from the projector.

Wear googles and safety gloves when replacing the lamp.

Never stick your hand into the lampholder. The contacts may still be live with residual voltage.

Never switch on the projector when the xenon lamp has been removed.

There is a risk of voltage discharge and damage to the lampholder.

The glass body of the xenon lamp is filled with different gases and metal gases and is under gauge pressure (risk of injury from splinters) If the xenon lamp breaks apart in closed room (workshop), all persons must leave the room and the room must be ventilated for at least 20 minutes to exclude any health risks caused by gases.

Further instructions Always hold the xenon lamp by the base. Never touch the glass bulb. Sweat and grease from the skin would evaporate when the lamp is in operation and obscure the reflector.

If the fingers have nevertheless come into contact with the glass bulb, the fingerprints must be removed with a clean cloth and some alcohol.

The replaced Xenon lamp must be disposed of as special waste.

Never switch on projectors when housing or electrical wiring is damaged.

Have damaged projectors be replaced by a qualified electrician as soon as possible.

3-57

BA 6015(3 847 019.01)-EN

Inspection and servicing Replacing a defective Xenon-lamp Read and observe the: „Xenon floodlight projector, replacing the lamp, Safety instructions“.  Switch off the projector, shut off the engine and cut out the battery main switch.  Wait until the housing of the floodlight projector has cooled down.  Withdraw the power supply connector from the projector.  Remove four bolts (1, Fig. 3-42) and withdraw the reflector (2) from the projector housing.

Fig. 3-42

 Withdraw connector (Fig. 3-43) from Xenon lamp socket.  Unscrew Xenon lamp holding clamp (Fig. 3-44).  Remove the defective Xenon lamp and replace by a new one. Do not touch the glass bulb of the lamp.  Reinstall the new lamp. Screw lamp holding clamp back in place.  Plug the power supply connector onto the lamp.  Re-assemble the housing.

Fig. 3-43

Fig. 3-44

3-58

BA 6015(3 847 019.01)-EN

Inspection and servicing Lighting systems in LED technonogy, instructions The lights of the maintenance lighting system (Fig. 3-45) as well as the working floodlights (Fig. 3-46) are equipped with lamps in LED technology (lightemitting diodes).

High-performance LEDs ensure the emission of light with high luminance. If the light is allowed to shine directly into the eyes from a short distance and over prolonged periods, there is a risk of injury to the retina.

Do not look for a prolonged period into the light cones of the LEDs. Adjust the lights in such way that they do not shine directly into the eyes and that you are not blinded by the glare.

The lights become hot in operation.

The heat is dispersed via the ribbed metal housing.

Fig. 3-45

For this reason, the housings must not be covered up and cleaning rags or similar things placed over them.

The high-performance LEDs in these lights have a very long service life and can therefore not be replaced. If one or more of these LEDs fail, the light can remain in service if the remaining luminance is still sufficient.

Fig. 3-46

3-59

BA 6015(3 847 019.01)-EN

Inspection and servicing Battery Warning!

Battery Posts, terminals and related accessories contain lead and lead compounds, chemicals known to cause cancer and reproductive harm.

Wash hands after handling.

Checking the battery fluid level (Not applicable in case of maintenance-free batteries)  Unscrew caps (Fig. 3-47:).  If checking inserts are provided, the battery acid must reach up to their bottom.  If no checking inserts are provided, insert a clean wooden rod into the battery until it contacts the upper edge of the cell plates. The rod must be moistened over at least 10 mm / 0.4 in.  If the fluid level is too low, top up with distilled water only

Fig. 3-47:

3-60

Checking battery charge The acid temperature must be 20 ° C / 68° F.  Unscrew caps of the battery  Measure the acid density of the battery using a commercial acid tester The acid density measured is in direct correlation with the battery charge.

Acid density kg / dm3 Charge Normal Tropical conditicondition ons 1,28 1,23 fully charged 1,20 1,12 half charged, recharge 1,12 1,08 discharged, recharge immediately

BA 6015(3 847 019.01)-EN

Inspection and servicing Charging batteries inside the machine, safety instructions Explosion hazard.

Battery gases are highly flammable.

Keep any potential ignition sources, such as unshielded lights or burning cigarettes, away from the batteries.

Risk of injury from acid splashes and battery gases.

Wear safety goggles or a face protection shield and acid proof protective gloves.

Do not lean over the batteries while charging.

The batteries of the machine can also be charged while installed in the machine.

For this purpose, the battery compartment (Fig. 3-48:) is equipped with a socket outlet for a charging cable.

Risk of fire

Charging the batteries  Cut out the battery main switch.  For battery ventilation unscrew the cover of the battery cabinet.  Connect the charging cable to the socket outlet (Fig. 3-48:).  Switch on the charger and watch the charging process.

Stop the charging process: 

if the batteries are getting hot,



if acid escapes from the batteries,



if the charge current is still insignificantly low even after 15 minutes of charging.

Before starting a new charging cycle, check the batteries and the connecting cable thoroughly and replace any damaged components. It may be necessary to remove the batteries and to charge them one by one.

When the batteries are full:  Shut off the charger first before withdrawing the charging cable from the socket outlet.

Read the instructions of the charger in order to know when the charging cycle has ended.

Do not use the socket outlet (Fig. 3-48:) for jump-starting of the engines.

The batteries are fully charged, if 

the charging current and voltage remain constant (for voltage-controlled chargers);

The connectors and the cables are not designed for the high currents flowing during the starting phase.



the charging current does not any rise longer for two hours (current-controlled chargers);



the charger shuts off or switches over to trickle charge (automatic chargers).

Check before charging why the batteries are discharged and replace the batteries if they are defective.

Check the connecting cables of the battery set for damage, corrosion and tight fit.

Never charge the batteries while they are frozen.

Warm them up beforehand and check for proper functioning.

Do not charge the batteries when they are warmer than "warm to the touch" (45 °C / 113 °F).

Use only approved chargers for 24 volts DC. Read and observe the instructions for the charger.

The charging cable must have a conductor cross2 section of at least 70 mm .

Fig. 3-48:

3-61

BA 6015(3 847 019.01)-EN

Inspection and servicing Removing and installing the battery Read and observe the "Inspection and servicing – Safety instructions" chapter.

Wear protective gloves and firm working clothing.

Shut off the engine before removing the batteries to avoid damaging the alternator and the regulator.

Turn key in key-switch to position "0" and withdraw.

Switch battery main switch to position II / OFF (Fig. 3-50:).

Disconnect and reconnect the terminal clamping lugs in the prescribed order.

Disconnecting and connecting in the wrong order may cause short-circuits.

The 12-volt batteries are connected in series and in parallel, so that the system voltage is 24 volts.

The batteries are located under the hatch (5, Fig. 3-49:).  Open hatch (5).  Unscrew battery holder (3, Fig. 3-51:).  Disconnect the cable lug from the negative terminal of the battery.  Disconnect the cable lug from the positive terminal of the battery.  Insulate the cable lugs.  Take out the batteries (1).

Before installing the new battery, the contact faces of the battery terminal posts and the cable lugs must be cleaned down to the bright metal.  Install the new batteries.  Connect the cable lug to the positive terminal of the battery.  Tighten the clamping screw of the cable lug.

Do not use too much force to avoid deformations.  Connect the cable lug to the negative terminal of the battery.  Apply special terminal grease or acid-free vaseline on the battery terminal posts and clamping lugs.

Loose or corroded clamping lugs will lead to alternator or regulator overloading.  Fix battery holder (3).

Fig. 3-49:

Fig. 3-51:

Fig. 3-50:

3-62

BA 6015(3 847 019.01)-EN

Inspection and servicing HYDRAULIC SYSTEM Hydraulic system - Safety instructions

Residual pressures disappear only gradually. If work is to be carried out on the hydraulic system immediately after the immobilization, the system must be freed from pressure, i.e. depressurized:

Read and observe the "Inspection and servicing – Safety instructions" chapter.

Before working on the hydraulic system, make sure that the system is without pressure and that the residual pressures have also been eliminated.

Shut off the engine.

Risk of burning caused by hot hydraulic components (e.g. hydraulic oil reservoir, cylinder, valves).

Secure the machine as described in the "Securing the mmachine section.

Fig. 3-52:

Avoid skin contact with hydraulic oil.

Contact with hydraulic oil can cause skin injury.

Wear protective gloves and firm working clothing.

Depressurizing the hydraulic system Hydraulic systems may only be opened if they are completely depressurized. Even when an excavator is parked on a horizontal surface with the working equipment resting on the ground (Fig. 3-52:and Fig. 3-53:) and with its drive engine stationary, there may still be a considerable amount of residual pressure in parts of the hydraulic system, as e.g. the primary pressure resulting from the last hydraulic movements before the immobilization.

Fig. 3-53:

 Locate the system section to be opened.  Depressurize the section to be opened. If required, the necessary measures described must be combined.  Open the depressurized system section with caution.

Examples of system sections: 1) working hydraulics 2) servo control circuit 3) precharged return-flow line Detailled information can be found in the “Service Manual, section 8, Hydraulic System”.

3-63

BA 6015(3 847 019.01)-EN

Inspection and servicing Depressurizing  Park the excavator on a horizontal surface.  Set the working equipment on the ground.  Shut off the drive engine, keep sitting on the operator’s seat.

Sections 1 and 2, servo control and working hydraulics:  Switch on electrical system (“Ignition ON”).  Shift both control levers and all pedals repeatedly into all directions (Fig. 3-54:).

Fig. 3-55:

Topping up with hydraulic oil  Remove cover (20, Fig. 3-56:) and retaining disk (23). One of the return-flow filters is now visible in the filter chamber.  Fill in hydraulic oil through this return-flow filter until the oil level lies between the ½ and ¾ marks of the inspection glass (oil grade see: "Refilling quantities - Oil").

Fig. 3-54:

Section 3. return-flow line: After shutting down the engine, the precharging pressure decreases rapidly through the precharging valve. No measures are required before opening the return-flow line.

 Before fitting retaining disk (23) and cover (20), check sealing ring (26) and replace if damaged.  Fit cover together with sealing ring.

Checking the hydraulic oil level  Bring hydraulic oil to operating temperature (abt. 50 °C / 122° F).  Park the machine on a horizontal surface.  Move all hydraulic cylinders to their central positions.

The oil level must lie between the ½ and ¾ marks of the inspection glass (1, Fig. 3-55:).

Two sensors are monitoring the hydraulic oil level in the hydraulic oil reservoir. If the warning lamp comes on, shut off the engine. Trace out the fault and eliminate.

Fig. 3-56:

3-64

BA 6015(3 847 019.01)-EN

Inspection and servicing Changing the hydraulic oil returnflow (hydraulic oil reservoir) Read and observe the "Inspection and servicing – Safety instructions" chapter.

The return-flow filters must be replaced: 

when servicing works in accordance with the servicing plan are carried out;



when the "Hydraulic oil filter" warning lamp lights up when the hydraulic oil is at operating temperature. The filter elements (25, Fig. 3-57:) are then heavily contaminated.

(The warning can be disregarded if the lamp lights up only shortly during starting of the engine);



after repairs on the hydraulic system;



in case of damage.

Shut off the engine.

Risk of scalding caused by hot hydraulic oil.

The hydraulic oil reservoir itself may also be hot.

Avoid skin contact.

Skin contact with hydraulic oil may cause skin injury.

Wear protective gloves and firm working clothing.

Wear fall arresters before working on the hydraulic tank.

Collect escaping hydraulic oil and discard without polluting the environment.

 Remove cover (20) and retaining disk (23) as described under "Topping up with hydraulic oil".  Clean the magnetic rod (24).

If abraded metal and metal filings adhere to the magnetic rod, locate the cause or contact the CGM HMS GmbH Service.  Withdraw filter element (25) together with sealing ring (22).

If the filter elements are damaged, remove basket (28) and clean down with spirits or petroleum.  Lower basket (28) into tank.  Insert new filter element (25) together with sealing ring (22).  Fit retaining disk (23) with sealing ring (27).  Refit cover (20) with sealing ring (26).

Proceed in the same way to replace the other filter elements (25).

Fig. 3-57:

3-65

BA 6015(3 847 019.01)-EN

Inspection and servicing Bypass valves (working circuit) Read and observe the "Inspection and servicing – Safety instructions" chapter.

Cleaning the filter screens  Remove cover (10, Fig. 3-58:). Remove bolts (12) and take out the bypass valve. Withdraw sieve (13) and clean in white spirit or paraffin oil. Replace, if required.

Shut off the engine.

 Check sealing ring (16) for damage and replace, if required.

Risk of scalding caused by hot hydraulic oil.

 Re-assemble the bypass valve.

The hydraulic oil reservoir itself may also be hot.

Avoid skin contact.

 Check sealing rings (14 and 15) for damage and replace, if required.

Skin contact with hydraulic oil may cause skin injury.

 Insert the bypass valve. Make sure the valve fits properly.

Wear protective gloves and firm working clothing.

 Refit cover (10) with sealing ring (15).

Wear fall arresters before working on the hydraulic tank.

Collect escaping hydraulic oil and discard without polluting the environment.

Fig. 3-58:

Replacing the bypass valves and the sealing rings  Remove the bypass valve as described under "Cleaning the sieve".  Re-assemble new bypass valve with sieve (13) and new sealing ring (16).  Insert bypass valve with new sealing ring (14).  Refit cover (10) with new sealing ring (15).

3-66

BA 6015(3 847 019.01)-EN

Inspection and servicing Bypass valves (cooling circuit) Read and observe the "Inspection and servicing – Safety instructions" chapter.

Cleaning the valve  Remove cover (7, Fig. 3-59:).  Unscrew bolts (33, Fig. 3-60:) and withdraw valve carrier (31) together with valve (32).

Shut off the engine.

 Clean valve (32) in white spirit or paraffin oil and replace, if required.

Risk of scalding caused by hot hydraulic oil.

 Insert valve (32) into valve carrier (31).

The hydraulic oil reservoir itself may also be hot.

 Fasten valve carrier (31) with bolts (33) in the hydraulic oil reservoir. Refit cover (7, Fig. 8) with a new sealing ring.

Avoid skin contact.

Skin contact with hydraulic oil may cause skin injury.

Wear protective gloves and firm working clothing.

Wear fall arresters before working on the hydraulic tank.

Collect escaping hydraulic oil and discard without polluting the environment.

Fig. 3-60: Fig. 3-59:

Changing the valve  Remove bypass valve as described under "Cleaning the valve".  Remove valve (32, Fig. 3-60:) and replace by a new one.  Fasten bypass valve (31) on the hydraulic oil reservoir.  Refit cover (7, Fig. 3-59:).

3-67

BA 6015(3 847 019.01)-EN

Inspection and servicing Breather filter Read and observe the "Inspection and servicing - Safety instructions" chapter.

Replacing the filter element The breather filter (6, Fig. 3-61:) ensures venting of the hydraulic oil reservoir at varying hydraulic oil levels.

Shut off the engine.

Risk of scalding caused by hot hydraulic oil.

The hydraulic oil reservoir itself may also be hot.

Avoid skin contact.

Skin contact with hydraulic oil may cause skin injury.

Wear protective gloves and firm working clothing.

Wear fall arresters before working on the hydraulic tank.

Fig. 3-61:

 Unscrew butterfly nut (50, Fig. 3-62:). Withdraw hood (51) and withdraw filter element (52) from the holding rod.  Insert new sealing ring (53) and new filter element and secure hood (51) with nut (50).

Fig. 3-62:

3-68

BA 6015(3 847 019.01)-EN

Inspection and servicing High-pressure filter for working hydraulics To filter the hydraulic oil on the high-pressure side of the working hydraulic system, the machine is equipped with two high-pressure filters (30, Fig. 3-63:).

The filters are attached to the valve block in front of the hydraulic oil tank.

Replacing the filter elements  Place a suitable collecting recipient under the filter housings (Fig. 3-64:).  Collect escaping hydraulic oil and used filter elements. Discard without polluting the environment.  Unscrew filter housing (31, Fig. 3-63:) by counterclockwise rotation. Pour out the oil.  Withdraw filter element (32) from housing (31).  Check filter housing (31) as well as used filter (32) surface for debris.  Clean filter housing (31) and the sealing faces at the filter head (35, Fig. 3-64:) with white spirit or paraffin oil.  Insert filter element into housing (31) and attach to the filter head (35) with new, slightly oiled sealing rings (33 and 34) and a new support ring (36).

Fig. 3-63:

Risk of scalding caused by hot hydraulic oil.

The filter housings themselves may also be hot.

 Screw in the filter housing (31) to stop. Then turn out the filter housing by an 1/8 turn so that the filter housing is not stuck due to pressure pulsation and can be easily loosened in case of maintenance works.  Check high-pressure filters for leaks after putting the hydraulic system back into operation.

Wear protective gloves and firm working clothing.

Skin contact with hydraulic oil may cause skin injury. Avoid skin contact.

Read and observe the "Inspection and servicing – Safety instructions" chapter.  Shut off the engine.  Depressurize the hydraulic system.  Clean the filter block and the filter housings carefully.

Fig. 3-64:

3-69

BA 6015(3 847 019.01)-EN

Inspection and servicing High-pressure filter for the servo circuit, replace The excavator is equipped with a high-pressure filter (Fig. 3-65:) for the servo circuit.

Replace filter element regulary according to the maintenance plans.

Replacing the filter element  Place a suitable collecting recipient under the filter housing (Fig. 3-65:).  Collect escaping hydraulic oil and used filter element. Discard without polluting the environment.  Unscrew filter housing (5, Fig. 3-65:) and pour out the oil.  Withdraw filter element (3) from housing (5).  Clean filter housing and contact faces at the filter head with white spirit or paraffin oil.  Insert new filter element into housing (5) and attach to the filter head with new, slightly oiled sealing rings (2 and 4).  Screw in the filter housing (5) to stop. Then turn out the filter housing by an 1/8 turn so that the filter housing is not stuck due to pressure pulsation and can be easily loosened in case of maintenance works.  Check the high-pressure filter for leaks after the system has been put into operation.

Fig. 3-65:

Risk of scalding caused by hot hydraulic oil.

The filter housings themselves may also be hot.

Wear protective gloves and firm working clothing.

Skin contact with hydraulic oil may cause skin injury. Avoid skin contact.

Read and observe the "Inspection and servicing – Safety instructions" chapter.  Shut off the engine.  Depressurize the hydraulic system.  Clean the filter housings as well as the immediate vicinity carefully.

3-70

BA 6015(3 847 019.01)-EN

Inspection and servicing Filter for swing circuit, replace

Replacing the filter element

The shovel has a high-pressure filter for the swing circuit (Fig. 3-66:).

 Place a suitable collecting recipient under the filter housing (Fig. 3-66:).

Replace filter element regulary according to the maintenance plans.

 Collect escaping hydraulic oil and used filter element. Discard without polluting the environment.  Unscrew filter housing (5, Fig. 3-66:) and pour out used oil.  Withdraw filter element (2) from housing (5).  Clean filter housing and contact faces at the filter head with white spirit or paraffin oil.  Insert new filter element into housing (5) and attach to the filter head with new, slightly oiled sealing ring (3) and support ring (4).  Screw in the filter housing (5) to stop. Then turn out the filter housing by an 1/8 turn so that the filter housing is not stuck due to pressure pulsation and can be easily loosened in case of maintenance works.

Fig. 3-66:

 Check the high-pressure filter for leaks after the system has been put into operation.

Risk of scalding caused by hot hydraulic oil.

The filter housings themselves may also be hot.

Wear protective gloves and firm working clothing.

Skin contact with hydraulic oil may cause skin injury. Avoid skin contact.

Read and observe the "Inspection and servicing – Safety instructions" chapter.

 Shut off the engine.  Depressurize the hydraulic system.  Clean the filter housings as well as the immediate vicinity carefully.

3-71

BA 6015(3 847 019.01)-EN

Inspection and servicing Changing the hydraulic oil Read and observe the "Inspection and servicing - Safety instructions" chapter.

Shut off the engine.

Risk of scalding caused by hot hydraulic oil.

The hydraulic oil reservoir itself may also be hot.

Avoid skin contact.

Skin contact with hydraulic oil may cause skin injury.

Wear protective gloves and firm working clothing.

Wear fall arresters before working on the hydraulic tank.

Collect escaping oil and discard without polluting the environment.

Do not start up the drive engine when the hydraulic oil reservoir is empty.

The hydraulic pumps may be destroyed if they are allowed to run dry.

Avoid mixing of different hydraulic fluids The machine has been run in at the factory with BM Long Term Hydraulic Fluid HSS (Part-No. 2482971). CGM HMS GmbH recommends using this high-grade hydraulic fluid also in operation as it has been made especially for use in these machines to which it is also perfectly adapted.

If oil analyses are performed regularly and with positive results, the BM Long Term Hydraulic Fluid can remain in the machine for up to 10 000 operating hours.

If an alternative hydraulic fluid is to be used, it must fulfil the same specifications. Please note that the change interval for alternative fluids is fixed at 5 000 operating hours.

There is an increased risk of damage to hydraulic components, if different hydraulic fluids are mixed during topping up as well as when changing over to a fluid of a different type or from another manufacturer.

For topping up, it is therefore necessary to use only same hydraulic fluid as the one that is already in the hydraulic system.

When changing over to an alternative hydraulic fluid, please observe that there is always a small amount of old fluid remaining in the hydraulic system even after the system has been emptied. The mixing of this residual amount of old fluid with the new alternative fluid reduces the properties of the fluid dramatically and can cause damage to components of the hydraulic system in operation.

To avoid this result, the change-over to the alternative fluid must be performed in strict compliance with the manufacturer's prescriptions. The manufacturer must confirm that his hydraulic fluid is compatible with the BM Long Term Hydraulic Fluid.

The remaining amount of old fluid must not exceed 2% of the total volume. This can only be achieved by repeated flushing with the total fluid volume.

If the remaining amount of fluid exceeds 2% of the total volume, the fluid becomes a detrimental "mixed fluid".

The operation of the system with mixed fluids must by all means be avoided.

CGM HMS GmbH assumes no warranty for damage caused as a result of the machine having been operated with consumables of inappropriate specification or with mixed fluids.

3-72

BA 6015(3 847 019.01)-EN

Inspection and servicing Drawing off hydaulic oil  Bring the hydraulic oil to operating temperature (abt. 50 ° C / 122° F).  Position the machine with a slight inclination towards the drain valve (5, Fig. 3-67:).

The drain valve is located at the back of the hydraulic oil reservoir and accessible from the bottom.  Retract the hydraulic cylinders as far as possible and stand the working equipment on the ground.  Shut off the engine.  Place suitable recipients under the drain valve (5) of the hydraulic oil reservoir. For the required capacity refer to the "Refilling quantities - Oil" table.

Fig. 3-67:

 Connect hose (15) to drain valve (5) and drain off used oil completely. Draining is facilitated if the breather filter (6, Fig. 3-68:) is removed during the process.

The use of the oil draining hose is described in the "Hose line for oil and cooling liquid changes" section.  Remove hose. The drain valve closes automatically.

Fig. 3-68:

3-73

BA 6015(3 847 019.01)-EN

Inspection and servicing Cleaning the hydraulic oil reservoir Explosion hazard.

Read and observe the "Inspection and servicing - Safety instructions" chapter.

Shut off the engine.

Use diesel fuel or a special flushing oil.

Do not use white spirit, paraffin oil or other solvents for cleaning.

Avoid skin contact.

Skin contact with hydraulic oil may cause skin injury.

Wear protective gloves and firm working clothing.

Wear fall arresters before working on the hydraulic tank.

Dispose of contaminated hydraulic oil without polluting the environment and separately from other waste.  Drain off hydraulic oil as described under "Draining off the hydraulic oil".  Remove cap (7, Fig. 3-69:).  Place a collecting recipient for the flushing oil under the hydraulic oil reservoir.  Clean the inside of the hydraulic oil reservoir with diesel fuel or flushing oil.

Remove all sediments and also the residues of the cleaning agent thoroughly  Refit cap (7).  Fill in hydraulic oil as described under "Topping up with hydraulic oil".  Vent the hydraulic system.  Check the oil level in the hydraulic oil reservoir and top up with oil, if required.

3-74

Fig. 3-69:

BA 6015(3 847 019.01)-EN

Inspection and servicing Venting the hydraulic system Hydraulic pumps, hydraulic motors, hydraulic cylinders, travel brake valves, suctionlines of hydraulic pumps, oil cooler manifolds and the servo control system must be vented 

after assembly on site and prior to initial commissioning,



before each recommissioning of the excavator, e.g. after extensive repair work to the hydraulic system or after prolonged downtimes,



after each hydraulic oil change,



after replacement of hoses or lines.

Fig. 3-71:

Venting the hydraulic components Hydraulic pumps and hydraulic motors (with engine shut off).  Open the highest leakage oil port and fill in clean hydraulic oil up to the lower edge of the opening.  Check the hydraulic system under load.  Pay attention to noises produced by the hydraulic pump or the hydraulic motors. Abrupt movements of the working equipment are a sign of entrapped air in the system. Remaining air pockets can be eliminated by actuating all hydraulic functions.

Hydraulic cylinder Before the initial admission of the cylinder with oil, the piston must be in either of the two extreme piston positions. In other words, the piston rod (1, Fig. 3-70: and Fig. 3-71:) must be either completely retracted or completely extended.

Always admit oil first to that side of the cylinder where the piston (2) is. This is 

the piston-side port (3) when the piston rod is retracted (1, Fig. 3-70:),



the rod-side port (4) when the piston rod is extended (1, Fig. 3-71:).

If, for assembly reasons, the piston rod is inmiddle position, admit oil first to the piston-side port (4).

When oil is admitted for the first time to the cylinder, the oil flow must be reduced. Therefore extend or retract the piston rod as slowly as possible.

The bolts/nozzles of the following components must be opened until oil emerges bubble-free from the opening: Always vent only the system section that has been opened.



the travel brake valve at the venting screw,



the oil cooler manifold at the mini-measuring ports,



the servo system at the venting bolts of the control blocks (under the servo caps),



the intake line at the venting screw (with drive motors stationary).

Fig. 3-70:

3-75

BA 6015(3 847 019.01)-EN

Inspection and servicing Cleaning the hydraulic oil cooler Risk of injury from rotating cooler fan blades.

Cleaning  Remove the grid (7, Fig. 3-73:) above the cooler.  Blow the cooling fins clean with compressed air proceeding from top to bottom.

Shut off the engine.

Never start cleaning work until the cooler fan blades have stopped turning.

Loose dirt drops through the cooler down to the ground.

The hydraulic oil coolers reach the same temperature as the hydraulic oil. Risk of burning.

Allow the hydraulic oil cooler to cool down.

Wear protective gloves and firm protective clothing.

If the machine is used in places with heavily contaminated ambient air, the hydraulic oil coolers must be cleaned more often than specified in the servicing plan.

The speeds of the fan motors are thermostatcontrolled. The fan motors run at maximum speed when the hydraulic oil temperature reaches ca.

60°C / 140° F.

3-76

Fig. 3-72:

BA 6015(3 847 019.01)-EN

Inspection and servicing Pressure accumulator To permit lowering of the working equipment in case of emergency, the machine is equipped with a pressure accumulator (1, Fig. 3-73:).

The pressure accumulator (1) is located under the superstructure baseplate.

The following regulations are applicable only in the Federal Republic of Germany. Please observe the corresponding regulations in your own country.

Extract from the German acceptance regulations Hydraulic accumulators are pressure vessels and are therefore subject to the "Druckbehälterverordnung (DruckbehV)" [Pressure Vessel Regulations].

Their installation, equipment and operation are governed by the "Technische Regeln Druckbehälter (TRB)" [Technical Rules for Pressure Vessels]. The pressure vessels of hydraulic accumulators are classified by the admissible operating pressure p in bars, the capacity l in liters and the product of pressure and capacity p x l. Depending on the class to which the accumulator belongs, the following inspections are mandatory: Checking the gas charging pressure in the pressure accumulator After commissioning (new installation or repair), the gas charging pressure in the pressure vessel must be checked at least once during the first week. If no pressure loss is detected, the second pressure test must be performed after ca. 3 months. If no pressure loss is detected in this test either, the testing interval can be fixed at once pressure test each year.

Fig. 3-73:

Extract from the German regulations The accumulator vessel must not be subjected to welding, soldering or any other mechanical work.

Work on systems containing accumulators (repairs, connection of pressure gauges or similar work) may be carried out only when the fluid pressure has been released Group II p  l bar and p·x l  200

Inspections prior to commissioning at the factory at the place of use Pressure testing Inspection certificate Prototype and pressure test (Check of correctness and certified by the manufacturer correct installation) issued by an expert

Regular inspections Inspection schedule to be drawn up by end user, based on experience with type of operation and fluid.

3-77

BA 6015(3 847 019.01)-EN

Inspection and servicing PUMP DRIVE GEARBOX Risk of scalding caused by hot gearbox oil.

The gearbox housings may be hot, too.

Shut off the engine.

Skin contact with gearbox oil is a potential health hazard. Protect the skin from contact with gearbox oil. Wear protective gloves and firm working clothing.

Secure the machine as described in the "Securing the machine" section.

Fig. 3-74:

Read and observe: "Inspection and servicing Safety instructions”.

Pump drive gearbox - Checking the oil level / Topping up with oil The pump drive must be in operation for at least 30 minutes prior to checking the oil level, because oil is accumulated in the pump mounting flanges for lubrication of the profile hollow shaft.

Checking the oil level when the pump drive is cold give wrong results.  Park the machine as described under "Securing the machine".

Fig. 3-75:

 Unscrew dipstick (1, Fig. 3-74:) and wipe clean.

Pump mounting flanges expansion reservoir, checking oil level

 Insert dipstick until the thread reaches the top of dipstick’s bore. Do not screw in! (2, Fig. 3-75:).

The oil level is visually at the inspection glas (3, Fig. 3-76) in expansion reservoir (1).

 Withdraw dipstick a second time.

Oil level should be between the two dipstick markers “min.” and “max.” (Fig. 3-75:).

Top up with fresh gearbox oil if required. Fill in gearbox oil through the dipsticks bore.

(Oil grade see : “LUBRICANTS / CONSUMABLES”).

The oil level should reach up at least to the middle of the inspection glas (3). Top up with gearbox oil, if required.

 Inspect dipstick’s sealing ring and replace if damaged.  Screw in dipstick (1) back in place.

Fig. 3-76

3-78

BA 6015(3 847 019.01)-EN

Inspection and servicing Pump drive gearbox - Changing the gearbox oil Change the gearbox oil when the gearbox is nearly at operating temperature. Warm oil flows better and carries suspended particles (carbon and abraded matter) better.

Recommendation: if the gearbox oil is heavily soiled, the gearbox should be flushed with fresh gearbox oil. In this case contact your Caterpillar dealer.

Draining off gearbox oil  Prepare a collecting recipient for used oil.

Choose the required capacity in accordance with the "Refilling quantities - Oil" table.  Unscrew plug (3, Fig. 3-77:), plug (3) is accessible from the ground.  Drain off oil.

Screwing out breather filter (2) facilitates draining off the used oil  Check sealing ring of plug (3), replace if damaged.  Screw plug (3) back in place.

Filling in gearbox oil (Oil grade see: “LUBRICANTS / CONSUMABLES” section).  Unscrew breather filter (2, Fig. 3-77:).  Fill in new oil through the bore of breather filter (2).  Fill in gearbox oil until the oil level reaches the “max.” mark on dipstick (1, Fig. 3-78:).  Start engine and allow to run for maximum two minutes at idle speed, then stop engine.

The pump drive oil cooling circuit has been filled now with gearbox oil.  Check gearbox oil level and top up to the correct filling level.  Check for leaks and for correct filling level after putting the machine back in operation.

Top up with gearbox oil if required.

Note: The oil level is to be checked after about 30, 60 and after 240 minutes running time as oil collects in the mounting flanges or is dammed there to lubricate the splined hollow shafts. The gearbox oil cooling system is also be filled with oil. Therefore it is absolutely necessary to check the oil level and top up with gearbox oil up to the correct level.

Fig. 3-77: Fig. 3-78:

3-79

BA 6015(3 847 019.01)-EN

Inspection and servicing Pump mounting flanges expansion reservoir, checking oil level

Pump drive gearbox breather, replace

Draining off oil  Prepare a collecting recipient for used oil.

The gearbox is vented through breather filter (2, Fig. 3-81:) on top of the gearbox housing.

Choose the required capacity in accordance with the "Refilling quantities - Oil" table.

Clean breather filter in accordance with the servicing plan.

 Unscrew plugs (7, Fig. 3-79:) and drain off oil.

Plugs (7) are accessible from the ground.

 Unscrew breather filter, clean in white spirit or paraffin oil and blow dry with compressed air.

 Screw plugs (7) back in place.

 Screw breather filter back in place.

Filling in oil  Unscrew breather filter (2, Fig. 3-80).  Fill in new oil through the bore of breather filter (2).

The oil level should reach up at least to the middle of the inspection glas (3). Top up with gearbox oil, if required.

Fig. 3-81:

Pump mounting flanges expansion reservoir, replace breather

Fig. 3-79:

The expansion reservoir is vented through breather filter (2, Fig. 3-82:) on top of the expansion reservoir.

Clean breather filter in accordance with the servicing plan.  Unscrew breather filter, clean in white spirit or paraffin oil and blow dry with compressed air.  Screw breather filter back in place.  Replace if damaged.

Fig. 3-80

Fig. 3-82:

3-80

BA 6015(3 847 019.01)-EN

Inspection and servicing Pump drive gearbox oil filter, replace In the oil cooling circuit of the pump drive gearbox there is a filterelement (Fig. 3-83:).

Check filter tell-tale (2) regulary - at operating temperature - for indication of contamination.

If the red sector is visible through transparent cap (1), the filter element must be replaced.

Filter element (7) must be replaced after 1000 operating hours at the latest.

To do so:  Place a suitable collecting recipient under the filter housing.  Collect escaping hydraulic oil and used filter element. Discard without polluting the environment.

Fig. 3-83:

 Remove flanges (4).  Pour oil out of filter pot (9) and remove filter element (7).  Clean filter head (3) and filter pot (9).  Place new filter element into filter pot. Oil the new O-rings (6 and 8) lightly and attach.  Re-assemble filter pot (9) with flanges (4).  Check filter for leaks after the system has been put into operation.

3-81

BA 6015(3 847 019.01)-EN

Inspection and servicing Pump drive gearbox, take an oil sample Risk of injury.

Components and oils can be hot.

The surfaces of engines, gearboxes and tanks are hot after operation.

Oil samples must however be taken shortly after engine stop when oils are still at their operating temperature.

The substances contained in the oil are then still in suspension.

Wear firm working clothing and gloves and be especially careful when taking oil samples.

 Place the recipient for the oil sample under the drain valve.  Open the valve (2) as described.

When the needed amount of oil has drained out, let the valve knob (2) go. The drain outlet closes automatically.  Refit the cap (1).  Label the oil sample, fill in the accompanying form of the oil analysis laboratory completely, pack up the oil sample carefully and send it to the oil laboratory.  Please make sure the oil samples can be correctly assigned in the case of assemblies of which two or more units are installed in the machine (engines, gearboxes).

Oilsamples can be taken by means of a sampling valve (arrow, Fig. 3-84:) mounted at the bottom of the gearbox.

To take an oil sample proceed as follows:  Shut off the engine.  Protect the machine against unauthorized starting.  Clean the surroundings of the sampling valve carefully. This precaution prevents that dirt gets into the sample and invalidates the analysis results.  Unscrew the cap of the drain opening (1).  Place a recipient for the used oil under the drain valve.  Open the valve by turning the knob counterclockwise and by holding it in this position (against the spring pressure). The oil now flows out of the outlet.  Let about 100 ml (5.2 oz) of oil flow out of the valve.

This measure serves the purpose of rinsing the screwed connections and the sampling valve so that accumulated dirt is removed.

This oil must be disposed of.

3-82

Fig. 3-84:

BA 6015(3 847 019.01)-EN

Inspection and servicing Pump drive gearbox, cleaning the oil cooler Risk of injury from hot surfaces on the oil cooler and from rotating cooler fan blades.

Cleaning  The oil cooler is mounted in front of the hydraulic oil cooler on the left side of the superstructure.  Open cover in front of the oil coolers on the left side of the superstructure (arrow, Fig. 3-85:).

Shut off the engine.

 Remove grid above the cooler elements.

Never start cleaning work until the cooler fan blades have stopped turning.

 Blow the cooling fins clean with compressed air proceeding from top to bottom.

The oil cooler reaches the same temperature as the gearbox oil. Risk of burning.

Loose dirt drops through the cooler down to the ground.

Allow the oil cooler to cool down.

Wear protective gloves and firm protective clothing.

If the machine is used in places with heavily contaminated ambient air, the oil cooler must be cleaned more often than specified in the servicing plan.

Fig. 3-85:

3-83

BA 6015(3 847 019.01)-EN

Inspection and servicing SWING GEARBOX Read and observe: "Inspection and servicing - Safety instructions.

Swing gearbox, changing the gearbox oil  Prepare a collecting recipient for used oil.

Shut off the engine The gearbox housings may be hot, too.

Choose the required capacity in accordance with the "Refilling quantities - Oil" table.

Secure the machine as described in the "Securing the machine" section.

Protect the skin from contact with gearbox oil.

Skin contact with cooling liquid is a potential health hazard.

Wear protective gloves and firm working clothing.

Fig. 3-87:

Draining off oil  Attach hose (8, Fig. 3-87:) to drain valve (7) and drain off oil completely.

Fig. 3-86:

The use of the oil draining hose is described in the "Hose line for oil and cooling liquid changes" chapter.

The drain valve (7, Fig. 3-87:) is accessible from the undercarriage.

Swing gearbox, checking the oil level / topping up with oil  Park the machine as described under "Securing the machine".  Screw out dipstick (1, Fig. 3-86:) and wipe clean.  Insert dipstick (1) fully again (do not screw in) and withdraw a second time.

The oil level must reach up at least to the lower mark on dipstick (1). Top up with gearbox oil, if required.  Screw dipstick (1) back in place.

3-84

 Remove hose. The oil drain valve closes automatically. See: “Hose line for oil and cooling liquid change" section.

BA 6015(3 847 019.01)-EN

Inspection and servicing Filling in new oil / Topping up 

Unscrew plug (4, Fig. 3-88:) and fill in new oil.

 Check oil level with dipstick (1, Fig. 3-88:).  Screw in plug (4) again.

Swing gearbox, clean / replace breather The gearbox is vented through breather filter (2, Fig. 3-88:).

Clean breather filter in accordance with the servicing plan.  Unscrew breather filter (2), clean in white spirit or paraffin oil and blow dry with compressed air.  Screw breather filter (2) back in place.

Swing gearbox output pinion, lubricate Grease bearing regulary.

Fig. 3-88:

 Fill in approximate 50 cm3 / 1,7 oz grease through grease nipple (5, Fig. 3-89:) by means of a hand grease pump.

Fig. 3-89:

3-85

BA 6015(3 847 019.01)-EN

Inspection and servicing TRAVEL GEARBOX (P/N 3712319, 3749594) Risk of scalding caused by hot gearbox oil. The gearbox housings may be hot too.

Shut off the engine.

Skin contact with gearbox oil is a potential health hazard. Protect the skin from contact with gearbox oil. Wear protective gloves and firm working clothing.

Park and secure the machine as described in the "Securing the machine" section.

Read and observe: "Inspection and servicing Safety instructions”.

Details about selecting the correct gear oil can be found in chapter “LUBRICANTS / CONSUMABLES”.

To identify the gearbox partnumber (P/N) check the name plate attached to the gearbox.

Travel gearbox, checking the oil level / topping up with oil  Move the hydraulic shovel into such a position that the screw plugs (1 and 2, Fig. 3-90:) are in the displayed position.  Unscrew checking plug (1).

The oil level should reach up to the lower edge of the opening. Top up with oil, if required.

(Oil grade see: “LUBRICANTS / CONSUMABLES”).  Screw checking plug (1) back in place.

Travel gearbox, changing the oil  Place a collecting recipient for used oil under the travel gearbox. Choose the required capacity in accordance with the "Refilling quantities - Oil" table.  Unscrew drain plug (2, Fig. 3-90:) and drain off oil completely. Screwing out the checking plug (1) facilitates draining off the used oil.

Before filling in new oil, screw drain plug (2) back in place.

Filling in new oil / Topping up  Unscrew checking plug (1) and fill in new oil through the borehole until the oil level reaches up to the lower edge of the opening.

Travel gearbox, clean / replace breather The gearbox is vented through breather filter (2, Fig. 3-91:).

Clean / change breather filter in accordance with the servicing plan.  Unscrew breather filter, clean in white spirit or paraffin oil and blow dry with compressed air.  Screw breather filter back in place.

Fig. 3-91:

Fig. 3-90:

3-86

BA 6015(3 847 019.01)-EN

Inspection and servicing TRAVEL GEARBOX (P/N 3709660) Risk of scalding caused by hot gearbox oil. The gearbox housings may be hot too.

Shut off the engine.

Skin contact with gearbox oil is a potential health hazard. Protect the skin from contact with gearbox oil. Wear protective gloves and firm working clothing.

Park and secure the machine as described in the "Securing the machine" section.

Read and observe: "Inspection and servicing Safety instructions”.

Travel gearbox, changing the oil  Place a collecting recipient for used oil under the travel gearbox. Choose the required capacity in accordance with the "Refilling quantities - Oil" table.  Unscrew drain plug (3, Fig. 3-92:) and drain off oil completely. Screwing out the plugs (1 and 2) facilitates draining off the used oil.

Before filling in new oil, screw drain plug (3) back in place.

Filling in new oil / Topping up  Unscrew plugs (1 and 2).  Fill in new oil through the borehole of plug (2) until the oil level reaches up to the lower edge of the opening of plug (1).

Details about selecting the correct gear oil can be found in chapter “LUBRICANTS / CONSUMABLES”.

 Screw all plugs back in place.

To identify the gearbox partnumber (P/N) check the name plate attached to the gearbox.

Travel gearbox, clean / replace breather

Travel gearbox, checking the oil level / topping up with oil  Move the hydraulic shovel into such a position that the screw plugs (Fig. 3-92:) are in the displayed position.  Unscrew checking plug (1).

The oil level should reach up to the lower edge of the opening. Top up with oil, if required.

(Oil grade see: “LUBRICANTS / CONSUMABLES”).  Screw checking plug (1) back in place.

The gearbox is vented through breather filter (2, Fig. 3-91:).

Clean / change breather filter in accordance with the servicing plan.  Unscrew breather filter, clean in white spirit or paraffin oil and blow dry with compressed air.  Screw breather filter back in place.

Fig. 3-93:

Fig. 3-92:

3-87

BA 6015(3 847 019.01)-EN

Inspection and servicing UNDERCARRIAGE Tracks, cleaning Clean tracks, track and support rollers, sprockets and idlers regularly and whenever required. Cleaning is especially important in winter to prevent 

the tracks from being thrown off,



oil from leaking out of track and support rollers, sprockets and idlers,



excessive wear,



the track from breaking.

To clean the tracks:  raise one side of the excavator with the working equipment and allow track to turn;  clean the side member supporting the track;  clean track and support rollers (1 and 2 , Fig. 3-94:) thoroughly, especially at those places indicated by arrows;  clean the sliding planes on the idler guides.

3-88

Fig. 3-94:

BA 6015(3 847 019.01)-EN

Inspection and servicing Track rollers, support rollers, track pads The track rollers (1, Fig. 3-95:) and the support rollers (2, Fig. 3-96) have a permanent grease filling.

Inspect all track and support rollers visually for leaks and free movement at regular intervals.

Track pads, check fastening  Check track pads fastening bolts (5, Fig. 3-97:) regularly for tightness.  If loose, tighten bolts with a torque wrench to the prescribed tightening torque (see: "Service Manual").

Track roller, check fastening  Check track rollers fastening bolts (3, Fig. 3-95:) regularly for tightness.  If loose, tighten bolts with a torque wrench to the prescribed tightening torque (see: "Service Manual").

Fig. 3-97:

Fig. 3-95:

Support roller, check fastening  Check supprt rollers fastening bolts (4, Fig. 3-96) regularly for tightness.  If loose, tighten bolts with a torque wrench to the prescribed tightening torque (see: "Service Manual").

Fig. 3-96

3-89

BA 6015(3 847 019.01)-EN

Inspection and servicing Track tensioner

Function

Design

The tensioning system is under permanent pressure of ca. 100 bar / 1450 psi which keeps both tracks permanently tensioned. Pressure losses are compensated as soon as the engine has been started. Retensioning is not required.

The tracks are tensioned with the help of the hydraulic pressure created during travelling. Fig. 3-98:and Fig. 3-99: show parts of the tracks and the tensioner:

For cleaning and servicing work, the tracks can be slackened.

To do so:  stop the engine  open both pressure limiting valves (6, Fig. 3-99:) to slacken the tracks.  After the work, screw down the pressure limiting valves (6) to the limit stop.

Fig. 3-98:

Pos. Function 4 Pressure accumulator 5 Pressure cylinder 6 Pressure limiting valve 9 Mini- measuring port 10 Support roller 11 Drive sprocket 12 Track roller 13 Crawler track 14 Idler

Techncal data Track tensioning pressure Pressure limiting valve Gas pressure in pressure accumulator (nitrogen filling pressure)

3-90

Approx. 100 bar / 1450 psi 250 bar / 3626 psi 80 bar / 1160 psi

Fig. 3-99:

The pressure-limiting valves (6) are preset to a pressure of 250 bar / 3626 psi and sealed in this position. The lead seal must not be removed and the pressure setting of 250 bar / 3626 psi must not be changed.

The track tensioners are maintenance-free.

BA 6015(3 847 019.01)-EN

Inspection and servicing Pressure-accumulator inspection regulations The following regulations are applicable only in Germany. Please observe the relevant regulations in force in your own country.

Extract from the German regulations The accumulator vessel must not be subjected to welding, soldering or any other mechanical work.

Work on systems containing accumulators (repairs, connection of pressure gauges or similar work) may be carried out only when the fluid pressure has been relieved.

Checking the gas charging pressure in the pressure accumulator After commissioning (new installation or repair), the gas charging pressure in the pressure vessel must be checked at least once during the first week. If no pressure loss is detected, the second pressure test must be performed after ca. 3 months. If no pressure loss is detected in this test either, the testing interval can be fixed at once pressure test each year.

The above-mentioned pressure tests are required to ensure the functioning of the track tensioner.

They are no substitute for the inspections as required by the "Pressure Vessel Regulations".

Extract from the German acceptance regulations Hydraulic accumulators are pressure vessels and are therefore subject to the "Druckbehälterverordnung (DruckbehV)" [Pressure Vessel Regulations].

Their installation, equipment and operation are governed by the "Technische Regeln Druckbehälter (TRB)" [Technical Rules for Pressure Vessels]. The pressure vessels of hydraulic accumulators are classified by the admissible operating pressure p in bars, the capacity l in liters and the product of pressure and capacity p x l. Depending on the class to which the accumulator belongs, the following inspections are mandatory:

Group III p  l bar p·x l  200 and p x l  1000

Inspections prior to commissioning at the factory at the place of use Preliminary inspection by an Acceptance inspection by an expert expert Prototype and pressure test certified by the manufacturer (type approval) or the expert

Regular inspections Test programme to be drawn up by end user based upon experience with the type of operation and fluid.

3-91

BA 6015(3 847 019.01)-EN

Inspection and servicing SWING RING Read and observe: "Inspection and servicing - Safety instructions.

Internal gearing The internal gearing and the pinion are enclosed in a housing (5, Fig. 3-101:). The housing forms a grease-filled trough in which the pinion of the swinging mechanism moves.

Shut off the engine.

Wear protective gloves and firm protective clothing.

Swing ring - Instructions The grease filling must be replaced: 

when repairs have been carried out on the swinging ring, the swinging ring seals or the swinging ring housing.

Remove old grease completely before filling in new grease.

If greater losses are detected, locate cause immediately to prevent damage to the swinging ring.

Greases and greasy cleaning rags must not be allowed to pollute the environment. Discard grease and greasy cleaning rags separately from other waste without polluting the environment.

Swing ring, bearing races

Fig. 3-101:

The grease is pumped to the greasing port of the grease trough by the distributor (Fig. 3-100:). The amount of grease used up during operation is replenished by the central lubricating system.

The housings have a check opening which is closed with a cover (6, Fig. 3-102:For checking, the cover must be removed.

The central lubricating system supplies grease continuously to the two roller bearing races and the internal gearing .

The grease is pumped to the greasing points of the bearing races by a distributor (Fig. 3-100:).

Fig. 3-102:

Fig. 3-100:

3-92

BA 6015(3 847 019.01)-EN

Inspection and servicing Swing ring - Checking the grease filling Read and observe: "Inspection and servicing - Safety instructions.

Swing ring - Filling in grease Prior to initial commissioning, the grease trough of the internal gearing must be filled with grease.

Add grease when

Shut off the engine.

Wear protective gloves and firm protective clothing.

At regular intervals  check internal gearing and teeth of swinging mechanism pinion for condition



the housing has been replaced



old grease has been removed in the course of other work.

Always fill in fresh grease by hand.

Risk of accidents. Never swing the superstructure when refilling grease.

 check that the grease filling is sufficient.

The housing must always contain enough grease for the gearing - measured from its lower edge - to run in at least 20 mm / 0.8” of grease over its whole circumference (Fig. 3-103:).

In the event of greater grease losses, eliminate cause immediately and add grease to prevent the internal gearing and the pinion from being damaged by continued swinging movements.

Swing ring - Checking the bolts for tightness The fastening bolts of the swinging ring in the superstructure and the undercarriage are tightened with their respective check torque (see: "Service Manual“).

When these values are reached, the fastening bolts are perfectly tight.

Loosen slack bolts before tightening them with a torque wrench to the prescribed torque (see: „Service Manual“).

Fig. 3-103:

3-93

BA 6015(3 847 019.01)-EN

Inspection and servicing CENTRAL LUBRICATING Design and function

All lubricating points connected to the system are greased at regular intervals. During the greasing cycle, indicator lamp (24, Fig. 3-104:) is lit up.

The excavator is equipped with an automatic central lubricating system ensuring regular the regular supply of grease to all greasing points except those mentioned in the "Lubricating chart - Grease" for the backhoe bucket.

A grease pump (5, Fig. 3-106:) with attached grease container (6) pumps the grease through lines (7) to the main distributors (17 and 18, Fig. 3-106: and Fig. 3-107:).

Fig. 3-106: Fig. 3-104:

When the electrical system is switched on with the key-switch, the indicator lamp (23, Fig. 3-104:) lights up and the lubricating system is activated.

The indicator lamp (23) is visible after removing cover (20, Fig. 3-105:).

There is no main distributor (18) if the excavator is equipped with a backhoe bucket.

Fig. 3-107:

Fig. 3-105:

3-94

BA 6015(3 847 019.01)-EN

Inspection and servicing

In the case of trouble-free operation, two control pins in the main distributors must always move up and down when the pertaining pistons in the main distributors are being switched over.

Control pin movement is monitored by means of sensors. Indicator lamp (24, Fig. 3-108:) flashes on and off in the event of a fault.

See fault indication table.

In the event of trouble, shut off engine and rectify.

Check during every working shift 

that no grease escapes from the pressurerelief valves (9, Fig. 3-109:) and



that the grease container contains a sufficient amount of grease.

Fig. 3-109:

Always refill the grease container in time to avoid malfunctions caused by air penetrating into the lubricating system.

The grease container (6) can also be filled by hand.

Switch off the electrical system and withdraw key from the key-switch.

Fig. 3-108:

The level of grease in the container is visible from outside.

Unscrew cover (8)of the grease container and fill in grease manually.

If grease escapes from the pressure valves (9), the line system is clogged. In this case, rectifiy the fault as described under "Unblocking a grease line".

Screw cover (8) back in place.

If the amount of grease left in the container is insufficient, refill container through greasing nipple (10, Fig. 3-109:) with a manual grease gun or with a mobile service station. The filling pressure must be ca. 5 - 8 bars / 72-116psi.

3-95

BA 6015(3 847 019.01)-EN

Inspection and servicing

The greasing cycle is initiated by a electronic unit.

The duration of a single cycle is controlled by the check-back signal from the sensors in the greasing circuit.

The optimal adjustment of the pause duration is attained when an increasing ring of grease forms at the greasing (friction) points. If one of the greasing points shows a different behaviour, it is not being supplied with sufficient grease. In this case, the pause duration must be adapted accordingly.

Presetting the pause duration

Indicators

The pause duration is preset with jumper (21, Fig. 3-110:) and rotary switch (22).

Diode (23, Fig. 7) lights up when the power supply in on.

Jumper (21) placed over contact pins on the left and in the middle: presetting of minutes.

Diode (24) lights up in the event of malfunctions (code flashing sequence see table in Fig. 8).

Greasing cycle

Do not change the setting.

The control panel indicator "Lubrication" in the operator›s cab flashes in the same sequence.

A = Drive motor defective

Rotary switch (22) is used to preset 15 time ranges 1 thru and A thru F.

B = Malfunction of lubricating circuit 1 C = Malfunction of lubricating circuit 2 D = Malfunction of lubricating circuits 1 and 2 E = Container empty (Optional) F = Pump running indicator extinguished during greasing pauses

Fig. 3-110:

Rotary switch (22) is set to range "1". The corresponding pause duration is the 4 minutes.

If rotorary switch (22) is set to range "2", the pause duration will 8 minutes. In range "3", the duration is 12 minutes.

Increasing the range by one step of the switch prolongs the pause duration by another 4 minutes.

Set the pause duration at first to 4 minutes.

If required, the pause can be prolonged later on.

3-96

Fig. 3-111

BA 6015(3 847 019.01)-EN

Inspection and servicing Malfunctions 

greasing point(s) blocked up



distributor (s) blocked up



main line to distributor with piston movement sensor interrupted



air in greasing system



container empty

The malfunctions mentioned above prevent the pistons in the monitored distributor from moving up and down. Lamp (24) will then indicate the corresponding fault by flashing on and off in the following intervals: Malfunction of lubricating circuit 1 B = 0,5 seconds - "ON" - 1 second "OFF" Malfunction of lubricating circuit 2 C = 1 second - "ON" - 0,5 seconds "OFF"

Reset button

Malfunction of lubricating circuit 1 and 2

(25, Fig. 3-112:)

D = 2 seconds - "ON" - 2 seconds "OFF"

Depressing reset button (25) for more than 2 seconds initiates an additional greasing cycle.

Container empty (option)

After having rectified a malfunction, reset button (25) must be depressed shortly (1 second) to cancel the fault message.

Indicator lamp (24) flashes in the following intervals E = 0,5 seconds - "ON" - 0,5 seconds " OFF" The "container empty" signal starts flashing only after 6 revolutions of the motor.

In the event of malfunction, the piston sensor (initiator) can no longer detect piston movements and therefore not switch off the motor.

The monitoring timer of the control unit operating in parallel switches off the pump after the monitoring time has elapsed.

The system indicates a fault.

Indicator lamp (24) flashes on and off.

The pump does not restart automatically.

Fig. 3-112:

3-97

BA 6015(3 847 019.01)-EN

Inspection and servicing Venting the grease pump

Venting the grease lines

 Refill grease container (6, Fig. 3-113:).  Unscrew lines (7) from connections (12).

If air has penetrated into the line system - e.g. when lines are being replaced - the lubricating system must be vented.

 Start up grease pump (5) until grease emerges from connections (12).

 Disconnect lines (7, Fig. 3-113:) from the distributors.

 Switch off grease pump and reconnect lines (7).

 Start up grease pump (5) until grease emerges from lines (7).  Switch off grease pump (5) and reconnect lines (7) to the distributors.  Disconnect all other lines one after the other from the distributors, start up grease pump (5) and wait until grease emerges from the respective connection.  Repeat these procedures at all other distributors.

Unblocking a grease line Fig. 3-113:

3-98

Proceed as described under "Venting the line system".

Put the excavator back into operation only after the lubricating system works properly and after activating the unloaded working equipment for abt. 5 minutes. This is required to supply sufficient grease to the cylinder bearings.

BA 6015(3 847 019.01)-EN

Inspection and servicing Cleaning the grease sieves Check the grease sieves (13, Fig. 3-114:) for contamination and clean, if required. The grease sieves must also be cleaned after a blockage in one of the grease lines has been removed

Cleaning  Loosen nut (12) by holding union (16) in place with a wrench.  Unscrew disk (14).  Remove sieve (13) and clean with white spirit or paraffin oil.  Refit (13) and fasten with disk (14).  Screw nut (12) onto the union.

Lubricating the grease distributor of the working equipment  Withdraw protective cap from greasing nipple.  Clean greasing nipple.  Press nozzle of the grease gun onto the greasing nipple.  Inject grease until the fresh grease squeezes the used grease out of the bearing joints.

Make sure that used grease emerges from all greasing points connected to the distributor.

Only then have all greasing points connected to the grease distributor been properly greased.  Wipe off used grease with cleaning rags.  After greasing, place protective cap back on the greasing nipple.

Dispose of cleaning rags without polluting the environment.

Fig. 3-114:

3-99

BA 6015(3 847 019.01)-EN

Inspection and servicing OTHER MAINTENANCE Heating and air conditioning Change the filter mats in the air suction regulary.

The filter mats are located under the operator`seat.

Fig. 3-115:

 Remove cover (1, Fig. 3-115:) Change filter mats (2)  Fasten cover (1) again.

3-100

BA 6015(3 847 019.01)-EN

Inspection and servicing PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING Putting the excavator out of operation

Battery storage

 Park the excavator on firm and level ground.

 Check the acid density and the electrolyte level of the battery every two weeks.

 Set the working equipment down on the ground, retracting the piston rods of the hydraulic cylinders as far as possible.  Set all control element to "0".  Clean the machine.

During prolonged machine downtimes, remove the batteries and store in a dry room at an ambient temperature of ca. 20°C / 68° F. Observe the following points with regard to maintenance:  Clean the batteries.

 Recharge the batteries at the latest, when the acid density has dropped to 1.23 kg/dm³.  Keep the batteries clean and dry on the outside.

 Lock the superstructure.  Carry out a visual inspection of the excavator.  Remove coarse dirt, snow and ice from the fins and fan wheel of the hydraulic oil cooler.

Recommissioning

 Carry out engine preservation

 Remove the covers.

 Protect all bright metal parts (e.g. piston rods) from rust and dirt.

 Degrease / clean all protected components.

 Check anti-freeze concentration of the cooling liquid to avoid freezing during the cold season.

 Remove engine preservation in acc. with the engine operationg anstructions  Unlock the superstructure

 Fill up the fuel tank.

 Check the fuel level in tank

 Remove the batteries; see: "Battery storage".

 Check track tension (visual inspection)

 Secure the machine against unauthorized starting by: - withdrawing the key from the key-switch

 Check level and condition of the cooling liquid in the cooling system.

- locking the cab door - securing all lockable hatches.  Cover up all openings

 Check grease filling in grease container.Oil level - drive engine - swinging gearbox - pump transfer gearbox - travel gearboxes  Check oil level in hydraulic oil reservoir.Check battery acid density and level.Install batteries and reconnect.  Function checks: - superstructure holding brake - track brake - lighting system - signalling equipmen  Check vacuummeter  Vent the hydraulic system.

3-101

BA 6015(3 847 019.01)-EN

Inspection and servicing

3-102

BA 6015(3 847 019.01)-EN

Inspection and servicing NOTES ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... .......................................................................................................................................................................

3-103

BA 6015(3 847 019.01)-EN

Inspection and servicing

3-104

BA 6015(3 847 019.01)-EN

Repair work 4 REPAIR WORK Operation and Maintenance Manual

Target group

Part 1 INTRODUCTION FUNDAMENTAL SAFETY INSTRUCTIONS

Operating personnel + Inspection and servicing personnel + Repair personnel

Part 2 OPERATION

Operating personnel The operating personnel must have knowhow relevant to the operation and the application of this or comparable machines.

Part 3 INSPECTION AND SERVICING Part 4 REPAIR WORK

Inspection and servicing personnel The inspection and servicing personnel must have know-how relevant to the inspection and servicing of this or comparable machines.

Repair personnel The repair personnel must have know-how and experience relevant to the repair of this or comparable machines.

Part 5 ANNEX

Part 6 INDEX

Operating personnel + Inspection and servicing personnel + Repair personnel Operating personnel + Inspection and servicing personnel + Repair personnel

4-1

BA 6015(3 847 019.01)-EN

Repair work

4-2

BA 6015(3 847 019.01)-EN

Repair work REPAIR WORK - SAFETY INSTRUCTIONS

Dismantling components

Operation and Maintenance Manual

Never do dismantling while the machine is at operating temperature.

Never carry out repair work without having read and understood the Operation and Maintenance Manual.

Oils, greases, or coolants may have a high temperature and result in burning or scalding.

Pay special attention to: "Fundamental Safety Instructions", "Inspection and servicing - safety instructions" and all warnings and safety instructions attached to the machine.

The descriptions of job sequences provide only experienced personnel with the necessary instructions.

The operating manual must be kept with the machine at all times.

Repair personnel Repair personnel must have know-how and experience relevant to repairing this or comparable machines.

In the absence of such know-how, meticulous training must be given by experienced repair personnel, e.g. from CGM HMS GmbH.

Working in greater heights Always wear safety harnesses when working at greater heights.

Wear an approved safety harness; it must be equipped with fall arresters and safety cables.

Prestressed units

Leave time for the machine to cool down.

Before starting work, depressurize piping and hoses, cylinders, radiator, hydraulic tank and other systems or units.

Replace defective components in good time to prevent major damage.

Clean the defective component carefully before dismantling it.

Mark the dismantled parts in the correct sequence to faciliate re-assembly.

When dismantling the component, close off exposed hose and piping connections, exposed drill holes and housings carefully to prevent any dirt from penetrating.

Never remove lead seals Never change rated pressure of pressure relief valves without the explicit authorization of CGM HMS GmbH. Never remove lead seals from pressure relief valves and accumulators.

After the repair work To prevent corrosion, coat all bright metal machine parts with a grease film.

Never open defective prestressed units but replace them as an entirety.

On completing the work, re-assemble all protective devices, covers and noise- and vibrationinsulation material.

In exceptional cases, open only when the system and the operating sequence are precisely known and any special tools required are available.

Never start up the drive engines while work is being done on the machine.

The operating manual contains no information on this point.

Check the repaired components and all machine functions in a trial run.

Never release the machine for recommissioning until it is fully functioning.

4-3

BA 6015(3 847 019.01)-EN

Repair work REPAIR WORK, FIRE AND EXPLOSION HAZARD Safety instructions Prior to commencing work, obtain informationon the national and corporate rules for the prevention of accidents and avoiding fires.

Pay particular attention to hazards caused by combustible and easily flammable substances.

Obtain information on the safe handling of the fire extinguishers to be used.

Avoid smoking and open fire on, next to and below the hydraulic shovel.

Even battery gases can ignite in open flames or fire.

Combustible and easily or highly inflammable substances or liquids increase the risk of fire and explosion. This is also valid for pressure vessels containing flammable substances as, for instance, spray oil or cold-starting fluid (ether). They are heat-sensitive and can explode even if exposed only to intensive sunlight.

These substance can also ignite themselves if they come close to hot units or objects as, for instance, a turbocharger.

Do not store these substances on the hydraulic shovel. If combustible, easily or highly flammable substances or liquids were used during maintenance operations, they must be completely removed from the hydraulic shovel at the end of the work.

Avoid parking the hydraulic shovel in places where 

combustible substances such as coal dust or tar are present.



open or smouldering fire may occur.

Remove the hydraulic shovel from such an area where combustible or easily flammable liquids have spilled from the hydraulic shovel onto the ground.

Flying sparks (caused by welding, flame cutting, grinding, electrical short-circuit) may cause fire on the ground that can spread to the hydraulic shovel.

4-4

Place suitable fire guardings (fire barriers) if open fire or flying sparks cannot be avoided during repair work.

If necessary, also cover the ground with fireprotective blankets.

Apply special protection to cables, cable ducts as well as to hose and pipe lines.

Have all your welding, flame cutting and grinding work approved before starting work.

The engine compartment can be equipped with pressure vessels containing cold-starting fluid (ether). Ether is toxic and highly flammable; the vessels are under pressure. These pressure vessels can explode if exposed to high temperatures (above 49°C / 120°F) or in the event of damage.

Protect the pressure vessels against damage before beginning to work in or close to the engine compartment.

Ensure sufficient ventilation.

Do not keep any fire extinguishers that are not suitable or have not been tested.

Do not extinguish flammable liquids with water.

Use: 

dry-powder, carbon-dioxide or foam extinguishing compounds.

When getting into contact with burning substances, the fire-fighting water would abruptly evaporate and distribute the substance such as oil over a wide area. Water causes short-circuits in the electrical system thus possibly entailing new hazards.

Call the fire brigade.

Clean the hydraulic shovel carefully after the maintenance, if oil, grease, fuel, detergents or cold-starting fluid have been spilt over the machine. If possible, use a steam-jet cleaner for cleaning.

BA 6015(3 847 019.01)-EN

Repair work REPAIR WORK, ENGINE Read and observe the "Repair - Safety instructions" chapter and the engine Operation and Maintenance Manual before working on the engine.

The engine compartment can be equipped with pressure vessels containing cold-starting fluid (ether).

Ether is toxic and highly flammable; the vessels are under pressure. These pressure vessels can explode if exposed to high temperatures (above 49°C / 120°F) or in the event of damage. Protect the pressure vessels against damage before beginning to work in or close to the engine compartment.

Carry out repair work only if the machine has been secured as described in the "Securing the machine" section of these Operation and Maintenance Manual.

Check and replace V-belts only when the engine is stationary.

These and other servicing works are described in the engine manufacturer's Operation and Maintenance Manual.

Risk of injury caused by rotating or hot parts of the engine.

Shut off the engine and allow to cool down.

Before cleaning the engine Exhaust pipes and turbo chargers in the engine compartments are covered with special heat-insulating material.

This material must not be spraywashed with steam-jet cleaners or high-pressure cleaners. It will be damaged. Therefore cover all the insulating material with plastic foils before using steam-jet cleaners or highpressure cleaners inside the engine compartments.

4-5

BA 6015(3 847 019.01)-EN

Repair work HYDRAULIC SYSTEM Repair instructions

Hydraulic hoses – Instructions

Always depressurize the hydraulic system before disconnecting any hydraulic hoses or pipes.

Even hoses that have been properly stored or used are subject to natural ageing. Their useful life is therefore limited.

Read and observe also the chapters "Inspection and servicing - Safety instructions" and "Repair Safety instructions".

Replace damaged and leaking hydraulic hoses and pipes as soon as possible by new ones.

Use original spare parts from CGM HMS GmbH. They are adapted to the respective function.

Do not re-use old hoses.

Never repair damaged hoses.

Discard escaped oil and oily wastes without polluting the environment. These substances must not be allowed to penetrate into the soil.

Hydraulic hoses must replaced after a service life of six years (including a storage time of 2 years).

Check the date of manufacture on the hose or on the hose fitting regularly.

The recommended interval after which hydraulic hoses - and especially those used in harsh conditions - must be replaced depends on the number of operating hours and on pressure loading.

The use of hoses close to their recommended load limit shortens the replacement interval (e.g. high temperatures, frequent working cycles, extremely high pulse frequencies as well as multi-shift operation and round-the-clock work).

Hydraulic hoses must be replaced, if one of the following defects is detected during a visual inspection: 

Damage to the outer fibre reinforcement layer reaching down to the inner layer (cuts, chafe marks, cracks).



Embrittlement of the outer fibre reinforcement layer (cracks in the hose material).



Changes in the ususal shape of the hose under pressure or in pressureless condition in bends or curves such as detachment of fibre layers, formation of bubbles or bulges.



Leaks.



Non-observance of fitting requirements.



Damage to or deformation of hose fittings that may result in a reduction of the strength of the screwed union.



Detachment of the hose from the fitting.

Corrosion in fittings reducing the strength of the function of the fitting.

4-6

BA 6015(3 847 019.01)-EN

Repair work ELECTRICAL SYSTEM Assisted starting (with jumper cables) – Safety instructions

Assisted starting (with jumper cables)

Keep any potential ignition sources, such as unshielded lights or burning cigarettes, away from the batteries.

Battery gases are highly flammable.

Explosion hazard.

Read and observe the section: "Assisted starting – Safety instructions".

Do not lean over the batteries when starting the machine from another vehicle.

Risk of injury from acid splashes and battery gases.

Never use assisted starting when the batteries are defective or frozen.

Never connect batteries (battery assemblies) unless they have the same voltage.

Use only tested jumper cables with insulated terminal clips and an adequate lead diameter.

Ensure that the bodies of the supplying and receiving machines are not in contact. Otherwise a current flow could result from connecting the positive poles. Risk of short-circuiting.

Never use welding generators or welding transformers as a source of current.

Position the jumper cables in such a way that they cannot be caught by rotating engine components.

Read and observe: "Inspection and servicing – Safety instructions", paying particular attention to the section "Handling batteries".

Prior to assisted starting

Starting the engine with jumper cables (external batteries Before connecting the jumper cables (external bateries) check the own batteries for proper operation. Checking is done by switching on the excavator's electrical system.

Do not switch on electrical consumers (e.g. floodlamps) when checking the batteries. In case of doubt, remove the batteries and have them tested.

Assisted starting with batteries installed  Connect first the positive terminal of the jumper cable to the batteries and then to the supplying unit.  Connect the negative terminals in the same order.  After starting, disconnect the jumper cable in reverse order, i.e. first the negative terminal and then the positive terminal.

Assisted starting without batteries installed (only for engine trial run) Do not disconnect the starting aid when the engine is running.

After disconnecting, the alternator runs without batteries.  Connect the jumper cable in the above- described order and disconnect after starting.  Switch off all consumers at the receiving machine and turn the key-operated switch to "0"  Switch off all consumers at the supplying machine (charged batteries) and shut off the engine.

4-7

BA 6015(3 847 019.01)-EN

Repair work Connecting the jumper cables  Connect the red jumper cable to the positive pole of the empty battery (1,Fig. 4-1:), then to the positive pole of the charged battery (2).

Starting up the engine

 Connect the black jumper cable first to the negative pole of the charged battery (3), then to the negative pole of the empty battery (4).

 Start up the engine of the receiving machine.

If the engine fails to start up after 15 seconds, wait for one minute and thenstart again.

Explosion hazard When the negative terminal is connected to ground, a strong current flows through the jumper cable.

The sparks produced in the contact area can ignite the gases emanating from the discharged battery.

The negative terminal must therefore be connected to ground at a place as far away from the discarged batteríes as possible.

 Start up the engine of the supplying machine and run at high speed.

 When the engine has started up, continue running both machines in no-load operation for about two or three minutes with the jumper cables still connected.

Disconnecting the jumper cables  Negative pole at the receiving machine (4)  Negative pole at the supplying machine (3)  Positive pole at the supplying machine (2)  Positive pole at the receiving machine (1)  For machines with electronic modules: - Run engine for about half an jour at low speed. The batteries are partially charged.

- Shut off engine - Make all electrical connections to the modules.

- Start up engine without jumper cables.

Fig. 4-1:

4-8

BA 6015(3 847 019.01)-EN

Repair work PRESSURE ACCUMULATORS SAFETY INSTRUCTIONS The hydraulic system is equipped with pressure accumulators containing nitrogen under high initial pressure.

Even when the hydraulic pressure in the system is reduced, the nitrogen in the accumulator will remain under pressure.

The accumulators are completely safe in operation. If incorrectly handled, however, there is a risk of explosion.

So:  Never handle accumulators mechanically, never weld or solder.  Testing and servicing work must be carried out by experts only.  Prior to any testing and servicing work, depressurize the hydraulic part of the system.  To dismantle the accumulator, always wear goggles and working gloves.  Fill accumulator with nitrogen only, never with compressed air or oxygen.  Report any defects or damage to the machine owner without delay.  Prior to recommissioning, an inspection by a specialist or expert is essential if the accumulator was damaged or if the admissible operating temperature or operating pressure was exceeded.

Never remove or paint over warning and information plates, rating plates or type identification markings. Replace illegible or damaged plates immediately

4-9

BA 6015(3 847 019.01)-EN

Repair work WELDING AND FLAME CUTTING WORKS - SAFETY INSTRUCTIONS The present safety instructions are valid for both types of work. For easier reading, the text only uses the terms "welding work", "welding" or simply "work". These terms do however always refer to both types of work, i.e. "welding and flame-cutting work".

Read these safety instructions before starting any welding or flame-cutting operations.

Welding work by qualified personnel only Carry out welding work only if you have received special training and if you have been ordered to perform such work.

Always bear in mind that you are performing welding work on heavily loaded components. The quality of your welding work can be decisive for the operational capability of the machine and also for the health and life of persons.

Observe the health protection and accident prevention laws and regulations as well as the fire protection regulations in force in your country.

Observe all warning and instruction signs attached to the machine.

Wear the prescribed personal protective equipment such as:  protective clothing,  protective gloves,  protective mask and,  a fall-arrest system for persons working at height.

4-10

Increased risk of fire during welding work Always bear in mind that the heat, the sparks or dripping red-hot metal or slag produced in the process constitute a considerable risk of fire.

The present safety instructions provide information on how to minimize the risk of fire.

Remove all combustible materials close to the welding location or cover them up with noncombustible materials.

If works in the vicinity of combustible materials cannot be avoided, further persons with firefighting equipment must be present on site as fireguards.

Observe the instructions of the machine owner and of the mine.

Health hazards Welding operations produce harmful gases. Do not inhale the fumes and gases and make sure the surroundings of the welding location are well ventilated or equipped with an exhaust system.

Remove all kinds of paint and all coatings as well as all residues of oils and greases from the weld area.

Do not wind the welding cables round your body or parts of your body. The electromagnetic fields produced may damage your health.

BA 6015(3 847 019.01)-EN

Repair work Tanks, pressure vessels and pressure accumulators Any work on vessels containing or having contained  combustible or combustion-accelerating substances,  potentially explosive substances or  substances susceptible to develop harmful gases, fumes, mists or dusts during welding may only be carried out under expert supervision and only by experienced personnel especially assigned to such work.

This prescription applies, for instance, to all tanks and reservoirs for hydraulic fluid, engine oil, diesel fuel or lubricating grease.

Welding work on pressure vessels and pressure accumulators is forbidden.

Pressure vessels containing cold-starting fluid (ether) may be installed in or near the engine compartment.

Ether is toxic and highly flammable; the vessels are under pressure. These pressure vessels can explode if exposed to high temperatures (above 49°C / 120°F) or in the event of damage.

Protect the vessels against damage and high temperatures.

Do not perform welding work in the vicinity of these pressure vessels before they have been covered up safely against accidental contact or flying sparks. Have the pressure vessels removed from the machine, if safe protection cannot be ensured.

Inform yourself about the locations in the machine where the pressure accumulators of the hydraulic system are installed. Do not perform welding work in the vicinity of these pressure accumulators before they have been covered up safely against accidental contact or flying sparks. Have the pressure accumulators removed from the machine, if safe protection cannot be ensured.

Swinging rings and articulated joints The welding current must not flow through ballbearing or roller-bearing swingings rings, through bolted connections or articulated joints or through hydraulic cylinders.

An electric current flowing through an air gap (e.g. in the bearing or in the articulation) produces a spark which damages the metallic surface.

The welding clamps must therefore always be connected very close to the weld area (max. 2 - 3 m away (6.6-9.8 ft)).

Information relating to the electrical system and to electronic modules Electric arc welding produces electromagnetic fields, electrostatic charges and voltage spikes which can cause damage to electronic modules.

Although the electronic modules of the machine are carefully protected against these influences, it is nevertheless necessary to take additional precautions in order to prevent such damage to the greatest possible extent. 

Switch off the electrical system ("ignition OFF").



Open the battery main switch (or disconnect the starter batteries from the machine).



Lay the welding cables as far away from electric lines as possible.

If it is not possible to implement all of the abovementioned precautions, all connectors must be removed from the electronic modules before beginning any welding work. 

Protect withdrawn terminals and connectors from short circuits and soiling. Cover up terminals and connectors with foils or adhesive tape.



Never touch the enclosures of electrical and electronic modules with the welding electrode.



Protect electric lines against the heat emanating from the weld area.



Restore all electrical connections when the welding operations are terminated.

Never connect the ground clamp of the welding cable to the enclosures of electric or electronic modules.

4-11

BA 6015(3 847 019.01)-EN

Repair work Welding on the counterweight

Welding on the cab

Counterweights may contain a build-up of flammable gases. Before starting to work, counterweights must be flushed for at least 20 minutes with compressed air in order to remove these build-ups of gas. To permit flushing, the counterweight has two bores in its upper part: a threaded bore M18x1.5 for the compressed-air line and another unthreaded bore to let the air out.

The operator's cab is designed in such a way that it meets the FOPS (Falling Objects Protective Structure) requirements in accordance with DIN EN ISO 3449.

Detailed information / instructions on this subject can be found in Service Information 2006-33 which is available on the CGM HMS GmbH website under Maintenance & Service.

Welding on components of the working equipment and on other fully or partly closed steel structures Components may be equipped with pipelines routed inside. These lines can contain combustible substances such as hydraulic oil or lubricating grease which may be set on fire by welding operations. 

Check whether pipes or hosepipes are connected to the steel component.



Depressurize these lines.



Open the screwed connections and empty the lines routed inside the component.



Start welding only after these operations have been carried out.

Electric lines may also be be laid inside partly open steel structures in order to protect them against damage. They are not always visible from each viewing direction. Electric lines may catch fire as a result of the heat produced during welding. 

Therefore check carefully whether electric lines are laid in the vicinity of the weld area.



Protect electric lines against the heat produced at the weld area or have them removed before starting the welding operations.

4-12

Welding and other mechanical work is forbidden as there is a risk of reducing the structural stability of the cab.

Further information More detailed information concerning the state-ofthe-art execution of welding operations can be found in the Service Manual "Welding for maintenance and repair".

For problems or queries please contact the competent service personnel.

If parts of the machine have to be removed or dismantled, please read and observe the chapters: "Assembly of working equipment, safety instructions", "Inspection and servicing, safety instructions", "Repair, safety instructions".

BA 6015(3 847 019.01)-EN

Repair work DISPOSAL AT THE END OF THE SERVICE LIFE Dismantling and removal instructions Before beginning work, think about the risks involved, e.g.: 



Risk of deflagrations In the course of time, flammable gases may have formed or accumulated in the hollow spaces of welded constructions, e.g. the counterweight. To remove these flammable gases, the hollow spaces must be purged carefully with compressed air before work with hand grinders, flame cutters or other sparking tools is being undertaken.

Most of the machine components have considerable mass. Therefore use only lifting gear and slings of sufficient bearing capacity.

Risk of fire

Risk of residual pressures still in the hydraulic system. Be very careful when opening hydraulic lines.

Remainders of fuel or oils may lead to the formation of flammable gases in tanks or other hollow spaces. When these tanks or hollow bodies are cut into pieces, the gases may ignite or even explode.

Read the following text attentively and observe the instructions given. Respecting the instructions will help you to protect yourself against health hazards and injuries and to prevent avoidable environment pollution.

For this reason, remove all fuel or oil remainders from these components and purge them carefully with compressed air in order to eliminate flammable gases (other efficient methods of removing flammable gases can also be applied) before work with hand grinders, flame cutters or other sparking tools is being undertaken.

Disposing of the machine without polluting the environment Before stripping down the machine at the end of its service life observe the following instructions: The assemblies of the machine contain various operating fluids or lubricants. These substances may pollute the environment (so-called hazardous substances) and must therefore be disposed of properly.

Observe the national laws and regulations governing the non-polluting disposal of these substances.

Remove all operating fluids from the systems, remove all lubricants and dispose of these substances properly. 

Fuel system: fuel tanks, fuel filters, fuel lines, filling station.

Auxiliary attachment and units, such as an onboard crane or an auxiliary heater have their own fuel tanks with the correpsonding line systems.



Hydraulic oil: hydraulic oil reservoir, hydraulic cylinders, hydraulic motors, hosepipes, piping, hydraulic pumps, hydraulic valves, hydraulic oil filter, filling station.



Engine coolant: engine, radiator, expansion reservoir, piping and hosepipes, filling station.



Gearbox oil in swing, travelling and transfer gearbox systems, expansion tanks, piping and

4-13

BA 6015(3 847 019.01)-EN

Repair work hosepipes, filling station; idlers, support and track rollers.

Further hazardous substances





Batteries contain lead and acid.

Have the refrigerant (R134A) sucked out of the air conditioner system.





Grease from the central lubricating system, grease drum, piping and hosepipes, distributors, filling station; grease accumulations in bearings of the working equipment, grease filling in the swing ring, grease filling in track and support rollers as well as in idlers.

Electronic modules are located in switch cabinets of the cab module, the engine module, the control column.



Pressure accumulators contain nitrogen under high pressure and possibly remainders of hydraulic oil.



Lamps of Xenon working lights contain mercury.

The required electronic control circuits are integrated in the housings of the working lights.



The fluorescent lamps of the maintenance lighting (discharge types) contain mercury.



Insulating material of cables can contain PVC.



The fire extinguishing system (if installed) contains trigger charges (ATTENTION, explosion risk) on the extinguishing agent containers.

Pressure accumulators, extinguishing gas and extinguishing powder.

For more detailed information please refer to the manufacturer's safety datasheets.

4-14

BA 6015(3 847 019.01)-EN

Repair work Appropriate disposal of batteries The machine is equipped with batteries containing lead and other harmful and polluting substances.

Damaged or used batteries must therefore not be disposed of in the environment. They must be disposed of properly and separately from other waste.

The batteries are marked with the corresponding symbols (Fig. 4-2:).

Since batteries contain also reusable materials, they are taken back free of charge by the manufacturer, dealer or by other specialized companies.

In the European Community, the final consumer is obliged by law to to dispose of used batteries in designated waste collections centers.

Observe the current regulations and laws of your country with regard to the handling of damaged or used batteries.

Fig. 4-2:

The symbols in Fig. 4-2: have the following meaning: 

Crossed-out waste bin= Do not dispose of batteries with normal household waste.



Pb……= Chemical symbol for lead.



Circle of bent arrows= Recycling symbol, ingredients of the battery can be reused.

4-15

BA 6015(3 847 019.01)-EN

Repair work

4-16

BA 6015(3 847 019.01)-EN

Repair work NOTES ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... .......................................................................................................................................................................

4-17

BA 6015(3 847 019.01)-EN

Repair work

4-18

BA 6015(3 847 019.01)-EN

Annex 5 ANNEX Operation and Maintenance Manual

Target group

Part 1 INTRODUCTION FUNDAMENTAL SAFETY INSTRUCTIONS

Operating personnel + Inspection and servicing personnel + Repair personnel

Part 2 OPERATION

Operating personnel The operating personnel must have knowhow relevant to the operation and the application of this or comparable machines.

Part 3 INSPECTION AND SERVICING Part 4 REPAIR WORK

Inspection and servicing personnel The inspection and servicing personnel must have know-how relevant to the inspection and servicing of this or comparable machines.

Repair personnel The repair personnel must have know-how and experience relevant to the repair of this or comparable machines.

Part 5 ANNEX

Operating personnel + Inspection and servicing personnel + Repair personnel

Part 6 INDEX

Operating personnel + Inspection and servicing personnel + Repair personnel

5-1

BA 6015(3 847 019.01)-EN

Annex

5-2

BA 6015(3 847 019.01)-EN

Annex TROUBLESHOOTING Instructions on troubleshooting

Layout of the fault table

Faults are often due to the machine not being correctly operated or serviced.

Fault

For this reason, it is vital to read through the relevant section of the Operation and Maintenance Manual once again before rectifying any faults.

If you are unable to detect the cause of the fault or to rectify it, apply to the CGM HMS GmbH aftersales service.

Describe the fault and all accompanying circumstances as precisely as possible when calling on the CGM HMS GmbH after-sales service. Exact data allow for fast troubleshooting.

Never do any jobs for which you are not qualified.

The fault table lists all faults which have been reported to date and outlines their possible causes and rectifying measures. In exceptional cases, a described fault may also have a different cause.

The fault is described here as the outcome of an observation or a previous activity.

Therefore make careful observations.

Study the problem carefully. First think, then act.

Ask yourself the following questions: 

Which warning signals preceded the fault?



What repair and servicing work was carried out previously?



Has this defect already occurred?



Is it one or several simultaneously occurring faults?

Possible causes The possible causes of the observed fault are outlined in this group. They are arranged in order of probability, i.e. the possible cause occurring in most cases heads the list.

Measures This describes the troubleshooting procedure.

Section This specifies where information on troubleshooting is given in the Operation and Maintenance Manual. If there is no entry, the CGM HMS GmbH after-sales service should be consulted

5-3

BA 6015(3 847 019.01)-EN

Annex FAULT TABLES Combustion engine - Fault table Fault Engine fails to start or starts only with difficulty Engine does not turn Engine starts, but runs enevenly or intermittently Engine gets too hot, temperature warning activated

Remedial action Check Adjust Replace Top up Reduce Clean

P E W A S R

Engine not working at full power Engine not working on full cylinder papacity Engine without oil pressure or oil pressure too low Engine oil comsumption too high Engine emits blue smoke Engine emits white smoke Engine emits black smoke Engine cannot be stopped Engine throttled down strongly Cause Oil level too low 

  

 









     

    

Oil level too high Engine inclination too big Engine oil of wrong SAE-class Fuel quality not corresponding to specification

 



Air filter contaminated / turbo-charger defective Fuel filter contaminated Charge-air line leaking



Radiator / cooling fins contaminated Cooling fan or water pump defective or loose



Cooling air gets too hot / heat buid-up



Battery defective or discharged

  

Cable connections in starter circuit loose or corroded Starter defective or pinion not in mesh 



   

 

      



 

Injection line leaking Injection valve defective Combustion engine blocked on output side

 

,

5-4



 

Chapter ref.

Engine oil level A Engine oil level S Engine Op. P Instr.

Lubricants W Engine Op. W Instr.

Air intake syst. P Fuel filter P/W P Cooler cleaning R Engine Op. P/W Instr.

P Battery P P P

Shut-off relay jamming Incorrect valve setting



1) Contact the CGM HMS GmbH Service

 PMS malfunction  Celect coding lamp flashing/lit Celect defective (software error)

Engine Instr.

Engine Instr.

1) Op. E P Op. P/W 1) 1) 1) 1)

BA 6015(3 847 019.01)-EN

Annex Working hydraulics – Fault table Fault

Remedial action

Working and swinging functions not operational Check No boom function No bucket function No backhoe function No stick function Working movements too slow Power loss in working hydraulics

Adjust Replace Top up Reduce Clean

P E W A S R

1) Contact the CGM HMS GmbH Uncontrolled working movements Service Cause Abschnitt Servo control not activated/defective Working P  1)       Malfunction of pressure-relief valve 1)   Servo system pump defective 1)       Malfunction of primary / sencondary pressure-relief valves Engine speed too low P  ECO-power switch in 80%-position P  Fuel filter contaminated Fuel filter P/W  Insufficient engine power Engine mal- 1)  function Hydraulic oil temperatur too high (warning lamp lit, PMS fault indicator Hydraulic oil P/R  lamp lit) oil cooler contaminated cooler cleaning Engine coolant temperature too high (warning lamp lit and PMS fault 1)  indicator lamp flashing) 1)  Malfunction of solenoid valves Malfunction of control spool 1)   Engine coupling defective 

5-5

BA 6015(3 847 019.01)-EN

Annex Track drive – Fault table Fault

Remedial action

No forward travel and no reversing travel Check Maximum travel speed cannot be reached Insufficient traction power

Adjust Replace Top up Reduce Clean

  

        

5-6

   

P E W A S R

1) Contact the CGM HMS GmbH Service Cause Chapter ref.

Malfunction of pressure-relief valves 1) Servo system pump defective 1) Malfunction of travel valve (pedal) 1) Engine nominal speed too low 1) Malfunction of control spool 1) ECO-power switch in 80%-position Travelling P Insufficient engine power Engine mal- 1) fuction Hydraulic oil temperatur too high (warning lamp lit, PMS fault indi- Hydraulic oil P/R cator lamp lit) oil cooler contaminated cooler cleaning Engine coolant temperature too high (warning lamp lit and PMS 1) fault indicator lamp flashing)

BA 6015(3 847 019.01)-EN

Annex Swinging mechnism – Fault table Fault

Remedial action

No swinging possible Check No righthand or lefthand swinging Swinging performance insufficient Uncontrolled swinging movement

     



 

    

Adjust Replace Top up Reduce

P E W A S R

Clean 1) Contact the CGM HMS GmbH Service Cause Chapter ref.

Servo control not activated / defective Working P Endschalter Aufstiegleiter (Option) defekt, nicht vollständig einge- Operation P fahren Superstructure holding brake applied P Pressure-relief valve adjusted too low level / defective 1) Servo system pump defective 1) Malfunction in feed-pressure circuit of swinging pump 1) Malfunction in high-pressure circuit of swinging system 1) Malfuction of moment-regulating valve 1) Malfunction in swinging pump displacement cylinder 1) Excessive leakage in swinging motor 1)

5-7

BA 6015(3 847 019.01)-EN

Annex Central lubricating system – Fault table Fault

Remedial action

Grease pump not working, the BCS does not indicate a warning Automatic circuit breaker on Check Grease pump not working, pilot lamp lit Grease pump working, no grease delivered Greasing pressure too high or too low

   

  



  

    

5-8

Cause Timer defective Lines between timer and hydraulic motor defective Hydraulikmotor defektive Grease pump defective Grease sieve clogged Distributor defective Grease container empty Grease pump does not suck grease Leaky lines Non-return valve defective Pressure switch defective

Adjust Replace Top up Reduce

P E W A S R L

Clean Vent 1) Contact the CGM HMS GmbHy Service Chapter ref.

P/W P/W P/W P/W P/R P/W P/A P/L P/L P/W E

BA 6015(3 847 019.01)-EN

Annex HYDRAULIC CIRCUIT DIAGRAM Detailled information can be found in the „Service Manual“ chapter 8 or contact CGM HMS GmbH Service.

5-9

BA 6015(3 847 019.01)-EN

Annex

5-10

BA 6015(3 847 019.01)-EN

Annex ABBREVIATIONS

API approx.

Ampere (SI base unit of electric current) about according to Ampere hours (SI base unit of quantity of electricity) American Petroleum Institute approximately

BA Bh

= OI = Operation and Maintenance Manual = OH = Operating hour

CE

Communauté Européenne = European community Committee for european Construction Equipment (Defines a measure for bucket, grab or scoop filling) European Standardization Committee 1 centimeter (= /100 m) Cubic centimeters per revolution

A abt. acc.

Ah

CECE

CEN cm cm 3/rev

dia.

DIN

Decibel (sound intensity according to measuring method A) Diameter German Industrial Standard

eff. e.g. etc.

effective for example etcetera

Fig. FOPS FS ft

Figure, serial number of illustration Falling objects protective structures Face shovel (working equipment) foot

gal GLR

gallon (3.71 litres) Full-load controller (electronic module for PMS)

HD Hydr.

Heavy duty Hydraulic, Hydraulics

i i.e.

IFN

Transmission ratio id est = that is ISO service rating, blocked

dB(A)

Incl.

ISO

including, inclusive of International Standardization Organization

kg 3 kg/dm

Kilogram (unit of weight) Kilograms per cubic decimeter (= unit of specific density) Kilometers per hour KiloNewtons per meter (1 kNm = 1000 Nm) = unit of torque Kilowatt (1 kW = 1.36 hp)

km/h kNm kW l lb Lb/in² LC LED l/min LpA LS LS LwA

Liter pound Pounds per square inch (= psi) Long crawler Light-emitting diode Liters per minute Sound pressure at workplace Limited slip Load sensing Sound power level of the machine in stationary operation

m MA MA max. min. min-1 mm

Meters Tightening torque Milliampere (=1/1000A) maximal, maximum minimal, minimum Revolutions per minute Millimeter (=1/1000 m)

N N, kN NLGI NLGI-Klasse Nm No.

Normal, standard version Newton, kiloNewton (unit of force) National Lubricating Grease Institute (USA) Consistency - lubricant classification acc. to DIN 51 818 Newtonmeter (unit of torque) Number

OH op.inst.

OW

Operating hour Operation and Maintenance Manual Superstructure

5-11

BA 6015(3 847 019.01)-EN

Annex ABBREVIATIONS PMS P/No. PS

Pump Managing System Part number (CGM HMS GmbH) Metric horsepower (1 PS = 0.74 kW)

Qty.

Quantity

R, r resp.

RH ROPS rpm

Radius Respectively Crawler hydraulics (excavator) Roll-over protective structures Revolutions per minute (= min-1)

SAE sec./s.

SN SW

Society of Aotomotive Engineers (USA) Second Item number Width across flats

t THB TL tm typ.

Metric ton (= 1000 kg) Technical Manual Backhoe dipper (attachment) Tons by meters (obsolescent unit of swing torque) Typical

U/min UW

Revolutions per minute Undercarriage

V VDMA

Volt (unit of electric voltage) Association of German Machinery and Systems Manufacturers

W

Watt (unit of electric power)

°C °F °kW

Degrees Celsius (temperature) Degrees Fahrenheit (temperature) Degrees crank angle

> <

greater than less than

5-12

BA 6015(3 847 019.01)-EN

Annex PRODUCT SPECIFICATION SHEET

5-13

BA 6015(3 847 019.01)-EN

Annex

5-14

Cat®

6015/6015 FS Hydraulic Shovel

Specifications Operating Weights With Standard Undercarriage Shovel Unit Standard track pads Track pads option Backhoe Unit Standard track pads Track pads option

Pad width A 600 mm 23.6 in 750 mm 29.5 in

Cat® C18 Width over Operating pads B weight 4 400 mm 105 200 kg 14 ft 5 in 231,920 lb 4 550 mm 106 600 kg 14 ft 11 in 235,010 lb

Ground pressure 16.7 N/cm2 24.2 psi 13.5 N/cm2 19.6 psi

Cummins® QSK19 Operating Ground weight pressure 102 900 kg 16.3 N/cm2 226,850 lb 23.6 psi 104 300 kg 13.2 N/cm2 229,940 lb 19.1 psi

600 mm 23.6 in 750 mm 29.5 in

Cat® C18 4 400 mm 105 600 kg 14 ft 5 in 232,810 lb 4 550 mm 107 000 kg 14 ft 11 in 235,890 lb

16.7 N/cm 24.2 psi 13.6 N/cm2 19.7 psi

Cummins® QSK19 103 300 kg 16.4 N/cm2 227,740 lb 23.8 psi 104 700 kg 13.3 N/cm2 230,820 lb 19.3 psi

110 500 kg 243,610 lb 112 100 kg 247,140 lb

Cummins® QSK19 16.1 N/cm2 17.5 N/cm2 23.3 psi 25.4 psi 13.0 N/cm2 14.2 N/cm2 18.8 psi 20.6 psi

2

Operating Weights With HD-LC Undercarriage (optional) Backhoe Unit Only Standard track pads Track pads option

600 mm 23.6 in 750 mm 29.5 in

Cat® C18 4 800 mm 16.4 N/cm2 15 ft 9 in 23.8 psi 4 950 mm 13.3 N/cm2 16 ft 3 in 19.3 psi

1 740 mm (5 ft 9 in)

1 580 mm (5 ft 2 in)

900 mm (2 ft 11 in)

5 180 mm (17 ft) 6 460 mm (21 ft 2 in)

B 5 160 mm (16 ft 11 in)

Hydraulic Shovel—6015/6015 FS Cat version

4 350 mm (14 ft 3 in)

5 340 mm (17 ft 6 in)

4 270 mm (14 ft)

4 150 mm (13 ft 7 in)

4 300 mm (14 ft 1 in)

3 720 mm (12 ft 2 in) 1 720 mm (5 ft 8 in)

1 580 mm (5 ft 2 in)

4 690 mm (15 ft 5 in) 6 010 mm (19 ft 9 in)

Cummins version

5 250 mm (17 ft 3 in)

B 4 760 mm (15 ft 7 in) 4 350 mm (14 ft 3 in)

4 740 mm (15 ft 7 in)

4 270 mm (14 ft)

4 050 mm (13 ft 3 in)

4 300 mm (14 ft 1 in)

3 520 mm (17 ft 7 in) 1 720 mm (5 ft 8 in)

5 250 mm (17 ft 3 in)

1 580 mm (5 ft 2 in)

4 690 mm (15 ft 5 in) 6 010 mm (19 ft 9 in)

B 4 610 mm (15 ft 1 in)

General Data

Features

Operating weight (with C18 engine) Face Shovel 105 tonnes 116 sht Backhoe 106 tonnes 117 sht

• TriPower shovel attachment • Independent oil-cooling system • 3-circuit hydraulic system • Torque control in closed-loop swing circuit • Automatic central lubrication system • Triple-race swing roller bearing

Engine output SAE J 1995 Cat® C18 Cummins® QSK19

522 kW 477 kW

700 HP 640 HP

Standard bucket capacity Face Shovel (SAE 2:1) Std. rock backhoe (SAE 1:1) M.E. backhoe (SAE 1:1)

7.0 m3 6.0 m3 7.0 m3

9.2 yd3 7.8 yd3 9.2 yd3

Hydraulic Shovel—6015/6015 FS Electrical System System voltage Version Cat Batteries (12 V each) 2 x 210 Ah in series/parallel installation 210 Ah–24 V Alternator 150 A Working spotlights • Battery isolation relays

24 V Cummins 2 x 170 Ah 170 Ah–24 V 175 A 6 x Halogen lights

Hydraulic Oil Cooling Oil flow of cooling pumps Cat Version 467 l/min (123 US gal/min) Cummins version 496 l/min (131 US gal/min) Diameter of fan 930 mm (3 ft 1in) • Cooling system is fully independent of all main circuits, i.e. controlled cooling capacity is available whenever engine is running • Gear-type cooling pump supplying high volume low-pressure oil to aluminium cooler • Variable axial piston pump supplying low-volume, highpressure oil to fan • Fan speed is thermostatically controlled • Extremely high cooling efficiency to ensure optimum oil temperature

Hydraulic System with Pump Managing System Main pumps 2 x variable swash plate pumps Max. oil flow Cat version 2 x 552 L/min (2 x 146 US gal/min) Cummins version 2 x 587 L/min (2 x 155 US gal/min) Max. pressure, attachment, travel 30 MPa = 300 bar (4,350 psi) Swing pump Reversible swash plate pump Max. oil flow Cat version 287 L/min (76 US gal/min) Cummins version 307 L/min (81 US gal/min) Max. pressure, swing system 32 MPa = 320 bar (4,640 psi) Total volume of hydraulic oil approx. 1 700 L (449 US gal) Hydraulic tank capacity approx. 1 300 L (343 US gal) • Pump Managing System contains: - Electronic load limit control - Flow on demand from main pumps depending on joystick position - Automatic regulation of main pumps to zero flow without demand - Automatic rpm reduction of engine speed during working breaks - Reduced oil flow of main pumps at high hydraulic oil temperature or high engine temperature • Pressure cut-off for main pumps

• Filters: - Full-flow high-pressure filters (100 μm) for the main pumps, installed directly behind each pump - Full-flow filters (10 μm) for the complete return circuit - Full-flow filter (10 μm) for the cooling return circuit - Pressure filter (40 μm) for servo circuit - Pressure filter (40 μm) for the feed pump of the closed swing circuit

Diesel Engine Engine features Fuel tank capacity 1 300 L (343 US gal) • Microprocessed engine management • Automatic rev. reduction • Heavy-duty air filters, STRATA 1 with automatic dust evacuation • Two-stage fuel filter, incl. water separator Version 1 - Cat® C18 Tier 3 Make and model Total rated net power ISO 3046/1 Total rated net power SAE J1349 Total rated gross power SAE J1995 No. of cylinders (each engine) Bore Stroke Displacement Aspiration

Cat C18 496 kW (665 HP) 1,800 min-1 496 kW (665 HP) 1,800 min-1 522 kW (700 HP) 1,800 min-1

6 145 mm (5.7 in) 183 mm (7.2 in) 18.1 L (1.105 in³) Turbocharged and charge air cooled Max. altitude without deration 1 500 m (4,900 ft) a.s.l.

Emission certification US EPA Tier 4i Europe NRMM Tier III B Version 2 - Cummins® QSK19 Tier 1 Make and model Cummins QSK19 Total rated net power ISO 3046/1 453 kW (607 HP) 1,800 min-1 Total rated net power SAE J1349 453 kW (607 HP) 1,800 min-1 Total rated gross power SAE J1995 477 kW (640 HP) 1,800 min-1 No. of cylinders (each engine) 6 Bore 159 mm (6.25 in) Stroke 159 mm (6.25 in) Displacement 19 L (1,159 in³) Aspiration Turbocharged and aftercooled Max. altitude without deration 3 100 m (10,200 ft) a.s.l.

Hydraulic Shovel—6015/6015 FS Undercarriage Travel speed Max. tractive force Gradability of travel drives Track pads (each side) Bottom rollers (each side) Support rollers (each side) Travel drives (each side)

Max. 2.7 km/h (1.68 mph) 652 kN (66 t = 146,520 lb) Max. 72 % 48 8 1 1 planetary transmission with 1 axial piston motor Parking brake Wet multiple disc brake, spring applied / hydraulically released • Rolled double-grouser track pads • All running surfaces of sprockets, idlers, rollers and track links are hardened • Fully hydraulic self-adjusting track tensioning system with membrane accumulator • Automatic hydraulic retarder valve to prevent overspeed on downhill travel • Acoustic travel alarm

Swing System Swing Drive

Compact planetary transmission with axial piston motor Parking Brake Wet multiple disc brake, spring loaded/hydraulically released Max. swing speed Cat version 5.1 rpm Cummins version 5.4 rpm Swing ring Triple race roller bearing with sealed internal gearing • Closed-loop swing circuit with torque control • Hydraulic braking of the swing motion by counteracting control • All raceways of swing ring, as well as grease bath for internal gearing, supplied by automatic central lubrication system

Automatic Lubrication System Capacity of grease drum 8 l (2.1 US gal) • Single line progressive automated lubrication system, electric motor driven and electronically controlled • Connected to the lubrication system are the swing roller bearing with internal gearing and all pivot points of attachment, bucket and cylinders except backhoe bucket and linkage • System failures displayed on control panel

Attachments • Booms and sticks are torsion-resistant, welded box design of high-tensile steel with massive steel castings at pivot areas • Booms and sticks are stress-relieved after welding • Pressure-free lowering of boom (FS) by means of a float valve • Shovel attachment with unique TriPower kinematics ensuring the following main features: - Horizontal automatic constant-angle bucket guidance - Vertical automatic constant-angle bucket guidance - Automatic roll-back limiter to prevent material spillage - Kinematic assistance to hydraulic forces - Constant boom momentum throughout the whole lift arc - Crowd force assistance • All buckets (FS and BH) are equipped with a universal wear package suitable for all standard applications, which consists of: - Lip shrouds between teeth - Side edge protection - Heel shrouds at bottom edges - Special liner material covering main wear areas inside and outside of bucket • Special wear packages for highly abrasive materials on request

Operator’s Cab Operator’s eye level Internal dimensions

approx. 4.3 m (14 ft 1 in) Length 1 800 mm (5 ft 11 in) Width 1 300 mm (4 ft 3 in) Height 1 900 mm (6 ft 3 in) • Pneumatically cushioned and multi-adjustable comfort seat with lumbar support, seat heating, safety belt, head-and armrests • Switch in seat cushion to automatically neutralize the hydraulic controls when operator leaves the seat • Joystick controls integrated in independently adjustable seat consoles • Fold-away auxiliary seat with safety belt • FOPS (rock guard; approved acc. to DIN ISO 3449) integrated into cab structure • All-round safety glass, armored windshield and sliding side window • Windshield with parallel intermittent wiper / washer • Roller blind at windshield • Robust instrument panel incl. large and easy-to-read instruments

Hydraulic Shovel—6015/6015 FS TriPower Face Shovel Attachment (FS) Working Diagram - Boom 5.05 m (16 ft 7 in) - Stick 3.55 m (11 ft 8 in) m 12 ft 45

11

10 40 9 35

30

25

8

7

6

5 20 4 15

10

3

2

1 5 0 0

5

10

1

2

3 12 40

11

10 35

Working Range Max. digging height Max. digging reach Max. digging depth Max. dumping height Crowd distance on level Face Shovels Type Tooth system Capacity SAE / PCSA 1:1 Capacity SAE / CECE 2:1≠ Total width Inner width Opening width No. of teeth Weight incl. universal wear kit Max. material density (loose)

9 30

11.0 m 10.5 m 2.2 m 8.8 m 3.9 m

8

7 25

36 ft 1 in 34 ft 5 in 7 ft 3 in 28 ft 10 in 12 ft 10 in

6 20

5

4 15

3 10

Digging Forces Max. crowd force Max. crowd force at ground level Max. breakout force

Heavy rock shovel ESCO V69 6.9 m3 (9.0 yd3) 6.0 m³ (7.8 yd³) 2 500 mm (8 ft 2 in) 2 300 mm (7 ft 7 in) 1 450 mm (4 ft 9 in) 5 9 500 kg (20,940 lb) 2.2 t/m3 (3,710 lb/yd3)

2

1 5

0

m

0

ft

650 kN

146,070 lb

480 kN 490 kN

107,870 lb 110,120 lb

Standard rock shovel ESCO V69 8.1 m3 (10.6 yd3) 7.0 m³ (9.2 yd³) 3 000 mm (9 ft 10 in) 2 800 mm (9 ft 2 in) 1 450 mm (4 ft 9 in) 6 10 100 kg (22,270 lb) 1.8 t/m3 (3,030 lb/yd3)

Hydraulic Shovel—6015/6015 FS Standard Backhoe Attachment (BH) Working Diagram - Boom 7.8 m (25 ft 7 in) - Stick 3.3 m (10 ft 10 in) ft 45

m 14 13

40

35

12 11 10

30

25

9 8 7

20

15

6 5 4

10

3 2

5 1 0

0 1

5 2 10

3 4

15

20

5 6 7

25

8 16

15 50

Working Range Max. digging depth Max. digging reach Max. digging height Backhoes Type Tooth system Capacity SAE 1:1 Capacity CECE 2:1 Capacity struck Total width Inner width No. of teeth Weight incl. universal wear kit Max. material density (loose)

14

13 45

7.3 m 13.5 m 13.0 m

12 40

11

10 35

9 30

23 ft 11 in 44 ft 3 in 42 ft 8 in

Heavy rock bucket ESCO V69 4.6 m3 (6.0 yd3) 4.1 m3 (5.4 yd3) 3.6 m3 (4.7 yd3) 2 040 mm (6 ft 8 in) 1 840 mm (6 ft) 4 6 200 kg (13 670 lb) 2.4 t/m3 (4,050 lb/yd3)

8

7 25

6 20

5

4 15

3 10

Digging Forces Max. crowd force Max. breakout force

Standard rock bucket ESCO V61 6.0 m3 (7.8 yd3) 5.2 m3 (6.8 yd3) 4.5 m3 (5.9 yd3) 2 390 mm (7 ft 10 in) 2 220 mm (7 ft 3 in) 5 6 300 kg (13 890 lb) 1.8 t/m3 (3,030 lb/yd3)

2

1 5

0

m

0

ft

390 kN 390 kN

87,640 lb 87,640 lb

Mass excavation bucket ESCO 65SV2 7.0 m3 (9.2 yd3) 6.2 m3 (8.1 yd3) 5.4 m3 (7.1 yd3) 2 800 mm (9 ft 2 in) 2 468 mm (8 ft 6 in) 5 7 750 kg (17 090 lb) 1.4 t/m3 (2,360 lb/yd3)

Hydraulic Shovel—6015/6015 FS Mass Excavation Backhoe Attachment (BH) Working Diagram - Boom 7.3 m (23 ft 11 in) - Stick 2.8 m (9 ft 2 in) ft 45

m 14 13

40

35

12 11 10

30

25

9 8 7

20

15

6 5 4

10

3 2

5 1 0

0 1

5 2 10

3 4

15

20

5 6 7

25

8 16

15 50

Working Range Max. digging depth Max. digging reach Max. digging height Backhoes Type Tooth system Capacity SAE 1:1 Capacity CECE 2:1 Capacity struck Total width Inner width No. of teeth Weight incl. universal wear kit Max. material density (loose)

14

13 45

6.0 m 12.6 m 13.0 m

12 40

11

10 35

19 ft 8 in 41 ft 4 in 42 ft 8 in

Heavy rock bucket ESCO V69 4.6 m3 (6.0 yd3) 4.1 m3 (5.4 yd3) 3.6 m3 (4.7 yd3) 2 040 mm (6 ft 8 in) 1 840 mm (6 ft) 4 6,200 kg (13,670 lb) 3.0 t/m3 (5,060 lb/yd3)

9 30

8

7 25

6 20

5

4 15

3 10

Digging Forces Max. crowd force Max. breakout force

Standard rock bucket ESCO V61 6.0 m3 (7.8 yd3) 5.2 m3 (6.8 yd3) 4.5 m3 (5.9 yd3) 2 390 mm (7 ft 10 in) 2 220 mm (7 ft 3 in) 5 6,300 kg (13,890 lb) 2.2 t/m3 (3,710 lb/yd3)

2

1 5

0

m

0

ft

430 kN 410 kN

96,630 lb 92,140 lb

Mass excavation bucket ESCO 65SV2 7.0 m3 (9.2 yd3) 6.2 m3 (8.1 yd3) 5.4 m3 (7.1 yd3) 2 800 mm (9 ft 2 in) 2 468 mm (8 ft 6 in) 5 7 750 kg (17,090 lb) 1.8 t/m3 (3,030 lb/yd3)

Hydraulic Shovel—6015/6015 FS

Standard 7 300 mm (23 ft 11 in) HD-LC 7 550 mm (24 ft 9 in)

2 000 mm (6 ft 7 in)

2 800 mm (9 ft 2 in)

1 280 mm (4 ft 2 in)

2 000 mm (6 ft 7 in)

Above values are approximate. Details may vary depending on scope of supply and destination.

Exact data subject to selected machine configuration and final packing list.

3 600 mm (11 ft 10 in)

3 600 mm (11 ft 10 in)

800 mm (2 ft 7 in)

2 450 mm (8 ft)

2 450 mm (8 ft)

4 080 mm (13 ft 5 in) 4 080 mm (13 ft 5 in)

800 mm (2 ft 7 in)

2 000 mm (6 ft 7 in)

3 300 mm (10 ft 10 in)

5 500 mm (18 ft 1 in)

2 900 mm (9 ft 6 in)

2 000 mm 1 280 mm (6 ft 7 in) (4 ft 2 in)

C18: 4 150 mm (13 ft 7 in) QSK19: 4 050 mm (13 ft 3 in) C18: 4 150 mm (13 ft 7 in) QSK19: 4 050 mm (13 ft 3 in) 2 900 mm (9 ft 6 in)

Standard 7 300 mm (23 ft 11 in) HD-LC 7 550 mm (24 ft 9 in) Standard 7 300 mm (23 ft 11 in) HD-LC 7 550 mm (24 ft 9 in)

5 500 mm (18 ft 1 in)

850 mm (2 ft 9 in)

2 400 mm (7 ft 10 in) C18: 18 000 kg (39,680 lb) 16 000 kg (35,270 lb)

2 450 mm (8 ft)

Pallet with counterweight Width Gross weight QSK19

850 mm (2 ft 9 in)

2 900 mm (9 ft 6 in) 5 500 mm (18 ft 1 in) 2 900 mm (9 ft 6 in)

4 300 mm (14 ft 1 in)

4 300 mm (14 ft 1 in)

Crate with cabin and FOPS Width 1 760 mm (5 ft 9 in) Gross weight 1 650 kg (3,640 lb)

2 800 mm (9 ft 2 in)

Basic unit with C18 engine Pad width Width Gross weight* With standard undercarriage 600 mm 4 550 mm 59 500 kg (23.6 in) (14 ft 11 in) (131,170 lb) 750 mm 4 550 mm 61 050 kg (29.5 in) (14 ft 11 in) (134,590 lb) With HD-LC undercarriage (optional) 600 mm 4,950 mm 67 350 kg (23.6 in) (16 ft 3 in) (149,140 lb) 750 mm 4,950 mm 68 900 kg (29.5 in) (16 ft 3 in) (151,900 lb) * Weights with QSK19 engine 300 kg / 660 lb less

4 300 mm (14 ft 1 in)

General Packing List

Boom with TriPower linkages, rods and boom cylinders Width 1 420 mm (4 ft 8 in) Gross weight 8 650 kg (19,070 lb) C18: 4 150 mm (13 ft 7 in) QSK19: 4 050 mm (13 ft 3 in) Standard 7 300 ft 11 in) 2 900 mmmm (9 ft(23 6 in) HD-LC 7 550 mm (24 ft 9 in)

C18: 4 150 mm (13 ft 7 in) QSK19: 4 050 (13 ft 3 in) 4Standard 080 mm (13 ftmm 5mm in) 7 300 (23 ft 11 in) HD-LC 550 mm (24 ft 9 in) 5 500 mm (18 ft 17 in)

Standard 7 300 mm (23 ft 11 in) 5 500 mm (18 ft 1 in) HD-LC 7 550 mm (24 ft 9 in)

1 280 mm (4 ft 2 in) 850 (6 mm 2 000 mm ft 7 in) (2 ft 9 in)

2 450 mm (8 ft)

Stick Width 1 160 mm (3 ft 10 in) Gross weight 3 300 kg (7,280 lb)

5 500 mm (18 ft 1 in)

4 300 mm (14 ft 1 in)

2 000 mm (6 ft 7 in)

4 300 mm (14 ft 1 in)

Standard 7 300 mm (23 ft 11 in) HD-LC 7 550 mm (24 ft 9 in)

2 000 mm (6 ft 7 in)

3 300 mm (10 ft 10 in) 3 600 mm (11 ft 10 in) 2 900 mm (9 ft 6 in)

2 900 mm (9 ft 6 in)

3 300 mm (10 ft 10 in)

Above values are approximate. Details may vary depending on scope of supply and destination.

Exact data subject to selected machine configuration and final packing list.

2 000 mm (6 ft 7 in)

2 000 mm (6 ft 7 in)

Gross weight 1 400 kg (3,090 lb)

3 300 mm (10 ft 10 in)

1 280 mm (4 ftmm 2 in)(6 ft 7 in) 2 000

800 mm (2 ft 7 in)

3 300 mm (10 ft 10 in)

2 450 mm (8 ft)

2 000 mm (6 ft 7 in)

Crate with 1 stick and 2 bucket cylinders Width 1 130 mm (3 ft 8 in) Gross weight 2 330 kg (5,140 lb) 2 450 mm (8 ft)

3 600 mm (11 ft 10 in) 3 300 mm (10 ft 10 in) 4 080 mm (13 ft 5 in) 5 500 mm (18 ft 1 in) 2 900 mm (9 ft 6 in)

5 500 mm (18mm ft 1(9 in)ft 6 in) 2 900

Crate with accessories Width 800 mm (2 ft 7 in)

2 450 mm (8 ft)

2 450 mm (8 ft)

2 000 mm (6 ft 7 in)

Face shovel incl. pin for stick Capacity (2:1) Width Gross weight 6.0 m³ (7.8 yd³) 2 500 mm (8 ft 2 in) 9 700 kg (21,380 lb) 7.0 m³ (9.2 yd³) 3 000 mm (9 ft 10 in) 10 300 kg (22,710 lb)

2 000 mm mm (6 ft800 7 in) (2 ft 7 in)

2 900 mm (9 ft 6 in)

2 000 mm (6 ft 7 in)

TriPower Shovel Attachment

850 mm (2 ft 9 in)

Hydraulic Shovel—6015/6015 FS

7 550 mm (24 ft 9 in)

2 800 mm (9 ft 2 in)

4 300 mm (14 ft 1 in)

4 300 mm (14 ft 1 i

HD-LC

Hydraulic Shovel—6015/6015 FS Backhoe Attachment

C

C

Monoboom with main valve block, boom and stick cylinders Boom A Length B Width 7.3 m³ (23 ft 11 in) 7 750 mm (25 ft 5 in) 1 580 mm (8 ft 2 in) 7.8 m³ (25 ft 7 in) 8 250 mm (27 ft 1 in) 1 620 mm (9 ft 10 in) Boom A Height C Gross weight 7.3 m³ (23 ft 11 in) 2 900 mm (9 ft 6 in) 12 100 kg (26,680 lb) 7.8 m³ (25 ft 7 in) 3 000 mm (9 ft 10 in) 12 600 kg (27,780 lb)

A B A B

C

C

Pallet with stick, linkage and bucket cylinders Stick A Length B Width 2.8 m³ (9 ft 2 in) 4 400 mm (14 ft 5 in) 1 100 mm (3 ft 7 in) 3.3 m³ (10 ft 10 in) 4 850 mm (15 ft 11 in) 1 100 mm (3 ft 7 in) Stick A Height C Gross weight 2.8 m³ (9 ft 2 in) 1 900 mm (6 ft 3 in) 5 000 kg (11,020 lb) 3.3 m³ (10 ft 10 in) 1 900 mm (6 ft 3 in) 5 400 kg (11,900 lb)

C

A B A A

B

6.0 m³ = 2 500 mm (8 ft 2 in) 7.0 m³ = 2 800 mm (9 ft 2 in) 6.0 m³ = 2 500 mm (8 ft 2 in) 7.0 m³ = 2 800 mm (9 ft 2 in)

A

3 300 mm (10 ft 10 in)

6.0 m³ = 2 500 mm (8 ft 2 in) 7.0 m³ = 2 800 mm (9 ft 2 B in) 3 300 mm (10 ft 10 in)

6.0 m³ = 2 500 mm (8 ft 2 in) 7.0 m³ = 2 800 mm (9 ft 2 in)

2 000 mm (6 ft 7 in)

Gross weight 1 400 kg (3,090 lb) 2 150 mm (7 ft 1 in)

Crate with accessories Width 800 mm (2 ft 7 in)

C

2 150 mm (7 ft 1 in) 2 150 mm (7 ft 1 in)

Backhoe bucket incl. pins for stick and linkage Capacity (1:1) Width Gross weight 6.0 m³ (7.8 yd³) 2 400 mm (7 ft 10 in) 6 400 kg (14,110 lb) 7.0 m³ (9.2 yd³) 2 800 mm (9 ft 2 in) 6 800 kg (14,990 lb)

3 300 mm (10 ft 10 in)

000mm mm(7(6ftft1 7in)in) 2 2150 2 000 mm (6 ft 7 in)

B

Hydraulic Shovel—6015/6015 FS Optional Equipment General

Cab

• Export crating • Finishing as per end user´s corporate colors • Customizing of logos as per customer’s specification

• Radio with loudspeaker and antenna • On roof-mounted air conditioning unit

Superstructure

• Track pad width 500 mm, 750 mm or 900 mm • Track guides • HD-LC undercarriage

• Environmentally compatible hydraulic oil • Xenon lighting • High-capacity water separator • Fast-filling connection for fuel • Catwalk with access steps at engine module (standard on C18 version) • Centrifuge for engine oil filtration • Various cold-weather packages

Undercarriage

Attachment • Xenon lighting on boom • Special wear packages Additional optional equipment available on request

Hydraulic Shovel—6015/6015 FS

For more complete information on Cat products, dealer services, and industry solutions, visit us on the web at mining.cat.com and www.cat.com © 2012 Caterpillar Inc. All rights reserved CAT, CATERPILLAR, their respective logos, “Caterpillar Yellow” and the “Power Edge” trade dress, as well as corporate and product identity used herein, are trademarks of Caterpillar and may not be used without permission.

AEHQ6521-01

BA 6015(3 847 019.01)-EN

Annex NOTES ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... .......................................................................................................................................................................

5-15

BA 6015(3 847 019.01)-EN

Annex

5-16

BA 6015(3 847 019.01)-EN

Index 6 INDEX

Operation and Maintenance Manual

Target group

Part 1 INTRODUCTION FUNDAMENTAL SAFETY INSTRUCTIONS

Operating personnel + Inspection and servicing personnel + Repair personnel

Part 2 OPERATION

Operating personnel The operating personnel must have knowhow relevant to the operation and the application of this or comparable machines.

Part 3 INSPECTION AND SERVICING Part 4 REPAIR WORK

Inspection and servicing personnel The inspection and servicing personnel must have know-how relevant to the inspection and servicing of this or comparable machines.

Repair personnel The repair personnel must have know-how and experience relevant to the repair of this or comparable machines.

Part 5 ANNEX

Operating personnel + Inspection and servicing personnel + Repair personnel

Part 6 INDEX

Operating personnel + Inspection and servicing personnel + Repair personnel

6-1

BA 6015(3 847 019.01)-EN

Index

6-2

BA 6015(3 847 019.01)-EN

Index

A ABBREVIATIONS..........................................5-11 Adjusting the control consoles........................2-15 After daily operation.......................................2-61 Air conditioner (optional)................................2-46 Air-intake lines...............................................3-48 AIR-INTAKE SYSTEM...................................3-45 Alternator - Instructions..................................3-56 Appropriate disposal of batteries....................4-15 ASSEMBLING WORKING EQUIPMENT SAFETY INSTRUCTIONS .........................2-62 Assisted starting (with jumper cables) ............. 4-7 Assisted starting (with jumper cables) – Safety instructions.................................................. 4-7 Automatic engine speed reduction .................. 2-9 Auxiliary heating (optional) ............................2-46 Avoid mixing of different hydraulic fluids.. 3-29, 372

B Selection and qualification of personnel .......... 1-7 Battery...........................................................3-60 Battery main switch........................................2-41 Battery storage ............................................3-101 Before starting work.......................................2-58 Breather filter.................................................3-68 Bypass valves (cooling circuit).......................3-67 Bypass valves (working circuit) ......................3-66

C CENTRAL LUBRICATING .............................3-94 Central lubricating system – Fault table .......... 5-8 Changing the coolant .....................................3-43 Changing the engine oil .................................3-39 Changing the hydraulic oil..............................3-72 Changing the hydraulic oil return-flow (hydraulic oil reservoir ................................................3-65 Charging batteries inside the machine, safety instructions.................................................3-61 Checking the engine oil level / Topping up.....3-38 Checking the gas charging pressure in the pressure accumulator........................................3-91 Checking the hydraulic oil level......................3-64 Cleaning the fuel tank ....................................3-52 Cleaning the grease sieves............................3-99 Cleaning the hydraulic oil cooler ....................3-76 Cold-starting fluid (ether) - Replacing the pressure vessel ........................................................3-41 Combustion engine - Fault table ..................... 5-4 Contents of the Declaration of Conformity ...... 1-3 Coolant for use on all combustion engines.....3-36 Cooler and cooling liquid................................3-42 COOLING SYSTEM ......................................3-42

Corrosion protection for pins and bearings (bushings and hubs)........................................... 2-64

D Demand control / Zero-flow regulation ............ 2-9 Depressurizing the hydraulic system ............. 3-63 DESCRIPTION OF THE EXCAVATOR........... 2-6 Design and function ...................................... 3-94 Designated use, unauthorized use .................. 1-4 Dismantling and removal instructions............ 4-13 Disposal at the end of the service life............ 4-13 Disposing of the machine without polluting the environment .............................................. 4-13 Drive............................................................... 2-8 Dust trap, cleaning........................................ 3-45

E Electrical circuit diagrams ............................. 3-56 Electrical system............................................. 2-9 ELECTRICAL SYSTEM ......................... 3-56, 4-7 Electrical system - Safety instructions........... 3-56 Electrical system switch-cabinets.................. 3-56 ENGINE........................................................ 3-38 Engine - Safety instructions .......................... 3-38 Entering and leaving the machine - Safety instructions................................................... 2-12 Environmentally compatible hydraulic fluid ..... 3-8 Environmentally compatible hydraulic fluid - Operation and Maintenance Manual................. 3-8 Environmentally compatible hydraulic fluid - Sampling ............................................................ 3-9 Environmentally compatible hydraulic fluid, conversion ........................................................ 3-8 Environment-friendly lubricants and gearbox oils ................................................................. 3-10 Excavator layout ............................................. 2-7

F FAULT TABLES ............................................. 5-4 Filling quantities - Grease ............................. 3-25 Filling quantities - oil ..................................... 3-28 Filling quantities - other................................. 3-28 Filter for swing circuit, replace ...................... 3-71 Fire and explosion hazard...................... 1-11, 2-5 Fire-extinguisher........................................... 2-17 Floodlight projector, safety instructions ......... 3-57 Fluid for hydraulic system ............................. 3-31 Fuel pre-filter, Draining off water................... 3-49 Fuel pre-filter, replace................................... 3-50 Fuel preheating system (optional) ................. 2-43 FUEL SYSTEM............................................. 3-49 Fuel system - Safety instructions .................. 3-49 Fuel tank - Venting........................................ 3-52 FUNDAMENTAL SAFETY INSTRUCTIONS... 1-3 Further hazardous substances ...................... 4-14 6-3

BA 6015(3 847 019.01)-EN

Index Further machine documentation ..................... 1-1

G Gearbox oils ..................................................3-10 Grease for idlers, track rollers and support rollers (Lifetime lubrication)...................................3-35 Greases for bearings and swing rings (Central lubrication system) .....................................3-34 Greasing cycle...............................................3-96

H Heating and air conditioning.........................3-100 High-pressure filter for working hydraulics......3-69 High-pressure filters for the servo circuit, replace ..................................................................3-70 Hose line for oil and cooling liquid changes....3-37 HYDRAULIC CIRCUIT DIAGRAM .................. 5-9 Hydraulic hoses – Instructions......................... 4-6 Hydraulic system ............................................ 2-8 HYDRAULIC SYSTEM ..................................3-63 HYDRAULIC SYSTEM ................................... 4-6 Hydraulic system - Safety instructions............3-63

I Inspection and servicing - Safety instructions.. 3-3 Inspection and Servicing plans - Instructions..3-11 inspection and servicing work, Fire and Explosion Hazard ........................................................ 3-7 INSPECTION PLAN - OIL..............................3-26 Inspection plan – Oil (Legend) .......................3-27 Instructions on troubleshooting........................ 5-3

L Layout of the fault table .................................. 5-3 LIFTING OPERATIONS ................................2-65 Lighting systems in LED technonogy, instructions ..................................................................3-59 Load-hooks on backhoe buckets). ..................2-66 Locking the superstructure .............................2-53 LUBRICANTS / consumables ........................3-29 Lubricants for bearings ..................................3-10 LUBRICATING CHART – GREASE...............3-24 Lubricating chart – Grease (legend) ...............3-25 Lubricating the grease distributor of the working equipment ..................................................3-99

M Main filter elements .......................................3-46 Measures........................................................ 5-3 MONITORING, WARNING AND CONTROL ELEMENTS................................................2-18

N Noise emission information............................. 1-5

6-4

NOTES.............................1-13, 2-71, 3-102, 4-17 NOTES......................................................... 5-15 Notes on the selection of oils and greases .... 3-29

O Oils for combustion engine ........................... 3-30 Oils for pump distribution gearbox and travel gearbox ..................................................... 3-32 Oils for swing gearbox .................................. 3-33 Operation - Safety instructions........................ 2-3 Operation and Maintenance Manual, where to store it in the operator’s cab ........................ 2-4 OPERATOR'S CAB ...................................... 2-12 Operator's seat ............................................. 2-14 Organizational measures ................................ 1-6 OTHER MAINTENANCE .............................3-100

P Personal protective equipment and the working clothing ....................................................... 1-6 Plan A - E ..................................................... 3-19 Plan N .......................................................... 3-15 Plan T and W................................................ 3-17 Plan V........................................................... 3-13 Possible causes .............................................. 5-3 Preface........................................................... 1-1 Preheating system for engine and hydraulic oil (optional)................................................... 2-42 Pressure accumulator ................................... 3-77 PRESSURE ACCUMULATORS - SAFETY INSTRUCTIONS............................................. 4-9 Pressure-accumulator inspection regulations 3-91 Product specification sheet ........................... 5-13 Programmable Logic Controller (PLC) ............ 2-8 PUMP drive GEARBOX................................ 3-78 Pump drive gearbox - Changing the gearbox oil 379 Pump drive gearbox - Checking the oil level / Topping up with oil .................................... 3-78 Pump drive gearbox breather, replace .......... 3-80 Pump drive gearbox oil filter, replace............ 3-81 Pump drive gearbox, cleaning the oil cooler.. 3-83 Pump drive gearbox, take an oil sample ....... 3-82 Pump Managing System (PMS) ...................... 2-8 Putting the excavator out of operation..........3-101 PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING.............3-101 PUTTING THE MACHINE INTO OPERATION . 237

R Recommissioning ........................................3-101 Reducing the operator's exposure to noise.... 2-37 Refuelling ..................................................... 2-37 Refuelling station (optional) .......................... 3-53 Removing and installing the battery .............. 3-62 Repair instructions .......................................... 4-6

BA 6015(3 847 019.01)-EN

Index Repair work - Safety instructions..................... 4-3 repair work, ENGINE ...................................... 4-5 repair work, Fire and Explosion Hazard........... 4-4 Replacing lamps and bulbs ............................3-56 Replacing the engine oil filters .......................3-40 Risk of deflagrations ......................................4-13 Risk of fire .....................................................4-13

S Safety instructions .........................................2-65 SAFETY INSTRUCTIONS .............................2-56 Safety instructions governing specific operational phases ........................................................ 1-7 Secondary filter element ................................3-48 Secondary fuel filter, replace .........................3-51 Section ........................................................... 5-3 Securing the machine ....................................2-63 SERVICING WORK.......................................3-37 Signs .............................................................2-11 Special work in conjunction with utilization of the machine and maintenance and repairs as well as troubleshooting during work; disposal of parts and consumables................................ 1-8 Starting and stopping the engine....................2-44 Starting the engine with jumper cables (external batteries ...................................................... 4-7 Superstructure ................................................ 2-8 SWING GEARBOX........................................3-84 Swing gearbox output pinion, lubricate...........3-85 Swing gearbox, changing the gearbox oil.......3-84 Swing gearbox, checking the oil level / topping up with oil........................................................3-84 Swing gearbox, clean / replace breather ........3-85 SWING RING ................................................3-92 Swing ring - Instructions.................................3-92 Swing ring, bearing races...............................3-92 Swinging and braking the superstructure........2-59 Swinging mechnism – Fault table ................... 5-7 Switching the electrical system on and off......2-40

T Topping up with coolant .................................3-43 Topping up with hydraulic oil..........................3-64 Track drive – Fault table ................................. 5-6

Track parking brake ...................................... 2-53 Track rollers, support rollers, track pads........ 3-89 Track tensioner ............................................. 3-90 Tracks, cleaning............................................ 3-88 Trainer's / instructor's seat ............................ 2-16 Transport - Safety instructions ...................... 2-54 Transporting and recommissioning ............... 1-10 Transporting the machine ............................. 2-54 TRAVEL GEARBOX (p/n 3709660)............... 3-87 TRAVEL GEARBOX (p/n 3712319, 3749594) 3-86 Travel gearbox, changing the oil ...........3-86, 3-87 Travel gearbox, checking the oil level / topping up with oil...............................................3-86, 3-87 Travel gearbox, clean / replace breather.. 3-86, 387 TRAVELLING ............................................... 2-49 TRAVELLING, SAFETY INSTRUCTIONS 2-47, 248 TROUBLESHOOTING.................................... 5-3

U Unblocking a grease line............................... 3-98 undercarriage................................................ 3-88 Undercarriage ................................................. 2-8

V Ventilation and heating ................................. 2-46 Venting the grease lines................................ 3-98 Venting the grease pump .............................. 3-98 Venting the hydraulic system ........................ 3-75 Vibration information....................................... 1-5

W Warning of special dangers............................. 1-9 Warnings and symbols.................................... 1-3 Warranty......................................................... 1-2 Water trap (option)........................................ 3-54 Welding and flame cutting works - Safety instructions .......................................................... 4-10 Windscreen washer ...................................... 2-13 Working hydraulics – Fault table ..................... 5-5 Working operation ........................................ 2-56 Working operations....................................... 2-60

6-5

© Copyright Caterpillar Global Mining HMS GmbH 2013

The reproduction, distribution and utilization of this manual / file as well as the communication of its content to others without express authorization is prohibited.

Offenders will be held liable for the payment of damages. All rights reserved in the event of the grant of a patent, utility model or design.

Printed in Germany