CAT 6020B Hydraulic Shovel Operation & Maintenance Manual DNR00101 - DNR00104 - PDF DOWNLOAD

BA 6020B(3 847 000.00)-EN 04 / 2013

Operation and Maintenance Manual 6020B Hydraulic Shovel DNR00101 - DNR00104

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Important Safety Information Most accidents that involve product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills and tools to perform these functions properly.

Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death.

Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information.

Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons.

The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as “DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.

The meaning of this safety alert symbol is as follows: Attention! Become Alert! Your Safety is Involved.

The message that appears under the warning explains the hazard and can be either written or pictorially presented.

A non-exhaustive list of operations that may cause product damage are identified by “NOTICE” labels on the product and in this publication.

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are, therefore, not all inclusive. You must not use this product in any manner different from that considered by this manual without first satisfying yourself that you have considered all safety rules and precautions applicable to the operation of the product in the location of use, including site-specific rules and precautions applicable to the worksite. If a tool, procedure, work method or operating technique that is not specifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that the product will not be damaged or become unsafe by the operation, lubrication, maintenance or repair procedures that you intend to use.

The information, specifications, and illustrations in this publication are on the basis of information that was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job. Cat dealers have the most current information available.

When replacement parts are required for this product Caterpillar recommends using Cat replacement parts or parts with equivalent specifications including, but not limited to, physical dimensions, type, strength and material. Failure to heed this warning can lead to premature failures, product damage, personal injury or death.

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

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

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

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Table of contents TABLE OF CONTENTS Important Safety Information __________________________________________________________ ii 1 INTRODUCTION __________________________________________________________________ 1-1 PREFACE _______________________________________________________________________ 1-3 About this Operation and Maintenance Manual _________________________________________ 1-3 Further machine documentation _____________________________________________________ 1-3 WARRANTY______________________________________________________________________ 1-4 FUNDAMENTAL SAFETY INSTRUCTIONS _____________________________________________ 1-5 Warnings and symbols ____________________________________________________________ 1-5 DESIGNATED USE, UNAUTHORIZED USE ____________________________________________ 1-6 Organizational measures __________________________________________________________ 1-7 Selection and qualification of personnel; basic responsibilities______________________________ 1-8 Safety instructions governing specific operational phases _________________________________ 1-8 Special work in conjunction with utilization of the machine and maintenance and repairs as well as troubleshooting during work; disposal of parts and consumables____________________________ 1-9 Warning of special dangers________________________________________________________ 1-10 FIRE AND EXPLOSION HAZARD____________________________________________________ 1-12 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 HYDRAULIC SHOVEL __________________________________________ 2-6 Hydraulic shovel layout ____________________________________________________________ 2-7 Undercarriage ___________________________________________________________________ 2-8 Upper structure __________________________________________________________________ 2-8 Power module ___________________________________________________________________ 2-8 Hydraulic system _________________________________________________________________ 2-8 Control and Monitoring Platform (CAMP) ______________________________________________ 2-8 Board-Control-System (BCS) – information ____________________________________________ 2-9 Demand control / Zero-flow regulation ________________________________________________ 2-9 Automatic reset to idling ___________________________________________________________ 2-9 Electrical system _________________________________________________________________ 2-9 Safety films and warning messages – overview and description ___________________________ 2-10 Safety messages________________________________________________________________ 2-16 Additional messages _____________________________________________________________ 2-23 Machine number plate – location ___________________________________________________ 2-25 Component numbers – location ____________________________________________________ 2-25 Engine number plate – location_____________________________________________________ 2-25 Engine information plate – location __________________________________________________ 2-25 Entering and leaving the machine ___________________________________________________ 2-26 Boarding ladder lighting – switching on / off ___________________________________________ 2-27 Hydraulic boarding ladder – raising / lowering _________________________________________ 2-28 Operator’s cab – lock / unlock the door_______________________________________________ 2-29

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Table of contents Operator’s cab – open the door from inside ___________________________________________ 2-29 Cab interior lights – switching on / off ________________________________________________ 2-30 Maintenance lights – switching on / off _______________________________________________ 2-31 Battery main switch – switching on / off ______________________________________________ 2-31 Emergency exit in operator’s cab and escape ladder ____________________________________ 2-32 Emergency ladder on the righthand side of upper structure _______________________________ 2-33 Emergency lowering the boarding ladder from the ground ________________________________ 2-33 Emergency shut-off – function______________________________________________________ 2-34 Putting the machine back into operation – reset of emergency shut off function _______________ 2-35 Starter isolator switch – shutting off starter voltage______________________________________ 2-36 Battery isolator switch – shutting off supply voltage _____________________________________ 2-36 Operator’s seat – adjustment ______________________________________________________ 2-37 Operators exposure to vibrations – reducing __________________________________________ 2-38 Operator’s seat belt – use _________________________________________________________ 2-38 Trainer's / instructor's seat – use____________________________________________________ 2-39 Jump seat – use ________________________________________________________________ 2-39 Fire extinguisher – location ________________________________________________________ 2-40 Windscreen wiper / washer – function________________________________________________ 2-41 Windscreen washer nozzles– adjust_________________________________________________ 2-41 Windscreen washer reservoir – refill _________________________________________________ 2-42 Mirror– adjusting position _________________________________________________________ 2-42 BCS display monitor – adjusting position _____________________________________________ 2-43 Operating hours meter – location ___________________________________________________ 2-43 Power receptacle inside cab – use __________________________________________________ 2-44 Roller blinds – adjusting position____________________________________________________ 2-44 MONITORING, WARNING AND CONTROL ELEMENTS IN CAB ___________________________ 2-46 Engine, control and monitoring _____________________________________________________ 2-51 MACHINE – PUTTING INTO OPERATION _____________________________________________ 2-62 Operator's exposure to noise - reducing ______________________________________________ 2-62 Refuelling _____________________________________________________________________ 2-63 Diesel fuel - recommendations _____________________________________________________ 2-63 Diesel fuel tank - refilling __________________________________________________________ 2-63 Refuelling using the Service Station _________________________________________________ 2-64 Electrical system – switching on and off ______________________________________________ 2-69 Engine – emergency shut-off ______________________________________________________ 2-69 ENGINE – STARTING AND STOPPING _______________________________________________ 2-70 Engine – starting ________________________________________________________________ 2-70 Engine – adjusting the speed ______________________________________________________ 2-71 Engine – starting at low temperatures________________________________________________ 2-71 Engine – shutting off _____________________________________________________________ 2-72 HVAC – UNIT, FUNCTION _________________________________________________________ 2-73 HVAC – unit, controls ____________________________________________________________ 2-74 MAXIMUM MACHINE INCLINATIONS – INFORMATION __________________________________ 2-76 TRAVELLING – SAFETY INSTRUCTIONS _____________________________________________ 2-78 TRAVELLING____________________________________________________________________ 2-79 Upper structure basic position______________________________________________________ 2-79 Travelling forwards/backwards _____________________________________________________ 2-79

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Table of contents Travelling speed – adjust _________________________________________________________ 2-80 Travelling uphill and downhill ______________________________________________________ 2-80 Cornering _____________________________________________________________________ 2-81 Turning _______________________________________________________________________ 2-81 Travelling over long distances______________________________________________________ 2-82 Travelling in water or mud _________________________________________________________ 2-83 Upper structure holding brake – function _____________________________________________ 2-84 Track parking brake – function _____________________________________________________ 2-84 TRANSPORTING THE MACHINE____________________________________________________ 2-85 Transport - Safety instructions _____________________________________________________ 2-85 WORKING OPERATION - SAFETY INSTRUCTIONS ____________________________________ 2-86 Hydraulic cylinders – running-in instructions ___________________________________________ 2-87 Hydraulic system – warming up ____________________________________________________ 2-87 WORKING OPERATION ___________________________________________________________ 2-89 Before starting work _____________________________________________________________ 2-89 Pilot hydraulic circuit – activating ___________________________________________________ 2-89 Upper structure – swinging ________________________________________________________ 2-90 Working movements _____________________________________________________________ 2-91 WORKING TECHNIQUES __________________________________________________________ 2-92 Restricted operation _____________________________________________________________ 2-92 Backhoe operation – digging and loading _____________________________________________ 2-93 Bench – climbing and leaving ______________________________________________________ 2-94 Emergency lowering of the working equipment_________________________________________ 2-95 After daily operation _____________________________________________________________ 2-95 OPTIONAL EQUIPMENT___________________________________________________________ 2-96 Additional silencers - function ______________________________________________________ 2-96 Rotary beacon – switching on / off __________________________________________________ 2-96 ASSEMBLING WORKING EQUIPMENT - SAFETY INSTRUCTIONS ________________________ 2-97 Securing the machine ____________________________________________________________ 2-98 CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS)____________ 2-99 NOTES________________________________________________________________________ 2-101 3 INSPECTION AND SERVICING ______________________________________________________ 3-1 INSPECTION AND SERVICING - SAFETY INSTRUCTIONS________________________________ 3-3 INSPECTION AND SERVICING WORK, FIRE AND EXPLOSION HAZARD ____________________ 3-7 INSPECTION AND SERVICING PLANS - INSTRUCTIONS _________________________________ 3-9 Plan V ________________________________________________________________________ 3-11 Plan N ________________________________________________________________________ 3-13 Plan T and W___________________________________________________________________ 3-15 Plan A – E _____________________________________________________________________ 3-17 LUBRICATING CHART – GREASE___________________________________________________ 3-24 Lubricating chart – Grease (legend) _________________________________________________ 3-25 Filling quantities – Grease_________________________________________________________ 3-25

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Table of contents LUBRICATING CHART – GREASE, WORKING EQUIPMENT______________________________ 3-26 Lubricating chart – Grease, working equipment (legend) _________________________________ 3-27 INSPECTION PLAN - OIL __________________________________________________________ 3-28 Inspection plan – Oil (legend) ______________________________________________________ 3-29 Filling quantities - oil _____________________________________________________________ 3-30 Filling quantities – other __________________________________________________________ 3-30 LUBRICANTS / CONSUMABLES ____________________________________________________ 3-31 Notes on the selection of oils and greases ____________________________________________ 3-31 Avoid mixing of different hydraulic fluids ______________________________________________ 3-31 I. Oils for combustion engines ____________________________________________________ 3-32 II. Fluid for hydraulic system ____________________________________________________ 3-33 III Oils for pump drive gearboxes, swing gearboxes and travel gearboxes_________________ 3-34 V. Grease for bearings and swing rings (Central lubrication system) _____________________ 3-35 Grease for idlers, track rollers and support rollers (Lifetime lubrication) ______________________ 3-36 Coolant for use on all combustion engines ____________________________________________ 3-37 SERVICING WORK _______________________________________________________________ 3-38 Maintenance access – doors and cover locations_______________________________________ 3-38 ENGINE ________________________________________________________________________ 3-39 Engine - Safety instructions________________________________________________________ 3-39 Engine oil level – Checking / Topping up _____________________________________________ 3-40 Engine oil – Changing ____________________________________________________________ 3-41 Engine oil filters – Replacing _______________________________________________________ 3-43 Cold-starting fluid (ether) - Replacing the pressure vessel ________________________________ 3-44 Cold-starting fluid (ether) - Replacing the pressure vessel ________________________________ 3-44 ENGINE COOLING SYSTEM - INFORMATION _________________________________________ 3-45 Radiator core – clean ____________________________________________________________ 3-46 Cooling-liquid – Checking level _____________________________________________________ 3-46 Cooling liquid – change ___________________________________________________________ 3-49 Cooling liquid - Testing the composition ______________________________________________ 3-51 Engine bearings – inspect _________________________________________________________ 3-51 Engine crankcase breather – clean__________________________________________________ 3-52 AIR-INTAKE SYSTEM - INFORMATION _______________________________________________ 3-53 Dust trap - Cleaning _____________________________________________________________ 3-53 Primary filter elements – Check, clean, replace ________________________________________ 3-54 Secondary filter element – replace __________________________________________________ 3-56 Clean-air lines and hoses – inspect _________________________________________________ 3-56 FUEL SYSTEM __________________________________________________________________ 3-57 Fuel system - Safety instructions ___________________________________________________ 3-57 Fuel filter – information ___________________________________________________________ 3-57 Fuel tank supply valve – function ___________________________________________________ 3-58 Fuel filter - drain water____________________________________________________________ 3-58 Fuel filter – replace ______________________________________________________________ 3-59 Fuel system – venting ____________________________________________________________ 3-60 Fuel tank breather filter – replace ___________________________________________________ 3-61 Fuel tank – cleaning _____________________________________________________________ 3-62 Fuel tank – drain water and sediment ________________________________________________ 3-63 Water trap (optional) – check ______________________________________________________ 3-64

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Table of contents ELECTRICAL SYSTEM ____________________________________________________________ 3-66 Electrical system - Safety instructions________________________________________________ 3-66 Alternator - Instructions ___________________________________________________________ 3-66 Electrical circuit diagrams _________________________________________________________ 3-66 Electrical system switch-cabinets ___________________________________________________ 3-66 Fuses - information ______________________________________________________________ 3-66 Lamps and bulbs – replace ________________________________________________________ 3-66 Charging batteries inside the machine – safety instructions _______________________________ 3-67 Battery - maintenance ____________________________________________________________ 3-68 Battery - removing and installing ____________________________________________________ 3-69 Equipotential bonding – inspect ____________________________________________________ 3-70 Lighting systems in LED technonogy - instructions______________________________________ 3-72 HYDRAULIC SYSTEM_____________________________________________________________ 3-73 Hydraulic system - Safety instructions _______________________________________________ 3-73 Hydraulic system - depressurize ____________________________________________________ 3-73 Hydraulic oil level - check _________________________________________________________ 3-74 Hydraulic oil return-flow filters (hydraulic oil reservoir) - replace____________________________ 3-76 Hydraulic oil return-flow filters (filter housing) - replace __________________________________ 3-78 Bypass valves (hydraulic oil tank) – clean / replace _____________________________________ 3-79 Hydraulic tank angled screens - inspect ______________________________________________ 3-80 Hydraulic tank breather filter - replace _______________________________________________ 3-80 Filter (pilot hydraulic circuit) - replace ________________________________________________ 3-81 High-pressure filter for working hydraulics - replace _____________________________________ 3-82 Hydraulic oil - change ____________________________________________________________ 3-83 Avoid mixing of different hydraulic fluids ______________________________________________ 3-83 Hydraulic system - venting ________________________________________________________ 3-87 Hydraulic oil cooler - clean ________________________________________________________ 3-88 Pressure accumulator - emergency lowering and pilot circuit ______________________________ 3-89 PUMP DRIVE GEARBOX P/N 3855122 _______________________________________________ 3-90 Pump drive gearbox - checking the oil level / Topping up with oil ___________________________ 3-90 Pump drive gearbox - change oil____________________________________________________ 3-91 Pump drive gearbox breather – replace ______________________________________________ 3-92 PUMP DRIVE GEARBOX P/N 3855121 _______________________________________________ 3-93 Pump drive gearbox - checking the oil level / Topping up with oil ___________________________ 3-93 Pump drive gearbox - change oil____________________________________________________ 3-94 Pump drive gearbox breather - replace_______________________________________________ 3-95 Pump drive gearbox oil filter – replace _______________________________________________ 3-96 SWING GEARBOX P/N 3857027 ____________________________________________________ 3-97 Swing gearbox – checking the oil level / Topping up with oil ______________________________ 3-97 Swing gearbox – change oil _______________________________________________________ 3-98 Swing gearbox breather – replace __________________________________________________ 3-99 TRAVEL GEARBOX _____________________________________________________________ 3-100 Travel gearbox main stage - Checking the oil level / Topping up with oil ____________________ 3-100 Travel gearbox pre-stage - Checking the oil level / Topping up with oil _____________________ 3-101 Travel gearbox brake housing - Checking the oil level / Topping up with oil__________________ 3-101 Travel motor coupling housing - Checking the oil level / Topping up with oil _________________ 3-102 Travel gearbox main stage - Changing oil____________________________________________ 3-102 Travel gearbox pre-stage - Changing oil _____________________________________________ 3-103 Travel motor coupling housing - Changing oil _________________________________________ 3-103 1-9

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Table of contents Travel gearbox brake housing - Changing oil _________________________________________ 3-104 Travel gearbox breather – replace _________________________________________________ 3-104 CRAWLER TRACKS _____________________________________________________________ 3-105 Tracks - Cleaning ______________________________________________________________ 3-105 Track roller, Support roller – Check tightening of bolts __________________________________ 3-106 Track tensioner – Checking ______________________________________________________ 3-107 Pressure accumulator – track tensioner _____________________________________________ 3-108 SWING RING ___________________________________________________________________ 3-109 Swing ring - Instructions _________________________________________________________ 3-109 Swing ring - Checking the grease filling Swing ring - Checking the grease filling ______________ 3-110 CENTRAL LUBRICATING SYSTEM _________________________________________________ 3-111 Central lubricating system - function ________________________________________________ 3-111 Grease drum - replace __________________________________________________________ 3-113 Grease pump – checking hydraulic pressure _________________________________________ 3-114 Grease lines - checking greasing pressure ___________________________________________ 3-115 Grease drum breather – replace ___________________________________________________ 3-116 Grease drum – check filling level __________________________________________________ 3-116 Grease filter – check / clean ______________________________________________________ 3-117 Grease pump – checking oil level __________________________________________________ 3-118 Grease pump – changing oil ______________________________________________________ 3-118 OTHER MAINTENANCE __________________________________________________________ 3-119 Engine – other maintenance ______________________________________________________ 3-119 HVAC, filter elements fresh air (outside) – replace _____________________________________ 3-120 HVAC, filter element inside cab – check / clean _______________________________________ 3-121 Additional silencers - check / clean _________________________________________________ 3-121 Excavator controls – clean, lubricate________________________________________________ 3-122 Window panes - cleaning ________________________________________________________ 3-123 Floor window pane - cleaning _____________________________________________________ 3-123 Seat belt - inspect ______________________________________________________________ 3-124 PUTTING THE HYDRAULIC SHOVEL OUT OF OPERATION AND RECOMMISSIONING_______ 3-125 Putting the hydraulic shovel out of operation _________________________________________ 3-125 Battery storage ________________________________________________________________ 3-125 Recommissioning ______________________________________________________________ 3-125 NOTES________________________________________________________________________ 3-127 4 REPAIR WORK ___________________________________________________________________ 4-1 REPAIR WORK - SAFETY INSTRUCTIONS_____________________________________________ 4-3 CONFINED SPACES - SAFETY INSTRUCTIONS ________________________________________ 4-4 REPAIR WORK - FIRE AND EXPLOSION HAZARD ______________________________________ 4-5 REPAIR WORK – ENGINE __________________________________________________________ 4-6 REPAIR WORK - HYDRAULIC SYSTEM _______________________________________________ 4-7 Repair instructions _______________________________________________________________ 4-7 Hydraulic hoses – Instructions ______________________________________________________ 4-7

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Table of contents PRESSURE ACCUMULATORS - SAFETY INSTRUCTIONS ________________________________ 4-8 OTHER MAINTENANCE WORK ______________________________________________________ 4-9 Windscreen wiper blade – replace ___________________________________________________ 4-9 Seat belt – replace _______________________________________________________________ 4-9 Bucket tip – replace______________________________________________________________ 4-10 Bucket lip shroud – replace ________________________________________________________ 4-11 Bucket wing shroud – replace ______________________________________________________ 4-11 WELDING AND FLAME CUTTING WORKS - SAFETY INSTRUCTIONS _____________________ 4-12 DISPOSAL AT THE END OF THE SERVICE LIFE _______________________________________ 4-15 Appropriate disposal of batteries____________________________________________________ 4-16 NOTES_________________________________________________________________________ 4-17 5 ANNEX__________________________________________________________________________ 5-1 BOARD-CONTROL-SYSTEM ________________________________________________________ 5-3 BCS III, what’s that? ______________________________________________________________ 5-3 BCSIII screens - Sitemap 1 _________________________________________________________ 5-4 BCSIII screens - Sitemap 2 _________________________________________________________ 5-5 The BCS housing – overview _______________________________________________________ 5-6 BCSIII, the first screen after startup __________________________________________________ 5-7 BCSIII, the start screen ____________________________________________________________ 5-8 Often used symbols and buttons_____________________________________________________ 5-9 Start screen - Information given in the top section ______________________________________ 5-10 Start screen - Information given in the central section ___________________________________ 5-11 Start screen - Information given in the lower section ____________________________________ 5-12 Start screen – Help section ________________________________________________________ 5-13 System status screen - Information given on the screen _________________________________ 5-14 System status – Engine, Information given on the screen ________________________________ 5-15 System status – Hydraulics, Main pump pressure screen ________________________________ 5-16 System status – Hydraulics, Attachment screen ________________________________________ 5-17 System status – Hydraulics, Slewing screen___________________________________________ 5-18 System status – Hydraulics, Oil tank screen ___________________________________________ 5-19 System status – Hydraulics, Travel screen ____________________________________________ 5-20 System status – Grease, Progressive grease system screen______________________________ 5-21 Service – Servosystem screen _____________________________________________________ 5-22 Service – More details screen ______________________________________________________ 5-23 Service – Slew brake test screen ___________________________________________________ 5-24 Help - Viewing PDF™ documents screen _____________________________________________ 5-25 PDF™ reader - functions__________________________________________________________ 5-26 PDF™ reader - settings screen_____________________________________________________ 5-27 PDF™ reader - search screen _____________________________________________________ 5-28 Software version screen __________________________________________________________ 5-29 Event list screen ________________________________________________________________ 5-30 Event list screen - location ________________________________________________________ 5-31 Screenshot - making and storing____________________________________________________ 5-32 Setup menu - login screen ________________________________________________________ 5-33 BCS III - interfaces ______________________________________________________________ 5-34 BCSIII - cleaning ________________________________________________________________ 5-35 BCSIII – replace battery __________________________________________________________ 5-35 BCSIII - disposal ________________________________________________________________ 5-35 1-11

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Table of contents TROUBLESHOOTING _____________________________________________________________ 5-36 Instructions on troubleshooting _____________________________________________________ 5-36 Layout of the fault table ___________________________________________________________ 5-36 Possible causes ________________________________________________________________ 5-36 Measures _____________________________________________________________________ 5-36 Section _______________________________________________________________________ 5-36 FAULT TABLES __________________________________________________________________ 5-37 Combustion engine - Fault table ____________________________________________________ 5-37 Working hydraulics – Fault table ____________________________________________________ 5-38 Track drive – Fault table __________________________________________________________ 5-39 Swing mechnism – Fault table _____________________________________________________ 5-40 Central lubricating system – Fault table ______________________________________________ 5-41 ENGINE MONITORING, CONTROL LAMPS ___________________________________________ 5-42 ABBREVIATIONS ________________________________________________________________ 5-43 CONTENTS OF THE DECLARATION OF CONFORMITY _________________________________ 5-45 NOISE EMISSIONS AND VIBRATION DATA ___________________________________________ 5-46 Noise emissions ________________________________________________________________ 5-46 Vibration data __________________________________________________________________ 5-46 PRODUCT SPECIFICATION SHEET _________________________________________________ 5-47 NOTES_________________________________________________________________________ 5-49 6 INDEX __________________________________________________________________________ 6-1

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Introduction 1 INTRODUCTION

Operating instructions

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

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Introduction

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Introduction PREFACE About this Operation and Maintenance Manual

The CGM HMS after-sales service will be pleased to deal with any queries you may have after reading through the operating instructions.

This Operation and Maintenance Manual is designed to familiarize the operator with the machine and its designated use.

All CGM HMS Operation and Maintenance Manuals are issued in German and then translated.

Even a good translation may give rise to questions which CGM HMS will be pleased to answer.

The Operation and Maintenance Manual 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,

The Operation and Maintenance Manual contain no work instructions for carrying out major repairs.

Such work is willingly done for you by the Caterpillar dealer 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 Catalog 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,



maintenance (inspection, servicing, repair) and / or

Volume 2:

spare-parts catalog of the machine,

Volume 3:

cross reference list of spare parts,



transport.

Volume 4:

electrical circuit diagram and key,

In addition to the Operation and Maintenance Manual and the mandatory rules and regulations for accident prevention and environmental protection in the user's country and at the place where the machine is to be used, the generally recognized technical rules for safe and proper working must 1 be observed .

Volume 5:

documentation of the engine and of other components,

Volume 6:

Service Manual Part 1

Volume 7:

Service Manual Part 2

The Operation and Maintenance Manual is directed to the mining-machine specialist. It cannot provide basic know-how. This can be acquired, for example, in several days' instruction by a qualified Caterpillar Global Mining Hydraulic Mining Shovels GmbH (CGM HMS GmbH) mechanic or by attending an CGM HMS training course for operators or maintenance personnel.

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.

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

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.

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Complies with VDMA recommendation "Operating instructions"

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

by your Caterpillar dealer service or CGM HMS service

or 

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

and 

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

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 Service.

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

Therefore:

by using the original spare parts of CGM HMS.

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

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

when one or several slewing 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 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.

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Introduction FUNDAMENTAL SAFETY INSTRUCTIONS Warnings and symbols The following safety alert symbols and signal words are used in the Operation and Maintenance Manual to designate instructions of particular importance:

DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury.

WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION, used with the safety alert symbol, indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

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

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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 bucket 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 operating instructions, and only by safety-conscious 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:

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 machines

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

 sand, oil sand,  gravel,  blasted rock,

Lifting eyes on the lower carriage

 ore,



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.

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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 6020B(3 847 000.00)-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 operating instructions, 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. 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.

1-7

BA 6020B(3 847 000.00)-EN

Introduction Selection and qualification of personnel; basic responsibilities

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

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

Start the machine from the operator's seat only.

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.

Safety instructions governing specific operational phases Standard operation 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.

1-8

During start-up and shut-down procedures always watch the indicators in accordance with the operating instructions.

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.

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 engines.

BA 6020B(3 847 000.00)-EN

Introduction 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 operating instructions, 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.

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.

Exhaust pipes and turbo chargers in the engine compartments are covered with special heatinsulating material. This material must not be spray-washed 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.

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.

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.

1-9

BA 6020B(3 847 000.00)-EN

Introduction Warning of special dangers

Gas, dust, steam and smoke

Electric energy

Always start and operate the engine in a wellvented area;

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 (XENON technology) require a high-voltage supply (ca. 25 kV).

The high voltage is generated by a ballast unit.

Switch off the electrical system of the hydraulic shovel 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.

1-10

If in an enclosed area, vent the exhaust to the outside; Do not modify or tamper with the exhaust system 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 fuel and Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

BA 6020B(3 847 000.00)-EN

Introduction Hydraulic equipment

Ether

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

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.

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.

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

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

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").

Always wear the prescribed ear protectors.

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

Oil, grease and other chemical substances

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

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).

Transporting and recommissioning The machine must be loaded and transported only in accordance with the operating instructions.

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

The recommisioning procedure must be strictly in accordance with the operating instructions.

1-11

BA 6020B(3 847 000.00)-EN

Introduction FIRE AND EXPLOSION HAZARD

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.

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.

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.

1-12

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.

BA 6020B(3 847 000.00)-EN

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

1-13

BA 6020B(3 847 000.00)-EN

Introduction

1-14

BA 6020B(3 847 000.00)-EN

Operation 2 OPERATION Operating instructions

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 6020B(3 847 000.00)-EN

Operation

2-2

BA 6020B(3 847 000.00)-EN

Operation OPERATION - SAFETY INSTRUCTIONS Operation and Maintenance Manual

Never operate the machine before having read and understood the instructions and warnings given in the Operation and Maintenance Manual (OMM).

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.

Safety belt For machines with safety belts for operating and training personnel: Check the safety belts attached to all seats. In the event of damage or after an accident, have it replaced immediately.

Every person must apply the safety belt 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. Clear-cut data are given in the technical specification.

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

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

Note on directions

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

Right-hand and left-hand sides, forward and rearward are determined by facing in the direction of travel.

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

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 mechanic or by attending an CGM HMS operator's training course.

Personal protective gear and working clothing 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.

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

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

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

Entering and leaving the machine 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 maintain a three point contact with the steps and grab handles.

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.

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.

2-3

BA 6020B(3 847 000.00)-EN

Operation Persons within the hazard zone Always use the horn to warn persons in the immediate vicinity of the machine before starting up the machine.

Operation and Maintenance Manual – where to store it in the operator’s cab

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

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

Replace the Operation and Maintenance Manual if lost, damaged or unreadable.

Marshallers The marshaller must keep outside the hazard zone.

The binder with the Operation and Maintenance Manual can be stored underneath the trainer’s seat (arrow, Fig. 2-1:).

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 6020B(3 847 000.00)-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.

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

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

Clean rubber or electrical with compressed air only.

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. 

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.

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

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.

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

open or smouldering fire may occur.

2-5

BA 6020B(3 847 000.00)-EN

Operation DESCRIPTION OF THE HYDRAULIC SHOVEL

Fig. 2-2:

2-6

BA 6020B(3 847 000.00)-EN

Operation Hydraulic shovel layout Fig. 2-2:

24 – Rotor / Swivel joint

Working equipment

25 – Swing ring

1 – Backhoe bucket

26 – Swing gearbox

2 – Bucket linkage

27 – Power module

3 – Backhoe cylinder

28 – Counterweight

4 – Stick

29 – Radiator, hydraulic fluid

5 – Stick cylinder 6 – Arm / boom

30 – Hydraulic pumps 31 – Pump drive gearbox

7 – Arm / boom cylinder 8 – Craddle

32 – Engine exhaust system 33 – Engine 34 – Engine air intake system

Upper structure

35 – Radiator, engine cooling liquid

10 – Operator’s cab

36 – Battery set

11 – Cab module

37 – Battery main switch cabinet

12 – Emergency ladder

38 – Service-Station for refilling

13 – Electrical switchbox in cab module

consumables and lubricants

14 – Operator’s seat 15 – Dashboard

Undercarriage

16 – Jump seat

40 – Idler

17 – Trainer’s seat

41 – Crawler track

18 – Heating, ventilation, air condition (HVAC)

42 – Track tensioning system

19 – Fire extinguishers

43 – Track roller

20 – Fuel tank 21 – Hydraulic boarding ladder

44 – Support roller 45 – Track drive / travel gearbox

22 – Grease tank central lubricating system 23 – Hydraulic oil tank

2-7

BA 6020B(3 847 000.00)-EN

Operation Undercarriage The undercarriage of the hydraulic hydraulic shovel serves as a stable base and for travelling.

The crawler tracks are driven hydraulically with oil motors and travel gearboxes. Undercarriage and upper structure are connected by means of a swing ring.

Upper structure The upper structure accommodates all the modules containing the systems that provide hydraulic and electrical power as well as the electronic control systems. Operator’s cab, cab module, power module, counterweight, diesel fuel tank, hydraulic fluid tank, central lubricating system are part of the hydraulic and electrical equipment.

Power module The power module comprises diesel engine, air intake filter system, engine exhaust system, pump drive gearbox, hydraulic pumps, cooling systems for hydraulic fluid as well as for engine cooling liquid, batteries and battery main switch box.

Hydraulic system All working and travelling movements are performed hydraulically. The movements are controlled by pilot valves. The working commands are initiated by hand and transmitted to the valves via control circuits. The oil supply from the upper structure 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.

2-8

Control and Monitoring Platform (CAMP) The electronic CAMP system ensures the control and monitoring of all electrical and hydraulical functions of the hydraulic shovel.

Interconnected electronic units ensure optimal use of the installed engine power. Microprocessors are used to adapt the power output of the hydraulic pumps optimally to actual operating conditions.

The machine is thus prevented from demanding more hydraulic power than the diesel engine can provide.

The desired working movements are detected by microcontrollers which permanently sense the position of hand levers (joysticks) and pedals.

As soon as movement is detected, the corresponding signals are transmitted to the electronic units. These units activate the drive control in order to provide the hydraulic energy needed for working. Only then do they activate the electrohydraulic valves which control the execution of the working movements.

BA 6020B(3 847 000.00)-EN

Operation Board-Control-System (BCS) – information

Demand control / Zero-flow regulation

The BCS is a micro-processor-controlled system for the acquisition and processing of measuring data. It's function consists in collecting data of the hydraulic shovel operating conditions and to evaluate, store and display these data to the hydraulic shovel operator. For this purpose, the BCS is connected via a bus system to the Control and Monitoring Platform (CAMP). An interface with the outside world ensures the transfer of stored data and software updating.

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.

The measured values (actual values) from the sensors and transducers installed in the hydraulic shovel are compared to the predefined reference values. Inadmissible deviations are indicated as fault messages on a display screen. Sensor or transducer defects or defective connecting cables are detected and indicated by plain-text messages.

The data from the engine electronics are acquired, processed and displayed in the same way.

Critical states of operation are brought to the operator's attention by means of optical and acoustic warning signals.

The display screen of the BCS is a touch-screen with a surface sensitive to the touch. This feature supports the hydraulic shovel operator or the service technician in navigating through the menus of the BCS sorftware.

For further information in this respect, please refer to section 5 in this Operation and Maintenance Manual or to the brochure "Board-Control-System – Operating instructions".

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 engines.

Automatic reset to idling If no pilotvalves are actuated by the control pedals or levers for more than 8 seconds (factory-set value, adjustable), the engine is automatically set back to idling speed (factory setting ca. 1000 rpm, adjustable). This feature, too, contributes to reducing the fuel consumption.

Electrical system The electrical system operates on 24 volts with negative (-) earth.

More detailed technical information useful for the service technician is given in chapter 9 of the Service Manual for this machine.

2-9

BA 6020B(3 847 000.00)-EN

Operation Safety films and warning messages – overview and description Warning and additional messages

Observe the safety films and warning and additional messages attached to the machine.

There are several specific safety messages on this machine. The exact location of the hazards and the description of the hazards are reviewed in this section. Become familiarized with all safety messages.

Make sure that all of the safety messages are legible.

Keep all the safety films and warning messages legible and clean.

Clean the safety messages if you cannot read the words.

When you clean the safety messages, use a cloth, water, and soap. Do not use solvent, gasoline, or other harsh chemicals to clean the safety messages.

Solvents, gasoline, or harsh chemicals could loosen the adhesive that secures the safety message. Loose adhesive will allow the safety message to fall.

Replace warning messages and films immediately if they have become illegible or have been lost.

New warning messages and films can be ordered from the CGM HMS Spare Parts Service. The ordering part numbers are set out in the spare-parts list of the machine.

Fig. 2-3: - Fig. 2-7: show the location of warning messages and films on the machine.

2-10

BA 6020B(3 847 000.00)-EN

Operation

Fig. 2-3:

2-11

BA 6020B(3 847 000.00)-EN

Operation

Fig. 2-4:

2-12

BA 6020B(3 847 000.00)-EN

Operation

Fig. 2-5:

2-13

BA 6020B(3 847 000.00)-EN

Operation

Fig. 2-6:

2-14

BA 6020B(3 847 000.00)-EN

Operation

Fig. 2-7:

2-15

BA 6020B(3 847 000.00)-EN

Operation Safety messages In this section you can find a description of all safety messages and additional messages fitted to the machine.

Electrical power lines (xx) This safety message is located in the cab at the dashboard, left next to the operator’s seat and the trainer’s seat.

The number in brackets, f.ex. (9), corresponds with the number of the film shown in the safety messages overview graphics.

The number corresponds also with the films item number in the spare parts list.

Keep off swing area (9) This safety message is located around the upper structure.

Fig. 2-9:

Electrocution Hazard!

Keep the machine and attachments a safe distance from electrical power. Stay clear 3 m (10 ft) plus twice the line insulator length.

Fig. 2-8:

Crushing hazard could cause serious injury or death.

Machine swings and moves unexpectedly and without warning.

Stay back.

2-16

Read and understand the instructions and warnings in the Operation and Maintenance Manual.

Failure to follow the instructions and warnings will cause serious injury or death.

BA 6020B(3 847 000.00)-EN

Operation Risk of scalding (4) This safety message is located on the cooling system expansion reservoir inside the power module.

Read and understand Operation and Maintenance Manual (xx) This safety message is located in the cab on the ldashboard, left next to the operator’s seat.

Fig. 2-10:

Pressurized system!

Hot coolant can cause serious burns, injury or death.

Fig. 2-11:

To open the cooling system filler cap, stop the engine and wait until the cooling system components are cool.

Lift the pressure release lever on cap slowly in order to relieve the pressure.

Read and understand the Operation and Maintenance Manual before performing any cooling system maintenance.

Do not operate or work on this machine unless you have read and understand the instructions and warnings in the Operation and Maintenance Manual. Failure to follow the instructions or heed the warnings could result in injury or death. Contact any Caterpillar dealer for replacement manuals.

Proper care is your responsibility.

2-17

BA 6020B(3 847 000.00)-EN

Operation Emergency-Shut Off push button (14) This safety message is located near all Emergency-Shut-Off push buttons:  on the dashboard, 

on the base of the trainer’s seat,



at the front of the battery main switch cabinet,



inside the pump compartment,



inside the engine cooler compartment,



and near the boarding ladder at the Emergency-Shut-Off pull rope.

Do not weld or drill on the FOPS-roof (xx) This safety message is located in the cab at the dashboard, left next to the operator’s seat and the trainer’s seat.

The operator’s cab is protected against falling objects by a “Falling Objects Protective Structure” (FOPS).

For more information about the Emergency-ShutOff function refer to chapter “Emergency-Shut-Off function”.

Fig. 2-13:

Structural damage, an overturn, modification, alteration, or improper repair, can impair this structure's protective capability thereby voiding this certification.

Fig. 2-12:

2-18

Do not weld on or drill holes in the structure.

Consult a Caterpillar dealer to determine this structure's limitations without voiding its certification.

BA 6020B(3 847 000.00)-EN

Operation Hazardous noise level (11)

Trip hazard (8)

This safety message is located at the access doors of the power module.

This safety message is located at the access doors of the power module.

Fig. 2-14:

Fig. 2-16:

Wear your hearing protection during maintenance work with engines running.

Surfaces may be uneven. Allways wear your safety boots or shoes and watch your step.

Burn hazard (12)

Low clearance (7)

This safety message is located at the access doors of the power module.

This safety message is located at the access doors of the power module and the cab module door.

Fig. 2-17: Fig. 2-15:

Components inside the power module can be hot while the engine is running or immediately after shutdown. The hydraulic tank also may be hot after machine operation.

Inside the machines modules there may be low headroom. This can cause head injury.

Allways wear a safety helmet / hard hat while staying inside a module.

Hot components can cause burns. Use your PPE to protect your skin. Allow the components to cool down before start working.

2-19

BA 6020B(3 847 000.00)-EN

Operation Oil or fuel flammable vapors (2)

Use safety belt (xx)

This safety message is located at the access doors of the power module.

This safety message is located in the cab at the dashboard, left next to the operator’s seat and the trainer’s seat.

Fig. 2-18:

Fig. 2-20:

Escaping oil and diesel fuel can create flammable explosive vapors. Do not smoke, do not use open flames. Check regularly for leaks and repair defective parts of the hydraulic system and the fuel system immediately.

A seat belt should be worn at all times during machine operation to prevent serious injury or death in the event of an accident or machine overturn.

Failure to wear a seat belt during machine operation may result in serious injury or death.

Flammable gas (3) This safety message is located in the power module outside the battery cabinet.

Falling down from height (14) This safety message is located on the upper structure near the steps to working equipment and at the hydraulic oil tank.

Fig. 2-19:

Fig. 2-21:

Batteries can create flammable explosive gases while being charged. Do not smoke, do not use open flames near batteries.

Before entering the working equipment or the hydraulic oil tank wear your fall arrest equipment. Use safety belts and lifelines to prevent from falling down from great height.

2-20

BA 6020B(3 847 000.00)-EN

Operation Aerosol Starting Aid (xx)

High pressure gas (17 / 18)

This safety message is positioned on the cover of the intake duct of the air cleaner.

This safety message is located on each pressure accumulator at the hydraulic oil tank and inside the crawler frames.

Fig. 2-22: Fig. 2-23:

Explosion hazard!

Do not spray ether into the air inlet!

Hand injection hazard.

This machine is equipped with an automatic ether starting system. Using additional ether can create explosions or fires that can cause personal injury or death.

This system contains high pressure gas and hydraulic oil under high pressure.

Read and follow the starting procedure in the Operation and Maintenance Manual.

Failure to follow the instructions and warnings could cause an explosion, resulting in possible injury or death.

Do not expose to fire. Do not weld. Do not drill.

Relieve pressure before discharging.

Read and understand the Service Manual before doing maintenance work on this equipmment, for example charging and discharging.

Contact your Caterpillar Dealer for tools and detailed information.

2-21

BA 6020B(3 847 000.00)-EN

Operation Wear Personal Protective Equipment (PPE) (10) This safety message is located at the access doors of the power module.

Moving V-Belts and rotating parts (13) This safety message is located at the engine’s vbelt guard.

Fig. 2-25: Fig. 2-24:

Risk of injury.

Always wear appropriate PPE when operating and maintaining this machine.

Wear a hard hat, protective glasses, and other protective equipment, as required.

Observe the safety messages on the machine and use the PPE components recommended for the situation.

Do not wear loose clothing or jewelry that can snag on controls or on other parts of the equipment.

2-22

Touching moving belts or rotating parts can cause serious injuries.

Do not remove guards.

If it is necessary to remove guards make shure that the engine could not be started.

Bring guards back in place immediately after finishing work.

BA 6020B(3 847 000.00)-EN

Operation Additional messages

Do not damage electronic units (5)

FOPS roof certification (xx)

This message is located on every electrical / electronical switch box in the cab module, in the power module and at the control box at the Servicestation.

This machine has been certified to the standards that are listed on the certification plate. The maximum mass of the machine, which includes the operator and the attachments without a payload, should not exceed the mass on the certification plate. The machine must be equipped with an approved boom, stick, and counterweight for the ROPS certification to remain valid.

This message is located inside the cab.

Fig. 2-28:

Contacts between water and electrical / electronical assemblies can cause short circuits.

This will damage the assembly.

Fig. 2-26:

Do not spray water on this assemblies when cleaning the machine.

Joystick control pattern (xy) This message is located inside the cab lefthand side from the operator’s seat.

The joystick control pattern on tis machine follows the SAE system.

Refer to OMM chapter “Monitoring, Warning and Control Elements in cab” for further information.

Fig. 2-27:

2-23

BA 6020B(3 847 000.00)-EN

Operation Alternative exit, Emergency exit from cab (xx) This message is located in the operator’s cab at the window pane which can be used as an emergency exit / alternative exit in case of emergency.

To break the window pane use the hammer located at the left side cab wall next to the operator’s seat.

Hydraulic oil level (15 / 16) This message is located on the front side of the hydraulic oil tank near the inspection glass. Correct hydraulic oil level should be between the “min” and “max” marks with the working equipment in the position shown and the engine shut down.

See OMM part “Inspection and servicing” for more information.

See OMM chapter “Emergency exit in operator’s cab and escape ladder” for more information.

Fig. 2-31:

Fig. 2-29:

Marking of lashing points (6) This message is located on the car body marking the lashing points used while transporting the car body. This points may not be used for lifting the car body with a crane.

See Service Manual chapter 3 for more information.

Fig. 2-30:

2-24

BA 6020B(3 847 000.00)-EN

Operation Machine number plate – location

Engine number plate – location

The identification plate with the machine number (Fig. 2-32:) is attached to the front side of the Aframe (arrow, Fig. 2-33:).

The serial number plate (1, Fig. 2-34:) for the diesel engine is located on the left side of the diesel engine.

Fig. 2-32: Fig. 2-34:

Engine information plate – location The engine information plate (2, Fig. 2-35:) is located on the right side of the engine. The plate gives information about the engine like horsepower, high idle, full load engine speed and others.

Fig. 2-33:

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

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

Fig. 2-35:

2-25

BA 6020B(3 847 000.00)-EN

Operation Entering and leaving the machine Risk of injury due to slipping.

Clean off oil, grease, soil, mud, snow, ice and other substances from footwear, grab handles, ladders and steps.

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

Do not enter or leave the machine by climbing the tracks.

Do not enter or leave a moving machine.

Never jump off the machine.

For entering and leaving use only the ladders, steps, platforms and grab handles provided (see: illustration in Fig. 2-36:).

Always face the machine when entering or leaving it.

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

Note: Three-point contact can be two feet and one hand. Three-point contact can also be one foot and two hands.

Do not carry tools or supplies when you try to enter or leave the machine.

Use a hand line to pull tools or equipment onto the machine.

2-26

Fig. 2-36:

BA 6020B(3 847 000.00)-EN

Operation Boarding ladder lighting – switching on / off The boarding ladder of the machine can be illuminated by means of a floodlamp on the operator’s cab roof (arrow, Fig. 2-37:).

From the ground: The pull-switch (2, Fig. 2-38:) of the lighting system is located near the boarding ladder (view “A”). The floodlamp is switched on from the ground by means of the pull-rope.

From the cab: The switch is located in the corner of the cab wall besides the door (arrow, Fig. 2-39:).

The lighting remains on during a presettable ON time. The ON time of the lighting is factory-adjusted to three minutes.

Fig. 2-37:

Fig. 2-38:

Fig. 2-39:

2-27

BA 6020B(3 847 000.00)-EN

Operation Hydraulic boarding ladder – raising / lowering The key switches to control boarding ladder movement (Fig. 2-40:) are located in the battery main switch cabinet at the power module (37).

The boarding ladder can also be lowered when the engine ist stopped. There is a hydraulic pressure accumulator in the hydraulic system of the boarding ladder. This allows to raise / lower the ladder one time.

Raising the ladder (from the upper structure)  Start engine.  Push key switch with “arrow up” symbol (1, Fig. 2-41:) on the battery main switch cabinet (37).

The boarding ladder is raised.

Fig. 2-40:

The upper structure can only be swung when the boarding ladder is raised completely.

Lowering the ladder (from the upper structure)  Push key switch with “arrow down” symbol (2, Fig. 2-41:) on the battery switch cabinet (37).

The boarding ladder is lowered (Fig. 2-40:).

Fig. 2-41:

2-28

BA 6020B(3 847 000.00)-EN

Operation Operator’s cab – lock / unlock the door

Operator’s cab – open the door from inside

The operator’s cab door (arrow, Fig. 2-42:) can be locked by means of a padlock (arrow, Fig. 2-43:).

 Press lever (Fig. 2-44:) to open the cab door from inside.

This prevents the machine from unauthorized use.

After unlocking and removing the padlock pull the handle to open the door.

Fig. 2-44:

Fig. 2-42:

Fig. 2-43:

2-29

BA 6020B(3 847 000.00)-EN

Operation Cab interior lights – switching on / off The cab interior lighting can be switched on and off:  With switch (arrow, Fig. 2-45:).

The switch is located in the corner of the cab wall besides the door.  With switch (77, Fig. 2-46:) in the dashboard.  With switches directly at the lamps at the cab roof (arrow, Fig. 2-47:).

The cab interior lights are supplied with power even when the electrical system is shut down.

When leaving the machine, the interior light must therefore be switched off. The batteries could be discharged if the interior light is allowed to remain on for a prolonged period.

Fig. 2-45:

Fig. 2-46:

Fig. 2-47:

2-30

BA 6020B(3 847 000.00)-EN

Operation Maintenance lights – switching on / off

Battery main switch – switching on / off

All the maintenance lights in the modules can be activated with switch (78, Fig. Fig. 2-48:) in the dashboard.

The battery main switch is located in the battery main switch cabinet at the power module (37, Fig. 2-50:).

It can be switched on and off by means of push switches located:  on the door of the battery main switch cabinet (1, Fig. 2-50:) and

The maintenance lights in the power module can be activated with switch (1, Fig. 2-49:).

The switch is located in the battery main switch cabinet at the power module (37).

The maintenance light in the cab module can be activated with a switch next the modules entrance door.



on the rear wall of the dashboard, in front of the trainer’s seat (arrow, Fig. 2-51:).

Function to be described.

Fig. 2-48:

Fig. 2-50:

Fig. 2-49: Fig. 2-51:

2-31

BA 6020B(3 847 000.00)-EN

Operation Emergency exit in operator’s cab and escape ladder The window (arrow, Fig. 2-53:) on the lefthand side of the operator’s cab serves as an alternative opening / emergency exit.

The emergency hammer (Fig. 2-52:) has a very sharp blade on one end (2).

Use this blade to cut the safety belt of your seat in case the seatbelt buckle is totally blocked.

The escape ladder (2, Fig. 2-54:) is located beside the operator´s cab.

Function of the trap door (1) as well as the fixation and condition of the ladder must be regularly checked according to the maintenance plans.

To open the emergency exit from inside the cab and leave the machine:  Take hammer out of its bracket beside the emergency exit window (Fig. 2-52:).  Use the pointed end (1) of the hammer to break the window pane (arrow, Fig. 2-54:).  Remove the glas and leave the cab.  Open the trap door (1) and lock it at the handrail.  Unlock the rope ladder and push down. Use the emergency ladder (2) to leave the machine.  Call the responsible service personnel immediately.

Fig. 2-53:

Serious injury may occur when jumping down from the hydraulic shovel in case of emergency.

If it is impossible to use the boarding ladder for leaving the hydraulic shovel, use the emergency ladder and the rope ladder.

Fig. 2-54:

Fig. 2-52:

2-32

BA 6020B(3 847 000.00)-EN

Operation Emergency ladder on the righthand side of upper structure

Emergency lowering the boarding ladder from the ground

The emergency ladder (arrow, Fig. 2-55:) is located on the right side of the upper structure near the hydraulic oil tank.

In case of emergency:

 In case of an emergency swing the barrier in direction of the curved arrow.  Use the emergency ladder (2) to leave the machine.

To make it possible to enter the machine while the boarding ladder is raised, the boarding ladder can be lowered from the ground.  Pull down rope (1, Fig. 2-56:).

The boarding ladder is lowered.

Serious injury may occur when jumping down from the hydraulic shovel in case of emergency.

If it is impossible to use the boarding ladder for leaving the hydraulic shovel, use the emergency ladder.

Fig. 2-56:

Fig. 2-55:

2-33

BA 6020B(3 847 000.00)-EN

Operation Emergency shut-off – function

Emergency shut-off switches in the cab

The emergency shut-off function can be triggered from six different places on the machine.

Inside the operator’s cab:  by pressing the switch on the dashboard (arrow, Fig. 2-57:),  by pressing the switch in the base of the trainer’s seat (arrow, Fig. 2-58:).

Outside the power module:  by pressing the switch (1, Fig. 2-59:) located in the front panel of the battery main switch cabinet (37) at the power module.

Inside the power module:  by pressing the switch inside the pump compartment right next to the door (Fig. 2-60:),

Fig. 2-57:

 by pressing the switch inside the engine compartment right next to the door (Fig. 2-61:), From the ground:  by pulling the rope actuated pull switch located on the left side of the machine between the power module and the counterweight (Fig. 2-62:).

The emergency shut-off function disconnects all power outputs of the electronic control units. In this case, the engine is shut off so that no working movements can be performed anymore.

The power supply of the electronic control units of the engine and of the machine is, however, not interrupted. For this reason, the trouble shooting and failure analisis functions continue to remain active.

Fig. 2-58:

Emergency shut-off switch at the battery main switch cabinet (37)

Other auxiliary functions such as:  the radio, the cab interior lighting and the boarding ladder lighting and maintenance lighting and,  the fire extinguishing system (optional), remain functional as well.

The emergency shut-off function can also be triggered before maintenance operations are performed on the machine. For this purpose, one of the switches is depressed and secured with a padlock. Any inadvertent starting of the engine is thus prevented. (continued next page)

2-34

Fig. 2-59:

BA 6020B(3 847 000.00)-EN

Operation Emergency shut-off switches, continued

Emergency shut-off pull switch between power module and counterweight

Emergency shut-off switch inside the power module, pump compartment

Fig. 2-62:

Putting the machine back into operation – reset of emergency shut-off function Fig. 2-60:

Emergency shut-off switch inside the power module, engine compartment

Fig. 2-61:

The machine can only be put back into operation when all emergency shut-off switches listed above are again in their basic position (i.e. not actuated / resetted). To reset pull out the red knob. The emergency shut-off switch on the rear side of the powermodule is resetted after pulling out the blue knob.

Additionally the Reset button switch (1, Fig. 2-63:) has to be pushed. The Reset button switch is located in the front door of the battery main switch cabinet (37) at the power module.

After pushing the Reset button switch (1) a green LED located inside the switch comes on.

Fig. 2-63:

2-35

BA 6020B(3 847 000.00)-EN

Operation Starter isolator switch – shutting off starter voltage The starter isolator switch (1, Fig. 2-64:) is located in the front panel of the battery main switch cabinet (37) at the power module.

After turning the “Starter Isolator” switch to position “OFF” the engine could not be started.

All other sections of the electrical system are supplied with voltage.

This is to ensure personal safety during testing and trouble shooting purposes.

Lock the starter isolator switch in position “OFF” by means of a padlock.

The engine can only be put back into operation when the starter isolator switch is unlocked and switched into the “ON” position. A green LED located near the switch (3) comes on.

Battery isolator switch – shutting off supply voltage The battery isolator switch (2, Fig. 2-64:) is located in the front panel of the battery main switch cabinet (37) at the power module.

The supply voltage is shut off when the battery isolator switch has been turned to position “OFF”.

This function shuts off the complete electrical system of the machine by disconnecting the two poles from the batteries (battery main switch).

In this case, the engine is shut off so that no working movements can be performed anymore.

The power supply of the electronic control units of the engine and of the machine is shut off after a brief delay. The delay ensures that the current operating data can be saved and the systems shut down properly.

Lock the battery isolator switch in position “OFF” by means of a padlock.

The machine can only be put back into operation when the battery isolator switch is unlocked and switched in the “ON” position. A green LED located near the switch (4) comes on.

2-36

Fig. 2-64:

BA 6020B(3 847 000.00)-EN

Operation Operator’s seat – adjustment The operator’s seat (Fig. 2-65: and Fig. 2-67:) can be adjusted in several positions.

Never adjust the seat while working or during travelling.

Before carrying out any seat adjustments stop the machine and set the control levers and pedals to "0", e.g. the “neutral” position.

Fig. 2-65: Pos. Element

Function

1

Lever

Armrest forward / rearward

2

Lever

Armrest swing to the left / right

3

Lever

Joystick console, adjust inclination angle

4

Lever

Armrest, adjust inklination angle

5

Lever

Armrest, adjust swing angle

6

Lever

Armrest, adjust swing angle

7

Knob

Armrest hight adjustment

Fig. 2-65:

Same functional elements are located at the lefthand armrest.

Fig. 2-66: Pos. Element

Function

1

Knob

Seat, operator weight adjustment

2

Lever

Seat cushion, pan angle adjustment

Fig. 2-66:

Fig. 2-67: Pos. Element

Function

1

Lever

Backrest adjustment

2

Lever

Seat forward / rearward

Fig. 2-67:

2-37

BA 6020B(3 847 000.00)-EN

Operation Operators exposure to vibrations – reducing Vibrations, oscillations and movements of the machine cannot be avoided when the machine is in operation. They also have an effect on the operator.

These effects on the operator can however be avoided, if the operator's seat is adjusted correctly.

Therefore, make use of the seat's various adjustment features (see Fig. 2-65: and Fig. 2-67:): 

shock absorption (Absorber),



body weight setting (Weight adjustment),



horizontal movement damping (Fore/aft isolator).

Adjust the seat before beginning work to suit your personal requirements. Check whether all adjustments are functional. If this is not possible, have the seat checked and repaired as soon as possible.

Operator’s seat belt – use Check the condition of the seat belt and the condition of the fastening devices before you operate the machine (arrows, Fig. 2-68: and Fig. 2-69:).

Fasten the seat belt securely before start working.  Pull seat belt (Fig. 2-68:) out of the retractor in a slow, continous motion.  Fasten seat belt catch into buckle (Fig. 2-69:).

Make sure that the seat belt is placed low across the lap of the operator.

The retractor will adjust the belt length and the retractor will lock in place. The comfort ride sleeve will allow the operator to have limited movement.

Releasing the seat belt  Push the release button on the buckle (Fig. 2-69:) in order to release the seat belt. The seat belt will automatically retract into the retractor.

Fig. 2-68:

Fig. 2-69:

2-38

BA 6020B(3 847 000.00)-EN

Operation Trainer's / instructor's seat – use

Jump seat – use

For operator training / instructing purposes it is often required that a trainer / instructor accompanies the operator in the cab.

For operator training / instructing purposes it may be required that another person accompanies the trainer / operator in the cab.

For the safety of the trainer / instructor during hydraulic shovel operation the cab is equipped with a second seat. This seat is installed behind the operator's seat (Fig. 2-70:).  Sit down on this seat and do not forget to fasten the seat-belt (arrows, Fig. 2-70:).

For the safety of this person during hydraulic shovel operation the cab is equipped with a jump seat. This seat is installed at the right wall (Fig. 2-71:).  Sit down on this seat and do not forget to fasten the seat-belt (arrow, Fig. 2-71:).

 Do not leave this seat during the training / instruction session and / or as long as the machine is in operation.

Do not leave this seat during the training / instruction session and / or as long as the machine is in operation.

Die Rücklehne des Notsitzes kann auf die Sitzfläche geklappt werden und so als Ablagefläche dienen, (arrow, Fig. 2-72:).

Wenn der Notsitz nicht gebraucht wird, kann man ihn an die Wand des Fahrerhauses hochklappen.

Fig. 2-70:

Fig. 2-71:

Fig. 2-72:

2-39

BA 6020B(3 847 000.00)-EN

Operation Fire extinguisher – location

Extinguishing agent

The hydraulic shovel is equipped with two fire extinguishers, attached to the handrails on the fuel tank (arrow, Fig. 2-73:).

Each fire-extinguisher delivered ex works is filled with 12 kg (26.4 lb) Adex-K. This extinguishing agent is used for fighting fires of classes A, B, C and E.

Diese Feuerlöscher dienen dem Schutz des Bedienungspersonals. Sie sind nicht dafür gedacht, größere Brände, z. B. im Motorraum, zu löschen.

Benutzen Sie den Feuerlöscher, um sich einen Fluchtweg von der Maschine frei zu halten.

The shovel / 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.

Note: Fire extinguishers attached to the machine in your country may vary. Familiarise yourself with the fire extinguishers.

Handling (See instruction label on fire extinguisher)  Pull out securing pin (2, Fig. 2-74:).  Take the hose with one hand, strike lever (1) hard, then release lever again.  Depress lever (1) to operate the extinguishing gun.

Inspection Have the extinguisher inspected at regular intervals by an expert. This is required by local authorities and insurance companies and is in the interest of your own safety.

Fig. 2-73:

Fig. 2-74:

2-40

BA 6020B(3 847 000.00)-EN

Operation Windscreen wiper / washer – function

Windscreen washer nozzles– adjust

 Push the switch knob (10, Fig. 2-75:) in order to activate the window washer.

Windscreen washer nozzles are located at the window wiper arm (Fig. 2-76:).

While the switch is depressed, washer fluid will spray from the nozzles at the wiper arm. The window wiper will also operate while the switch is depressed. After the switch is released for approximately 3 seconds, the window wiper will stop.

For adjusting the nozzles use a small needle.

The washing fluid should reach the window in the near of the wiper blade.

Continous operation to be described.

If the wiper does not operate with the switch in the ON position, turn the switch off immediately. Check the cause. If the switch remains on, motor failure can result.

Fig. 2-76:

Fig. 2-75:

2-41

BA 6020B(3 847 000.00)-EN

Operation Windscreen washer reservoir – refill The fluid reservoir (Fig. 2-77:) of the windscreen washer system is located in the cab module. The capacity of the reservoir is indicated under "Refilling quantities - Other".

When operating in freezing temperatures, use Caterpillar or any commercially available nonfreezing window washer solvent.  Open the access door to the cab module.  Remove the filler cap.  Fill the window washer reservoir with washer fluid through the filler opening.  Install the filler cap.  Close the access door.

Mirror– adjusting position

Adjust all mirrors as specified in this Operation and Maintenance Manual. Failure to heed this warning can lead to personal injury or death.

Slips and falls can result in personal injury. Use the machine's access systems when adjusting the mirrors.

Mirrors provide additional visibility around your machine.

Make sure that the mirrors are in proper working condition and that the mirrors are clean.

Adjust the rearview mirrors (if equipped) for the best visibility close to the machine.

Adjust all mirrors at the beginning of each work period and adjust the mirrors when you change operators.  Park the machine on a level surface.  Lower the work tool to the ground.  Stop the engine.  Adjust rear view mirrors in order to provide maximum visibility besides and behind the machine (arrow, Fig. 2-78:).

Hand tools may be needed in order to adjust the mirrors.

Fig. 2-77:

Fig. 2-78:

2-42

BA 6020B(3 847 000.00)-EN

Operation BCS display monitor – adjusting position Der Monitor des BCS (Board Control Systems) ist auf einem doppelten Kugelgelenk gelagert (Fig. 2-79:). Abhängig vom einfallenden Sonnenlicht oder der Größe des Bedieners kann es erforderlich sein, den Monitor in eine andere Position zu bewegen. Dann können angezeigte Informationen weitgehend ohne Spiegelungen oder Blendungen abgelesen werden. Dazu:

Operating hours meter – location The operating hours meter (arrow, Fig. 2-80:) is part of the BCS (Board Control System).

The machine operating hours counter is displayed on the basic screen.

More detailed information are available for service personnel after entering the “Service Level” of BCS display system (password required).

 Knebel zwischen den Kugelgelenken lösen (Doppelpfeil, Fig. 2-79:).  Monitor in die optimale Position bewegen.  Knebel wieder festschrauben.

Fig. 2-80:

Fig. 2-79:

2-43

BA 6020B(3 847 000.00)-EN

Operation Power receptacle inside cab – use A 12 volt power receptacle is located on the dasboards rearwall (arrow, Fig. 2-81:).

This power receptacle can be used for powering automotive electrical equipment or accessories.

Remove the cap before use.

Roller blinds – adjusting position The operator’s cab is equipped with roller blinds (Fig. 2-82:) which keep direct sunlight out.  To pull down the roller blinds use gripping plates (1, Fig. 2-82:).  To bring the roller blinds upwards use string (2).

Note: Maximum permissable load is 12 Volt, 120 Watts.

Fig. 2-82:

Fig. 2-81:

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Operation

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Operation MONITORING, WARNING AND CONTROL ELEMENTS IN CAB

Fig. 2-83:

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Operation (Fig. 2-83:) No. 1

Element BCS (Board Control System)

Function Computerized system for measured data acquisition and processing

Board Control System, acquisition and display of important operating data of the hydraulic shovel.

The surface of the monitor is sensitive to the touch (touch-screen technology). A touchscreen permits selecting menus and programs by touching graphic control symbols and to recall, for instance operating data of the excavator.

For further information please refer to section 5 of this Operating Instructions, chapter “BoardControl-System”.

2

Monitor

BCS

The monitor displays collected operating data, warning messages and – if needed –instruction for help.

3

Push-button

EMERGENCY STOP

De-energizes the outputs of the electronic control units: The engine is shut of, all valves are deenergized, working movements no longer possible.

4

Audio player / tuner

See description in chapter “Audio player / Tuner”.

5

Speaker

Connected to the audio player.

6

Plug

Connection of electronic devices for engine fault diagnosis purposes.

7

Push switch

Battery main switch

To be described.

8

Socket connector

12 volt outlet

For connecting electrical driven devices, e. g. for charging accumulators.

Operating voltage: 12 Volts.

Maximum power output : 120 Watts.

9

Socket connectors

10

Knob / switch

11

Keyswitch

Symbol

Connection of electronic devices for fault diagnosis purposes.

(See part 5 of this OMM “BCS, interfaces”).

Front window wiper / washer

Two speed, one intermittend.

Turn: Press: Switches the electrical system on and off.

Pos. 0: Electrical system switched OFF. Pos. 1: Pos. 2: Electrical system switched ON; control systems start boot sequences.

12

Cup holder

13

Emergency hammer, Safety belt cutter

In case of emergency: When it is impossible to use the cab door for leaving the cab: Use the hammer to destroy the emergency window pane beneath the trainer’s seat.

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Operation

Fig. 2-84

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Operation (Fig. 2-84) BCS, Board Control System, display screen example (For further information please refer to section 5 of this Operation and Maintenance Manual, chapter “BoardControl-System”).

No.

Element

Function

1

Status line

Indicates activated functions, operating hours and dumper counter.

Symbol

Touch-sensitive areas have rectangle shaped borders.

Displaying only areas have circle shaped or rounded borders.

2

Touch-screen Monitor

BCS

Indicates collected operating data graphically and / or numerically, displays warning messages, fault messages and – if needed – instructions for help.

3

Status line

Fault messages

Displays fault messages as a code number and as plain text. The “Fault” button permits displaying further fault messages stored in the system.

4

Touch-screen buttons

Tapping the buttons opens other informational screens.

5

Sensor

Lightsensor, used when display brightness is automatically controlled by software.

6

LED

7

Pushbutton

Pushing the button decreases the brightness level of the display.

8

Pushbutton

Pushing the button increases the brightness level of the display.

9

Pushbutton

10

Internal buzzer

Status LED

ON / OFF

Indicates different device states using colors and flashing patterns. LED behaviour is controlled both by the operating system and the BCS software.

Switches the BCS system computer ON / OFF. Not used on this machine.

Acoustic warning signals were given by louder buzzers in the cab.

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Operation

Fig. 2-85:

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Operation (Fig. 2-85:)

Engine, control and monitoring All switches and pushbuttons have an illuminated symbol face.

The opposite side is equipped with an LED. The LED lights up when the switch / pushbutton is actuated.

No.

Element

Function

41

Warning lamp

Alternator

Lit up when the batteries are not being charged or in the event of an alternator defect.

41

Warning lamp

Engine oil pressure

Lit up when the engine oil pressure is too low.

43

Warning lamp

Cooling liquid level

Lit up when the engine cooling liquid level is too low.

44

Warning lamp

Cooling liquid temperature

Lit up when the cooling liquid temperature is too high.

45

Diagnosis lamp

Engine monitoring

Lits up when malfunctions occur on the engine. The indication uses so-called flashcodes (see section 5 of this Operating Instructions: “Engine monitoring, Control lamps”).

Check the BCS display for further fault messages and give an information to the responsible service personnel.

46

Warning lamp

Engine monitoring

STOP! Shut off the engine immediately.

Symbol

Lits up when a serious fault occurs on the engine. The diagnosis lamp (45) provides the event code at the same time (flashing). (see part 5 of this Operating Instructions: “Engine monitoring, Control lamps”).

Check the BCS display for further fault messages and give an information to the responsible service personnel.

47

Push-button

Start

Starting of the engine. For starting, press the push-button face with the symbol.

48

Push-button

Stop

Stopping of the engine. For stopping, press the push-button face with the symbol.

49

Push-button

Idle timer

Stopping of the engine with an after-run delay of 5 min. For delayed stopping, press the push-button face with the symbol.

50

Push-button

Increase engine speed

Press and hold the switch face: the speed of the engine increases as long as you hold the switch.

Reduce engine speed

Press and hold the switch face: the speed of the engine reduces as long as you hold the switch.

51 70

Not used on this machine.

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Operation

Fig. 2-86:

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Operation (Fig. 2-86:) All switches and pushbuttons have an illuminated symbol face.

The opposite side is equipped with an LED. The LED lights up when the switch / pushbutton is actuated.

No.

Element

Function

71

Switch

Automatic speed reduction

Reduces the speed of the diesel engines to about 1000 min-1, if no working movement is being executed during about 8 seconds.

72

Switch

Upper structure holding brake

Blocks the upper structure.

Symbol

Actuate this switch only when the upper structure is stationary.

Do not use this switch while the upper structure is still in motion. Risk of damage to the brake and the swing gearboxes.

73

Switch

Hydraulic shovel parking brake

Not actuated: The parking brake is applied automatically ca. 5 secs after the hydraulic shovel has stopped moving.

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

Press the switch face with the symbol: The parking brake is applied permanently.

The hydraulic shovel cannot be moved.

Actuate this switch only when the hydraulic shovel is stationary.

Do not use this switch while the hydraulic shovel is still in motion. Risk of damage to the brakes and the travel gearboxes.

74

Switch

Servo-control

Press the switch face with the symbol: The electro-hydraulic pilot-control is enabled.

75

Switch

Working lights

Press the switch face with the symbol: Workinglights on the operator´s cab are ON.

76

Switch

Rotary beacon (optional)

Press the switch face with the symbol: Rotary beacon is ON.

77

Switch

Cab lights

Press the switch face with the symbol: Lights in the operator's cab are ON.

78

Switch

Maintenance lights

Press the switch face with the symbol: Maintenance lights in the modules are ON.

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Operation

Fig. 2-87:

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Operation (Fig. 2-87:) All switches and pushbuttons have an illuminated symbol face.

The opposite side is equipped with an LED. The LED lights up when the switch / pushbutton is actuated.

No.

Element

81

Switch

Function Travelling speed

Symbol

Not actuated: 1st travelling stage travelling forwards / backwards is possible.

Press the switch face with the symbol: 2nd travelling stage, only parallel forward travel is possible. In case of backward travel and cornering, the machine switches back automatically into the 1st travelling stage.

82

Push-button

Central lubricating system reset

Reset function of the central greasing system control (Press for at least 3 sec.).

Press switch face to the left: Resets the control of the upper structure.

Press the switch face to the right: To be decribed.

83

Push-button

Emergency lowering

Lowering of the working equipment, for instance, if the engine has failed.

Press and hold the switch face with the symbol using at the same time the control lever to lower the working equipment.

Not connected.

84 85

Switch

Working light (optional)

Press the switch face with the symbol: Workinglights on the boom / arm are ON.

86

Switch

When the machine has to be manoeuvered out of dangerous situations

Press the switch face with the symbol: The machine can be driven and the upper structure be slewed although these functions are automatically deactivated.

Use this function only in dangerous situations to manouever yourself or the machine out of hazard zones.

Risk of damaging parts of the machine, e.g. the hydraulic ladder.

87

Not connected.

88

Not connected.

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Operation

Fig. 2-88:

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Operation (Fig. 2-88:)

HVAC unit (Heating, ventilation, air condition) No.

Element

Function

91

Switch

Not connected.

92

Switch

HVAC in cooling only mode.

Symbol

HVAC in automatic mode.

93

Knob

Select the temperature in cab by turning the knob: To the left (blue colour): set lower temperature.

To the right (red colour): set higher temperature.

94

Knob

Select the fan speed by turning the knob: To the left: lower fan speed or fan off.

To the right: higher fan speed or automatic.

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Operation

Fig. 2-89:

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Operation (Fig. 2-89:)

Working and travelling functions No.

Element

101 Push-button

Function (Free for options)

Symbol

Can be used as a push-to-speak button on a radio, or to switch over from one camera to another one, or to switch on / off the water spraying system.

Not used on this machine.

102 Push-button

(Truck counter ?)

103 Push-button

Boom floating position

Button is pressed: The boom cylinders are pressurized on retracting.

Press button (103) only in position "0" of control lever (116).

104 Push-button

Warning signal

Button is pressed: Acoustic warning signal / horn is activated.

105 Push-button inside the seat

Electronic shovel control (servocontrol)

The electronic shovel control (servo-control) is activated when the operator sits down on the seat.

The electronic shovel control (servo-control) is deactivated when he leaves the seat. Hydraulic functions are then switched off.

112 Pedal

Travel, left track

Forwards – forward travel Backwards – backward travel.

113 Pedal

Travel, right track

Forwards – forward travel; Backwards – backward travel.

Forwards – raising the stick Backwards – lowering the stick.

115 Control lever (joystick)

To the left / right – slewing and braking of the upper structure.

Forwards – lowering the boom; Backwards – raising the boom.

116 Control lever (joystick)

To the left – closing (filling) of bucket; To the right – dumping (emptying) of bucket.

117 Push-button

Not used on this machine.

118 Thumb wheel

Not used on this machine.

119 Push-button

120 Thumb wheel

By-pass for the automatically switch off for stickand /or backhoe cylinders (Option)

Lower half pushed – automatically stopped stick- and/or backhoe cylinders can be driven slowly to the limit stopps.

Upper half pushed – Each press on the button increments the loaded dumper count for by "1". (Count reset with button (XX)).

Not used on this machine.

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Operation

Fig. 2-90:

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Operation (Fig. 2-90)

Audio Player / Tuner (optional) Refer to the audio player manufacturer’s Operating Instructions for more details.

No.

Element

Function

1

Push-button

ON / OFF / Mute

Press to turn on the unit.

When on, press to mute the volume.

When on, press longer than 2 seconds to turn off the unit.

2

Push-button

SRC

Press button to toggle the audio source: TUNER > USB > CARD > AUX IN.

3

Display

4

Push-button

BAND (AM, FM, LW)

In TUNER mode, press once or more to select band. Press longer than 2 seconds to auto search and store stations in available memory.

In USB / CARD mode, press to enter TUNER mode.

5

Push-button

DISP

In TUNER mode: Press once or more to select display content in following sequence: Frequ > PTY > Time.

In USB / CARD mode: Press once or more to select display content in following sequence: Time > Folder > File > Title > Artist > Album.

Press longer than 2 seconds to enter system MENU (see “SYSTEM MENU”).

6

Push-button

PTY

Program type.

7

Push-button

AF

Alternative frequency, REG on/off (long press).

8

Push-button

TA

Traffic announcement identification.

9

Remote sensor

(optional)

10

Push-buttons

11

SD / MMC card slot

12

USB connector

13

AUX-IN jack

14

Push-buttons

15

16

Shows information about selections, tuner frequency, running music track and other.

Radio tune, Skip to next or previous track.

Button 1: Play / Pause.

Press longer than 2 seconds to start playback from the beginning of the first track of USB or SD/MMC card.

Button 2: Play intro (10 seconds) Button 3: Track repeat play Button 4: Track random play th Button 5: Folder down. Previous 10 file (long press) th Button 6: Folder up. Next 10 file (long press) 1-6 radio preset. Press to tune a preset station. Hold for more than 2 seconds to store station.

Knob

Volume

Push-button

Audio setup menu Equalizer (EQ)

Reset hole

Rotate knop to adjust volume.

Push to enter audio setup menu, then press briefly once or more to select BASS / TREBLE / BALANCE / FADER, rotate knob to adjust level.

Push longer than 2 seconds to enter EQ mode, then rotate knob to change EQ preset: EQ off, FLAT, ROCK, POP, CLASSIC. To reset the unit: Press SRC push-button longer than 2 seconds and then press RESET button.

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Operation MACHINE – PUTTING INTO OPERATION

Operator's exposure to noise reducing

Before daily start-up, carry out works in accordance with servicing plan T (see: Part 3 "Inspection and servicing").

All noise protection devices of the machine must be in place and fully functional when the machine is in operation. e.g. 

doors, flaps and covers of the power module must be closed,

Increased fire and explosion hazard will exist.



Prior to your daily start-up, make sure the machine has been cleaned of combustible and easily flammable substances.

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



the cab door must be closed,



all silencer elements must be in place and functional,



the exhaust silencers must be checked for holes and other damages,



covers of exhaust silencers must be in place and fixed properly,



the bolted 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.

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Operation Refuelling

Diesel fuel tank - refilling

Refuelling - Safety instructions

Fuels and fuel gases are inflammable.

The use of the Service Station is highly recommended for refilling the fuel tank. This is the faster and safer way for refilling the fuel tank. The risk to contaminate the fuel is much higher than refilling using the Service Station. In situations where a service vehicle isn’t available, the diesel fuel tank can exceptionally be refilled using the fillertube.

Avoid open flames and stop smoking.

 Clean the area around the filler tube carefully.

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

 Flip up cover of filler tube (Fig. 2-91:).

Stand working equipment on the ground.

 Fill in fuel through the filter sieve which is inside the filler tube.

Do not remove the sieve.

Explosion hazard. Risk of fire.

Shut off the engine.

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

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.

 Unsrew cap of filler tube (arrow, Fig. 2-91:).

 Stop filling when the fuel tank is nearly full.

Do not spill diesel fuel.

Fuel level in the fuel tank is displayed on the BCSscreen (Fig. 2-93:).

Report fuel accidents immediately to the responsible personnel.

Check the grounding straps (equipotential bonding) at the Service Station regularly for proper fastening.

Grounding straps can remove voltages and prevent fire during refuelling only when properly fastened.

Fig. 2-91:

Diesel fuel - recommendations Diesel fuel must meet the “Caterpillar Specification for Destillate Fuel” and the latest versions of “ASTM D975” (Nr. 1-D or Nr. 2-D fuel) or “EN 590” in order to ensure optimum engine performance.

Note: Handrails and guards were removed on graphic (Fig. 2-91:) only for a better view on the details.

Refer to Special Publication, SEBU6251, “Caterpillar Commercial Diesel Engine Fluids Recommendations” for the latest fuel information and for Cat fuel specification. This manual may be found on the Web at www.safety.cat.com or contact your Cat dealer.

Failures that result from the use of improper fuels are not Caterpillar factory defects. Therefore the costs of repairs would not be covered by a Caterpillar warranty.

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Operation Refuelling using the Service Station The hydraulic shovel is equipped with a central Service Station (Fig. 2-92:) for refilling consumables and lubricants. A service vehicle is needed for filling and/or draining of the fluids.

The Service Station is accessible from the ground below the upper structure near the counterweight.

The Service Station is devided in two sections, section “A” is with express couplings for Diesel fuel and cooling liuid. Section “B” is for hydraulic oil, engine oil and pump drive gearbox oil.

Express couplings are provided for refilling / draining the following lubricants / consumables.

Note: Connections used may vary depending on how the machine is equipped.

Pos. Fig. 2-92:

Consumable / lubricant

Express coupling for

1

Diesel fuel

Filling

2

Cooling fluid

Filling and/or draining

3

Engine oil

Filling and/or draining

4

Gearbox oil for pump drive gearbox

Filling and/or draining

5

Hydraulic fluid

Filling and/or draining

Swing gear (optional)

Filling

Refilling and draining Read and observe the " Refuelling - Safety instructions “.

When using the Service Station follow these steps:  Carefully clean express couplings and the area surround before detaching the protective cap.

Fig. 2-92:

 For filling in or for draining lubricants / consumables, detach the protective cap of the corresponding express coupling (Fig. 2-92:).  Attach express coupling of filling hose from the service vehicle to the corresponding express coupling at the Service Station.  Open the ball valve above the express coupling you want to use.  Fill in or drain off lubricant / consumable.  Stop filling when the correct filling level is reched.  Close the ball valve.  Take off filling hose.  Refit protective cap on the express coupling at the Service Station.

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Operation

Assemblies resp. Level measuring device reservoirs

Remarks

Fuel tank

Remove protective cap from express coupling at the Service-Station (arrow, Fig. 2-94:).

BCS fuel indicator (Fig. 2-93:)

Attach filling hose from the service vehicle to express coupling.

Fill in fuel.

Stop filling when the fuel tank is full.

Detach filling hose.

Push protective cap back on to express coupling.

Fig. 2-93: Fig. 2-94:

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Operation

Assemblies resp. Level measuring device reservoirs

Remarks

Pump drive gearbox

Dipstick (Fig. 2-95:)

Attach filling hose from the service vehicle to express coupling (4, Fig. 2-96:) at the Service Station.

Open ball valve.

Fill in gear oil.

Stop filling when the oil reaches the "max" mark on the dipstick (see: Part 3, chapter "Pump drive gearbox Checking the gearbox oil level/Filling in oil").

Close ball valve. Detach filling hose.

Engine

Dipstick (Fig. 2-97:)

Attach filling hose from the service vehicle to express coupling (3, Fig. 2-98:) at the Service Station.

Open ball valve.

Fill in engine oil.

Stop filling when the oil reaches the "max" mark on the dipstick (see: Part 3, chapter "Engine - engine oil level/filling in oil").

Close ball valve. Detach filling hose.

Fig. 2-95:

Fig. 2-97:

Fig. 2-96:

Fig. 2-98:

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Operation

Assemblies resp. Level measuring device reservoirs

Remarks

Hydraulic oil tank

Bring working equipment into the position shown on the message film (Fig. 2-100:). Stand working equipment on the ground.

Check oil level at an oil temperature of ca. 50 °C / 122°F, with the engine stationary.

Fill in oil through express coupling (5, Fig. 2-101:) when the oil level in the inspection glass has dropped below the "min" mark on film (2).

Stop filling if the monitoring lamp (6) lights up and oil level reaches the "max" mark on film (2) near the inspection glass (see: chapter "Hydraulic system Checking the hydraulic oil level / Refilling hydraulic oil").

Inspection glass (1, Fig. 2-99:), films (2, Fig. 2-99: and Fig. 2-100:)

Fig. 2-101:

Fig. 2-99:

Fig. 2-100:

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Operation

Assemblies resp. Level measuring device reservoirs

Remarks

Cooling system

Remove protective cap from express coupling at the Service-Station (2, Fig. 2-102:). Attach filling hose from the service vehicle to express coupling.

BCS level indicator (Fig. 2-103:)

Open ball valve (1).

Fill in cooling fluid using express coupling. Stop filling when the level indicator indicates maximum filling level. (see: chapter "Cooling system – Topping up").

Close ball valve (1). Detach filling hose.

Push protective cap back on to express coupling.

Grease container Dipstick in grease drum – cental lubricating (arrow, Fig. 2-104:) and system BCS display (Fig. 2-103:)

During daily routine check: Check grease level in grease drum using the dipstick.

During machine operation: BCS (arrow, Fig. 2-103:) gives a warning if the grease container is nearly empty.

Replace the grease drum if necessary (see chapter “Grease drum - replace”).

Fig. 2-102:

Fig. 2-104:

Fig. 2-103:

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Operation Electrical system – switching on and off The electrical system is switched on with keyswitch (11, Fig. 2-105:).  Insert key into key-switch and turn to the right.

If the electrical system cannot be switched on, check first whether the battery main switch is on (see: "Battery isolator switch, shutting off the supply voltage").

Engine – emergency shut-off In an emergency, the engine can be stopped out of full load.

To do so:  Depress the emergency shut-off switch in the dashboard (arrow, Fig. 2-106:) or the emergency shut-off switch near the trainer’s / instructor’s seat (arrow, Fig. Fig. 2-107:) The engine stopps. (see chapter "Emergency shut-off function").  Switch off the electrical system with key-switch in the dashboard (10, Fig. 2-105:).

Fig. 2-105: Fig. 2-106:

Fig. 2-107:

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Operation ENGINE – STARTING AND STOPPING Engine – starting

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. 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.

Fig. 2-108:

All control levers and pedals must be in position "0".

Pull out all emergency shut-off switches.

Pull out push-switches for the battery main switch.  Switch on the electrical system with key-switch (11, Fig. 2-108:).

Warning lamps (41 – 44, Fig. 2-109:) light up.  Wait until the start screen on the BCS display (Fig. 2-110:) is fully visible. All electronical systems are then booted and ready to work.  Press push-button (47, Fig. 2-109:) to start the engine. Release push-button (47) as soon as the engine has fired.

Warning lamps (41 – 44) go out.

Fig. 2-109:

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

If warning lamps (41 – 44, Fig. 2-108:) do not go out or when the BCS (Fig. 2-110:) displays a fault message after starting, the engine must be stopped immediately.

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

Do not run engine at full load unless it has been allowed to run for at least 3 minutes at idling.

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

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".

Fig. 2-110:

Engine – adjusting the speed Adjust the speed of the engine with push-switch (50, Fig. 2-109:).  Press and hold the switch face with the “+ plus” symbol the engine speed is raised up as long as the switch face is pressed (up to maximum speed).  Press and hold the switch face with the “- minus” symbol the engine speed is reduced as long as the switch face is pressed (down to idling speed).

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Operation Engine – shutting off During interruptions of the work and after the work, stand working equipment on the ground.

Do not shut off the engine before the working equipment rests on the ground.

Do not shut off the engine out of full load.

The engine should be run at no more than onehalf of the rated rpm 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.  Reduce engine speed to idling by pressing the right side ( the “- minus” symbol) of the speed adjusting switch (50, Fig. 2-111:).

Fig. 2-111:

 Press push-button (48, Fig. 2-111:). The engine is stopped.

Warning lamps (41 – 44) light up.  Switch off the electrical system with key-switch (11, Fig. 2-112:).

Warning lamps (41 – 44, Fig. 2-111:) go out.

The engine will be shut off with a delay of a few seconds. During this time, the current operating data are saved and the electronic units shut down.

Fig. 2-112:

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Operation HVAC – UNIT, FUNCTION The heating, ventilation and air conditioning system (HVAC) is installed at the rear wall outside the operator’s cab.

The heating section of the HVAC-unit uses the engine cooling liquid. Therefore full heating power is available after the engine reaches operating temperature.

The air condition section of the HVAC-unit is driven hydraulically. Air condition function is available when engine is running.

The system ensures that the cab is permanently under slight air pressure. This prevents the cab from being contaminated with dust.

The air outlets (examples in Fig. 2-113: and Fig. 2-114:) are adjustable so that the warmed or cooled airflows can be routed as desired.

Fig. 2-113:

Fig. 2-114:

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Operation HVAC – unit, controls The illustration (Fig. 2-115:) shows the control unit for the HVAC located in the dashboard.

Pos. Element 92

Switch

Function Sets the desired mode: Press to the left= - set cooling mode.

Press to the right= - set automatic mode.

93

Knob

Sets the desired temperature inside the cab.

Turn to left (blue colour)= - set lower temperature.

Turn to right (red colour)= - set higher temperature.

94

Knob

Selects the intensity level of the blower.

Turn to left (0)= - set lower fan speed or fan off.

Turn to right (AUTO)= - set higher fan speed or automatic mode.

2-74

Fig. 2-115:

BA 6020B(3 847 000.00)-EN

Operation

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2-75

BA 6020B(3 847 000.00)-EN

Operation MAXIMUM MACHINE INCLINATIONS – INFORMATION

Instruction film “Maximum inclination”

The machine must not exceed the inclinations indicated for working, travelling and servicing operations and during downtimes. The values specified in the tables below (next page) are valid for all types of working equipment.

Observe all the warning messages and films attached to the machine.

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.

This film (Fig. 2-116) is attached inside the operators cab.

Keep the warning messages and films legible and clean.

Replace warning messages and films immediately if they have become illegible.

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 slewing 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 %.

Fig. 2-116

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BA 6020B(3 847 000.00)-EN

Operation

Maximum machine inclinations during working operations:

forward inclination

rearward inclination

side inclination

10° / 17.6%

10° / 17.6%

10° / 17.6%

Maximum machine inclinations during travelling: Type 6020B

Engine Cat C32

Forward

Rearward

Side

deg / %

deg / %

deg / %

20° / 36.4%

20° / 36.4%

20° / 36.4%

Maximum machine inclinations during maintenance operations:

forward inclination

rearward inclination

side inclination

0° - 2° / 3.4%

0° - 2° / 3.4%

0° - 2° / 3.4%

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BA 6020B(3 847 000.00)-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 safety belts for all persons in the operators cab, fasten the belt.

If the upper structure is turned by more than 90° from the BASIC POSITION, the hydraulic shovel travels in the opposite direction to that selected.

If the position of the upper structure in relation to the under structure is not exactly known, touch the accelerator lightly to see which direction the machine takes, before initiating the full travelling movement.

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” chapter).

Fig. 2-117:

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:  Raise working equipment (Fig. 2-117:).  Drive the hydraulic shovel in reverse, approx. 50 m (164 ft).  Drive the hydraulic shovel in forwards, approx. 50 m (164 ft).  Stop the hydraulic shovel.  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 10 times.  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 upper structure must be secured against turning by means of the upper structure holding brake.

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BA 6020B(3 847 000.00)-EN

Operation TRAVELLING Upper structure basic position Travel direction and sense of actuation of pedals (112 and 113, Fig. 2-119:) are identical only when the hydraulic shovel is in its BASIC POSITION (Fig. 2-118:).

Travelling forwards/backwards Travelling forwards:  depress pedals (112 and 113) forwards.

The hydraulic shovel travels in the direction of the idler (2, Fig. 2-118:).

Travelling backwards:  depress pedals (112 and 113, Fig. 2-119:) backwards.

The hydraulic shovel travels in the direction of the drive sprocket (4, Fig. 2-118:).

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

Fig. 2-118:

If the upper structure is swung out of its basic position by more than 90° (Fig. 2-120:), the shovel moves in a direction opposite to that expected when pedals (112 and 113, Fig. 2-119:) are depressed.

Fig. 2-120:

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

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

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

Be extremely careful on slippery and greasy ground.

Fig. 2-119:

If the operator is not completely sure of the position of the upper structure with regard to the undercarriage, pedals (112 and 113) should be depressed slightly in order to find out which way the shovel moves before initiating the full travelling movement.

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

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BA 6020B(3 847 000.00)-EN

Operation Travelling speed – adjust While travelling on level ground adjust the travelling speed with  pedals (112 and 113, Fig. 2-121:) and  switch (81, Fig. 2-122:) to the right (slow gear).

All forward/reverse travel movements are possible with this gear.  switch (81, Fig. 2-122:) to the left (fast gear).

The hydraulic shovel can be driven only parallel forwards with this fast gear.

The travel gearbox changes automatically into the 1st gear as soon as another travelling function (e.g. reversing, cornering) is initiated.

Change speed range only when the hydraulic shovel is stationary.  Press engine speed regulator switch (50) to the left (full-throttled position).

Fig. 2-122:

Travelling uphill and downhill Do not exceed the maximum machine inclination (see “Maximum machine inclinations” chapter).

Read and observe the "Travelling - Safety instructions" chapter.  Depress pedals (112 and 113, Fig. 2-121:) fully to the limit stop.  Adjust the travel speed only with the engine speed control.

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

The travel retarder valve works correctly if pedals (112 and 113) are fully depressed down to the limit stop.

Fig. 2-121:

Should the travelling speed become too high when travelling downhill release pedals (112 and 113) to stop the hydraulic shovel.

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BA 6020B(3 847 000.00)-EN

Operation Cornering To take a right-hand corner forwards  depress only pedal (112, Fig. 2-123:) forwards To take a lefthand corner forwards  depress only pedal (113) forwards -

Turning To turn to the right  depress pedal (112) forwards and pedal (113) backwards To turn to the left  depress pedal (113) forwards and pedal (112) backwards.

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 hydraulic shovel's designated use. There is a risk of accident.

Moreover, the tracks, swing gear, roller bearing swing ring, backhoe or bucket back-wall and the front part of the bucket are subjected to inadmissibly high stresses.

Fig. 2-124: Fig. 2-123:

Note: Change the position of the under structure - parallel or perpendicular to the working face - only by cornering forwards/backwards (Fig. 2-124:).

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

The same procedure should be adopted if the hydraulic shovel is to be driven out of depressions (Fig. 2-125:): Cornering to the left

from pos. 1 to pos. 2

Cornering to the right

from pos. 2 to pos. 3

Fig. 2-125:

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BA 6020B(3 847 000.00)-EN

Operation Travelling over long distances For a more uniform loading of the tracks, the equipment must be kept at a steep angle (Fig. 2-126:).

Travel only forwards with the hydraulic shovel in its basic position.

 Fully extend boom cylinders (1).

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

 Retract backhoe cylinders (2).

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

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

 Retract stick cylinders (3).  Extend backhoe cylinders (2) and stick cylinders (3) to such an extent as to reach the position of the equipment shown in (Fig. 2-126:).

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

Fig. 2-126:

Lower the equipment when travelling underneath obstacles.

If the equipment position must be changed:  stop the hydraulic shovel,  change the position,  continue to travel.

After travelling for 15 minutes without interruption, stop the hydraulic shovel and check the temperature of the track rollers.

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

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

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BA 6020B(3 847 000.00)-EN

Operation Travelling in water or mud

Do not allow the machine to swing from the force of traveling when you use the bucket , the stick, or the boom to assist in travel.

If the force from traveling causes the machine to swing, damage may occur to the swing motors and to the swing drives.

When working in or around any body of water, or in conditions of heavy mud, be careful that the travel gearboxes do not dip completely into water or mud. Otherwise water may penetrate the gearbox through the breather filters. This may damage the gearbox.

To free the machine from water or mud You may not be able to move the machine by using the travel controls only. In this case use both the travel control pedals and the stick to pull the machine out of the water or ground.

The machine may slip because of a steep slope.

The procedure described above may not work. In this case, first rotate the upper structure by 180°.

Then use both the travel control pedals and the stick to move the machine up the slope.

It may be impossible to travel because the bottom of the frame comes into contact with the ground or the undercarriage is clogged with mud or gravel.

In this case, operate the boom and the stick together. Raise the track and rotate the track forward and backward in order to remove the mud and the gravel.

While you cross any body of water or heavy mud, carefully confirm the depth of the water or mud with the bucket. Do not move the machine into an area that has a water or mud depth that is greater than Dimension A in Fig. 2-127:.

The machine may sink gradually on soft ground.

Therefore, you should frequently check the height of the undercarriage from ground level and the depth of water or mud on the ground.

Check the travel gears by looking through the port for inspection that is in the travel gear housing. If there is water or mud inside the housing and you suspect that water has penetrated the travel gearbox, contact your Caterpillar dealer for the required maintenance on the travel gearbox.

After you travel through water or mud, carefully clean the machine in order to remove any mud, salt, sand, or other foreign matter.

Fig. 2-127:

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BA 6020B(3 847 000.00)-EN

Operation Upper structure holding brake – function The hydraulic shovel is equipped with two upper structure holding brakes which are integrated in the swing gearboxes. The upper structure holding brakes lock the upper structure with respect to the undercarriage.

The gearbox brakes are holding brakes.

Track parking brake – function The hydraulic shovel is equipped with four travel brakes which are integrated in the travel drives.

The travel brakes are parking brakes protecting the hydraulic shovel from rolling forwards or backwards. They are applied automatically when the shovel is parked (engine is shut off, hydraulic system depressurized).

Do not press the button unless the upper structure is stationary. Do not use this button while the upper structure is still in motion. Risk of damage to the brakes and the swing gears.

During operation (engine is running) the travel brakes are deactivated.

Apply the holding brake:  when the hydraulic shovel is parked,

Whenever loading work is interrupted, stand working equipment on the ground. This avoids movement of the shovel and possible consequential damage of the lowered ladder in case ignition remains engaged.

 when travelling longer distances.  To apply the holding brakes, press switch (72, Fig. 2-128:).

The shovel could slightly move in the direction of excavating.

The parking brake is released automatically when the "Travel" function (112, 113, Fig. 2-129:) is activated.

Switch (73) can remain in the “activated” position the during work. Switch off before travelling.

Fig. 2-128:

Fig. 2-129:

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BA 6020B(3 847 000.00)-EN

Operation TRANSPORTING THE MACHINE Transport - Safety instructions 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 hydraulic shovel's transport modules 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 hydraulic shovel are set out in the "Product Specification Sheet").

Transport The dimensions and the service weight of the fully assembled hydraulic shovel do not allow the hydraulic shovel to be transported in an undismantled state on a low-bed trailer over public roads.

Therefore, the machine must be disassembled into the transportable field assembly modules beforehand.

Lifting and lashing points as well as the center of gravity are marked on the modules (see example, Fig. 2-130:).

Dimensions and weights of the machines modules can be found in the annex, chapter “Product Specification Sheet” as well as in the “Service Manual”.

In chapter 3 of the Service Manual you can find a detailled description about disassembly and assembly procedures.

Fig. 2-130:

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BA 6020B(3 847 000.00)-EN

Operation WORKING OPERATION - SAFETY INSTRUCTIONS Serious injury or death by electrocution can occur if the machine or the working equipment are not kept a safe distance from electrical power lines.

Know the maximum height and the maximum reach of your machine.

Keep a distance of at least 3000 mm (118 inch) plus an additional 10 mm (0.4 inch) for each 1000 volts over 50000 volts.

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

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

Inspect the site for overhead lines. Contact with high tension lines is a risk to life!

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

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.

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.

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

Never swing a load over a truck cab or workers.

Position the truck so that material can be loaded from the rear of the truck or from the side of the truck. Load the truck evenly so that the rear axles are not overloaded.

If the cylinders are operated at the end of the stroke during operations, excessive force will occur on the stopper on the inside of the cylinder. This will reduce the life of the cylinders and structures.

To avoid this problem, always leave a small margin of play when the cylinders are operated.

2-86

Do not operate the machine, 

when several track rollers or support rollers have been removed;



when one or several slewing 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 as "unauthorized utilization".

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

BA 6020B(3 847 000.00)-EN

Operation Hydraulic cylinders – running-in instructions 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

Hydraulic system – warming up 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 / CONSUMABLES".

If the BCS indicates problems with the cooling liquid temperature, engine oil pressure, coolant level, alternator or hydraulic oil filter control (with hydraulic oil at service temperature) light up: Lower the working equipment and shut off engine.

 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 hydraulic shovel can operate at a higher engine speed.

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Operation Avoid extreme positions of the attachment

Parts of the attachment may damage the machine if they are moved into extreme positions (see illustrations Fig. 2-131 - Fig. 2-132).

Work carefully, avoiding extreme positions of this kind.

Fig. 2-131

Fig. 2-132

Fig. 2-133

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BA 6020B(3 847 000.00)-EN

Operation WORKING 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.

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; see 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 hydraulic shovel.

Pilot hydraulic circuit – activating The hydraulic shovel can execute working movements only after the electronic control (pilotcontrol) has been activated.

The pilot-control block is enabled by switch (74, Fig. 2-134:).

At the beginning of the work, the electronic control (pilot-control) is activated by a contact in the operator's seat (105):  Pilot-control ON The operator is sitting on his seat.  Pilot-control is OFF The operator's seat is empty.

Fig. 2-134:

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BA 6020B(3 847 000.00)-EN

Operation Upper structure – swinging Swinging of the upper structure is possible only when the upper structure holding brake is released and when the operator is sitting on his seat.  To swing the upper structure to the right move control lever to the right (115, Fig. 2-135:).  To swing the upper structure to the left move control lever to the left (115).

After releasing, the control lever returns automatically to position "0".

Releasing the control lever (115) is sufficient to brake the upper structure movement automatically.

In order to brake the upper structure movement more faster, the control lever can be moved in the direction opposite the swing movement (reversing).

In an emergency, activate the holding brakes by pressing switch (72, Fig. 2-136:) to stop upper structure movement.

But remember: Doing this will damage the holding brakes and probably the gear boxes!

Fig. 2-135:

Blocking the upper structure When the upper structure is stationary, it can be blocked by means of the upper structure holding brakes (72, Fig. 2-136:).

Fig. 2-136:

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BA 6020B(3 847 000.00)-EN

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

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

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

Do not level off a surface with the front shell of the bucket open.

Close bucket completely before beginning to dig.

Operating efficiency can be increased by using more than one machine control to perform a task.

Fig. 2-137:

Extending and retracting the stick  To extend the stick: push control lever (115, Fig. 2-137:) forwards.  To retract the stick: pull control lever (115) backwards.

Raising and lowering the boom  To raise the boom: pull control lever (116, Fig. 2-138:) backwards.  To lower the boom: push control lever (116) forwards.  To lower the boom with pressure: depress button (103) and push control lever (116) forwards.

Fig. 2-138:

Filling and emptying the backhoe bucket  To close (fill) the bucket: shift control lever (116, Fig. 2-138:) to the left.  To dump (empty) the bucket: shift control lever (116) to the right.

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BA 6020B(3 847 000.00)-EN

Operation WORKING TECHNIQUES Restricted operation Do not use the swing force to perform the following operations (Fig. 2-139:): 

Soil compaction,



Ground breaking.

Do not swing the machine while the bucket tips are in the soil.

These operations will damage the boom, the stick, and the work tool and the operations will reduce the life of the equipment.

While the bucket is in the ground, do not use the travel force for any excavation. This operation will cause excessive force on the rear of the machine.

Do not use the dropping force of the rear of the machine for excavation. This operation will damage the machine.

Do not allow the machine to swing from the force of traveling when you use the bucket, the stick, or the boom to assist in travel. If the force from traveling causes the machine to swing, damage may occur to the swing motor and to the swing drive.

Do not use the force of the bucket, the stick, or the boom to assist in turning the machine while the machine is traveling. This technique is referred to as “jump steering”. This technique will damage the swing motor and the swing brake.

When deep holes are dug, do not lower the boom so that the bottom side of the boom touches the ground.

When deep holes are dug, do not allow the boom to interfere with the tracks.

If working on weak / soft surfaces or loading high density materials, operate the machine with reduced bucket loads.

Fig. 2-139:

Do not use the dropping force of the bucket or work tool as a hammer (Fig. 2-140:). This will bring excessive force on the rear of the machine. Possible damage to the machine could result.

Fig. 2-140:

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BA 6020B(3 847 000.00)-EN

Operation Backhoe operation – digging and loading Backhoe excavators are traditionally used in digging and loading overburden. Two different setups for using a backhoe are applicable: 

Excavator and truck on the same level,



Excavator on top of the bench and the truck below (Fig. 2-141:).

Excavator and truck on different levels gains 15-20 % more production, clear separation of equipment positioning and less risk for collision.

Loading over body side walls of the truck gains reduced swing angle, loading over body tail gains reduced lifting effort for faster cycles.

Fig. 2-141:

Refer to (Fig. 2-141:):  Position the stick at a 70 degree angle to the ground. Move the stick toward the cab and keep the bucket parallel to the ground.  If the stick stops due to the load, raise the boom and / or perform a curl in order to adjust the depth of the cut.  To apply the greatest force at the cutting edge, decrease the down pressure as you move the stick toward the cab.  Maintain a bucket attitude that ensures a continous flow of material into the bucket.  Continue the pass in a horizontal direction so that material peels into the bucket.  Close the bucket and raise the boom when the pass has been completed.  Engage the swing control when the bucket is clear of the excavation.  Swing the load from the rear of the truck or from the side of the truck.

Never swing a load over a truck cab or workers.  To dump a load, move the stick outward and open the bucket in a smooth motion.  When bucket is empty swing upper structure back and begin the next loading cycle.

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Operation Bench – climbing and leaving Climbing onto a bench Refer to (Fig. 2-142:):

Risk of machine slipping or tipping over.

Do not exceed the maximum machine inclination (see chapter “Maximum machine inclination”).

First build the ramp. Travel up the ramp onto a bench with idlers first, keep bucket close to the ground.

If necessary engage bucket into the ground and move working equipment towards the machine, this supports the machine while climbing the steep ramp.

Fig. 2-142:

Leaving a bench Refer to (Fig. 2-143:):

Risk of machine slipping or tipping over.

Do not exceed the maximum machine inclination (see chapter “Maximum machine inclination”).

First build the ramp. If bench is very steep bring excavator down bench with sprockets first, keep bucket close to the ground.

Fig. 2-143:

More information about working techniques and about optimizing machine effectiveness gives an operator training, contact your Caterpillar dealer.

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Operation Emergency lowering of the working equipment

After daily operation

With the engine not functional, the working equipment can be lowered to the ground as follows:

 Park the machine on level and stable ground.

This is particularly important in winter to avoid freezing of the tracks.

 Switch on electrical system (24V) with keyoperated switch (11, Fig. 2-144:).

Parking the machine

 Stand the working equipment on the ground.

 Actuate switch (83) and hold.

 Shut off the engine.

 Push control lever (116) forwards. The working equipment comes to the ground.

 Shift both control levers into all directions to depressurize the hydraulic cylinders.  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.  Clean off gross dirt, ice and snow from the fins and the fan wheel of the hydraulic oil cooler.  Fill up the fuel tank.  Inspect the engine, the hydraulic system, the track rollers, support rollers, sprockets, idlers and gearboxes visually for leaks.

Escaping oil pollutes the environment.

Repair leaks immediately (or have them repaired).

Report oil accidents to the responsible person.

Fig. 2-144:

 Check the upper structure, undercarriage and the working equipment for damage and all steel components for cracks or fractures.

Report detected damage immediately to the responsible person.  Withdraw the key from the electrical system key-switch.  Lock the cab door and all lockable doors, hatches and covers on the machine.

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Operation OPTIONAL EQUIPMENT

Rotary beacon – switching on / off

Additional silencers - function

The rotary beacon is mounted on the operator’s cab roof (arrow, Fig. 2-146:).

This hydraulic shovel is equipped with additional silencers (arrows, Fig. 2-145:). The silencers are mounted at the power module:

 To switch the rotary beacon on / off, actuate switch (76, Fig. 2-147:).



in front of air outlet of hydraulic oil cooling system,



in front of air outlet of engine cooling system,



inside the power modules doors.

The silencers and the silencer elements must be checked and maintained in the same intervals like the hydraulic shovel’s air intake system.

See the „Inspection and maintenance plans“ in the Operation and Maintenance Manual for more information.

Fig. 2-146:

Fig. 2-145: Fig. 2-147:

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BA 6020B(3 847 000.00)-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. The Operation and Maintenance 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 equipment 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 your personal protective equipment: a safety helmet, safety goggles, safety footwear and gloves.

When carrying out work on the working equipment, f.ex. on the boom (Fig. 2-148:), use a fall arrester.

Falling down from great hight may cause severe injuries. Connect the fall arrester to the safety line on the boom (arrow, Fig. 2-148:).

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 for this type of machine.

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

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

Fig. 2-148:

Do not make any modifications on it, do not weld, do not drill.

2-97

BA 6020B(3 847 000.00)-EN

Operation

Risk of injury

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

The machine must not be started by unauthorized persons.



Securing the machine

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.

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

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

2-98

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

 Park the machine on level and stable ground.  Stand the working equipment on the ground.  Shut off the engine.  Depressurize the hydraulic system.  Withdraw the key from the key-switch.

BA 6020B(3 847 000.00)-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. 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.

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.

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

2-99

BA 6020B(3 847 000.00)-EN

Operation

2-100

BA 6020B(3 847 000.00)-EN

Operation NOTES .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. 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2-101

BA 6020B(3 847 000.00)-EN

Operation

2-102

BA 6020B(3 847 000.00)-EN

Inspection and servicing 3 INSPECTION AND SERVICING

Operating instructions

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 6020B(3 847 000.00)-EN

Inspection and servicing

3-2

BA 6020B(3 847 000.00)-EN

Inspection and servicing INSPECTION AND SERVICING SAFETY INSTRUCTIONS Operating manual No inspection and servicing work must be carried out until the operating manual has been read and understood.

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

The operating manual lists all jobs to be done. The descriptions of job sequences, however, provide only Experienced personnel with the necessary instructions.

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 mechanic or by attending an CGM HMS training course.

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

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

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.

Always face the machine when climbing on and off.

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

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 Personal protective equipment 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 your personal protective equipment: a safety helmet, safety goggles, safety footwear and gloves.

When carrying out work on the working equipment, f.ex. on the boom, use a fall arrester. Falling down from great hight may cause severe injuries. Connect the fall arrester to the safety line on the boom.

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.

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 spray-washed 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 engine.

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 6020B(3 847 000.00)-EN

Inspection and servicing Handling flammable liquids

Visible 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,

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

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

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)

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

 Stand working equipment on the ground.

Replace any damaged parts.

 Shut off the engine.

Spare parts

 Move all control levers and pedals repeatedly into all directions.

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

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

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

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

Never set foot withing reach of the emerging oil jet.

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

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

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

Used oil may be harmful to the skin.

Never repair damaged piping; always replace them.

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.

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.

3-4

BA 6020B(3 847 000.00)-EN

Inspection and servicing Non-polluting disposal

Engine exhaust gases

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.

Start and operate combustion engine only on wellventilated premises.

Do not dispose of these substances together with household wastes.

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;.

Fill these substances into the containers provided for such purposes.

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

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

Handling batteries

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

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

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.



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.

Seals Cat equipment and replacement parts that are shipped from Caterpillar are asbestos free.

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

Wash hands after handling.

Batteries give off explosive gases.

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

Battery acid is toxic and corrosive.

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

Wear gloves, firm protective clothing and goggles when handling batteries.

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

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

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

Caterpillar recommends the use of only genuine Cat replacement parts.

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

Inspect all seals when replacing parts or opening components.

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

Replace the seals if worn or even slightly damaged.

Clean sealing faces prior to assembly.

When assembling, ensure a perfect fit.

3-5

BA 6020B(3 847 000.00)-EN

Inspection and servicing 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 batteries must be disconnected using the battery isolator switch, alternatively: Disconnect first the negative and then the positive terminal.

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

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

Reconnect first the positive and then the negative terminal.

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

Handling of cold-starting fluid (ether)

Oil-level check and oil change

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.

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.

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 / 120°F. They must therefore be handled in the same way as full pressure vessels.  Do not keep them on the machine.

Position the machine horizontally.

After the work:



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.

3-6

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

Lubricating Clean the lubricating nipple and the area around, 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 6020B(3 847 000.00)-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.

Avoid parking the hydraulic shovel in places where 

combustible substances such as coal dust or tar are present.



open or smouldering fire may occur.

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 coldstarting fluid have been spilt over the machine. If possible, use a steam-jet cleaner for cleaning.

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 6020B(3 847 000.00)-EN

Inspection and servicing

3-8

BA 6020B(3 847 000.00)-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.

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.

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

Air-intake system Plan

Do all jobs ....

V

...once prior to initial commissioning.

N

...after initial commissioning and during the running-in period (up to 100 OH).

T

...every 10 OH or every working shift 2

W

...every 60 OH or weekly . 2

A

...after every 250 OH.

B

...after every 500 OH.

C

...after every 1000 OH.

D

...after every 5000 OH.

E

...after every 10000 OH.

OH = Bh = Operating hours

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: I

Oils for combustion engines and compressors

II

Oils for hydraulic systems

III

Oils for gearboxes

V

Greases for bearings and swing rings

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

2

Whichever comes first.

3-9

BA 6020B(3 847 000.00)-EN

Inspection and servicing

3-10

BA 6020B(3 847 000.00)-EN

Inspection and servicing Plan V Page 1 of 2

Plan V - Once prior to initial commissioning Location

Servicing work

Quantity

Checked

Issues without engine running Undercarriage: Track roller

Check for leaks and free movement

2x7

Support roller

Check for leaks and free movement

2x2

Idler

Check for leaks and free movement

2

Travel gearbox (PN 3857025) - Pre-stage (spur gear section)

Check oil level

2x1

- Main stage

Check oil level

2x1

- Motor coupling housing

Check oil level

2x2

Backhoe bucket

Check proper fixation of bucket

- Adapters, shrouds and tips

Check proper fixation

Hydraulic boarding ladder - Lubricating points

Lubricate

All lines, fittings and connections

Inspect visually for leaks, wearing marks

All articutated joints and hinges

Grease, oil

Upper structure: Engine

Check oil level

1

Air intake system

Inspect air intake filters

2

Inspect clean-air lines, hoses and clamps

2

Cooling system

Inspect linings Check for leaks

- Cooling liquid

Check level

1

Check cables for proper fixation

6

- Hydraulic oil tank

Check oil level

1

Pump drive gearbox

Check oil level

1

- Hydraulic pumps coupling housings Check oil level

3

Swing gearbox

Check oil level

2

Escape ladder

Check function

- Trap door

Check function

- Rope ladder

Check free movement

- Ladder

Check fastening bolts

Mirrors (if equipped)

Adjust, clean

All lines, fittings and connections

Inspect visually for leaks, wearing marks

All articutated joints and hinges

Lubricate

Electrical system Batteries Hydraulic system

3-11

BA 6020B(3 847 000.00)-EN

Inspection and servicing

Page 2 of 2

Plan V - Once prior to initial commissioning Location

Servicing work

Quantity

Issues with engine running Undercarriage: Track tension

Check pressure (see „Service Manual“)

Service – Station

Check operation

All lines, fittings and connections

Inspect visually for leaks, wearing marks

All articutated joints and hinges

Lubricate

2

Upper structure: Electrical system - Emergency stop switches

Check function

4

- Battery main switches

Check function

2

- Battery isolator switch

Check function

1

- Starter isolator switch

Check function

1

- Working lights

Check operation

- Maintenance lights

Check operation

Hydraulic system

Check function of working and travelling movement Check pressure (see: “Service Manual”)

- Hydraulic oil tank

Check oil level

- Hydraulic cylinders

Vent (see chapter: “Hydraulic system“)

Central lubricating system - Grease container

Check filling level

- Greasing and pause cycles

Check setting

- Level monitoring and dipstick

Check function

Inside cab: Monitoring, warning and control elements

Check function of monitoring, warning and control elements

- Board Control System

Check function

- Slewing system

Perform slew brake test (see: “Service – slew brake test screen”)

- Emergency stop switches

Check function

- Emergency hammer

Check condition

HVAC unit

Check function

- Fresh air filter

Check visually

- Circulation filter

Check visually

Working equipment:

Lubricate (see: “Lubricating chart – Grease, working equipment”)

Boom, stick, bucket, H-link

Check structure for cracks

Pins and pin covers

Check tightness of bolts

All lines, fittings and connections

Inspect visually for leaks

3-12

2

Checked

BA 6020B(3 847 000.00)-EN

Inspection and servicing Plan N Plan N – After initial commissioning and during the running-in period (after approx. 100 OH) Page 1 of 2 Location

Servicing work

Quantity

Checked

Undercarriage: LH / RH crawler structure

Inspect visually for cracks / damage

Carbody

Inspect visually for cracks / damage

- Fastening bolts

Check for tightness (see: „Service Manual“)

- Hoses

Check for leaks, tightness of flange bolts

Track chain assembly - Bolts

Check for tightness (see: „Service Manual“)

- Chain links

Check for cracks / broken pins

- Shoes

Check for cracks

Track tensioning system - Cylinder

Check for leaks

- Pressure accumulator

Check pressure (see: „Service Manual“)

- Hoses

Check for leaks / damage

- Idler assembly

Check axle for leaks

Travel gearbox (PN 3857025) - Pre-stage (spur gear section)

Change oil

2x13

- Main stage

Change oil

2x13

- Motor coupling housing

Change oil

2x23

- Fastening bolts at gearbox, sprocket, motors and guards

Check for tightness (see: „Service Manual“)

All lines, hoses, fittings and connections

Inspect visually for leaks, wearing marks, tightness of flange bolts

Upper structure: Engine (After 20 – 40 OH, cf. Engine Operation and Maintenance Manual) - V-belts, Poly-V-belts

Check tension, check condition

- Bearing, fastening bolts

Check for tightness

Cooling system

3

- Cooling liquid

Carry out cooling liquid analysis after 250 OH (see: “Engine Operation and Maintenance Manual”)

- Radiator bearings, fastening bolts

Check for tightness (see: „Service Manual“)

- Coolant lines

Check for leaks, check tightness of clamps

see: “Refilling quantities – Oil“ table 3-13

BA 6020B(3 847 000.00)-EN

Inspection and servicing

Plan N – After initial commissioning and during the running-in period (after approx. 100 OH) Page 2 of 2 Location

Servicing work

Quantity

Hydraulic system

Check oil level

- Oil cooler bearing, fastening bolts

Check for tightness (see: „Service Manual“)

- Return-flow filters

Replace

9

- Magnetic rod

Clean

1

- Angled screens inside tank

Inspect visually for damage

2

Pressure accumulator – pilot hydraulic Check function circuit

1

Pressure accumulator – track tensioning system

Check function

2

Pump drive gearbox

Change oil

24

- Hydraulic pumps coupling housings

Change oil

2x34

- Gearbox oil filter (cooling circuit)

Replace filter element

- Fastening bolts

Check for tightness (see: „Service Manual“)

Swing gearbox (PN 3857027)

Change oil

- Fastening bolts

Check for tightness (see: „Service Manual“)

Swing gearbox (PN 3857026)

Change oil

24

- Motor coupling housing

Change oil

24

- Fastening bolts

Check for tightness (see: „Service Manual“)

Swing ring Fastening bolts: - swing ring to undercarriage

Check for tightness (see: “Service Manual”)

- swing ring to upper structure Upper structure Fastening bolts of all modules

Check for tightness (see: “Service Manual”)

Central lubrication system - Lubricating points

Check visually for proper lubrication

All lines, fittings and connections

Inspect visually for leaks, wearing marks

4

see: “Refilling quantities – Oil“ table

3-14

1 24

Checked

BA 6020B(3 847 000.00)-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

Plan

Plan

T

W





Undercarriage: Undercarriage - Tracks

Inspect track tension visually

2

- Track roller

Check for leaks and free movement

2x7



- Support roller

Check for leaks and free movement

2x2



- Idler

Check for leaks and free movement

2



Travel gearbox

Check for leaks

2





Check oil level

1













Upper structure: Engine

Check visually for leaks and damages Engine cooling system - Cooling fluid level

Check

1

- Radiator

Check / clean if soiled

1





Check condition

1





- Primary fuel filter

Check bowl for water, drain if necessary

1





- Fuel tank

Drain off water and sediment





Air-intake system

Check BCS – indication





- Intake and clean-air lines

Check for tightness and leaks

- Dust trap

Remove dust

2x1





- Cyclone prefilter

Check, remove dust

2x1





- Fan wheel Fuel system



Electrical system - Working lights

Check operation





- Maintenance lights

Check operation





- Emergency-off buttons

Check function





Monitoring, warning and control elements

Check function of monitoring, warning and control elements





- Board Control System

Check function and messages





6

3-15

BA 6020B(3 847 000.00)-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) Page 2 of 2 Location Hydraulic system

Servicing work

Quantity

Plan

Plan

T

W

Check function of working and travelling movement





Inspect visually for leaks





- Hydraulic oil tank

Check oil level

1





- Radiator

Check / clean

1





- Fan wheel

Check condition

1





Pump drive gearbox

Check oil level

1

- Hydraulic pumps coupling housings

Check oil level

3

- Oil filter (tell-tale)

Check

1

Swing gearbox

Check oil level

2

 

 





Central lubricating system - Grease container

Check filling level





- Lubricating points

Check visually





HVAC unit - Fresh air filter (outside cab)

Check visually / clean

1





- Circulation filter (inside cab)

Check visually / clean

1





Escape ladder

Check function

- Trap door

Check function





- Rope ladder

Check free movement





- Ladder

Check fastening bolts





Mirrors (if equipped)

Adjust, clean





Fire extinguisher

Check condition









All lines, fittings and connections Inspect visually for leaks, wearing marks Hydraulic shovel

3-16

Inspect visually, overall cleaning

2



BA 6020B(3 847 000.00)-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)

Page 1 of 7 Location

Servicing work

Quantity Plan Plan Plan Plan Plan

Servicing in acc. with W or T

A

B

C

D

E











Monitoring, warning and control elements - Joystick grease lightly

2x45







- Control spool grease lightly (machine with face shovel)

3x25







- Control spool (machine with backhoe bucket)

2x25







- Control spool, plate and cardan joint - Pedal

5

grease lightly

apply a thin layer of low temperature grease.

3-17

BA 6020B(3 847 000.00)-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) Page 2 of 7 Location

Servicing work

Quantity Plan Plan Plan Plan Plan

Servicing in acc. with W or T

A

B

C

D

E





















Engine For more detailed information on Inspection and servicing work see: “Engine Operating and Maintenance Manual”

1

Analyse engine oil 6

1









Change engine oil

1

7









Replace engine oil filter

4





















Clean engine V-belt



Check condition and tension

Engine 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

Engine valve rotators

Inspect

After every 3000 OH:

See: Engine Operating and Maintenance Manual

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

Long time cooling liquid (ELC)

Add if necessary

Cooling liquid thermostat

Replace

Engine

Clean









6

For detailed information on taking oil samples see: “Service Manual for Oil Samples and Oil Analysis”.

7

see: “Refilling quantities – Oil“ table.

3-18

BA 6020B(3 847 000.00)-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) Page 3 of 7 Location

Servicing work

Quantity Plan Plan Plan Plan Plan A

B

C

D

E

Cooling system

Inspect visually for leaks











Radiator

Clean











- Fastening bolts

Check tightness







- Rubber bearing

Check condition













Cooling liquid ELC (see: “Engine Operating and Maintenance Manual”)



Carry out cooling liquid analysis stage 1



Carry out cooling liquid analysis stage 2 (after 1 year at the latest) Change

18



Cooling liquid additive (SCA)

Check concentration / add

Anti-freeze

Check







Lines

Check for leaks







Hose clamps

Check tightness



































2x19







10























Fuel system Secondary fuel filter

Replace

2

Primary fuel filter

Replace

1

Breather filter fuel tank

Replace

1

Air-intake system Main filter element

Check / replace

Secondary filter element

Replace

Air-intake line and clean-air lines

Check for tightness and leaks

Intercooler

Check / clean

Hoses

2x1





Replace

Electrical system Battery cable connections

Check for tightness

Battery

Check fluid level (not with maintenance-free batteries)

 6

8

Cooling-liquid (ELC) replacement after 12000 OH or after 6 years at the latest.

9

Replacement of main filter element after one year resp. after 3 cleaning cycles.

















10

Replacement of safety filter element after one year resp. after 3 cleaning cycles of the main filter element at the latest.

3-19

BA 6020B(3 847 000.00)-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) Page 4 of 7 Location

Servicing work

Quantity Plan Plan Plan Plan Plan A

C

D

E

Check pressure (see: “Service Manual”)







- Fastening bolts

Check for tightness (see: “Service Manual”)







- Rubber bearing

Check condition







High-pressure filters

Replace

6







Return-flow filters in hydraulic Replace tank

9







Magnetic rod hydraulic tank

1











Hydraulic system

B

Oil radiator bearing

Check / clean

Bypass valves hydraulic tank

Check / clean filter sieve

4



Filter (pilot control circuit)

Replace

1







Breather filter hydraulic tank

Replace

2













Hydraulic oil tank

Carry out oil analysis

11

Change oil



1 1

12 13



Pressure accumulator (pilot control circuit)

Check pressure (see: “Service Manual”)

1



Pressure accumulators (track tension circuits)

Check pressure (see: “Service Manual”)

2x1



Cylinder (seals and guide rings)

Replace

Central lubricating system

Check function

- Grease pump

Check oil level

1

Change oil

1

























 

- Oilfilter (hydraulic circuit grease pump)

Replace

1



- Grease filter (grease lines)

Replace

1





- Breather filter tank

Replace

1







11

For detailed information on taking oil samples see: “Service Manual for Oil Samples and Oil Analysis”.

12

see: “Refilling quantities – Oil“ table.

13

Unless it is regulary analyzed, the hydraulic oil must be changed every 5000 OH or after 3 years at the latest.

3-20

BA 6020B(3 847 000.00)-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) Page 5 of 7 Location

Servicing work

Quantity Plan Plan Plan Plan Plan A

Working equipment

Lubricate (see: “Lubricating chart – Grease, working equipment”

Pump drive gearbox

Carry out oil analysis 14

1

Change oil

15

- Hydraulic pumps coupling housings

1

B

C

D

E





































Check oil level Change oil

- Oil filter

Replace

1







- Breather filter

Clean

1







Replace

1

- Oil cooler

Check / clean

1

- Fastening bolts

Check for tightness (see: „Service Manual“)

Travel gearbox (PN 3857025)

Carry out oil analysis 14

- Main-stage - Pre-stage (spur gear section) - Hydraulic motor coupling housings - Disk brake housings

 













2









Check oil level

2





15































Change oil

2

Check oil level

2

Change oil

2 15

Check oil level

2

Change oil

2 15

Check oil level

2







15















Change oil

2

- Magnetic rod

Clean

6







- Breather filter

Clean

2x3







Replace

2x3

















- Fastening bolts

Check for tightness (see: „Service Manual“)

Drive sprocket

Check for abnormal wear

Travel gearbox

Rebuild, replace seals

 2



14

For detailed information on taking oil samples see: “Service Manual for Oil Samples and Oil Analysis”

15

see: “Refilling quantities – Oil“ table



3-21

BA 6020B(3 847 000.00)-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) Page 6 of 7 Location

Servicing work

Quantity Plan Plan Plan Plan Plan A

Swing gearbox

Carry out oil analysis

16

2

Change oil

2

- Breather filter

Replace

2x1

Check for tightness (see: „Service Manual“)

Swing gearbox

Carry out oil analysis 16

(PN 3857026)

Change oil

C

D

E















17

(PN 3857027) - Fastening bolts

B























2x1

17





17









2

- Motor coupling housing

Change oil

2x1

- Breather filter

Replace

2x1

- Fastening bolts

Check for tightness (see: „Service Manual“)

Swing ring

Check grease filling

- Gearing / pinion

Check condition

- Fastening bolts swing ring - undercarriage swing ring - upper structure

Check for tightness (see: “Service Manual”)

Undercarriage

Check wear on all components (see: “Service Manual”)

- Diaphragm accumulator

Check pressure (see: “Service Manual”)

2

- Diaphragm

Replace (see: “Service Manual”)

2

HVAC-unit

Carry out all maintenance accord. to manufacturers manual)

1

- Fresh air filter element

Replace

- Recirculate filter element

Clean, replace if damaged





















































1







1







1





Hydraulic boarding ladder - Lubricating points hinges

Lubricate

2x1







- Cylinder bearings

Lubricate

2x1







16

For detailed information on taking oil samples see: “Service Manual for Oil Samples and Oil Analysis”

17

see: “Refilling quantities – Oil“ table

3-22

BA 6020B(3 847 000.00)-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) Page 7 of 7 Location

Servicing work

Quantity Plan Plan Plan Plan Plan A

Steel components

B

C

D

E

Visual inspection acc. to "Structural Inspection Report every 500 OH" 18









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.









Modules – Fastening bolts

Check for tightness (see: “Service Manual”)







All articulated joints and hinges

Lubricate







18

"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 6020B(3 847 000.00)-EN

Inspection and servicing LUBRICATING CHART – GREASE

Fig. 3-1:

3-24

BA 6020B(3 847 000.00)-EN

Inspection and servicing Lubricating chart – Grease (legend) No. Greasing point

Number

Lubricant properties

1

V 19

Lubricate every .... operating hours 10 (Check filling level)

- lubricating points on hinge pins

2x1

V 19

1000

- lubricating points on hydraulic cylinder pins

2x1

1

Central lubricating system – grease container

2

Hydraulic ladder

1000

Control elements 3 4

- Pedals - Joystick

2 x 2 20 2x4

1000

V 19

20

1000

All other greasing points are supplied with grease by the central lubricating system.

Filling quantities – Grease Greasing point

Lubricant properties

Central lubricating system – grease drum

Filling quant. in liter

oz / gal

appr. 205 l

appr. 54 gal

appr. 000 2 x appr. 4.4 l 14 x appr.

2.7 l

appr. 000 2 x appr.

149 oz 14 x appr.

91 oz

4 x appr.

3.4 l

4 x appr.

115 oz

V 19 Internal gearing – Roller-bearing swing ring Idler (permanent grease filling) Track rollers (permanent grease filling)

Support rollers (permanent grease filling)

19

see: "LUBRICANTS / CONSUMABLES" section.

20

apply a thin layer of low temperature grease

Tribol CGM HMS part no.

2764564

3-25

BA 6020B(3 847 000.00)-EN

Inspection and servicing LUBRICATING CHART – GREASE, WORKING EQUIPMENT

Fig. 3-2:

3-26

BA 6020B(3 847 000.00)-EN

Inspection and servicing Lubricating chart – Grease, working equipment (legend) No. Lubricating point

Nipples

Lubricant properties

1 2

Fixed pin: H-link / bucket Fixed pin: H-link / gooseneck

2x1 2x1

Grease every .... operating hours 500 500

3

Fixed pin: Stick / bucket

2x1

500

4

Fixed pin: Stick / gooseneck

2x1

V

500 21

5

Fixed pin: Bucket cylinder / stick

2x2

500

6

Fixed pin: Stick cylinder / stick

2x2

500

7

Fixed pin: Boom cylinder / boom

2x1

500

8

Fixed pin: Stick cylinder / boom

2x2

500

9

Fixed pin: Boom cylinder / A-frame

2x2

500

All other lubricating points on the working equipment are supplied with grease by the central lubricating system.

21

see: "LUBRICANTS / CONSUMABLES" section.

3-27

BA 6020B(3 847 000.00)-EN

Inspection and servicing INSPECTION PLAN - OIL

Fig. 3-3:

3-28

BA 6020B(3 847 000.00)-EN

Inspection and servicing Inspection plan – Oil (legend) No. Location

Lubricant properties 22

Check oil level

Change oil

every ... OH

every ... OH

1

Grease pump, crankcase

1

I

250

1000

2

Hydraulic system

1

II

10

10000 23

3

Swing gearbox (PN 3857027)

2

III

10

1000

3

Swing gearbox (PN 3857026)

2

III

10

5000 24

2x1

III

10

5000 24

- Motor coupling housing

22

Number

4

Pump drive gearbox

1

III

60

1000

5

Engine

1

I

10

500

6

Travel gearbox (PN 3857025) 500

5000 24

500

5000 24

500

5000 24

- Main-stage

2x1

- Pre-stage (spur gear section)

2x1

- Hydraulic motor coupling housings

2x2

III

see: "LUBRICANTS / CONSUMABLES" section

23

Change hydraulic oil every 5000 OH unless the oil is analyzed at regular intervals, but not later than every 3 years.

24

Change interval for gearbox oil can be expanded to 5000 OH depending on the results of regular oil analyses every 500 OH.

3-29

BA 6020B(3 847 000.00)-EN

Inspection and servicing Filling quantities - oil Location

Filling quantity

Oil

liter

gal (US)

Engine (with filter changed)

approx. 114

approx. 30.1

Hydraulic oil tank Hydraulic system

approx. 2800 approx. 0000

approx. 740 approx. 000

Pump drive gearbox (PN 3855122)

approx. 17

approx. 4.5

- Hydraulic pumps-coupling housings

3 x approx. 00

3 x approx. 00

- Cooling system

approx. 8

approx. 2.1

Pump drive gearbox (PN 3855121)

approx. 43

approx. 11.4

- Hydraulic pumps-coupling housings

4 x approx. 0,4

4 x approx. 13.5 oz

- Cooling system

approx. 8

approx. 2.1

Swing gearbox (PN 3857027)

approx. 17

approx. 4.5

III

Swing gearbox (PN 3857026)

approx. 25

approx. 6.6

2 x approx. 0,2

2 x approx. 0.05

III

- Main stage

approx. 37

approx. 9.78

- Pre-stage (spur gear section)

approx. 10

approx. 2.64

2 x approx. 0,5

2 x approx. 0.13

approx. 0,4

approx. 15 oz

- Motor coupling housing

I II III

III

Travel gearbox (PN 3857025)

- Hydraulic motor coupling housing Grease pump, crankcase

III I

Filling quantities – other Location

Filling quantity

Specification

liter

gal (US)

Cooling system - engine

approx. 000

approx. 000

Cat ELC

Fuel tank

approx. 3600

approx. 951

ASTM D975 Nr. 1-D or Nr. 2-D Diesel fuel / EN590

Screen washer

approx. 18,6

approx. 4.9

Air conditioning system

approx. 000

approx. 000

3-30

R134a

BA 6020B(3 847 000.00)-EN

Inspection and servicing LUBRICANTS / CONSUMABLES

Avoid mixing of different hydraulic fluids

Notes on the selection of oils and greases

The machine has been run in at the factory with BM Long Term Hydraulic Fluid HSS (Part-No. 2482971). CGM HMS 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.

Original CGM HMS 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 Operation and Maintenance Manual contain specifications for the oils and greases that are approved for use in CGM HMS machines. These oils and greases are especially adapted to CGM HMS 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 only approves the use of the specified oils and greases.

All other qualities are not approved.

Alternative oils and greases The oils and greases filled into the machine must meet at least the specifications mentioned in the lubricants tables of the CGM HMS Operating Instructions.

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 specifications, CGM HMS does not assume any responsibility and does not accept any warranty claims.

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 assumes no warranty for damage caused as a result of the machine having been operated with consumables of inappropriate specification or with mixed fluids.

3-31

BA 6020B(3 847 000.00)-EN

Inspection and servicing I.

Fig. 3-4:

3-32

Oils for combustion engines

BA 6020B(3 847 000.00)-EN

Inspection and servicing

II.

Fluid for hydraulic system

Fig. 3-5:

3-33

BA 6020B(3 847 000.00)-EN

Inspection and servicing III Oils for pump drive gearboxes, swing gearboxes and travel gearboxes

Fig. 3-6:

3-34

BA 6020B(3 847 000.00)-EN

Inspection and servicing V.

Grease for bearings and swing rings (Central lubrication system)

Fig. 3-7:

3-35

BA 6020B(3 847 000.00)-EN

Inspection and servicing Grease for idlers, track rollers and support rollers (Lifetime lubrication)

Fig. 3-8:

3-36

BA 6020B(3 847 000.00)-EN

Inspection and servicing Coolant for use on all combustion engines

Fig. 3-9:

3-37

BA 6020B(3 847 000.00)-EN

Inspection and servicing SERVICING WORK Maintenance access – doors and cover locations

Open a door from the outside (Fig. 3-12:).

Doors and covers at the front side of the power module (arrows, Fig. 3-10:).

Fig. 3-10:

Fig. 3-12:

Open a door from the inside (Fig. 3-13:).

Doors and covers at the rear side of the power module (arrows, Fig. 3-11:). These doors and covers are accessible after crossing the power module through the engine compartment.

Fig. 3-11:

3-38

Fig. 3-13:

BA 6020B(3 847 000.00)-EN

Inspection and servicing ENGINE Engine - Safety instructions

Start and operate the combustion engine 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.

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.

Read and observe: "Inspection and Servicing – Safety Instructions" and the “Engine Operation and Maintenance Manual”.

Before starting inspection and maintenance work, secure the machine as described in the “Securing the machine “ section.

Risk of injury from hot or rotating parts of the engine.

Other servicing works are described in the “Engine Operation and Maintenance Manual”.

Shut off engine and allow to cool down.

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.

Before cleaning the engine

Exhaust pipes and turbo chargers in the engine compartments are covered with special heatinsulating material. This material must not be spray-washed 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.

3-39

BA 6020B(3 847 000.00)-EN

Inspection and servicing Engine oil level – Checking / Topping up The engine oil temperature is constantly monitored by the BCS (Fig. 3-14:) when the machine is in operation. Temperature and pressure can be displayed on the BCS screen.

BCS and the oil pressure monitoring devices give acoustic warnings to the operator if the engine oil temperature too high or the oil pressure is too low.

 Park the machine on a horizontal surface and secure against inadvertent movements.  Shut off engine.  Draw out oil dipstick (2, Fig. 3-15:).  Wipe oil off the dipstick with a clean, lintfree cleaning rag and re-insert.  Draw out dipstick a second time. The oil level should now lie between the marks (arrows, Fig. 3-16:). If the oil level is at the "min" mark or below, top up with engine oil through filler tube (1, Fig. 3-15:). (oil grade see: “LUBRICANTS / CONSUMABLES” section).

Small amounts of engine oil can be topped up through the filler tube at the engine until the oil level has reached the "max" mark on dipstick.

Engine oil can also be filled in from the ServiceStation (Fig. 3-17:) through express coupling (3).

(See chapter "Engine oil - changing").

Fig. 3-14:

Fig. 3-16:

Fig. 3-15:

Fig. 3-17:

3-40

BA 6020B(3 847 000.00)-EN

Inspection and servicing Engine oil – Changing

Engine oil - Drawing off through the Service Station  Bring engine oil to operating temperature.

Risk of scalding from hot engine oil.

 Park the machine on a horizontal surface and secure.

The engine may also be hot.

 Shut off the engine.

Wear protective gloves and firm working clothing.

 Draw off the engine oil through express coupling (3, Fig. 3-18:), to do so:

Collect escaping oil and discard without polluting the environment.

 Remove protective cap of express coupling and connect hose line of the service vehicle.  Set ball valve to position “I”.

Read and observe: "Inspection and servicing – Safety instructions".

 Draw off engine oil.

After the engine oil has been drawn off:  Replace the engine oil filters.  Fill in fresh engine oil using the ServiceStation.  Remove the hose line. The express coupling closes automatically.  Set ball valve to position “0”.  Attach protective cap.

Fig. 3-18:

3-41

BA 6020B(3 847 000.00)-EN

Inspection and servicing Engine oil – Filling in through the Service Station (Oil grade see: “LUBRICANTS / CONSUMABLES” section).

Small amounts of engine oil can be topped up through the filler tube at the engine (1, Fig. 3-19:) until the oil level has reached the "max" mark (Fig. 3-20:) on dipstick (2, Fig. 3-19:).

When changing the engine oil, use the ServiceStation to fill in engine oil. To do so:  Remove protective cap of express coupling (3, Fig. 3-21:) and connect filling hose of the service vehicle.  Set ball valve to position “I”.  Fill in engine oil through express coupling (3) until the oil level has reached the "max." mark (Fig. 3-20:) on dipstick (2, Fig. 3-19:).  Start the engine and allow to run at idling for abt. 2 minutes.  Check oil level at dipstick (2, Fig. 3-19:) and top up with oil to the "max" mark (Fig. 3-20:) if required.

Fig. 3-19:

 Remove the filling hose.

The express coupling closes automatically.  Set ball valve to position “0”.  Attach protective cap.

Fig. 3-20:

Fig. 3-21:

3-42

BA 6020B(3 847 000.00)-EN

Inspection and servicing Engine oil filters – Replace

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.

Read and observe: "Inspection and servicing – Safety instructions".  Carry out servicing of the oil filters (Fig. 3-22:) in accordance with the engine operating instructions.

Fig. 3-22:

 Shut off the engine.  Unscrew the four filters (arrow, (Fig. 3-22:).  Install new filters together with slightly oiled sealing ring and tighten by hand.  Run engine at idling speed for a short time and check filters for leaks. Shut off engine.  After 10 minutes check oil level, top up if neccessary.

(Oil grade see: “LUBRICANTS / CONSUMABLES” section).

3-43

BA 6020B(3 847 000.00)-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.

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.

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.

Before replacing an empty pressure vessel:

 Insert a new seal into the valve (supplied with the new pressure vessel).

Read and observe the instructions on the pressure vessels.

 Screw the new pressure vessel onto the metering valve and tighten by hand.

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

 Fasten the clamp round the pressure vessel.

Provide for sufficient ventilation of the surroundings.

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

Do not inhale the vapours of escaping coldstarting fluid (ether).

Avoid skin contact. Wear suitable protective gloves and goggles.

Read and observe: "Inspection and servicing Safety instructions"

3-44

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.



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



Do not dispose of in fire.



Keep the vessels in a place unaccessible to unauthorized persons.



Dispose of the vessels properly.

BA 6020B(3 847 000.00)-EN

Inspection and servicing ENGINE COOLING SYSTEM - INFORMATION

Risk of scalding from hot cooling liquid.

The engine, the radiator and the expansion reservoir as well as all other parts of the cooling system may also be hot.

Shut off the engine and allow to cool down.

Skin contact with cooling liquid is a potential health hazard.

Protect the skin from contact with cooling liquid.

Fig. 3-23:

Wear protective gloves and firm working clothing.

Secure the machine as described in the "Securing the machine" section.

Collect escaping cooling liquid and discard without polluting the environment.

Read and observe: "Inspection and servicing Safety instructions".

The engine cooling system is controlled by the electronic board control system. The max. admissible temperature is ca. 100° C (212°F).

In case of higher temperatures, the BCS displays a warning on the screen (arrow, Fig. 3-23:).

The radiators are located on the upper structure in the powermodule, behind the silencer elements (Fig. 3-24:).

Unscrew the bolts of the silencer and swing silencer (Fig. 3-24:) to the counterweight. The radiators are then acessible (Fig. 3-25:).

Fig. 3-24:

Check radiator fins weekly for dirt and clean, if required (Fig. 3-25:).

In very dusty environments it may be necessary to clean the radiators in shorter intervals (see: “Radiator core – clean”).

Fig. 3-25:

3-45

BA 6020B(3 847 000.00)-EN

Inspection and servicing Radiator core – clean

Cooling-liquid – Checking level An insufficient cooling-liquid level is displayed on the BCS screen (Fig. 3-26:).

Risk of burning.

The radiators reach the same temperatures as the cooling liquid.

Allow the radiators to cool down before starting work.

The cooling-liquid level should be between the “FULL” and the “LOW” marking. Top up with cooling liquid, if required (see “Cooling liquid - Topping up”).

Personal injury can result from air pressure.

Personal injury can result without following proper procedure. When using pressure air, wear a protective face shield and protective clothing.

Maximum air pressure at the nozzle must be less than 205 kPa (30 psi) for cleaning purposes.  Unscrew the bolts of the silencer and swing silencer (Fig. 3-24:) to the counterweight. The radiator for coolant liquid and the charge air cooler are then acessible (Fig. 3-25:).

Fig. 3-26:

 Check all of the core fins for debris.  Remove dust and debris from all of the core fins and from the screens.  Compressed air is preferred, but high pressure water or steam can be used to remove dust and general debris from a core.  Clean the fan blades and remove all accumulated dirt.  Remove all debris and dirt from the battery room and from the engine room.  Close the access doors.  Swing silencer (Fig. 3-24:) back in place and fasten the bolts of the silencer.

3-46

Fig. 3-27:

BA 6020B(3 847 000.00)-EN

Inspection and servicing Cooling liquid - Topping up Fill in cooling liquid through filler tube (Fig. 3-28:) or through express coupling of the Service-Station (2, Fig. 3-29:) into the cooling system (see “Cooling liquid - Topping up using the Service-Station”).

The cap of the expansion reservoir (Fig. 3-28:) is accessible from above.

Risk of scalding from hot cooling liquid under pressure.

Before opening the radiator cap: Release pressure by lifting the red lever on top of the radiator cap.

Open radiator cap cautiously.

Fig. 3-29:

Do not fill in cold cooling liquid when the engine is at operating temperature.

Before refilling, allow engine to cool down to below 50° C (122°F).

For topping up of the cooling system use specially prepared cooling liquid Caterpillar ELC, CGM HMS-Part No. 2482777 only.

This gives an anti-freeze protection down to -37 °C / -34.6°F. For use at lower temperatures, ask the CGM HMS GmbH - Service or ask your CAT-dealer.

 Release pressure by lifting the red lever on top of the cap of the expansion reservoir (arrow, Fig. 3-28:).

After filling in cooling liquid allow the engine to run for short period to eliminate air voids before topping up with cooling liquid to the lower edge of the filler tube.

 Turn cap of the expansion reservoir back to the first notch.

In case of significant cooling-liquid losses, the whole cooling system must be checked for leaks.

 When the pressure has been released completely, turn cap into the "open" position and remove.

Check regularly all lines for leaks and all hose clamps for tightness.

Checking the SCA concentration (if equipped with)

Observe the instructions of the engine manufacturer with regard to the SCA concentration (see “Engine Operation and Maintenance Manual”).

Fig. 3-28:

3-47

BA 6020B(3 847 000.00)-EN

Inspection and servicing Cooling liquid - Topping up using the Service-Station A description of the Service Station can be found in Part 2 of this manual, chapter “Service Station”.

The cooling liquid can be filled in through express coupling (2, Fig. 3-30:) of the Service Station.  Prior to topping up cooling liquid release pressure from the cooling system.

To do so lift red lever on the cap of the expansion reservoir (arrow, Fig. 3-31:).

The pressure is released then.  Remove cap of express coupling. Connect the filling hose of the service vehicle.  Set ball valve (1, Fig. 3-30:) to position “I”.  Fill with coolant until the cooling-liquid level lies between the “FULL” and the “LOW” marking of the level indicator on the BCS-screen.

Fig. 3-30:

 Remove hose.

The express coupling closes automatically.  Set ball valve (1, Fig. 3-30:) to position “0”.  Push on protective cap.

In case of significant cooling-liquid losses, the whole cooling system must be checked for leaks.

Fig. 3-31:

3-48

BA 6020B(3 847 000.00)-EN

Inspection and servicing Cooling liquid – change

Risk of scalding from hot cooling liquid.

The radiator and the expansion reservoir as well as all other parts of the cooling system may also be hot.

Skin contact with cooling liquid is a potential health hazard.

Protect the skin from contact with cooling liquid.

Wear protective gloves and firm working clothing.

Collect escaping cooling liquid and discard without polluting the environment.

Only use “ELC” cooling liquid, see: “Cooling liquid Topping up” and the engine manufacturers recommendations. Do not use pure water.

Cooling liquid - Drawing off Cooling liquid can be drawn off from the cooling system by means of the express coupling (2, Fig. 3-33:) at the Service Station section A, which is located under the upper structure frame, near the counterweight (Fig. 3-32:).

A description of the Service Station can be found in Part 2 of this manual, chapter “Service Station”.  Prior to drawing off cooling liquid release pressure from the cooling system.

To do so lift red lever on the cap of the expansion reservoir (arrow, Fig. 3-31:).

The pressure is released then.  Remove cap of express coupling (2, Fig. 3-33:).

Connect hose line of the service vehicle.  Set ball valve (1) to position “I”.  Draw off cooling liquid.  Fill in fresh cooling liquid, see “Cooling liquid – Filling in”.

The cooling liquid must be analized regularly. It must be changed after 12000 operating hours or after six years at the latest.

For information about testing procedures refer to the “Engine Operation and Maintenance Manual”.

Fig. 3-33:

Fig. 3-32:

3-49

BA 6020B(3 847 000.00)-EN

Inspection and servicing Cooling liquid - Filling in A description of the Service Station can be found in Part 2 of this manual, chapter “Service Station”.  Fill in cooling liquid through express coupling (2, Fig. 3-34:) at the Service-Station.  Remove cap of express coupling.

Connect hose of the service vehicle.  Fill with coolant until the cooling-liquid level lies between the “FULL” and the “LOW” marking of the level indicator at the BCS-screen (Fig. 3-35:).  Set ball valve (1) to position “0”.  Remove hose from express coupling.

The coupling closes automatically.

Fig. 3-34:

 Push on protective cap.

Fig. 3-35:

3-50

BA 6020B(3 847 000.00)-EN

Inspection and servicing Cooling liquid - Testing the composition The “Engine Operating 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 ELC is sufficiently concentrated to prevent corrosion under the corresponding operating conditions.

Engine bearings – inspect Inspect engine bearings for deterioration and for proper bolt torque (Fig. 3-37:).

Engine vibration can be caused by improper mounting of the engine or deterioration of the engine berings.

Any engine bearing that shows deterioration should be replaced.

All bolts on engine bearings must be checked for tightness. If loose, fasten using a torque wrench.

Contact your Caterpillar dealer for more information or for assistance.

Coolant samples can be taken at the express coupling located at the Service Station section A (2, Fig. 3-36:).

Release pressure from the cooling system before taking a cooling liquid sample. To do so lift the red lever at the cap of the expansion reservoir.

See chapter “Cooling liquid - change / Cooling liquid drawing off”.

Fig. 3-37:

See Fig. 3-37:

Fig. 3-36:

Pos.

Quant .

Bolt, torque

1

4

M16 x 2; 10.9; 250Nm

2

2

M20 x 2,5; 10.9; 490Nm

3

16

M10 x 1,5; 10.9; 41Nm

4

4

M16 x 2; 10.9; 250Nm

5

16

M10 x 1,5; 10.9; 41Nm

3-51

BA 6020B(3 847 000.00)-EN

Inspection and servicing Engine crankcase breather – clean If the crankcase breathers are not cleaned on a regular basis, they will become plugged. Plugged crankcase breathers will cause excessive crankcase pressure that may cause crankcase seal leakage.

The crankcase breathers are located on the valve covers on top of the engine (arrows, Fig. 3-38:).

Loosen clamps and remove the tubes from the outlet.  Loosen clamps of the breathers and remove from the valve covers.  Remove O-ring seals from the breathers seats at the valve covers.  Inspect O-rings for good condition. Replace if damaged.  Clean breather elements with clean, non flammable solvent. If the breather elements remain contaminated after cleaning, discard breathers and obtain new breathers.  Do not attempt to disassemble the breathers.  Allow breathers to dry before installation. Use compressed air to dry if necessary.  Inspect hoses and clamps, replace if damaged.  Coat O-ring seals lightly with clean engine oil.  Re-assemble breathers and fit hoses to the breather outlets.  Tighten clamps.

3-52

Fig. 3-38:

BA 6020B(3 847 000.00)-EN

Inspection and servicing AIR-INTAKE SYSTEM - INFORMATION Risk of injury caused by hot parts of the engine exhaust system.

Let exhaust cool down.

Do not start the engine when parts of the airintake 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.

Read and observe the "Engine - Safety instructions" chapter.

Fig. 3-40:

The engine is equipped with two dry-air filters consisting of Cyclone pre-cleaner, dust trap, main filter element and secondary filter element (Fig. 3-40:).

The Cyclone pre-cleaners are located on the deck of the power module. They work automatically, no cleaning work is necessary.

The two air filters are mounted inside the power module (Fig. 3-39:). One is accessible from the machine’s center and one is accessible from the counterweight-side after opening an access door.

Dust trap - Cleaning The dust trap (arrow, Fig. 3-41:) collects dust and dirt that infiltrates the air filter housing.  Open access doors of the power module.  To remove dust and dirt, squeeze the flexible part of the dust trap several times.

Dust and dirt will be detached and come off.

Fig. 3-39:

Fig. 3-41:

3-53

BA 6020B(3 847 000.00)-EN

Inspection and servicing Primary filter elements – Check, clean, replace Insufficient air-intake performance, caused by a contaminated primary filter element, is displayed on the BCS-screen (Fig. 3-42:).

Clean or renew primary filter elements only if the BCS displays a warning on the screen with the engine running at high speed.

New or cleaned primary filter elements (3, Fig. 3-43:) should always be at hand to shorten hydraulic shovel downtimes.

Removal and installation  Loosen clamps (1, Fig. 3-43:) at the air filter housing and remove cover (2).  Withdraw primary filter element (3).

Do not remove secondary filter element (4).  Replace or clean primary filter element.  Before installing the primary filter element, clean contact faces at cover (2, Fig. 3-43:) and at filter housing.  Put on cover (2) using clamps (1).

Fig. 3-42:

Fig. 3-43:

3-54

BA 6020B(3 847 000.00)-EN

Inspection and servicing Checking and cleaning the primary filter element  Examine the filter paper of the element with a lamp which is introduced into the element (Fig. 3-44:). 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.

Fig. 3-44:

 Blow filter element (Fig. 3-45:) 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 / 43 psi.

Cleaning is terminated when all visible dust has been blown out of the filter element.

Never clean filter element by beating against hard objects.

Replace the primary filter element after 1000 operating hours or 3 cleaning cycles; and, after one year of operation at the latest.

Fig. 3-45:

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BA 6020B(3 847 000.00)-EN

Inspection and servicing Secondary filter element – replace

Clean-air lines and hoses – inspect

Removal and installation

Due to leaks in clean-air lines and hoses contaminated air can enter the engine. Contaminated air damages the engine.

 Replace the secondary filter elements (4, Fig. 3-46:) after 1000 operating hours or 3 cleaning cycles of the primary filter elements. After one year of operation at the latest.

Never clean the secondary filter element, but always renew.  Remove cover (2, Fig. 3-46:) and primary filter element (3) as described above.  Withdraw secondary filter element (4).  Clean the air filter housing.  Install the new secondary filter element and a cleaned or a new primary filter element.

During all work on the air-intake system ensure proper sealing to prevent unfiltered air from reaching the engine.

Inspect all clean-air lines and hoses according to the maintenance plans. Look carefully for damages, leakages and loose clamps.

Replace all defective components immediately.

Check all clamps for proper fixation. All threaded hose clamps must be tightened using a torque wrench.

Double clamps (arrow, Fig. 3-47:) must be arranged 90 degrees offset against each other to ensure leak tightness.

Fig. 3-47:

Fig. 3-46:

3-56

BA 6020B(3 847 000.00)-EN

Inspection and servicing FUEL SYSTEM Fuel system - Safety instructions Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. Therefore, 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.

Diesel fuel may cause skin injury.

Avoid skin contact with diesel fuel.

Wear firm working clothing.

Wear protective gloves or use a barrier cream.

Fuel filters – information The primary fuel filter is mounted inside the power module, nearby the engine (1, Fig. 3-48:). The primary fuel filter acts also as a water seperator.

Two secondary fuel filters are attached directly to a filter head at the engine (2, Fig. 3-48:).

Water in the fuel can cause the engine to run rough.

Water in fuel may cause an electronic unit injector to fail. If the fuel has been contaminated with water, the filter element should be changed before the regular interval.

Do not allow dirt to enter the fuel system. Thoroughly clean the area around a fuel system component that will be disconnected. Fit a suitable cover over disconnected fuel system component.

For further information see: “Engine Operation and Maintenance Manual“.

Before start working on the fuel system: Secure the machine as described in the "Securing the machine" section.

Read and observe the "Inspection and servicing – Safety instructions" chapter.

Fig. 3-48:

3-57

BA 6020B(3 847 000.00)-EN

Inspection and servicing Fuel tank supply valve – function

Primary fuel filter - drain water

The fuel tank supply valve (arrow, Fig. 3-49:) is mounted in the fuel line from the fuel tank to the engine. It is located under the fuel tank.

Read and observe the "Fuel system – Safety instructions” chapter.

This ball valve cuts the fuel flow to the engine when closed.  To close the ball valve, shift the lever in position “0”.  To open the ball valve, shift lever in position “I”.

Read and observe the "Fuel system – Safety instructions” chapter.

Fig. 3-50:

The primary fuel filter (1, Fig. 3-50:) serves also as a water separator. Separated water is catched in bowl (2). Bowl (2) should be monitored daily for signs of water. If water is present, drain the water from the bowl.  Shut off the engine.  Turn the start switch to the “OFF” position  Turn the battery disconnect switch “OFF” when working on the fuel system.

Fig. 3-49:

 Shut off the fuel tank supply valve to the engine.  Use a suitable container to catch the drained water mixture. Dispose of the fluid properly.  Open valve (3) and drain off water until fuel emerges.  Close valve (3).

The water separator is under suction during normal engine operation. Ensure that the drain valve is tightened securely to help prevent air from entering the fuel system.

For further information see: “Engine Operation and Maintenance Manual“.

3-58

BA 6020B(3 847 000.00)-EN

Inspection and servicing Primary fuel filter – replace Read and observe the "Fuel system – Safety instructions” chapter.  Shut off the engine.  Turn the start switch to the “OFF” position  Turn the battery disconnect switch “OFF” when changing fuel filters.  Shut off the fuel tank supply valve to the engine.  Use a suitable container to catch the drained fuel from the filter. Dispose of the fuel properly.  Open valve (3, Fig. 3-51:) and drain off fuel.  Close valve (3).  Remove the fuel filter bowl (2) and wash the fuel filter bowl with clean diesel fuel.  Unscrew fuel filter (1) and dispose of properly.  Clean gasket sealing surface at the filter head.

Ensure that all of the old gasket is removed.  Do not fill new fuel filter with fuel. This prevents the injection system from beeing contaminated by unfiltered fuel after fuel filter change.

Fig. 3-51:

 Apply clean diesel fuel to the new filter gasket and screw it onto the filter head by hand. Use the rotation index marks on the filters as a guide for proper tightening. Tighten the filter for an ¾ turn by hand.

Tightening the filter element with a tool may damage or deform the filter head.  Remove cap (3, Fig. 3-52:) from the bottom of the new fuel filter.  Remove new seal (4) from cap (3) and inspect the seal for damage. Replace the seal if the seal is damaged.

Fig. 3-52:

 Remove old seal inside the bowl (2).  Apply clean diesel fuel to the new seal (4).

Place the seal in the groove in the bowl (2).  Screw fuel filter bowl (2) onto the new fuel filter (1) by hand. Do not overtighten the bowl.  Open the fuel tank supply valve to the engine.  Vent fuel filter, see "Fuel system - venting".  Start engine and check fuel system for leaks.

For further information see: “Engine Operation and Maintenance Manual“.

3-59

BA 6020B(3 847 000.00)-EN

Inspection and servicing Secondary fuel filter – replace Read and observe the "Fuel system – Safety instructions” chapter.  Shut off the engine.  Turn the start switch to the “OFF” position  Turn the battery disconnect switch “OFF” when changing fuel filters.  Shut off the fuel tank supply valve to the engine.  Use a suitable container to catch the drained fuel from the filter. Dispose of the fuel properly.  It may be necessary to relieve residual fuel pressure from the fuel system before removing the fuel filters (2, Fig. 3-53: and arrow, Fig. 3-54:).

Loosen one of the fuel supply connections (1, Fig. 3-54:) in order to purge any residual pressure.

Fig. 3-53:

Do not loosen fuel lines or fittings at the fuel manifold or ECM. The engine components may be damaged.  Remove the used fuel filters and dispose of properly.  Clean gasket sealing surface at the filter head.

Ensure that all of the old gasket is removed.

Do not fill new fuel filter with fuel. This prevents the injection system from beeing contaminated by unfiltered fuel after fuel filter change.

Fig. 3-54:

 Apply clean diesel fuel to the new filter gasket.  Install the new filter.  Spin the new filter onto the fuel filter base until the the gasket contacts the base. Use the rotation index marks on the filters as a guide for proper tightening. Tighten the filter for an additional ¾ turn by hand. Do not overtighten the filter.

For further information see: “Engine Operation and Maintenance Manual“.

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BA 6020B(3 847 000.00)-EN

Inspection and servicing Fuel system – venting

Fuel tank breather filter – replace

Prime the fuel system in order to fill the fuel filter, and prime the fuel system in order to purge trapped air. The fuel system should be primed under the following conditions:

The fuel tank is vented by means of a breather valve (arrow, Fig. 3-56:).



The fuel tank is running low.



The machine has been stored.



The fuel filter is being replaced.

 Place a collecting recipient under the air bleed valve (1, Fig. 3-55:).

 Replace breather valves regularly according to the maintenance plan.

To do so unscrew cap (1) of breather valve and replace with a new one. The filter element is integrated in the cap.

For a better view on the breather filter, the fuel tank is shown in the graphic without the handrails and guards located on top. During machine operation all guards and handrails must be on place.

 Unscrew air bleed valve (1) and switch on the pre-fuel pump with switch (2).  Close air bleed valve (1) and switch off prefuel pump (2) when fuel emerges at the air bleed valve without any bubbles.  Start the engine at low idle.  If the engine runs rough, continue to run the engine at low idle until the engine runs smoothly.

Do not crank the engine continously for more than 30 seconds. Allow the starting motor to cool for two minutes before cranking the engine again.

Fig. 3-56:

Fig. 3-55:

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Inspection and servicing Fuel tank – cleaning Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. Therefore, before working on the fuel tank: Shut off the engine.

Keep away naked flames.

Do not smoke.

Collect escaping fuel and discard without polluting the environment.

Diesel fuel may cause skin injury.

Avoid skin contact with diesel fuel.

Wear firm working clothing.

Wear protective gloves or use a barrier cream.

Do not use white spirit, paraffin oil or other solvents.

For flushing and cleaning use diesel fuel.  Use up as much fuel as possible.  Check how much fuel remains in the tank and place a collecting recipient of sufficient size under the drain plug of the tank.  Shut off the fuel tank supply valve to the engine. To do so, shift lever of the ball valve to position “0” (Fig. 3-57:).  Loosen drain plug (arrow, Fig. 3-57:) and drain off fuel.  Flush tank with diesel fuel.  Inspect fuel tank inside for damages.  Screw drain plug back in place.  Fill in fuel as described in chapter “Refuelling“.

Open fuel tank supply valve.

3-62

Fig. 3-57:

BA 6020B(3 847 000.00)-EN

Inspection and servicing Fuel tank – drain water and sediment Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. Therefore, before working on the fuel tank: Shut off the engine.

Keep away naked flames.

Do not smoke.

Collect escaping fuel and discard without polluting the environment.

Diesel fuel may cause skin injury.

Avoid skin contact with diesel fuel.

Wear firm working clothing.

Wear protective gloves or use a barrier cream.  Shut off the fuel tank supply valve to the engine. To do so, shift lever of the ball valve to position “0” (Fig. 3-57:).

Fig. 3-58:

 Collect escaping liquid in a recipient suitable for diesel fuel and discard without polluting the environment.  Loosen drain plug (arrow, Fig. 3-57:) and drain off water and sediment.  Screw drain plug back in place.  Open fuel tank supply valve. To do so, shift lever of the ball valve to position “I”

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BA 6020B(3 847 000.00)-EN

Inspection and servicing Water trap (optional) – check Read and observe the "Fuel system – Safety instructions” chapter.

Water contained in the fuel is removed by the water trap (Fig. 3-59:).

Draining off water  Carry out the following works in accordance with the servicing schedule and at regular intervals.  Collect escaping liquid in a recipient suitable for diesel fuel and discard without polluting the environment.

Fig. 3-59:

 Loosen venting plug (9, Fig. 3-60:) and leave drain valve (3) open until there is no more water in the diesel fuel flowing out of the valve.

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).

Fig. 3-60:

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Inspection and servicing Checking / cleaning the filter element Replace filter element (6, Fig. 3-61:) only when the suction resistance is too high.  Collect escaping liquid in a recipient suitable for diesel fuel and discard without polluting the environment.  Loosen venting plug (9) and leave drain valve (3) open until the reservoir is completely empty.  Remove cover (5).  Remove spring holder (7) and filter element (6) from filter housing (4).  Check / replace filter element (6).

Fig. 3-61:

 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.

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Inspection and servicing ELECTRICAL SYSTEM Electrical system - Safety instructions

Electrical circuit diagrams

Risk of injury caused by battery acid and gases and short circuits.

Electrical system switch-cabinets

Read and observe the "Inspection and servicing – Safety instructions" chapter.

Carry out every work on the electrical / electronical systems only if you are a qualified electrician and after having received special trainings.

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 BCS.

Alternator - Instructions

The electrical circuit diagrams and wiring diagrams are annexed to the spare-parts list. Further information can be found in the CGM HMS Service Manual "Working with circuit diagrams".

The electrical system switch-cabinets are located in the cab module, in the power module and in front of the hydraulic reservoir. The cabinets and their components are described in the spare-parts list (electrical circuit diagram) together with the designation of the electrical components.

Fuses - information Fuses and their function are listed on a sheet inside the switch-cabinet in the cab module.

There are risks of short circuits and sparking, therefore always deenergize corresponding circuits before remove fuses: 

Shut off the engine,



Switch ignition key of the electrical system to “0” and withdraw,



Switch battery isolator switch to “OFF” and lock.

Never disconnect cables from the alternator and the batteries when the engine is running to avoid damage to the alternator.

Use only original fuses with the specified current rating.

Do not interchange the cables when connecting the battery (observe polarity).

Lamps and bulbs – replace

Carry out voltage and continuity checks only by means of a measuring instrument. Do not check by "touching ground" with a bare wire. The shortcircuit thus produced may damage the alternator and other electronical components like the controller units.

Cables and cable lugs must not get in contact with other metal parts. Replace broken or damaged cables and the respective cable lugs.

3-66

If a bulb does not work after replacement, the pertaining fuses, connection cables and contacts must be checked.

Worklights and maintenance lights as well as the cab lights work with LED-technology. They do not have replacable lamps / bulbs. The light must be replaced if defective.

BA 6020B(3 847 000.00)-EN

Inspection and servicing Charging batteries inside the machine – safety instructions

Charging the batteries  Cut out the battery main switch.  For battery ventilation open the cover of the battery cabinet.

Explosion hazard.

Battery gases are highly flammable.

Keep any potential ignition sources, such as unshielded lights or burning cigarettes, away from the batteries.

 Connect the charging cable to the socket outlet (Fig. 3-62:) at the Service-Station.  Switch on the charger and watch the charging process.

Stop the charging process:

Risk of injury from acid splashes and battery gases.



if the batteries are getting hot,



if acid escapes from the batteries,

Wear safety goggles or a face protection shield and acid proof protective gloves.



if the charge current is still insignificantly low even after 15 minutes of charging.

Do not lean over the batteries while 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.

The batteries of the machine can also be charged while installed in the machine.

For this purpose, the Service-Station (Fig. 3-62:) is equipped with a socket outlet for a charging cable.

Risk of fire.

Do not use the socket outlet (Fig. 3-62:) for jump-starting of the engine.

The connectors and the cables are not designed for the high currents flowing during the starting phase.

Check before charging why the batteries are discharged and replace the batteries if they are defective.

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.

The batteries are fully charged, if 

the charging current and voltage remain constant (for voltage-controlled chargers);



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 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 crosssection of at least 70 mm2.

Fig. 3-62:

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Inspection and servicing Battery - maintenance Battery Posts, terminals and related accessories contain lead and lead compounds, chemicals known to cause cancer and reproductive harm.

Wear protective gloves and firm working clothing.

Wash hands after handling.

Six batteries are located in the battery compartment at the lefthand side of the powermodule (arrow, Fig. 3-63:).

They are accessible after unlocking and swinging the silencer towards the counterweight.

The batteries are sealed, “maintenance free” type batteries. Checking the charge level by measuring the acid concentration is not possible and not necessary here.  Before opening the battery compartment, disconnect the battery isolator switch (2, Fig. 3-64:) and lock with a padlock. Monitoring lamp (4) is off.

Fig. 3-63:

 Check tightness of cable lugs at all battery terminals regularly (see maintenance plan).

Loose or corroded clamping lugs will lead to alternator or regulator overloading.  Check battery terminals for corrosion. If so clean battery terminals and apply special terminal grease or acid-free vaseline on the battery terminal posts and clamping lugs.

Fig. 3-64:

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Inspection and servicing Battery - removing and installing Battery Posts, terminals and related accessories contain lead and lead compounds, chemicals known to cause cancer and reproductive harm.

Wear protective gloves and firm working clothing.

Wash hands after handling.

Read and observe the "Electrical system – Safety instructions" chapter.

The batteries (Fig. 3-65:) are located in the battery compartment at the lefthand side of the powermodule.

The 12-volt batteries are connected in series and in parallel, so that the system voltage is 24 volts.

Disconnect and reconnect the terminal clamping lugs in the prescribed order.

Disconnecting and connecting in the wrong order may cause short-circuits and burns.

 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.  Disconnect the battery isolator switch.  Unscrew the silencer and swing towards the counterweight.  Open the battery compartment and detach the battery holders.  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.  Lift battery out of battery box.

Before installing new batteries, 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 bolts of the cable lugs. Do not use too much force to avoid deformation.  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.

Fig. 3-65:

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BA 6020B(3 847 000.00)-EN

Inspection and servicing Equipotential bonding – inspect The frame of the hydraulic shovel is used as electrical ground (negative (-) earth).

The electric current must be able to flow undisturbed to the frame.

The individual modules of the machine are therfore interconnected by electrical wires (equipotential bonding).

Check all screwed connections for corrosion and for proper tightening.

Position of electrical connections Bonding

Fig.

Operator's cab – cab module

Fig. 3-66: Fig. 3-67: Fig. 2-66: Fig. 2-67:

Main frame – LH walkway (LH side of the machine) Main frame – RH walkway Main frame – hydraulic tank Main frame – ballast Main frame – power module (LH side of the machine) Main frame – fuel tank Main frame – cab module

Fig. 3-66:

Fig. 2-68: Fig. 2-69: Fig. 3-67:

Fig. 3-68:

Continued next page

3-70

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Inspection and servicing Equipotential bonding – inspect (continued)

Fig. 3-69:

Fig. 3-71:

Fig. 3-70:

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BA 6020B(3 847 000.00)-EN

Inspection and servicing Lighting systems in LED technonogy - instructions The lights of the maintenance lighting system (sample, Fig. 3-72) as well as the working floodlights (sample, Fig. 3-73) are equipped with lamps in LED technology (light-emitting 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. 3-72

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. 3-73

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BA 6020B(3 847 000.00)-EN

Inspection and servicing HYDRAULIC SYSTEM Hydraulic system - Safety instructions Hydraulic oil under pressure!

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.

Hydraulic system - depressurize Hydraulic systems may only be opened if they are completely depressurized. Even when an hydraulic shovel is parked on a horizontal surface with the working equipment resting on the ground (Fig. 3-74:) and with its 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.

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:  Locate the system section to be opened.

Risk of burning caused by hot hydraulic oil components (e.g. hydraulic oil tank, cylinder, valves).

Contact with hydraulic oil can cause skin injury.

 Depressurize the section to be opened. If required, the necessary measures described must be combined.  Open the depressurized system section with caution.

Avoid skin contact with hydraulic oil.

Wear protective gloves and firm working clothing.

Secure the machine as described in the "Securing the machine“ section.

Read and observe the "Inspection and servicing – Safety instructions" chapter.

Fig. 3-74:

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BA 6020B(3 847 000.00)-EN

Inspection and servicing Examples of system sections: 1) working hydraulics,

Hydraulic oil level - check

2) pilot control circuit,

 Bring hydraulic oil to operating temperature (abt. 50 °C / 122 °F).

3) precharged return-flow line.

 Park the machine on a horizontal surface.

Depressurizing

 Move all hydraulic cylinders to their central positions.

 Park the hydraulic shovel on a horizontal surface.  Set the working equipment on the ground (Fig. 3-74:).  Shut off the engine.  Do not switch off the electrical system.

Sections 1) and 2): Pilot control and working hydraulics

The oil level must lie between the “min” and “max” marks of films (2, Fig. 3-76:) near the level indicator tube (1).

The hydraulic oil level is also monitored by the BCS. The BCS displays a warning on the screen (Fig. 3-77:) if the hydraulic oil level is too low or too high.  Shut off the engine, locate cause and rectify.

 Shift both control levers and all pedals repeatedly into all directions (Fig. 3-75:).

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.

Fig. 3-76:

Fig. 3-75:

Fig. 3-77:

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BA 6020B(3 847 000.00)-EN

Inspection and servicing

 Before fitting the lid (2), check the sealing ring and replace, if damaged.  Fit lid (2) together with sealing ring.

Fig. 3-78:

 Stand working equipment on the ground as shown on films (Fig. 3-78:).

Films (2, Fig. 3-79:) are attached beside the level indicator tube (1).

Fig. 3-80:

Hydraulic oil (Oil grade see: “LUBRICANTS / CONSUMABLES” section) can also be filled in by means of the Service Station (Fig. 3-81:).  Remove cap of express coupling (5).

Connect filling hose of the service vehicle.  Set lever of the ball valve to position “I”.  Fill in hydraulic oil until the oil level lies between the “min” and “max” marks of the sign (2, Fig. 3-79:) near the level indicator tube (1).

The indicator light “Hydraulic tank full” (6, Fig. 3-81:) at the Service-Station lights up.  Remove the filling hose; the express coupling closes automatically.  Set lever of the ball valve to position “0”.  Fit protective cap back in place.

Fig. 3-79:

 Fill in small amounts of hydraulic oil through the return-flow filters. (Oil grade see: “LUBRICANTS / CONSUMABLES” section).  To do so, remove lid (2, Fig. 3-80:).  Fill in hydraulic oil through the opening until the oil level lies between the “min” and “max” marks of the films (2, Fig. 3-79:) near the level indicator tube (1).

(Oil grade see: “LUBRICANTS / CONSUMABLES” section).

Fig. 3-81:

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BA 6020B(3 847 000.00)-EN

Inspection and servicing

Hydraulic oil return-flow filters (hydraulic oil reservoir) - replace

Return-flow filters – remove  Unscrew plug (2, Fig. 3-83:), this releases residual air pressure.  Remove cover (1) together with sealing ring (3).

Risk of scalding caused by hot hydraulic oil.

 Remove bracket (4).

The hydraulic oil reservoir itself may also be hot.

 Remove press parts (5) together with O-rings (6) and (7).

Shut off the engine and let the system cool down before starting work.

 Withdraw filter elements (8) from basket (12).

Skin contact with hydraulic oil may cause skin injury. Avoid skin contact.

 Check filter elements for damages.

If not damaged, insert new filter elements.

Dispose used elements off properly.

Wear protective gloves and firm working clothing.

Collect escaping hydraulic oil and discard without polluting the environment.

 If a filter element is damaged, remove basket (12) and check, see “Filter basket - remove / check”.

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 BCS displays a warning on the screen (Fig. 3-82:). In this case, the filter elements (8, Fig. 3-83:) are heavily contaminated;



after repairs on the hydraulic system;



in case of damage.

Fig. 3-82:

Fig. 3-83:

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BA 6020B(3 847 000.00)-EN

Inspection and servicing Return-flow filters – install  Insert new filter elements (8, Fig. 3-84:) watching the correct direction. The elements are marked “TOP”.  Insert new O-rings (6) and (7) into press parts (5).  Put press parts (5) on top of filter elements (8).  Attach bracket (4).  Clean magnetic rod (3, Fig. 3-85:). The magnetic rod is attached to lid (2).

If metal filings are detected, locate cause and rectify. Contact your Caterpillar dealer service, if required.

It is absolutely necessary to find out where the filings come from. Otherwise serious damage of hydraulic components may occur.  Attach lid (2) with magnetic rod.  Attach lid (1, Fig. 3-84:) together with new sealing ring (3).

Crossover-tighten bolts with torque (79Nm).

Fig. 3-84:

 Replace also the return-flow filters in the filter housing (cooling-system).

(See: "Hydraulic oil return-flow filters (filter housing) - replace“).

Filter basket – remove / check In case one of the filter elements is found damaged, remove basket (12, Fig. 3-84:) and check.

To do so:  Loosen bolts (9) and take off washer (10) and bracket (11).  Remove basket (12) and clean in paraffin oil.

Fig. 3-85:

 Check filter housing inside the hydraulic tank for soiling and clean if necessary.  If significant debris or foreign particles were found contact your Caterpillar dealer service.

It is absolutely necessary to find out where the debris and particles come from. Otherwise serious damage of hydraulic components may occur.  After cleaning refit basket (12).  Attach brackets correctly, fit washers to bolts (9) and tighten bolts with torque (YY Nm).  Insert new filter elements, see „Return flowfilters - install“.

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BA 6020B(3 847 000.00)-EN

Inspection and servicing Hydraulic oil return-flow filters (filter housing) - replace Risk of scalding caused by hot hydraulic oil.

The hydraulic oil reservoir itself may also be hot.

Shut off the engine and let the system cool down before starting work.

Skin contact with hydraulic oil may cause skin injury. Avoid skin contact.

Wear protective gloves and firm working clothing.

Collect escaping hydraulic oil and discard without polluting the environment. Dispose used filter elements off properly.

Read and observe the "Inspection and servicing – Safety instructions" chapter.  Replace the return-flow filters (8, Fig. 3-86:) together with the return-flow filters in the hydraulic oil tank.  Detach lids (1) together with sealing rings (2).  Unscrew bolts (3) and take off washer (4) and bracket (5).  Withdraw press parts (6) and O-rings (7).  Withdraw filter elements (8).  Check filter elements for damages and particles.  If significant debris or foreign particles were found contact your Caterpillar dealer service.

It is absolutely necessary to find out where the debris and particles come from. Otherwise serious damage of hydraulic components may occur.  Inspect filter housings for contamination, clean if necessary.  Insert new filter elements (8) watching the correct direction. The elements are marked “TOP”.  Insert press parts (6) with new O-rings (7).  Attach brackets (5) correctly, fit washers (4) to bolts (3) and tighten bolts with torque (YY Nm).  Refit lids (1) with new sealing rings (2).

3-78

Fig. 3-86:

BA 6020B(3 847 000.00)-EN

Inspection and servicing Bypass valves (hydraulic oil tank) – clean / replace Risk of scalding caused by hot hydraulic oil.

The hydraulic oil reservoir itself may also be hot.

Shut off the engine and let the system cool down before starting work.

Replacing the bypass valves and sealing rings  Remove damaged bypass valve as described under "Cleaning the filter screens".  Insert new bypass valves (3, Fig. 3-88:) with bracket (2) and new sealing ring (4) and fasten with bolts (1).  Refit lids (arrows, Fig. 3-87:) with sealing rings.

Skin contact with hydraulic oil may cause skin injury. Avoid skin contact.

Wear protective gloves and firm working clothing.

Collect escaping hydraulic oil and discard without polluting the environment.

Read and observe the "Inspection and servicing – Safety instructions" chapter.

The six bypass valves (3, Fig. 3-88:) are accessible after the lids (arrows, Fig. 3-87:) have been removed.

Fig. 3-87:

Cleaning the filter screens  Remove lids (arrows, Fig. 3-87:) together with sealing rings.  Unscrew bolts (1, Fig. 3-88:).  Withdraw bypass valves together with brackets (2) and sealing ring (4).  Clean in white spirit or paraffin oil. Replace, if damaged.  Check sealing rings (4) for damage and replace, if required.  Insert cleaned bypass valves and fasten with brackets (2) and bolts (1).

Fig. 3-88:

 Refit lids (arrows, Fig. 3-87:) with sealing rings.

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Inspection and servicing Hydraulic tank angled screens inspect

Hydraulic tank breather filter - replace

Risk of scalding caused by hot hydraulic oil.

Risk of scalding caused by hot hydraulic oil.

The hydraulic oil tank itself may also be hot.

The hydraulic oil tank itself may also be hot.

Shut off the engine and let the system cool down before starting work.

Shut off the engine and let the system cool down before starting work.

Skin contact with hydraulic oil may cause skin injury. Avoid skin contact.

Skin contact with hydraulic oil may cause skin injury. Avoid skin contact.

Wear protective gloves and firm working clothing.

Wear protective gloves and firm working clothing.

Collect escaping hydraulic oil and discard without polluting the environment.

Collect escaping hydraulic oil and discard without polluting the environment.

Read and observe the "Inspection and servicing – Safety instructions" chapter.

Read and observe the "Inspection and servicing – Safety instructions" chapter.

Inspecting the angled screens

Replacing the filter elements

The angled screens (arrow, Fig. 3-89:) are installed inside the hydraulic tank.

The breather filters (4, Fig. 3-90:) are installed on top of the hydraulic tank.

They eliminate large particles from the hydraulic oil.

They ensure venting of the hydraulic oil tank at varying hydraulic oil levels.

The angled screens are visible after detaching the hydraulic tank lid with the breather filters.

To replace:

Inspect the screens for damage and contamination. Use a torch if necessary.

 Remove holding brackets (2) with sealing rings (3)

 Unscrew bolts (1).

 Withdraw filter elements (4).  Check filter elements and replace, if required.

Fig. 3-89:

Fig. 3-90:

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Inspection and servicing Filter (pilot hydraulic circuit) - replace The pilot hydraulic circuit (servo circuit) is equipped with a high-pressure filter (Fig. 3-91:).

On top of the filter head there is an electronic contamination switch (arrow, Fig. 3-91:) which gives a signal to the BCS in case the filterelement is contaminated. A red signalizing pin is visible on the switch as well.

Replacing the filter element Replace filter element regulary according to the maintenance plans and when the BCS indicates a contamination.  Depressurize the pilot hydraulic circuit.  Unscrew filter housing (3, Fig. 3-92:).  Withdraw filter element (2) from filter housing.  Clean filter housing and the sealing face at the filter head with white spirit or paraffin oil.  Insert new filter element into filter housing (3) and refit to the filter head with new, lightly oiled sealing ring (1).

Risk of scalding caused by hot hydraulic oil.

The filter housing itself may also be hot.

 Check for leaks after putting the hydraulic system into operation.

Shut off the engine and let the system cool down before starting work.

Skin contact with hydraulic oil may cause skin injury. Avoid skin contact.

Wear protective gloves and firm working clothing.

Collect escaping hydraulic oil and discard without polluting the environment.

Read and observe the "Inspection and servicing – Safety instructions" chapter.

Fig. 3-91:

Fig. 3-92:

3-81

BA 6020B(3 847 000.00)-EN

Inspection and servicing High-pressure filter for working hydraulics - replace

Replacing the filter elements

To filter the hydraulic oil on the high-pressure side of the working hydraulic system, the machine is equipped with six high-pressure filters (Fig. 3-93:).

The filters are located in the pump compartment, one set of four filters and one set of two filters.

 Unscrew drain plug (6, 7, Fig. 3-94:) and drain the hydraulic oil from the filter housing (5).

(Place a suitable resipient under the filter housing).

 Depressurize the hydraulic system.

 Unscrew filter housing (5).  Disengage filter element (2) with a slight turn from its retaining catch and withdraw from filter head.  Clean filter housing (9, Fig. 3-94:) and the sealing faces at the filter head with white spirit or paraffin oil.  Insert new filter element (2) with a new, lightly oiled O-ring (1) to the filter head.  Refit filter housing (5) with new, lightly oiled Oring (3) and retaining ring (4) to the filter head.  Screw in drain plug (6 and 7).  Check for leaks after putting the hydraulic system back into operation.

Fig. 3-93:

Risk of scalding caused by hot hydraulic oil.

The filter housing itself may also be hot.

Shut off the engine and let the system cool down before starting work.

Skin contact with hydraulic oil may cause skin injury. Avoid skin contact.

Wear protective gloves and firm working clothing.

Collect escaping hydraulic oil and discard without polluting the environment.

Read and observe the "Inspection and servicing – Safety instructions" chapter.

3-82

Fig. 3-94:

BA 6020B(3 847 000.00)-EN

Inspection and servicing Hydraulic oil - change Risk of scalding caused by hot hydraulic oil.

The hydraulic oil tank itself may also be hot.

Shut off the engine and let the system cool down before starting work.

Skin contact with hydraulic oil may cause skin injury. Avoid skin contact.

Wear protective gloves and firm working clothing.

Collect escaping hydraulic oil and discard without polluting the environment.

Read and observe the "Inspection and servicing – Safety instructions" chapter.

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

Do not start up the drive engine when the hydraulic oil tank 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 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 assumes no warranty for damage caused as a result of the machine having been operated with consumables of inappropriate specification or with mixed fluids.

3-83

BA 6020B(3 847 000.00)-EN

Inspection and servicing Hydaulic oil - Draining off  Bring the hydraulic oil to operating temperature (abt. 50 ° C / 122 °F).  Retract the hydraulic cylinders as far as possible and stand the working equipment on the ground.  Shut off the engine.  Remove protective cap of express coupling (5, Fig. 3-95:).  Connect hose line of the service vehicle.  Set lever of the ball valve to position “I”.  Draw off hydraulic oil.

Fig. 3-95:

 Remove hose line. The coupling closes automatically.  Put protective cap back in place.  Place suitable recipients under the drain plug of the hydraulic oil tank (arrow, Fig. 3-97:), under the drain valve of the oil suction line (Fig. 3-96:) and under the drain valve of the hydraulic oil cooler.  Unscrew drain plugs and drain hydraulic oil.

Collect escaping hydraulic oil and discard without polluting the environment.  Clean the hydraulic oil tank (see: “Hydraulic oil tank – clean”).

Fig. 3-96:

Fig. 3-97:

3-84

BA 6020B(3 847 000.00)-EN

Inspection and servicing Hydraulic oil tank - clean

Explosion hazard.

Shut off the engine.

Do not use white spirit, paraffin oil or other solvents for cleaning.

Use diesel fuel or a special flushing oil.

Skin contact with hydraulic oil, diesel fuel or flushing oil may cause skin injury. Avoid skin contact.

Wear protective gloves and firm working clothing.

Dispose of contaminated hydraulic oil without polluting the environment and separately from other waste.

Read and observe the "Inspection and servicing Safety instructions" chapter.

Fig. 3-98:

 Drain off hydraulic oil as described under "Hydraulic oil - draining off".  Close shutoff valves on the front and on the rearside of the hydraulic tank (arrows, Fig. 3-98:).  Remove lids on top of the hydraulic tank (arrows, Fig. 3-99:).  Detach the return-flow filters.  Place a collecting recipient for the flushing oil under the hydraulic oil tank.  Unscrew the drain plug of the hydraulic tank (arrow, Fig. 3-97:).  Clean the inside of the hydraulic oil tank with diesel fuel or flushing oil.

Remove all sediments and also the residues of the cleaning agent thoroughly.

Fig. 3-99:

 Refit drain plug (arrow, Fig. 3-97:).  Refit return flow filters (see : “Return flowfilters – install”).  Attach lids (arrows, Fig. 3-99:).  Open shutoff valves on the front and on the rearside of the hydraulic tank (arrows, Fig. 3-98:).  Fill in fresh hydraulic oil.

(Oil grade see: " LUBRICANTS / CONSUMABLES" section).

3-85

BA 6020B(3 847 000.00)-EN

Inspection and servicing Hydraulic oil - filling in Fill in small amounts of hydraulic oil through the return-flow filters. To do so:

Hydraulic oil can also be filled in by means of the Service-Station (Fig. 3-102:).

 Remove lid (arrow, Fig. 3-100:).

 Remove protective cap of express coupling (5). Connect filling hose from the service vehicle.

 Fill in hydraulic oil through the opening until the oil level is between the “min” and “max” marks of the film (2, Fig. 3-101:) near the level indicator tube (1).

(Oil grade see: "LUBRICANTS / CONSUMABLES" section).

 Fill in hydraulic oil until the oil level is between the “min” and “max” marks of the film (2, Fig. 3-101:) near the level indicator tube (1).

(Oil grade see: " LUBRICANTS / CONSUMABLES" section).

 Vent the hydraulic system (see: ”Hydraulic system venting”).  Check the oil level in the hydraulic oil tank again. Top up with oil, if required.  Refit lid (arrow, Fig. 3-100:).

 Set lever of the ball valve to position “I”.

 The indicator light “Hydraulic tank full” (6, Fig. 3-102:) lights up.

The oil level is also displayed on the BCSscreen (Fig. 3-103:).  Vent the hydraulic system (see: ”Hydraulic system - venting”).  Check the oil level in the hydraulic oil tank again. Top up with oil, if required.  Disconnect the filling hose. The express coupling closes automatically.  Set lever of the ball valve to position “0”.  Put protective cap back in place.

Fig. 3-100:

Fig. 3-102:

Fig. 3-101:

Fig. 3-103:

3-86

BA 6020B(3 847 000.00)-EN

Inspection and servicing

Hydraulic system - venting Hydraulic pumps, hydraulic motors, hydraulic cylinders, travel brake valves, suction lines of hydraulic pumps, oil cooler manifolds and the pilot control system must be vented 

after assembly on site and prior to initial commissioning,



before each recommissioning of the hydraulic shovel, 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. 3-105:

Venting the hydraulic components 

Hydraulic pumps and hydraulic motors (with engine shut off):

Always admit oil first to that side of the cylinder where the piston (2) is. This is

Open the highest leakage oil port and fill in clean hydraulic oil up to the lower edge of the opening.

• the piston-side port (3) when the piston rod is retracted (1, Fig. 3-104:), • the rod-side port (4) when the piston rod is extended (1, Fig. 3-105:).

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. 3-104: and Fig. 3-105:) must be either completely retracted or completely extended.

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 screws/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 pilot system at the venting screws of the control blocks (under the pilot caps),



the intake line at the venting screw (with engine stationary).

Fig. 3-104:

3-87

BA 6020B(3 847 000.00)-EN

Inspection and servicing Hydraulic oil cooler - clean

Cleaning The hydraulic oil coolers are located in the right side of the power modul, near by the pump compartment (Fig. 3-106:).

Risk of injury from rotating cooler fan blades.

Never start cleaning work until the cooler fan blades have stopped turning.

Clean the hydraulic oil cooler at regular intervals.  Shut off the engine.  Remove any accumulated dirt.

Shut off the engine.

 Clean the fan blades.

The hydraulic oil cooler reach the same temperature as the hydraulic oil. Risk of burning.

 Clean the radiator with a jet of water or compressed air from outside to inside.

Allow the hydraulic oil cooler to cool down.

Wear protective gloves and firm protective clothing.

 Leave hydraulic oil cooler to dry.  Check the hydraulic motor for free movement.

If the machine is used in places with heavily contaminated ambient air, the hydraulic oil cooler must be cleaned more often than specified in the servicing plan.

The speed of the fan motor depends on the temperature of the hydraulic oil. Speed is electronically controlled. The fan motor runs at maximum speed when the hydraulic oil temperature reaches ca.

60°C / 140°F. In winter-time, check that the fan turns freely and that the fan blades and cooling fins are free from ice and snow.

Fig. 3-106:

3-88

BA 6020B(3 847 000.00)-EN

Inspection and servicing Pressure accumulator - emergency lowering and pilot circuit

Pressure accumulator inspection regulations

To permit the working equipment to be lowered in an emergency, the machine is equipped with a pressure accumulator (arrow, Fig. 3-107:).

Hydraulic accumulators are pressure vessels and are therefore subject to several safety regulations and laws. Please observe the relevant regulations in force in your own country before working on pressure accumulators.

The pressure accumulator is located on the hydraulic oil tank wall. It is a component integrated in the pilot hydraulic circuit.

This pressure accumulator contains high pressure gas (Nitrogen).

Failure to follow the instructions and warnings could cause an explosion, resulting in possible injury or death.

The accumulator vessel must not be subjected to welding, soldering or any other mechanical work. Do not expose to fire.

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.

Read and observe all safety films attached on or nearby the pressure accumulator.

Pressure accumulator – checking gas pressure 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.

Checking the gas charging pressure in the pressure accumulator is described in the “Service Manual”.

See your Caterpillar Dealer for tools and detailed information.

Fig. 3-107:

3-89

BA 6020B(3 847 000.00)-EN

Inspection and servicing PUMP DRIVE GEARBOX P/N 3855122

Pump drive gearbox - checking the oil level / Topping up with oil  Park the machine as described under "Securing the machine".

Risk of scalding caused by hot gearbox oil.

 Unscrew dipstick (1, Fig. 3-108:) and wipe.

The gearbox housings may be hot, too.

 Insert dipstick until the thread reaches the top of dipsticks housing, do not screw in.

Shut off the engine and let cool down.

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.

Read and observe: "Inspection and servicing Safety instructions”.

To identify the gearbox partnumber (P/N) check the name plate attached to the gearbox.

 Withdraw a second time.

Oil level should be between the two dipstick markers “min” and “max”.

Top up with gearbox oil if required. Fill in gearbox oil through dipsticks bore.

(Oil grade see: „LUBRICANTS / CONSUMABLES“ section).  Screw in dipstick (1) back in place.  In case of significant oil losses check for leaks on the gearbox and on all components of the gearbox oil cooling circuit.

Fig. 3-108:

3-90

BA 6020B(3 847 000.00)-EN

Inspection and servicing Pump drive gearbox - change oil Change the oil when the gearbox is at operating temperature. Warm oil flows better and carries suspended particles (carbon or abraded matter) better.

Filling in gearbox oil (Oil grade see: „LUBRICANTS / CONSUMABLES“ section).  Fill in gearbox oil with the Service Station (Fig. 3-109:) through express coupling (4).

Drawing off gearbox oil

 Connect hose line of the service vehicle.

The gearbox oil is drained with the Service-Station (Fig. 3-109:) through express coupling (4).

 Fill in gearbox oil.

The oil level must reach the upper mark “max” on dipstick (1, Fig. 3-111:).

 Remove protective cap of express coupling (4).

 Fill gearbox oil cooler with gearbox oil.

 Connect hose line of the service vehicle.

 Remove hose after the oil has been filled in.

The coupling closes automatically.

 Set lever of the ball valve to position “I”.  Draw off gearbox oil.  Drain gearbox oil from the oil cooler (Fig. 3-110:).  Fill in fresh gearbox oil (see: “Filling in gearbox oil”).

Fig. 3-109:

 Set lever of the ball valve to position “0”.  Put protective cap back in place.  Check for leaks and for correct filling level after putting the machine back into operation.

Top up with gearbox oil if required.

Fig. 3-111:

Fig. 3-110:

3-91

BA 6020B(3 847 000.00)-EN

Inspection and servicing Pump drive gearbox breather – replace The pump drive gearbox is vented through a breather, mounted on top of the gearbox housing (arrow, Fig. 3-112:).  Replace breather in accordance with the servicing plan.  Clean area around the breather to prevent contamination of the gearbox.  Unscrew breather and replace by a new one.

Fig. 3-112:

3-92

BA 6020B(3 847 000.00)-EN

Inspection and servicing PUMP DRIVE GEARBOX P/N 3855121

Risk of scalding caused by hot gearbox oil.

The gearbox housings may be hot, too.

Shut off the engine and let cool down.

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.

Read and observe: "Inspection and servicing Safety instructions.

To identify the gearbox partnumber (P/N) check the name plate attached to the gearbox.

Fig. 3-113:

Pump drive gearbox - checking the oil level / Topping up with oil  Park the machine as described under "Securing the machine".  Unscrew dipstick (1, Fig. 3-113: and Fig. 3-114:) and wipe.  Insert dipstick until the thread reaches the top of dipstick’s tube, do not screw in (2, Fig. 3-114:).  Withdraw a second time.

Oil level should be between the two dipstick markers “min” and “max”.

Top up with gearbox oil if required. Fill in gearbox oil through dipsticks bore.

(Oil grade see: „LUBRICANTS / CONSUMABLES“ section).

Fig. 3-114:

 Screw in dipstick (1) back in place.

3-93

BA 6020B(3 847 000.00)-EN

Inspection and servicing Pump drive gearbox - change oil Change the oil when the gearbox is at operating temperature. Warm oil flows better and carries suspended particles (carbon or abraded matter) better.

Filling in gearbox oil (Oil grade see: „LUBRICANTS / CONSUMABLES“ section).  Fill in gearbox oil with the Service Station (Fig. 3-115:) through express coupling (4).

Drawing off gearbox oil

 Connect hose line of the service vehicle.

The gearbox oil is drained with the Service-Station (Fig. 3-115:) through express coupling (4).

 Fill in gearbox oil.

The oil level must reach the upper mark “max” on dipstick (1, Fig. 3-117:).

 Remove protective cap of express coupling (4).

 Fill gearbox oil cooler with gearbox oil.

 Connect hose line of the service vehicle.

 Remove hose after the oil has been filled in.

The coupling closes automatically.

 Set lever of the ball valve to position “I”.  Draw off gearbox oil.  Drain gearbox oil from the oil cooler (Fig. 3-116:).  Fill in fresh gearbox oil (see: “Filling in gearbox oil”).

 Set lever of the ball valve to position “0”.  Put protective cap back in place.  Check for leaks and for correct filling level after putting the machine back into operation.

Top upwith gearbox oil if required.

Fig. 3-115:

Fig. 3-117:

Pump coupling housing – oil filling The coupling housings between pumps and gearbox housing have lifetime oil fillings. It is not necessary to change oil regularly.

Change oil when repair work is to be done and the pump is unmounted.

Fig. 3-116:

3-94

BA 6020B(3 847 000.00)-EN

Inspection and servicing Pump drive gearbox breather replace The pump drive gearbox is vented through a breather, mounted on top of the gearbox housing (arrow, Fig. 3-118:).  Replace breather in accordance with the servicing plan.  Clean area around the breather to prevent contamination of the gearbox.  Unscrew breather and replace by a new one.

Fig. 3-118:

3-95

BA 6020B(3 847 000.00)-EN

Inspection and servicing Pump drive gearbox oil filter – replace In the oil cooling circuit of the pump drive gearbox oil there is a filterelement (arrow, Fig. 3-119:).

Check filter tell-tale (1, Fig. 3-120:) regulary - at operating temperature - for indication of contamination.

If the red sector is visible through transparent cap (2), the filter element must be replaced.

Filter element (5) must be replaced after 1000 operating hours at the latest.

To do so:  Remove flange (3, Fig. 3-120:).  Pour oil out of filter pot (4) and remove filter element (5).  Clean filter head (6, Fig. 3-120:) and filter pot (4).  Place new filter element into filter pot. Oil the new O-ring (7) lightly and attach.

Fig. 3-119:

 Re-assemle filter pot (4) with flanges (3).  Check filter for leakage after recommencing operation.

Fig. 3-120:

Fig. 3-121:

3-96

BA 6020B(3 847 000.00)-EN

Inspection and servicing

(For swing gearbox P/N 3857027 only)

Swing gearbox – checking the oil level / Topping up with oil

Risk of scalding caused by hot gearbox oil.

 Park the machine as described under "Securing the machine".

SWING GEARBOX P/N 3857027

The gearbox housings may be hot, too.

Shut off the engine and let cool down.

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.

Read and observe: "Inspection and servicing Safety instructions.

 Screw out dipstick (Fig. 3-122:) and wipe clean.  Insert dipstick fully again (do not screw in) and withdraw a second time.

Oil level should be between the two dipstick markers “min” and “max”.

Top up with gearbox oil if required. Fill in gearbox oil through dipsticks bore.

(Oil grade see “LUBRICANTS / CONSUMABLES” section).  Screw dipstick back in place.

To identify the gearbox partnumber (P/N) check the name plate attached to the gearbox.

Fig. 3-122:

3-97

BA 6020B(3 847 000.00)-EN

Inspection and servicing Swing gearbox – change oil Change the oil when the machine is at operating temperature. Warm oil flows better and carries suspended particles (carbon or abraded matter) better.  Prepare a collecting recipient for used oil.

Choose the required capacity in accordance with the "Refilling quantities - Oil" table.

Draining off oil The swing gearboxes are equipped with automatic drain valves (arrow, Fig. 3-123:).

These automatic drain valves permit oil changes without polluting the environment.

The drain valves are accessible from ground at the center of the carbody.

Fig. 3-123:

Change oil as follows:  Unscrew protective cap from automatic drain valve (1, Fig. 3-124:).  Screw on draining hose (2) to open the valve, so that the oil can flow out.  When the oil has drained away, unscrew hose line to allow the valve to close automatically.  Screw protective cap back in place.

Filling in new oil / Topping up  Unscrew plug (arrow, Fig. 3-125:) and fill in new oil.

(Oil grade see “LUBRICANTS / CONSUMABLES” section).

Fig. 3-124:

 Check oil level with dipstick (Fig. 3-122:).  Screw in plug (arrow, Fig. 3-125:) again.

Fig. 3-125:

3-98

BA 6020B(3 847 000.00)-EN

Inspection and servicing Swing gearbox breather – replace The swing gearbox is vented through a breather, mounted on top of the gearbox housing (arrow, Fig. 3-125:).  Replace breather in accordance with the servicing plan.  Clean area around the breather to prevent contamination of the gearbox.  Unscrew breather and replace by a new one.

Fig. 3-126:

3-99

BA 6020B(3 847 000.00)-EN

Inspection and servicing TRAVEL GEARBOX

Travel gearbox main stage Checking the oil level / Topping up with oil

Risk of scalding caused by hot gearbox oil.

 Move the hydraulic shovel into such a position that the screw plugs (1, 2 and 3, Fig. 3-127:) are in the displayed position.

The gearbox housings may be hot, too.

Shut off the engine and let cool down.

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.

Read and observe: "Inspection and servicing Safety instructions.

 Clean the screw plugs and the area around carefully.  Unscrew checking screw (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” section).  Screw checking plug (1) back in place.

Fig. 3-127:

3-100

BA 6020B(3 847 000.00)-EN

Inspection and servicing Travel gearbox pre-stage - Checking the oil level / Topping up with oil

Travel gearbox brake housing Checking the oil level / Topping up with oil

 Open cover of the travel motors.

 Clean the screw plugs and the area around carefully.

 Check oil level at the inspection glass (3, Fig. 3-128:). The oil level should the center of the inspection glass.

If required screw out plug (1) and top up with gearbox oil through the opening.

(Oil grade see “LUBRICANTS / CONSUMABLES” section).  Screw in plug (1) back in place.

 Unscrew checking plug (2, Fig. 3-129:).

The oil level should reach up to the lower edge of the opening. If required screw out plug (1) and top up with gearbox oil through the opening.

(Oil grade see “LUBRICANTS / CONSUMABLES” section).  Screw checking plug (2) back in place.

Fig. 3-128: Fig. 3-129:

3-101

BA 6020B(3 847 000.00)-EN

Inspection and servicing Travel motor coupling housing Checking the oil level / Topping up with oil  Clean the screw plugs and the area around carefully.

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

 Unscrew checking plugs (2, Fig. 3-129:).

The oil level should reach up to the lower edge of the opening. If required screw out breather (1) and top up with gearbox oil through the opening.

(Oil grade see “LUBRICANTS / CONSUMABLES” section).

Draining off oil

 Screw checking plugs (2) back in place.

 Place a collecting recipient for used oil under the travel gearbox.

Choose the required capacity in accordance with the "Refilling quantities - Oil" table.

 Move the hydraulic shovel into such a position that the screw plugs (1, 2 and 3, Fig. 3-131:) are in the displayed position.  Clean the screw plugs and the area around carefully.

 Unscrew drain plug (3) and drain off the oil completely.

Slackening plug (2) allows the oil to run out more readily.  Clean screw plugs (2 and 3)  Screw screw plug (3) back in place.

Filling in oil  Unscrew screw plug (1).

Fig. 3-130:

 Fill in oil through opening of plug (2) until it flows out of opening of plug (1).

(Oil grade see “LUBRICANTS / CONSUMABLES” section).  Screw plugs (1 and 2) back in place.

Fig. 3-131:

3-102

BA 6020B(3 847 000.00)-EN

Inspection and servicing Travel gearbox pre-stage Changing oil

Travel motor coupling housing Changing oil

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

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

Draining off oil

Draining off oil

 Open cover of the travel motors.

 Open cover of the travel motors.

 Place a collecting recipient for used oil under the gearbox pre-stage.

Choose the required capacity in accordance with the "Refilling quantities - Oil" table.

 Place a collecting recipient for used oil under the brake housing.

Choose the required capacity in accordance with the "Refilling quantities - Oil" table.

 Unscrew drain plug (2, Fig. 3-132:) and drain off the oil completely.

Slackening plug (1) allows the oil to run out more readily.

 Unscrew drain plugs (3, Fig. 3-134:) and drain off the oil completely.

Slackening breather (1) allows the oil to run out more readily.

 Clean screw plugs (1 and 2)

 Clean screw plugs (3).

 Screw screw plug (2) back in place.

 Screw plugs (3) back in place.

Filling in oil

Filling in oil

 Fill in oil through opening of plug (1) until it reaches the center of inspection glas (3).

(Oil grade see “LUBRICANTS / CONSUMABLES” section).

 Unscrew screw plug (2).

 Screw plug (1) back in place.

 Fill in oil through opening of breather (1) until it flows out of opening of plug (2).

(Oil grade see “LUBRICANTS” section).  Screw plugs (2) and breathers (1) back in place.

Fig. 3-132: Fig. 3-133:

3-103

BA 6020B(3 847 000.00)-EN

Inspection and servicing Travel gearbox brake housing Changing oil

Travel gearbox breather – replace

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

The travel gearbox is vented through a breathers, mounted on top of the pre-stage and the travel motor coupling housings (1 and 2, Fig. 3-135:).

Draining off oil  Place a collecting recipient for used oil under the brake housing.

Choose the required capacity in accordance with the "Refilling quantities - Oil" table.

 Replace breathers in accordance with the servicing plan.  Clean area around the breathers to prevent contamination of the gearbox.  Unscrew breathers and replace by a new one.

 Unscrew drain plugs (3, Fig. 3-134:) and drain off the oil completely.

Slackening breather (1) allows the oil to run out more readily.  Clean screw plugs (3).  Screw plugs (3) back in place.

Filling in oil  Unscrew screw plug (2).  Fill in oil through opening of breather (1) until it flows out of opening of plug (2).

(Oil grade see “LUBRICANTS” section).  Screw plugs (2) and breathers (1) back in place.

Fig. 3-134:

3-104

Fig. 3-135:

BA 6020B(3 847 000.00)-EN

Inspection and servicing CRAWLER TRACKS 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 hydraulic shovel 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. 3-136:) thoroughly.  Clean the sliding planes on the idler guides.

Fig. 3-136:

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Inspection and servicing Track roller, Support roller – Check tightening of bolts Inspect all track and support rollers (arrows, Fig. 3-137:) visually for leaks and free movement at regular intervals.

Track roller (2) fastening  Check fastening bolts (3) regularly for tightness.  Tighten lightly oiled bolts (3) with a torque wrench to the prescribed tightening torque.

Support roller (1) fastening  Check fastening bolts (4) regularly for tightness.  Tighten lightly oiled bolts (4) with a torque wrench to the prescribed tightening torque.

Pos.

Quant .

Bolt, torque

3

16 x 4

M30 x 3,5; 10.9; 1570±160Nm

4

4x4

M24 x 3; 10.9; 790±80Nm

3-106

Fig. 3-137:

BA 6020B(3 847 000.00)-EN

Inspection and servicing Track tensioner – Checking Function The tracks are tensioned with the help of the hydraulic pressure created during travelling.

Fig. 3-138: and Fig. 3-139: show parts of the tracks and the tensioner:

Technical data Track tensioning pressure ca. 70 bars / appr.

1015 psi Pressure limiting valve

330 bars / 4786 psi

Gas pressure in pressure accumulator (nitrogen filling pressure)

55 bars / 797 psi

Slackening the tracks The tensioning system is under permanent pressure of ca. 70 bars / appr. 1015 psi which keeps both tracks permanently tensioned.

Pressure losses are compensated as soon as the engine have been started. Retensioning is not required.

For cleaning and servicing work, the tracks can be slackened.

To do so:  Shut off the engine.  Open both ball valves (2, Fig. 3-139:) to slacken the lefthandside and righthandside tracks. To do so, shift lever from position “I” to “0”.

Fig. 3-138:

 After the work, close ball valves (2). To do so, shift lever from position “0” to “I”.

1

Crawler track

2

Travel gearbox and sprocket

3

Track roller

4

Pressure accumulator

5

Pressure cylinder

6

Support roller

The lead seal must not be removed and the pressure setting of 330 bars / 4786 psi must not be changed.

7

Idler

The track tensioners are maintenance-free.

8

Pressure limiting valve

9

Mini- measuring port

10

Ball valve

The pressure-limiting valves (1, Fig. 3-139:) are preset to a pressure of 330 bars / 4786 psi and sealed in this position.

Fig. 3-139:

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Inspection and servicing Pressure accumulator – track tensioner The pressure accumulators in the track tensioning circuit stores hydraulic oil in situations of high stresses on the idles and the tracks.

One pressure accumulator is located in each of the crawler frames (Fig. 3-140:). It is a component integrated in the track tensioner hydraulic circuit.

The pressure accumulators can be cut from the hydraulic track tensioning circuit by means of the ball valves attached near by the accumulators. To do so, shift lever on the ball valve from position “I” to “0”.

Pressure accumulator inspection regulations Hydraulic accumulators are pressure vessels and are therefore subject to several safety regulations and laws. Please observe the relevant regulations in force in your own country before working on pressure accumulators.

Read and observe all safety films attached on or nearby the pressure accumulator.

Pressure accumulator – checking gas pressure

This pressure accumulator contains high pressure gas (Nitrogen).

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.

Failure to follow the instructions and warnings could cause an explosion, resulting in possible injury or death.

Checking the gas charging pressure in the pressure accumulator is described in the “Service Manual”.

The accumulator vessel must not be subjected to welding, soldering or any other mechanical work. Do not expose to fire.

See your Caterpillar Dealer for tools and detailed information.

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.

Fig. 3-140:

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Inspection and servicing SWING RING Shut off the engine.

Make shure that no one can put the machine into operation while working on the swing ring.

Internal gearing - Lubrication The internal gearing (1, Fig. 3-142:) and the pinions of the swing gearboxes (2) are enclosed in a housing (2, Fig. 3-143:). The housing forms a grease-filled trough in which the pinions of the swing mechanism move.

Skin contact with used grease is a potential health hazard. Protect the skin from contact with grease. Wear protective gloves and firm working clothing.

Read and observe: "Inspection and servicing Safety instructions”.

Swing ring - Instructions The grease filling must be replaced when repairs have been carried out on the swing ring, the swing ring seals or the swing ring housing.

Remove old grease completely before filling in new grease.

If greater losses are detected, locate cause immediately to prevent damage to the swing 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.

Bearing races – Lubrication

Fig. 3-142:

The grease is pumped to the greasing port of the grease trough by the distributor (Fig. 3-141:). The amount of grease used up during operation is replenished by the central lubricating system.

The housing has check openings which are closed with covers (3, Fig. 3-143:).

For checking the grease filling, the covers must be removed.

The central lubricating system supplies grease continuously to the roller bearing races and the internal gearing.

The grease is distributed to the greasing points of the bearing races by two distributors (Fig. 3-141:).

Fig. 3-141:

Fig. 3-143:

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Inspection and servicing Swing ring - Checking the grease filling

Swing ring - Filling in grease Prior to initial commissioning, the grease trough of the internal gearing must be filled with grease.

Add grease when 

the housing has been replaced,

Make shure that no one can put the machine into operation while working on the swing ring.



old grease has been removed in the course of other work.

Skin contact with used grease is a potential health hazard. Protect the skin from contact with grease. Wear protective gloves and firm working clothing.

Always fill in fresh grease by hand.

Shut off the engine.

Read and observe: "Inspection and servicing Safety instructions”.

At regular intervals:  Check internal gearing and teeth of swing mechanism pinions for condition,  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 / 0.78“ of grease over its whole circumference (Fig. 3-144:).

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 swing movements.

Fig. 3-144:

3-110

Risk of accidents. Never swing the upper structure when refilling grease.

Swing ring - Checking the bolts for tightness The fastening bolts of the swing ring in the upper structure and the undercarriage are tightened with their respective 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").

BA 6020B(3 847 000.00)-EN

Inspection and servicing CENTRAL LUBRICATING SYSTEM Central lubricating system - function The hydraulic shovel is equipped with an automatic central lubricating system which provides grease regularly to all greasing points except those mentioned in the "Lubricating chart - Grease".

The central lubricating system is activated when the electrical system is switched on with the keyswitch and the engine is running.

All greasing points connected to the system are greased at regular intervals.

Fig. 3-145:

The automatic greasing is interrupted when the engine is stopped with the idle timer.

The central lubricating system is controlled electrohydraulically by the Board Control System (BCS and CAMP). Grease and pause cycles are programmed in the system. Depending on the circumstances the machine is working in, the grease and pause cycles can be adjusted.

If a fault occurs, BCS gives a warning on the screen (Fig. 3-145:). This happens, for example, if the filter element in the hydraulic line is contaminated. The same time the red “Error” lamp in the control box located at the hydraulic oil tank (1, Fig. 3-147:) lights up.

If one of the following faults occurs, BCS gives a warning and at the same time the grease pump is switched off: 

Grease drum is empty,



Greasing pressure in the grease lines is above 250 bars (3626psi),



Cable break at pressure sensor,



Pilot pressure below 70 bars (1015 psi).

Fig. 3-146:

In this cases, BCS switches off the hydraulic function of the backhoe cylinders after 15 minutes. This prevents damages from lack of greasing.

Inform the responsible maintenance personnel immediately. Keep on working after the fault has been fixed.

After the fault has been fixed, actuate the "Reset" switch in the dashboard (82, Fig. 3-146:) or the “Reset” button in the control box located at the hydraulic oil tank (2, Fig. 3-147:). The buttons must be actuated for at least one second.

For further information on the function and setting refer to the Service Manual, chapters 9 and 11.

Fig. 3-147:

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Inspection and servicing

Grease drum, pump, manometers, filter and valves of the luricating system are located in the frame of the upper structure, in front of the hydraulic tank (Fig. 3-148:). The components are accessible after removing the plates (1 and / or 2).

The mechanical control components elements of the lubricating system are installed on the lid of the grease drum and in the compartment near by the grease drum, covered with plate (1).

The grease is pumped from the grease drum by a hydraulically driven pump (2, Fig. 3-148:) via greasing lines to the main distributors on the upper structure and on the working equipment.

The distributors support greasing points on upper structure and working equipment.

As soon as the grease container is empty, the BCS (Fig. 3-149:) gives a warning signal (fault). In the event of a fault, the "dumping” function (backhoe cylinders) is switched off automatically after 15 min.

Fig. 3-148:

Work can be continued when the grease drum is replaced by a new one filled with fresh grease.

In the event of faults at the central greasing system inform the responsible maintenance personnel immediately. Detailled information about the central greasing system can be found in the “Service Manual” chapter 11.

Even when the grease pump isn’t active, there can be residual pressures in the grease lines up to 30 bars (435psi).

Relieve this residual pressure before opening a grease line.

Put the hydraulic shovel back into operation only after the greasing system works properly and after having actuated the unloaded working equipment for abt. 5 minutes. This is necessary in order to supply sufficient amounts of grease to the cylinder bearings.

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Fig. 3-149:

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Inspection and servicing Grease drum - replace Always replace the grease drum in time to avoid air from penetrating into the greasing system. Air in the greasing may cause malfunctions.  Stand working equipment to the ground.  Shut off the engine.  Switch off the electrical system of the machine.  Depressurize hydraulic system.  Detach plate (2, Fig. 3-148:). The grease drum is accessible then (Fig. 3-150:).  Clean the lid of the grease drum and all components carefully to prevent the grease system from being contaminated.  Depressurize grease lines by pressing down lever (arrow, Fig. 3-150:).

Fig. 3-150:

 Detach hydraulic lines (1 and 2, Fig. 3-151:) and grease line (3) from the express couplings.  Detach all electrical connections to sensors and valves.

Continued next page

Fig. 3-151:

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Inspection and servicing Continued  Attach lifting devices to ring screws (2, Fig. 3-152:).  Unscrew wing nuts (1) and lift lid of the grease drum.

Be careful because of the suction tube of the grease pump.

Lay down lid on a clean and safe place.  Replace empty drum by a new one filled with fresh grease.  Use an appropriate lifting device to move the grease drum (example see Fig. 3-153:).

Do not damage the edge of the grease drum.

The lid may get leak then and the grease may become contaminated.

Fig. 3-152:

 Bring lid with grease pump back in position and fasten with wing nuts (1, Fig. 3-152:).  Clean express couplings and re-install hydraulic lines as well as the grease line.  Attach all electric connections to sensors and valves.  Bring machine back to work. Check the central lubricating system is working properly.

Fig. 3-153:

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Inspection and servicing Grease pump – checking hydraulic pressure

Grease lines - checking greasing pressure

Check regularly (accord. to the maintenance plan), whether the oil pressure indicated by pressure gauge (arrow, Fig. 3-154:) at the valve block of the grease pump is 55 - 60 bars / 798 - 870 psi.

Check regularly (accord. to the maintenance plan), whether the grease pressure indicated by pressure gauge (Fig. 3-154:) at the control block 250 bars / 3625 psi.

The pressure is depending on temperature and viscosity of the oil and may vary.

The pressure is depending on temperature and viscosity of the grease and may differ slightly.

In the event of deviating pressure values, shut off the engine and inform the responsible maintenance personnel. The central greasing system has to be checked.

The necessary greasing pressure of 250 bar / 3625 psi is generated by means of a pressure translator.

In the event of deviating pressure values, shut off the engine and inform the responsible maintenance personnel. The central greasing system has to be checked.

Lower grease pressure means that not all of the greasing points are supplied with grease.

Higher grease pressure may cause bursting of a greasing line.

Fig. 3-154:

Fig. 3-155:

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Inspection and servicing Grease drum breather – replace

Grease drum – check filling level

Replace the breather filter of the grease container at regular intervals, accord. to the maintenance plans.

For checking the filling level of the grease drum without using the BCS, there is a dipstick on top of the grease drum (arrow, Fig. 3-157:).

 Detach cover plate above the grease drum.

Check the filling level accord. to the maintenance plans.

 Clean breather and the area around to prevent contamination of the lubricating system.

 Detach cover plate above the grease drum.

 Unscrew breather (arrow, Fig. 3-156:) and replace with a new one.

 Clean the area around the dipstick to prevent contamination of the lubricating system.

 Re-install cover plate.

 Withdraw dipstick (arrow, Fig. 3-157:) and wipe clean.  Re-insert dipstick and withdraw again. Check filling level on dipstick.  If filling level is low, inform the responsible service personnel.  Re-install cover plate.

Fig. 3-156:

Fig. 3-157:

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Inspection and servicing Grease filter – check / clean One grease filter (arrow, Fig. 3-158:) is installed inside the control block. The grease is pumped through before it goes to the greasing lines to the grease distributors.

Check / clean the grease filter regularly according to the maintenance plans.  Stand working equipment to the ground.  Shut off the engine.  Switch off the electrical system of the machine.  Detach cover plate (1) above the control block.  Clean control block and the area around to prevent contamination of the lubricating system.  Unscrew grease filter (arrow).  Diassemble grease filter as shown in (Fig. 3-159:).  Clean all components with white spirit or paraffin oil and blow with compressed air.

Fig. 3-158:

 Re-assemble the components (nos. 1-6).  Screw grease filter back into the control block.

Fig. 3-159:

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Inspection and servicing Grease pump – checking oil level

Grease pump – changing oil

The crank case of grease pump is filled with oil (Fig. 3-160:).

The crank case of grease pump is filled with oil (Fig. 3-161:).

Check oil level regularly according to the maintenance plans.

Change oil regularly according to the maintenance plans.

 Stand working equipment to the ground.

 Stand working equipment to the ground.

 Shut off the engine.

 Shut off the engine.

 Switch off the electrical system of the machine.

 Switch off the electrical system of the machine.

 Detach cover plate above the grease drum.

 Detach cover plate above the grease drum.

 Wait until grease pump is cooled down.

 Wait until grease pump is cooled down.

 Clean the area around the dipstick to prevent contamination of the crank case.

 Clean the area around the dipstick to prevent contamination of the crank case.

 Unscrew dipstick (arrow, Fig. 3-160:) and withdraw.

 Unscrew dipstick (arrow, Fig. 3-160:) and withdraw.

 Wipe dipstick clean and screw back in.

 Use a suction pump to pump-out the used oil from the crank case.

 Unscrew dipstick a second time.

Oil level should be at the dipsticks marking.

Top up with engine oil if required. Fill in oil through dipsticks bore.

(Oil grade see “LUBRICANTS / CONSUMABLES” section).  Screw dipstick back in place.

 Fill in fresh engine oil through the dipsticks bore.  Screw dipstick back in place.  Check for leaks after putting the greasing system into operation.

 Attach cover plate above the grease drum.

Fig. 3-161:

Fig. 3-160:

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Inspection and servicing OTHER MAINTENANCE Engine – other maintenance Information about maintenance work can be found in the Engine manufacturer’s Operation and Maintenance Manual.

Further servicing works not described are carried out by the Caterpillar dealer service or the engine manufacturer.

Means of fastening  Check fastening bolts regularly for tightness.

The seating planes of the bolts must be free from paint, dirt and rust.

Refer to the Service Manual for a table with tightening torques.

Cooling system Check the radiators regularly.

Cleaning

 Shut off the engine.  Remove any accumulated dirt.

Exhaust pipes and turbo chargers in the engine compartments are covered with special heatinsulating material. This material must not be spray-washed 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.

 Clean the fan blades.  Clean the radiators with a jet of water or compressed-air from the outside.  Dry up coolers.

Do not clean radiators with a wire brush or similar hard objects.

In case of firmly adhering dirt, remove radiator and clean.

Check the engine regularly.

Exhaust system



If the engine is cleaned with a steam-jet cleaner, make sure that the jet is not directed towards electrical components.

 Check the fastening bolts and clamps regularly for tightness when the exhaust system is cold.



If no steam-jet cleaner is available, the engine must be cleaned with suitable cleaning agents (cold cleaners).

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Inspection and servicing HVAC, filter elements fresh air (outside) – replace The fresh air filter of the HVAC system is installed on top of the system (arrow, Fig. 3-162:).

Change the filter element regulary accord. to the maintenance plans.

Wear appropriate personal protection equipment such as gloves, mask, and overall to protect against contaminants.  Shut off engine.  Release the latches of filter element and remove filter element (Fig. 3-163:).  Bag and seal used filter element and dispose of according to local regulation.  Inspect filter housing and remove any loose debris using a clean rag, never use compressed air.  Install new filter element, watch the correct orientation.

Do not clean or re-use filter elements.

Fig. 3-162:

 Check all air lines, seals and latches for damage and tightness.

Fig. 3-163:

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Inspection and servicing HVAC, filter element inside cab – check / clean

Additional silencers - check / clean

The recirculation air filter of the HVAC system is installed in the rear wall of the cab, behind the trainer’s seat console (Fig. 3-164:).

Read and observe the “Inspection and Servicing, Safety Instructions”.

 Unscrew knob and remove filter cover plate.

 Check the perforated plates of all the silencer elements (examples see in Fig. 3-165:), if soiled:

 Detach filter element and check.  Clean with compressed air if necessary and re-install.

Observe the correct placement, there is an arrow on the filter element.  If damaged, replace filter element by a new one.

Carry out the following work steps:



brush the soil off by means of a soft brush,



blow the soil off by means of pressurized air or water.

Please note: blast parallel to the surface (max. angle 15°), pressure maximum 5 bars, distance to the surface minimum 0,5 meters.

 Check fastening bolts of the silencers for tightness.

Fig. 3-164:

Fig. 3-165:

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Inspection and servicing Excavator controls – clean / lubricate At regular intervals acc. to the maintenance plans:

Joysticks  Loosen gaiter and move upwards.  Clean all mechanical elements from dirt and old grease.  Apply a thin layer of low temperature grease on the control spools, the actuator plate above and the cardan joint of the joysticks (arrows, Fig. 3-166:) to prevent jamming of the joysticks.  Refit gaiter using a cable strap.

Fig. 3-166:

Pedals  Remove old grease and dirt from the control spools and the actuator plate of the pedals (arrows, Fig. 3-167:).  Apply a thin layer of low temperature grease on the control spools of the pedals to prevent jamming of the control spools.

Fig. 3-167:

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Inspection and servicing Window panes - cleaning

Floor window pane - cleaning

 Clean the outside of the cab windows from the walkways (see Fig. 3-168:).

 Clean the floor window in front of the operator’s seat from inside the cab (see Fig. 3-169:).

 Use a clean sponge or a soft cloth.

 Unscrew grids, mounted above the window (arrow, Fig. 3-169:).

 Wash the windows with a mild soap or with a mild detergent. Also use plenty of lukewarm water.

 Use a vacuum cleaner to remove coarse dirt laying on the pane..

 Rinse the windows thoroughly.

 Use a clean sponge or a soft cloth.

 Dry the windows with a moist chamois or with a moist cellulose sponge.

 Wash the windows with a mild soap or with a mild detergent. Also use plenty of lukewarm water.  Rinse the windows thoroughly.  Dry the windows with a moist chamois or with a moist cellulose sponge.  Attach the grids back in space.

Fig. 3-168:

Fig. 3-169:

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Inspection and servicing Seat belt - inspect Always check the condition of the seat belts (Fig. 3-170: - Fig. 3-173:) and the condition of the seat belts mounting hardware before you operate the machine. Replace any parts that are damaged or worn before you operate the machine.

Check the seat belt mounting hardware for wear or for damage. Replace any mounting hardware that is worn or damaged. Make sure that the mounting bolts are tight.

Check buckle for wear or for damage. If the buckle is worn or damaged, replace the seat belt.

Inspect the seat belt for webbing that is worn or frayed. Replace the seat belt if the seat belt is worn or frayed.

Fig. 3-171:

Consult your Caterpillar dealer for the replacement of the seat belt and the mounting hardware.

Note: Within three years of the date of installation or within five years of the date of manufacture, replace the seat belt. Replace the seat belt at the date which occurs first. A date label for determining the age of the seat belt is attached to the seat belt, the seat belt buckle, and the seat belt retractor.

If your machine is equipped with a seat belt extension, also perform this inspection procedure for the seat belt extension.

Fig. 3-172:

Fig. 3-170:

Fig. 3-173:

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Inspection and servicing PUTTING THE HYDRAULIC SHOVEL OUT OF OPERATION AND RECOMMISSIONING Putting the hydraulic shovel out of operation

Battery storage

 Park the hydraulic shovel on firm and level ground.

 Check the acid density and the electrolyte level of the battery every two weeks.

(Not at “maintenance-free” batteries).

 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".  Carry out a visual inspection of the hydraulic shovel.

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.

(Not at “maintenance-free” batteries).  Keep the batteries clean and dry on the outside.  Check battery charge status in regular intervals, re-charge if necessary.

 Clean the machine.  Remove coarse dirt, snow and ice from the fins and fan wheel of the hydraulic oil cooler.

Recommissioning

 Carry out engine preservation (refer to : ”Engine Operation and Maintenance Manual”).

 Degrease / clean all protected components.

 Protect all bright metal parts (e.g. piston rods) from rust and dirt.  Check anti-freeze concentration of the cooling liquid to avoid freezing during the cold season.

 Remove the covers.  Remove engine preservation (refer to : ”Engine Operation and Maintenance Manual”).  Check the fuel level in tank.  Check track tension (visual inspection).

 Fill up the fuel tank.

 Check level and condition of the cooling liquid in the cooling system.

 Remove the batteries; see: "Battery storage".

 Check grease filling in grease drum.

 Secure the machine against unauthorized starting by: 

withdrawing the key from the key-switch,



locking the cab door,



securing all lockable hatches.

 Cover up all openings.

 Check oil level in: 

engine,



swing gearboxes,



pump drive gearbox,



travel gearboxes,



hydraulic oil tank.

 Check battery charge status.  Install batteries and reconnect.  Perform functional checks: 

upper structure holding brake,



track brake,



lighting system,



signalling equipment,



Emergency Stop switches.

 Vent the hydraulic system.

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Inspection and servicing NOTES .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. ..............................................................................................................................................................................

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Inspection and servicing

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Repair work 4 REPAIR WORK Operating instructions

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

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Repair work

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Repair work REPAIR WORK - SAFETY INSTRUCTIONS Operating instructions Never carry out repair work without having read and understood the operating instructions.

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.

Personal protective equipment 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 your personal protective equipment: a safety helmet, safety goggles, safety footwear and gloves.

When carrying out work on the working equipment, f.ex. on the boom, use a fall arrester. Falling down from great hight may cause severe injuries. Connect the fall arrester to the safety line on the boom.

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.

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.

Prestressed units Never open defective prestressed units but replace them as an entirety.

In exceptional cases, open only when the system and the operating sequence are precisely known and any special tools required are available.

The operating manual contains no information on this point.

Dismantling components Never do dismantling while the machine is at operating temperature.

Oils, greases, or coolants may have a high temperature and result in burning or scalding.

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. 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.

On completing the work, re-assemble all protective devices, covers and noise- and vibrationinsulation material.

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

Check the repaired components and all machine functions in a trial run.

Never release the machine for recommissioning until it is fully functioning.

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Repair work CONFINED SPACES - SAFETY INSTRUCTIONS Work in confined spaces can lead to unexpected dangerous situations, such as 

the formation of flammable vapours exploding during welding operations or



the lack of oxygen and harmful gases causing loss of consciousness.

What are "confined spaces"?

A confined space on this machine is, for instance, the monoblock boom (Fig. 4-1:).

This component is provided with a manhole. Manholes offer access to the inside of this component in order to carry out inspections or repairs such as welding work.

Dangerous situations can also exist in other spaces which are not very often visited or which are badly ventilated. In these spaces, harmful or flammable gases can accumulate unnoticed.

Work in such spaces may only be carried out by specially qualified persons who have been instructed as to the situational risks.

Before visiting these spaces, the following safety precautions must be taken:  The narrow space must be ventilated for a prolonged time, e.g. with a blower. Do not blow oxygen into the space. Oxygen increases the risk of fire.  Use your personal protective equipment, e.g. respiratory mask.  Use a safety harness and have a second person stand by with a rescue rope attached to the harness.  Evacuate the gases produced during welding.

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Fig. 4-1:

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Repair work REPAIR WORK - FIRE AND EXPLOSION HAZARD

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.

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. 

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 coldstarting fluid have been spilt over the machine. If possible, use a steam-jet cleaner for cleaning.

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.

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Repair work REPAIR WORK – ENGINE

Before cleaning the engine

Risk of fire and explosion.

Exhaust pipes and turbo chargers in the engine compartments are covered with special heatinsulating material. This material must not be spray-washed 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.

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.

Risk of injury caused by rotating or hot parts of the engine.

Shut off the engine and allow to cool down.

Read and observe the "Repair - Safety instructions" chapter and the engine operating instructions before working on the engine.

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Carry out repair work only if the machine has been secured as described in the "Securing the machine" section of these operating instructions.

Check and replace V-belts only when the engine is stationary.

Refer to additional literature, e. g. the Engine Manufacturer’s Operation and Maintenance Manual.

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Repair work REPAIR WORK - HYDRAULIC SYSTEM Repair instructions Always depressurize the hydraulic system before disconnecting any hydraulic hoses or pipes.

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. 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 – Instructions Even hoses that have been properly stored or used are subject to natural ageing. Their useful life is therefore limited.

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.

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Repair work PRESSURE ACCUMULATORS SAFETY INSTRUCTIONS Risk of explosion.

The hydraulic system is equipped with pressure accumulators containing nitrogen under high initial pressure.

Follow the instructions given before starting work in order to minimize risks.

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 never weld or solder.

mechanically,

 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

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Repair work OTHER MAINTENANCE WORK

Seat belt – replace

Windscreen wiper blade – replace

Within three years of the date of installation or within five years of the date of manufacture, replace the seat belts at all seats equipped with seat belts (f.ex. Fig. 4-3:).

Always use the walkways when working on the windscreen wiper.  Inspect the condition of the wiper blade (Fig. 4-2:).  Replace the wiper blade if the wiper blade is worn or damaged or if streaking occurs.

Replace the seat belt at the date which occurs first.

A date label for determining the age of the seat belt is attached to the seat belt, the seat belt buckle, and the seat belt retractor.

Consult your Caterpillar dealer for the replacement of the seat belt and the mounting hardware.

If your machine is equipped with a seat belt extension, also perform this replacement procedure for the seat belt extension.

Fig. 4-2:

Fig. 4-3:

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Repair work Bucket tip – replace Bucket tips (aka “tooth”) (Fig. 4-5:) assist the bucket while penetrating the soil.

They were made from highly wear-resistant steel.

Nevertheless they must be replaced when they reach the wear limits. This prevents the bucket from being damaged and enhances digging performance.

Tips are large, heavy parts. Use appropriate lifting devices to move this parts safely.

Wear appropriate personal protection equipment such as gloves, safety goggles, protective shoes and overall to protect against injuries.

Fig. 4-5:

Tips are fastened to the adapters at the bucket lip using the CapSure™ locking system (Fig. 4-4:).

To replace worn or damaged tips:  Carefully clean tip, the locking device and the area around from dirt.  Weld a lug made from strong wire onto the tip to be replaced.  Fasten tip with a lifting device (Fig. 4-5:).  Unlock the tip by turning the locking device with a ¾” ratchet. Turn by 180° (Fig. 4-5:).  Remove worn tip.  Carefully clean the adapter. Remove any dirt and corrosion.

Fig. 4-6:

 Move new tip over the adapter (Fig. 4-6:).  Lock the tip by turning the locking device with a ¾” ratchet. Turn by 180° (Fig. 4-7:).

Fig. 4-7:

Fig. 4-4:

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Repair work Bucket lip shroud – replace

Bucket wing shroud – replace

Lip shrouds are large, heavy parts. Use appropriate lifting devices to move this parts safely.

Wing shrouds (2, Fig. 4-9:) protect the bucket side walls from excessive wear.

Wear appropriate personal protection equipment such as gloves, safety goggles, protective shoes and overall to protect against injuries.

They were made from highly wear-resistant steel.

Nevertheless they must be replaced when they reach the wear limits. This prevents the bucket from being damaged.

Lip shrouds are fastened to the bucket lip using the CapSure™ locking system (Fig. 4-4:).

Wing shrouds are large, heavy parts.

 Carefully clean lip shroud (1, Fig. 4-8:), the locking device (2) and the area around from dirt.

Wear appropriate personal protection equipment such as gloves, safety goggles, protective shoes and overall to protect against injuries.

 Weld a lug made from strong wire onto the shroud to be replaced.

Wing shrouds are fastened to the bucket walls using spring clips (1) and bolts (3).

 Fasten lip shroud with a lifting device.

To replace worn or damaged wing shrouds:

 Unlock locking device like described in chapter “Bucket tip – replace”.

 Drive out bolts (3).  Detach wing shroud (2).

 Remove worn lip shroud.

 Remove spring clips (1) from the bores.

 Carefully clean the lip and the adapter (3) for the lip shroud. Remove any dirt and corrosion.

 Carefully clean the bucket side walls and the bores. Remove any dirt and corrosion.

 Move new lip shroud over the adapter.

 Insert new spring clips (1) into the bores. Fix with grease if necessary.

 Lock locking device like described in chapter “Bucket tip – replace”.

 Place the new side shroud (2) to the side wall, watch for aligned bores.  Drive in bolts (3).

Fig. 4-8: Fig. 4-9:

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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.

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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.

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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.

Slewing rings and articulated joints The welding current must not flow through ballbearing or roller-bearing slewings 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.

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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 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.

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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 6020B(3 847 000.00)-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.: 

Most of the machine components have considerable mass. Therefore use only lifting gear and slings of sufficient bearing capacity.



Risk of residual pressures still in the hydraulic system. Be very careful when opening hydraulic lines.

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.

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.

Risk of fire 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.

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 corresponding line systems.



Hydraulic oil: hydraulic oil tank, 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 gearboxes, travel gearboxes and pump drive gearbox systems, expansion tanks, piping and hospipes, filling station; idlers, support and track rollers.



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 slewing ring, grease filling in track and support rollers as well as in idlers.

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Repair work Further hazardous substances

Appropriate disposal of batteries



Batteries contain lead and acid.



Electronic modules are located in switch cabinets of the cab module, the engine module, the control column.

The machine is equipped with batteries containing lead and other harmful and polluting substances.



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.

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. 4-10:).

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. 4-10:

The symbols in Fig. 4-10: have the following meaning:

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

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.

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Repair work NOTES .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. ..............................................................................................................................................................................

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Repair work

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Annex 5 ANNEX Operating instructions

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

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Annex

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Annex BOARD-CONTROL-SYSTEM BCS III, what’s that?

What it is The BCSIII is the third generation of the Board Control System. This generation represents the current stage of development of this reliable monitoring and control system for hydraulic mining hydraulic shovels from CGM HMS. The BCSIII communicates with other electronic units in the hydraulic shovel and makes up the CAMP system, the Control And Monitoring Platform.

Controllers actuate and monitor functions such as the motor management, drive and control of the hydraulic pumps, the pilot control and others. The controllers are basically computers that have been configured for their special application.

Other electronic units of the CAMP system that communicate with the BCSIII are located in cabinets in the module below the operator’s cab, the pump compartment and the engine compartment.

Fig. 5-1:

Benefits for the operator

The exchange of data between sensors, controllers, the BCSIII and other involved components takes place via the CAN bus.

Because BCS automatically warns of any abnormal conditions that require a corrective action, the operator can concentrate fully on the work in hand, and is not distracted by constantly having to keep an eye on many instruments or by having to decide upon appropriate actions to be taken in case of limit values being exceeded.

What it does

The operator and the servicing crew also have the means of calling up particular background information from the BCS archive.

The Board Control System, abbreviated to BCS, monitors all the essential functions of the hydraulic shovel and its components.

It releases an appropriate signal if any maximum value is exceeded and also sends a report to be archived in the memory bank.

The housing – installed at the dashboard inside the operator’s cab (Fig. 5-1:) – integrates the computer, the monitor, the control elements and the interfaces.

If a normal operating status can be reached by temporarily reducing the hydraulic shovel's output, then this is monitored by BCS and done by the CAMP system.

If it is necessary for the operator to take certain action, e.g. to stop the engine a relevant command is sent to the BCS display screen.

Take care

BCS also gives information on servicing and trouble-shooting.

Sensors installed at various points on the hydraulic shovel constantly transmit their readings to the controllers of the CAMP system.

All essential pieces of operating data are displayed on the BCSIII screen in the form of simulated instruments (dial gauges) as well as they are archived and can be called up as and when required.

If the display computer (arrow, Fig. 5-1:) becomes too hot it can be damaged. Therefore, do not cover the unit by laying things on it, f.ex. hanging a jacket or other clothes on it.

The screen of the display computer is sensitive to the touch. Carefully follow all instructions and warnings given in this manual.

Want more information?

In this Orearating and Maintenance Manual you can find a description of the screens displayed on operator’s level. There are two additional levels for service personnel.

More detailed and more technical information for service personnel could be found in the “Service Manual”, chapter 9.

There are more extensive information given about the communicating units and about troubleshooting.

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Annex BCSIII screens - Sitemap 1 This is an overview of the BCS screens, available on the operator’s level (white background), the service level I (blue background) and service level II (yellow background).

Fig. 5-2:

5-4

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Annex BCSIII screens - Sitemap 2

Fig. 5-3:

5-5

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Annex The BCS housing – overview

5

The brightness sensor measures the ambient brightness. The BCS automatically controls the background illumination of the screen.

6

The LED lights up in green color when the electrical system of the machine is switched on, operating voltage is available.

The LED flashes during the boot procedure, with each keypress and when the background lighting of the screen is turned off.

See graphic (Fig. 5-4:), details on following pages.

1

2

3

4

Fig. 5-4:

5-6

Status line. Indicates activated / deactivated functions, number of dumpers loaded and operating hours. Rectangled areas with graphics are touch-sensitive areas.

Touch-screen monitor for BCS. Indicates collected operating data graphically and / or numerically, displays warning messages, fault messages and – if needed – instructions for help.

Status line. Displays fault messages as a code number and as plain text. The "Fault" button permits displaying further fault messages stored in the system.

Touch screen buttons to navigate through screens and open menus.

The LED flashes yellow if the temperature inside the device lies outside the permissible range. The automatic heating system is then active.

7

Background lighting control; set darker.

8

Background lighting control; set brighter.

9

Power ON / OFF key.

10

Buzzer, not used on this machine.

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Annex BCSIII, the first screen after startup This screen (Fig. 5-6:) is displayed once after starting up the machine.

The screen may contain important messages given from the service personnel to the operator.

In the lower part of the screen a fault log may appear.

The operator should follow the massages given.

After tapping the button, the BCS start screen will appear.

With tapping this button the operator confirms that he read the messages given on this screen.

The BCS screen is designed as a touch-screen. By slightly touching the active areas, the user can perform activities such as changing to another screen page.

Active areas are shown on the screen as threedimensional graphics. In the basic configuration – not activated - they seem to project out of the user interface. When touched, they appear to be lowered.

Never use pointed objects such as a ball pen, screwdriver, nail or similar.

This could damage the active surface of the touch-screen.

Do not press on the sensitive areas, just slightly touch them with your fingertip!

Fig. 5-5:

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Annex BCSIII, the start screen The screen displays the graphical user interface of the Board Control System. The basic screen (Fig. 5-6:) appears when all electronic units of the CAMP system have started and when their selftests have been completed.

Note: At low outside temperatures it is possible that the basic screen appears a few minutes after switching on the electrical system (warming up phase).

Active areas are shown on the screen as threedimensional graphics. In the basic configuration – not activated - they seem to project out of the user interface. When touched, they appear to be lowered.

Starting from this basic screen, the user can access a number of other screens. This does not require an input device such as a keyboard, mouse or similar.

Never use pointed objects such as a ball pen, screwdriver, nail or similar.

The BCS screen is designed as a touch-screen. By slightly touching the active areas, the user can perform activities such as changing to another screen page.

Do not press on the sensitive areas, just slightly touch them with your fingertip!

Fig. 5-6:

5-8

This could damage the active surface of the touch-screen.

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Annex Often used symbols and buttons These button shaped touch sensitive sections as well as other sections of the screen appear nearly on every screen of the BCS system. Therefore they are listed and explained here at the beginning.

Tapping this button produces a graphics file which shows the current screen.

This is to store a complete screen for maintenance purposes.

Area shows current date and time. Can be set in the “Setup” menu screen.

Tapping this button opens the “Help-screen”. Short text messages are displayed which describe the elements shown on the screen.

Tapping this button leaves the current screen and opens the previous screen.

Tapping this button leaves the current screen and opens the main screen.

Tapping this button opens the “Event list” screen.

Events stored in systems memory were listed (see chapter “Event list”).

Tapping this button opens a login window that permits access to the BCS “Service level I”, a section that is exclusively for service personnel. A password is needed to get access Tapping this button opens the “View documents screen”. The machines Technical Documentation is available as pdf-files.

Tapping this button opens a gate to much more information about the shovels current behaviour. A menu will appear where you can select the section you want information about (see chapter “System status”).

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Annex Start screen - Information given in the top section The symbols shown in the top row of the start screen (Fig. 5-7:) appear in grey colour if function is not activated, in green colour if everything is OK or in red if a warning is given. In this case more information is displayed in the red “failure row” below.

1

Operating hours meter.

2

The number of dumpers you loaded is displayed here (if counted with the key in the right joystick).

3

Selected travel speed stage: - Turtle = slow gear; - Rabbit = fast gear.

4

5

Fig. 5-7:

5-10

Hydraulic ladder, turns to red colour if lowered. Swinging upper structure or travelling the machine not possible then.

Track parking brakes monitoring, red when brakes applied.

6

Upper structure holding brakes monitoring, red when brakes are applied.

7

Servo-switch inside seat monitoring, red when no one is sitting on the operator’s seat.

8

Central lubrication system monitoring, red when a fault appears. Button opens the “Progressive grease system” screen.

9

Hydraulic system monitoring. Button opens the “System status – Hydraulics” screen.

10

Engine monitoring. Button opens the “System status – Engine” screen.

11

Button opens the “Event list”. A screen which lists all events, may be faults.

12

Short text messages are displayed which describe the elements shown on the screen.

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Annex Start screen - Information given in the central section 1

2

Oil press. bar = Engine oil pressure displayed graphically and numerically.

Temperature data during operation:

Engine rpm = Revolutions per minute displayed graphically and numerically.

Hyd. Oil = Hydraulic oil temperature in degrees Celcius, displayed graphically and numerically.

Fuel level Ltr = Fuel in fuel reservoir displayed graphically and numerically, red means: top up with fuel soon.

Coolant = Temperature of cooling fluid in degrees Celcius, displayed graphically and numerically.

Battery V = On-board voltage, displayed graphically and numerically.

Ambient = Temperature of the ambient area around the machine in degrees Celcius, displayed numerically.

The large graphic with the “red dot and E” is a symbol for the Emergency Stop switches. It appears alternating with a graphic showing a green pushbutton switch. This means that one of the Emergency Stop switches has been actuated.

The Emergency Stop function has to be reset by pushing the Emergency Stop reset pushbutton (see chapter “Putting the machine back into operation – reset of emergency shut off function”

Fig. 5-8:

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Annex Start screen - Information given in the lower section 1

2

Fig. 5-9:

5-12

Button “System Status”.

Tapping with your fingertip opens a gate to much more information about the hydraulic shovel’s current behavior.

A menu will appear where you can select the section you want information about (see chapter “System status”).

Button “Service Level I”.

Tapping with your fingertip opens a login window that permits access to the BCS section that is exclusively for service personnel.

A password is needed to get access.

3

The “Event / fault row”.

Here the system displays detailed information about the event / fault occurred and gives instructions about what to do.

To display the whole list of stored events, tap on the row.

A detailed description of events can be found in the “Service Manual”, chapter 9.

4

Tapping this button produces a graphics file which shows the current screen. This is to store a complete screen for maintenance purposes.

5

Date and clock.

Can be adjusted in the “Setup” section by service personnel.

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Annex Start screen – Help section Tapping this button has opened this “Help-screen” with short text messages.

Tapping this button opens the “Help” screen on which you have access to the Technical Documentation of the machine in PDFformat (see chapter “Help screen – viewing PDF documents”.

Tapping this button closes the screen with text messages. Returns to “Start screen”.

Fig. 5-10:

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Annex System status screen - Information given on the screen 1

Tapping on the photo of the engine opens a screen displaying current engine data (see “System status - Engine”).

3

Same result when tapping on the button with the engine-symbol on the “Start screen”.

2

Tapping on the photo of the hydraulic pumps opens a screen displaying current hydraulic data (see “System status Hydraulics”).

Same result when tapping on the button with the hydraulic-symbol on the “Start screen”.

Fig. 5-11:

5-14

Tapping on the photo of the lubrication control opens a screen displaying current lubrication data (see “System status Grease – Progressive Grease System”).

Same result when tapping on the button with the lubepump-symbol on the “Start screen”.

4

Tapping on the photo of the control lever (joystick) opens a screen displaying control elements adjusting data (see “Servosystem”).

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Annex System status – Engine, Information given on the screen This screen (Fig. 5-12:) displays data coming from the engine and from the main pumps.

1

This section of the screen displays current engine data.

2

Displays current pressure of the six main hydraulic pumps driven by the engine via the pump distribution gearbox.

3

Here the engine oil change interval is displayed as well as the remaining operating hours (h) until the next engine oil change.

4

Temperature of the ambient area around the machine in degrees Celcius, displayed numerically.

5

In this section information about faults and malfunctions are displayed coming from the engine’s ECM. Fault description follows the SAE J1939 standard.

SPN Number = Suspect Parameter Number, FMI = Failure Mode Indentifier.

The severity level of the fault is displayed as well: “Malfunction” is the less significant fault, should be eliminated with the next service.

“Warning”, the fault should be eliminated immediately to prevent the engine from damages.

“Protect”, engine power is automatically reduced to prevent the engine from serious damages.

“Engine Stop”, engine has been stopped automatically to prevent engine destruction.

A detailed description for service personnel can be found in the “Service Manual”, chapter 9.

Fig. 5-12:

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Annex System status – Hydraulics, Main pump pressure screen

1



the hydraulic pressures coming from each of the six main pumps;

The contamination status of the six main hydraulic pumps is monitored. In case of contamination a red light is activated. Inform the responsible service personnel immediately.

2

Monitored pressure may vary depending on the hydraulic power currently needed for machine operation. This is controlled by the BCS. 3

Tapping one of the buttons leaves the current screen and opens screens with information about further hydraulic sections: Attachment, Slew, Travel.

5-16

hydraulic

Hydraulic pressure coming from the hydraulic main pumps 1 - 6.

Oil tank,

Fig. 5-13:

pilot

35bar-circuit – pressure should be between 30bar and 40 bar.

hydraulic pressures in pilot hydraulic (servo-) circuits.

The pointers should be in the green coloured sections of the dial gauges. If in the yellow or red sections an event / fault occurs. Check the “Event list” for details.

in

100bar-circuit – pressure should be between 80bar and 120bar.

This screen (Fig. 5-13:) displays graphically and numerically: 

Hydraulic pressure (servo) circuits:

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Annex System status – Hydraulics, Attachment screen This screen (Fig. 5-14:) displays graphically and numerically the current hydraulic pressures in the cylinders of backhoe attachment.

The pointers should be in the green coloured sections of the dial gauges. If the pointer is in the red section an event / fault occurs.

Check the “Event list” for details. Call the responsible service personnel.

HE = Piston side of the hydraulic cylinder; RE = Rod side of the hydraulic cylinder.

Fig. 5-14:

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Annex System status – Hydraulics, Slewing screen This screen (Fig. 5-15:) displays graphically and numerically: 

the hydraulic pressure going to the slew motors when slewing to the right or slewing to the left;



the hydraulic pressures in pilot hydraulic (servo-) circuit when slewing to the right or slewing to the left,



the slew brake pressure.

The pointers should be in the green coloured sections of the dial gauges. If in the red sections an event / fault occurs. Check the “Event list” for details.

Fig. 5-15:

5-18

The slew brake symbol appears in red colour in case the slew brake is applied.

The contamination status of the two slew motors is monitored. In case of contamination a red light is activated. Inform the responsible service personnel immediately.

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Annex System status – Hydraulics, Oil tank screen This screen (Fig. 5-16:) displays graphically and numerically information around the status of hydraulic oil and hydraulic oil filters.

1

2

3

Hyd oil °C = Hydraulic oil temperature is displayed.

4

Information from the hydraulic oil cooling circuit is displayed in this section:

Pressure inside the two filter chambers of the hydraulic tank is displayed.

Pump set = The current value which controls the cooling pump in mA.

The pointers should be in the green coloured sections of the dial gauges. If in the red section, the filters are contaminated.

In case of contamination the filter elements must be replaced. Inform the responsible service personnel immediately.

Cooler °C = The hydraulic oil temperature at hydraulic oil radiator inlet.

Hydraulic tank’s filling level is displayed: Low = Check the level indicator tube at the hydraulic tank. Top up hydraulic oil.

Low Low = Stop working. Risk of damaging hydraulic pumps. Call the responsible service personnel. Top up hydraulic oil.

Cooler bar = Hydraulic oil pressure inside the radiator. The pointer should be in the green coloured section of the dial gauge. If in the red section, the radiator may be contaminated. Inform the responsible service personnel immediately.

Cooled °C = The hydraulic oil temperature at hydraulic oil radiator outlet.

There must be a significant difference between inlet and outlet temperature. If not, check radiator fins for contamination.

Fig. 5-16:

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Annex System status – Hydraulics, Travel screen This screen (Fig. 5-17:) displays graphically and numerically information around the status of the hydraulic travel system. 

the hydraulic pressure coming from pump 4 for the lefthand travel motors;



the hydraulic pressure coming from pump 3 for the righthand travel motors;

The pointers should be in the green coloured sections of the dial gauges. If in the red sections an event / fault occurs. Check the “Event list” for details.

The deflection angle of the correponding travel pedal (lefthand / righthand) is displayed as well.

Fig. 5-17:

5-20

Symbol colored red when slow gear is activated.

Symbol colored red when travel parking brakes are applied.

Symbol colored red when track tension is slackened.

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Annex System status – Grease, Progressive grease system screen

1

Here are information about the status of the lubrication system.

2

Pressure inside the grease lines is displayed.

This screen (Fig. 5-18:) displays data related to the central lubrication system.

The pointer should be in the green coloured section of the dial gauge.

If in the yellow or in the red section, an event / fault occurs. In this case check the “Event list” and call the responsible service personnel immediately.

3

If the system detects faults or malfunctions in the lubrication system they are marked here with a red dot.

Call the responsible service personnel.

Malfunctions must be fixed as soon as possible. Serious damage of bearings and other parts of the equipment may occur when working without lubrication.

Fig. 5-18:

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Annex Service – Servosystem screen The characteristic curves (ramps) of control levers (1, Fig. 5-19:) and control pedals (2) are adjustable by service personnel. The adjusted values are shown here graphically and numerically.

If adjustment is needed, call the responsible service personnel.

Adjustment is to be done in the “Setup” section of BCSIII. Access to this area is for service personnel only (password required).

Functioning of key switches and thumb wheel in joysticks (3) can be checked as well.

1

Tapping on a joystick symbol displays the current value settings assigned to the lefthand / righthand joystick.

Function of the key switches in the joystick are displayed as well.

2

Tapping on a pedal symbol displayes the current value settings of the pedal.

3

Key switches and thumb wheel in joysticks (3) can be checked by tapping on the touch sensitive areas below the joystick graphic. The color changes from red to green.

Tapping the button “More details” leaves the current screen and opens a screen with all the current values assigned to pedal and joystick functions.

Tapping the button “Slew brake test” leaves the current screen and opens a screen on which the slew brake test can be performed.

Fig. 5-19:

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Annex Service – More details screen 1

This area of the screen displays all actual current values for the lefthand joystick.

While moving the joystick the mA value shown will alter.

The mA value represents the current going to the corresponding valve (f.ex. “2Y13”, which can be found in the schematics).

2

This area of the screen displays all currently set values for the pedals. While moving the pedal the mA value shown will alter.

3

This area of the screen displays all actual current values for the righthand joystick.

While moving the joystick the mA value shown will alter.

Note: The screenshot shown in (Fig. 5-20:) was taken from a test-system. Because of that the joystick and pedal symbols were crossed and the current valus are zero. On life machines the symbols will not be crossed and there will be values which make sense (In case of an event / fault they will be not).

mA = milliampere

Fig. 5-20:

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Annex Service – Slew brake test screen A slew brake test must be performed during commissioning of the machine and after repair work or maintainance work carried out on the slewing system.

1

The slew brake test should be performed at every maintenance scheduled by the customer.

This is to ensure proper functioning of the slew brake system. Proper functioning of the slew brake system has influence to machine safety.

Before performing the slew brake test, ensure the machine is in a safe workplace where the machine can rotate 360° without hitting an obstacle. Check that all persons have left the area around the machine. Activate the horn.

To perform the slew brake test, follow the instrucions (4) given on the screen.

Fig. 5-21:

5-24

Preconditions to be fulfilled before performing the slew brake test, symbols from left to right: - swing brake applied, - engine running with more than 1200 rpm, - servo control switch in dashboard OFF, - operator sitting on his seat.

Time space to fulfill preconditions is 60 seconds.

2

Button to start the test. Appears in green color when the test can be started.

3

Hydraulic pressures in components of the slewing system.

4

Instructions to perform the slew brake test.

5

Instruments displaying hydraulic pressure in lefthand / righthand slewing system.

6

Indicators showing the progress during testing: - “pending”, colour red after starting test, - “progress”, colour yellow when 300 bar, - “passed”, colour green when test OK.

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Annex Help - Viewing PDF™ documents screen Technical documentation for the machine is stored in memory.

Button “Software versions” opens a screen which displays the version number of software installed in the BCS components (see chapter “Software version screen”).

Tapping on the buttons opens the appropriate PDF™ file and displays it on the screen by means of the build in viewer.

You can navigate inside the documents using the navigation elements known from other computer usage, like buttons, sliders, links from the contents page and so on (see chapter “PDF™ reader, functions”).

Fig. 5-22:

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Annex PDF™ reader - functions After choosing a button on the “Help” – screen the corresponding PDF™ file will be displayed on the screen by means of the build in viewer.

Zoom in.

Zoom out.

Maximize height.

You can navigate inside the documents using the navigation elements on the left side of the screen (Fig. 5-23:).

Maximize wide.

In this example the “Electrical Schematics” file has been opened.

One page back.

One page forward.

Tools menu.

Search menu, see chapter “PDF™ reader, search screen.

Settings menu, see chapter “PDF™ reader, settings screen”.

Close, return to “Help” – screen.

Fig. 5-23:

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Annex PDF™ reader - settings screen In this screen some settings can be made that influence the appearance of the PDF™ file viewer. 

Arrangement of the menu bar, left or right side of the window.



Possibility to invert swipe.



Background color black or white.

Fig. 5-24:

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Annex PDF™ reader - search screen The files of the machines Technical Documentation stored in memory are generic PDF™ files.

Generic PDF™ files can be searched for letters, words or numbers at your choice. This does not work with scanned files, because these are graphics.

To key in your search term, tap on the input field named “Find what:”.

The on-screen keyboard appears (Fig. 5-25:).

Enter your search term, choose the search parameters and start search by tapping the binocular icon.

Fig. 5-25:

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Annex Software version screen Most of the electronic components have build in microcontrollers which need software programs.

In this screen the software version numbers are listed as well as the serial numbers of major components.

These information may be helpful for service personnel and for ordering spare parts.

Fig. 5-26:

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Annex Event list screen

1

This is a listing of all the events / faults stored in memory since the last memory delete.

Events / faults were described with a plain text.

They were characterized with a colored icon for severity, with a code and with a status information.

In the “Details” column date and time is listed of first recorded appearance.

2

Events / faults are characterized in three classes, depending on their severity: Error = red icon, highest severity; Warning = yellow icon, middle severity; Info = green icon, lowest severity.

The “Event list” can be filtered depending on these classes by tapping one of the buttons “Filter”.

The list in (Fig. 5-27:) is filtered relating „Error“.

That means that only events / faults with the highest severity class “Red” are listed. All others are still in memory.

3

4

Fig. 5-27:

5-30

Description and characterization of events / faults occurred on the machine.

List can be displayed sorted or filtered in different ways, see pos. 3 and 4.

Longer lists can be scrolled up / down by sliding the blue colored bar or tapping the up / down arrows.

Tapping on button “Location” opens a screen showing more information related to the defective component. This is to make identification of the defective component easier and helps solving the problem.

In this screen the first event in the list has been tapped, a underlay in gray color appears. Tapping on button “Location” opens a new screen (see Fig. 5-28:).

Sort the event / fault list relating severity: ascending / descending.

Sort the event / fault list relating status: active / inactive.

Filter the event / fault list relating severity: Only “Error”, only “Warning” or only “Info” characterized event were listed.

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Annex Event list screen - location On the “Event list” screen (Fig. 5-27:) the event / fault in the first line has been tapped and therefore got an underlay in gray color. After then button “Location” has been tapped, the screen (Fig. 5-28:) appears showing details for the event.

There is a photo showing the location of the defective component, a description of the fault and hints on possible causes as well as recommendation on what to do to solve.

Tap on the “Back to previous screen” – button to go back to the “Event list”.

Fig. 5-28:

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Annex Screenshot - making and storing After tapping the “Screenshot” button the system produces a graphics file of all the information visible on the screen. This is useful to store information for further use.

The system shows a list of available drives (Fig. 5-29:). Select the drive you want to write the file to.

The graphics file is named automatically and written to the drive.

Service personnel can open the drives on the system and read the files.

Fig. 5-29:

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Annex Setup menu - login screen Tapping the “Setup” button opens a login window (Fig. 5-30:) that permits access to the BCS “Service level I”, a section that is exclusively for service personnel. A password is needed to get access.

Fig. 5-30:

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Annex BCS III - interfaces The BCS system comes with different data interfaces. This feature allows the communication with external electronic devices.

Three connectors are located on the rear-wall of the dashboard, lefthand side from the operator’s seat (Fig. 5-31:): 1

Ethernet, jack type RJ45.

For the connection of future extensions, for example, the remote servicing system.

2

USB 2.0, jack type A. This jack accepts, for example, a USB stick used to save operating data for evaluation on an external computer.

3

Jack D sub, 9 pins.

Used to connect a computer with a diagnosis software with access to the CAN bus. This connection is reserved for service personnel.

A USB stick can be connected to the USB plug-in connection of type A (2, Fig. 5-31:).

Suitable are such USB sticks that would also work on computers with WINDOWS® operating systems; they may be formatted with the NTFS or the FAT32 file system.

If a screen page displays the symbol of a photo camera, all visible information of this screen page can be saved as a graphics file (= screenshot).

The BCS will create a graphics file.

For a detailed description see: “Screenshot - making and storing”.

The display computer of the BCS system has a integrated Compact Flash memory card for data storage.

5-34

Fig. 5-31:

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Annex BCSIII - cleaning

BCSIII - disposal

Clean dirty screens with a soft, slightly moist cloth.

In order to remove persistent dirt, you can use in addition a conventional cleaning agent for LCD monitors.

This electronic device contains substances that might be harmful to the environment.

The electronic components may contain, for example, lead (Pb) and mercury (Hg).

The background illumination lamps are LED-typelamps.

Never use solving or scouring cleaning agents.

This could damage the surface of the screen.

Do not use compressed air or water under pressure (high pressure cleaner or steam cleaner).

This could damage the electronic components.

The battery for backing up the memory contains lithium.

Therefore, this device must not be disposed of with your regular household waste. It must be disposed of properly as electronic scrap.

The escaping liquid from a damaged LCD screen may be harmful.

BCSIII – replace battery Time and date information on the display computer is stored in a memory sustained by a back-up battery (Lithium battery).

Do not come in contact with escaping liquids.

In case of skin contact, wash immediately with water and soap.

This battery has a limited lifetime and must therefore be replaced at regular intervals. The life time of the battery is approximately ten years.

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Annex TROUBLESHOOTING Instructions on troubleshooting Faults are often due to the machine not being correctly operated or serviced.

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 after-sales service.

Describe the fault and all accompanying circumstances as precisely as possible when calling on the CGM HMS 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.

Layout of the fault table Fault 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 operating instructions. If there is no entry, the CGM HMS after-sales service should be consulted

5-36

BA 6020B(3 847 000.00)-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 Engine not working at full power Engine not working on full cylinder papacity Engine without oil pressure or oil pressure too low

Remedial action Check P Adjust E Replace W Top up A Reduce S Clean R

1) Contact your

Cat dealer 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 •

• • •

• • • • •

•

Chapter ref.

Engine oil level

A

Oil level too high

Engine oil level

S

Engine inclination too big

Engine Op. P Instr.

Lubricants W

Engine oil of wrong SAE-class

•

•

•

•

•

•

• •

Fuel quality not corresponding to specification •

Air filter contaminated / turbo-charger defective

Engine Op. W Instr.

Air intake syst. P

Fuel filter contaminated

Fuel filter

•

Charge-air line leaking

• • •

P/W P

•

Radiator / cooling fins contaminated

Cooler cleaning R

•

Cooling fan or water pump defective or loose

Engine Instr.

•

Cooling air gets too hot / heat buid-up

•

Battery defective or discharged

•

Cable connections in starter circuit loose or corroded

• •

•

•

• • • •

•

•

•

• • • •

•

• • • •

Battery

• •

P P

Starter defective or pinion not in mesh

P

Shut-off relay jamming

1)

Incorrect valve setting

Injection valve defective Combustion engine blocked on output side

•

Op. P/W P

Engine Instr.

Injection line leaking

• • •

Service

• PMS malfunction • Celect coding lamp flashing/lit Celect defective (software error)

Op. E P

Engine Instr.

Op. P/W 1) 1) 1) 1)

5-37

BA 6020B(3 847 000.00)-EN

Annex Working hydraulics – Fault table Fault

Remedial action

Working and swing functions not operational No boom function No bucket function No backhoe function No stick function Working movements too slow Power loss in working hydraulics Uncontrolled working movements Cause Electronic hydraulic shovel control not activated/defective

•

Check Adjust Replace Top up Reduce Clean

P E W A S R

1) Contact your Cat dealer Service Abschnitt Working P

•••••

•

Malfunction of pressure-relief valve

1)

•

•

Servo system pump defective

1)

••••• • •

ECO-power switch in 80%-position

•

Fuel filter contaminated

•

Insufficient engine power

• •

• •

5-38

• Malfunction of primary / sencondary pressure-relief valves Engine speed too low

1) P P Fuel filter

P/W

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 1) • Malfunction of control spool Engine coupling defective

BA 6020B(3 847 000.00)-EN

Annex Track drive – Fault table Fault

Remedial action

No forward travel and no reversing travel Maximum travel speed cannot be reached Insufficient traction power

•

•

•

• •

• • • • • •

• •

• •

•

Cause Malfunction of pressure-relief valves

Check Adjust Replace Top up Reduce Clean

P E W A S R

1) Contact your Cat dealer Service Chapter ref.

1)

Servo system pump defective Malfunction of travel valve (pedal) Engine nominal speed too low Malfunction of control spool ECO-power switch in 80%-position Insufficient engine power

1) 1) 1) 1) Travelling P 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)

5-39

BA 6020B(3 847 000.00)-EN

Annex Swing mechnism – Fault table Fault

Remedial action

No swing possible No righthand or lefthand swinging Slewing performance insufficient Uncontrolled swinging movement

Cause Electronic hydraulic shovel control not activated / defective

• • • • • •

•

• •

• • • • •

5-40

Limiting switch optional, ramp-type ladder not complete retracted Upper structure holding brake applied Pressure-relief valve adjusted too low level / defective Servo system pump defective Malfunction in feed-pressure circuit of swing pump Malfunction in high-pressure circuit of swing system Malfuction of moment-regulating valve Malfunction in swing pump displacement cylinder Excessive leakage in swing motor

Check Adjust Replace Top up Reduce Clean 1) Contact your Cat dealer Service Chapter ref.

Working Operation

P E W A S R

P P P 1) 1) 1) 1) 1) 1) 1)

BA 6020B(3 847 000.00)-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 Grease pump not working, pilot lamp lit Grease pump working, no grease delivered Greasing pressure too high or too low

• • • •

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

Check P Adjust E Replace W Top up A Reduce S Clean R Vent L 1) Contact your Cat dealer Service Chapter ref.

P/W P/W P/W P/W P/R P/W P/A P/L P/L P/W E

5-41

BA 6020B(3 847 000.00)-EN

Annex ENGINE MONITORING, CONTROL LAMPS The control lamps (45 and 46, Fig. 5-32:) indicate malfunctions and signal when certain limit values have been exceeded.

An automatic check is performed after switching on the electrical system of the machine; both lamps will light up for approx. 5 seconds and turn off afterwards.

Warning lamp, red (46):

Ignoring the signal lamp may lead to a potential engine breakdown.

The warning lamp lights up as soon as certain limit values for the following operating parameters of the engine have been exceeded: (An "Event“ occurred): 

Charge air temperature at engine intake,



Temperature of coolant,



Engine oil pressure,



Engine speed (protection against overspeed),



Fuel pressure,



Fuel temperature.

In case of an event (e.g. temperature of coolant is too high), the lamp will light up. The diagnosis lamp provides the event code at the same time (flashing).

Fig. 5-32:

Diagnosis lamp, yellow (45): The diagnosis lamp indicates malfunctions of the electronic control of the engine.

For example: faulty sensors, cable breaks etc.

The indication uses so-called flash codes.

In case of a malfunction, the diagnosis lamp represents two digits, the "diagnosis code" or an "event code“.

This takes place by the flashing of the diagnosis lamp in quick succession.

The first and second digits of the flash code are derived by counting the flash signals.

There is a time interval of approx. 2 seconds between the flashing sequence of the first and second digit.

In case of several diagnosis codes, the time interval between two different diagnosis codes is approx. four seconds.

Refer to the engine's operating and maintenance manual for matching the diagnosis and event codes with the cause of malfunction.

Diagnosis codes are intended to isolate an error and are not suitable for detailed fault diagnostics.

5-42

In case of a previously specified threshold value, the engine will reduce the output (so-called "engine derate“). This is not indicated by the lamps, e. g.: 

Engine oil pressure approx. 1bar (14.5psi) (rotation speed dependent),



Temperature of coolant above 111°C (231.8°F),



Temperature of intake air above 86°C (186.8°F),



Temperature of fuel above 91°C (195.8°F).

In case of a reduced output, for example by exceeding the maximum working height, none of the lamps will light up or flash.

The limit values and the engine's response when those values are exceeded can be adjusted in the so-called monitoring system within certain limits (service provided by the engine manufacturer).

BA 6020B(3 847 000.00)-EN

Annex ABBREVIATIONS A abt. acc.

Ah ANSI API approx.

Ampere (SI base unit of electric current) about according to Ampere hours (SI base unit of quantity of electricity) American National Standards Institute, Inc. American Petroleum Institute approximately

bar BH

unit of pressure, 1 bar = 14.5 psi Backhoe working equipment

CAMP CE

Control and Monitoring Platform Communauté Européenne = European community Committee for european Construction Equipment (Defines a measure for bucket, grab or scoop filling) European Standardization Committee Caterpillar Global Mining centimeter (= 1/100 m) Cubic centimeters per revolution counterclockwise clockwise

CECE

CEN CGM cm cm3/rev CCW CW

dia.

DIN ECM eff.

ELC e.g. etc.

Electronic Control Module on engine effective Extended Life Coolant for example etcetera

Fig. FMI FOPS FS ft

Figure, serial number of illustration Failure Mode Identifier, description of malfunctions according to SAE J1939 Falling objects protective structures Face shovel (working equipment) foot (unit of distance), 1 ft = 0.30 meter

gal GmbH

gallon (unit of volume), 1 gal = 3.78 liters German legal business form

HD HMS Hydr.

Heavy duty Hydraulic Mining Shovels Hydraulic, Hydraulics

i i.e.

id est = that is

Transmission ratio

ISO service rating, blocked Including, inclusive of International Standardization Organization

kg kg/dm3

Kilogram (unit of weight), 1 kg = 2.2 lb Kilograms per cubic decimeter (= unit of specific density) Kilometers per hour Kilopascal (unit of pressure), 100kPa = 1bar = 14.5 psi KiloNewtons per meter (1 kNm = 1000 Nm) = unit of torque Kilowatt (1 kW = 1.36 hp)

km/h kPa kNm

Decibel (sound intensity according measuring method A) Diameter German Industrial Standard

dB(A)

IFN Incl.

ISO

to

kW l lb Lb/in² LED l/min LpA LwA

Liter (unit of volume), 1 liter = 0.26 gal pound (unit of mass), 1 lb = 0.45 kg Pounds per square inch (= psi) Light-emitting diode Liters per minute Sound pressure at workplace Sound power level of the machine in stationary operation

m MA mA max. min. min-1 mm

Meter (unit of distance), 1 m = 3.28 ft Tightening torque 1 Milliampere (= /1000 A) maximal, maximum minimal, minimum Revolutions per minute Millimeter (=1/1000 m)

N, kN NLGI NLGI– Klasse Nm No.

Newton, kiloNewton (unit of force) National Lubricating Grease Institute (USA) Consistency – lubricant classification acc.

To DIN 51 818 Newtonmeter (unit of torque) Number

OH OMM oz

Operating hour Operation and Maintenance Manual ounce (unit of volume) 1 oz = 0.03 liter

PMS P/No. PPE PS psi PLC

Pump Managing System Part number Personal Protective Equipment Metric horsepower (1 PS = 0.74 kW) pound per sqare inch (unit of pressure), 1 psi = 0.069 bar Programmable logic controller

Qty.

Quantity

5-43

BA 6020B(3 847 000.00)-EN

Annex ABBREVIATIONS R, r resp.

RTF ROPS rpm

Radius Respectively Rich Text Format, textbased file format Roll-over protective structures Revolutions per minute (= min-1)

SAE sec./s.

SCA SM SN SPN

Society of Aotomotive Engineers (USA) Second Supplemental Coolant Additive Service Manual CGM HMS GmbH partnumber Suspect Parameter Number, description of malfunctions according to SAE J1939 Width across flats

SW t tm typ.

Metric ton (= 1000 kg) Tons by meters (obsolescent unit of swing torque) Typical

U/min USB

Revolutions per minute Universal Serial Bus, interface for fast data exchange

V VDMA

Volt (unit of electric voltage) Association of German Machinery and Systems Manufacturers

W

Watt (unit of electric power)

°C °F > <

Degrees Celsius (temperature) Degrees Fahrenheit (temperature) greater than less than

5-44

BA 6020B(3 847 000.00)-EN

Annex CONTENTS OF THE DECLARATION OF CONFORMITY Manufacturers: Caterpillar Global Mining HMS GmbH Karl-Funke-Strasse 36 44149 Dortmund Federal Republic of Germany Fon: 0231-922-3 Fax: 0231-922-5300 EC Declaration of Conformity in acc. with EC Machine Directive 2006/42/EC The manufacturer declares that the following machine: Hydraulic Mining Shovel 6020B 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: Herr Uwe Friedhoff (Design dept.).

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

5-45

BA 6020B(3 847 000.00)-EN

Annex NOISE EMISSIONS AND VIBRATION DATA Noise emissions Static and dynamic measurements of the sound pressure were carried out at different measuring points according to ISO 6395:2008 Annex B. For measurements, the fan speed of the oil/water cooler was adjusted to 70% (ISO 6395).

Inside operator’s cab: 65dBA; Outside power module: 110dBA.

Vibration data On the condition that the hydraulic shovel 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) fulfill the requirements with respect to the protection against whole-body vibrations in acc. with EC Vibration Directive 2002/44/EG. The vibrations transferred are indicated in acc. with EC Machine Directive 2006/42/EG, Annex I; Section 3.6.3.1, resp. the "Lärm - und Vibrations-Arbeitsschutzverordnung" of 18.12.2008, Section 4.

The effective value of the weighted acceleration to which the wole body is exposed, does not exceed 0.5 m/s2.

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

5-46

BA 6020B(3 847 000.00)-EN

Annex PRODUCT SPECIFICATION SHEET

5-47

Cat

®

6020B HYDRAULIC SHOVEL PRELIMINARY FEATURES: Industry-leading efficiency with dedicated pump flow allocation technology Safety and productivity enhancing state-of-the-art operator’s cab Class-leading in-pit visibility via cab floor window and large front and side windshields Easy serviceability and component accessibility via spacious walk-through engine module

Fast field assembly via modular design Optimized hydraulic oil temperature and cooling flow control via independent cooling system Minimized regular service activities via automatic centralized lubrication system

Specifications General Data Operating Weight Engine Output SAE J1995 Standard Bucket Capacity

Electrical System 220 tonnes 778 kW 12 m³

240 tons 1,043 hp 15.7 yd³

800 mm 220 000 kg 21.3 N/cm²

2 ft 7 in 485,000 lb 30.9 psi

Operating Weight – Backhoe Standard Track Pads Operating Weight Ground Pressure

Diesel Engine Make and Model Rated Net Power ISO 3046/1 Rated Net Power SAE J1349 Rated Gross Power SAE J1995 No. of Cylinders Bore Stroke Displacement Aspiration Maximum Altitude without Deration above sea level (a.s.l.)

Alternator Emission Certification Fuel Tank Capacity

Cat® C32 (Tier 2) 778 kW 1,043 hp, 1,800 min-1 778 kW 1,043 hp, 1,800 min-1 778 kW 1,043 hp, 1,800 min-1 12 145 mm 5.71 in 162 mm 6.38 in 32 L 1,959 in³ Turbocharged and air-to-air aftercooled 2000 m 6,560 ft 275A U.S. EPA Tier 4 Capable Flex 3600 L 951 U.S. gal

• Hydraulically driven radiator fan with variable electronically controlled fan speed • Reversible fan for self cleaning of engine radiator • Micro processed engine management • Heavy-duty air filters • Two-stage fuel filter • Additional high-capacity water separator including electric priming pump • Large fuel tank allows for 24 hour machine operation

System Voltage Batteries (12V each) In Series/Parallel Installation Working Spotlights Battery isolation relays

24V 6 × 210 Ah 630 Ah – 24V 6 high brightness LED lights 4 × front/2 × rear manual lockable disconnect switch and automatic disconnect relay

• Emergency stop buttons inside cab, accessible from all seating locations, and engine module • Additional ground-level emergency stop

Hydraulic System with Electronic Pump Management Main Pumps Maximum Total Oil Flow Maximum Swing Oil Flow Maximum Pressure, Attachment Maximum Pressure, Travel Maximum Pressure, Swing

6 × variable swash plate pumps 2350 L/min 621 U.S. gal/min 783 L/min 216 U.S. gal/min 310 bar 4,495 psi 310 bar 4,495 psi 350 bar 5,080 psi

• Electronic pump management contains: – Electronic load limit control – Dedicated circuit pump allocation – Automatic return of main pumps to zero flow – Automatic rpm reduction of engine speed during working breaks – Reduced oil flow of main pumps at high hydraulic oil temperature and at high engine temperature • Pressure cut-off function for all main pumps • Cooling of pump transmission gear oil • Filters: – Full-flow high-pressure filters (100 μm) for main pumps, installed directly behind each pump – Full-flow filters (10 μm) for complete return circuit – Full-flow filters (10 μm) for cooling return circuit – Pressure filters (6 μm) for servo circuit – Transmission oil filter (40 μm)

6020B Hydraulic Shovel Hydraulic Oil Cooling Oil Flow of Cooling Pumps Diameter of Fan

Operator’s Cab 800 L/min 1500 mm

211 U.S. gal/min 4 ft 11 in

Operator’s Eye Level (approximate) Internal Dimensions of Cab: Length Width Height

• Cooling system fully independent of all main circuits, i.e. controlled cooling capacity available whenever engine is running • Variable electronically controlled flow of oil through cooler and fan speed • Reversible fan for self cleaning of oil cooler • Superior cooling efficiency to ensure optimum oil temperature

Parking Brake Maximum Swing Speed Swing Ring

2 compact planetary transmissions with axial piston motors Wet multiple-disc brake, springloaded/hydraulically released 4.9 rpm Triple-race roller bearing with sealed internal gearing

• Open swing circuit with auto slow down when joysticks in neutral • All slew ring raceways and grease tub for internal gearing supplied by automatic, central lubrication system

Centralized Service Area Centralized service area accessible from ground level.

Equipped with: • Quick couplings for: – Diesel fuel – Engine coolant – Pump transmission gear oil – Engine oil (oil pan) – Hydraulic oil • Cat jump-start socket • Indicator light for hydraulic tank full

Parking Brakes

2230 mm 1625 mm 2070 mm

7 ft 4 in 5 ft 4 in 9 ft 9 in

Automatic Lubrication System Capacity of Grease Barrel

205 L

54 U.S. gal

• Single-circuit progressive system with hydraulically driven heavy-duty pump and electronic time control • Grease supplied to swing roller bearing, all pivot points of attachment, and swing gearbox bearing • System condition and failures displayed by Board Control System

Undercarriage Travel Speed (2 Stages): 1st Stage (maximum) 2nd Stage (maximum) Maximum Tractive Force Gradeability of Travel Drives Track Pads (each side) Bottom Rollers (each side) Support Rollers (each side) Travel Drives (each side)

18 ft 1 in

• Large cab floor window with removable grating for easy cleaning • Pneumatically cushioned and multi-adjustable operator seat with lumbar support, safety belt, head- and armrests • Safety switch in operator’s seat for automatic motion shutdown • Joystick integrated in adjustable seat armrest • Full sized trainer seat with safety belt and work table • Auxiliary fold-away seat with safety belt for 3rd person • FOPS (rock guard; approved according to DIN ISO) compliant • Safety glass, including armored windshield • Windshield with parallel intermittent wiper/washer • Roller blinds • New Board Control System (BCS): Electronic monitoring, data logging and diagnostic system for vital signs and service data of engines, hydraulic and lubrication system, featuring: – Robust instrument panel including large (254 mm/10 in) color touch screen – On-screen PDF documentation (e.g. operating instructions, technical handbook, spare parts catalog, electric circuit diagram) – On-screen troubleshooting assistance – Graphical data logging – Fault memory capabilities – USB, Lan (TCP/IP) and CAN BUS interfaces for data export • Retractable, hydraulically operated boarding ladder • Additional emergency ladder in close proximity to emergency escape window

Swing System Swing Drives

5.5 m

1.2 km/h 0.75 mph 2.7 km/h 1.68 mph 1052 kN 107 t = 236,420 lbf Approximately 54% 49 8 2 plus slide 1 planetary transmission with 2 two-stage axial piston motors Wet multiple disc brake, spring loaded/hydraulically released

Attachment • Boom and stick torsion-resistant with welded box design • High-tensile steel with solid steel castings at pivot areas • Boom and stick stress-relieved after welding • Catwalks with rails at boom • Float valve for boom down function • Buckets equipped with: – Special liner material covering main wear areas inside and outside – Lip shrouds – Wing shrouds – Heel shrouds

• Forged double-grouser track pads • Chain links connected by hardened pins and bushings • All running surfaces of sprockets, idlers, rollers and track chain links hardened • Fully hydraulic self-adjusting track tensioning system with accumulator • Automatic hydraulic retarder valve to prevent overspeed on downhill travel • Audible travel alarm

2

6020B Hydraulic Shovel Backhoe Attachment (BH) Working Diagram – Boom 8.7 m (28 ft 7 in) – Stick 3.9 m (12 ft 10 in) ft

m 16

50

45

40

14

12

35 10 30

25

20

8

6

15 4 10 2 5

0

0

–5 –2 –10 –4 –15

–20

–25

–6

–8

–30 –10 18 60

16 55

50

14

12

45

40

10 35

8 30

6 25

20

Working Range Maximum Digging Depth Maximum Digging Reach Maximum Digging Height

15

0m

2 10

5

0 ft

Backhoes 8.1 m 15.9 m 13.9 m

26 ft 7 ft 52 ft 2 in 45 ft 7 in

Type Tooth System Capacity 1:1 Capacity 2:1 Capacity Struck Total Width Inner Width No. of Teeth Weight including standard wear package Maximum Material Density (loose)

Digging Forces Maximum Crowd Force Maximum Breakout Force

4

640 kN 665 kN

143,830 lb 149,450 lb

3

Standard rock bucket Cat C85 penetration tip with CapSure lock 12.0 m³ 15.7 yd³ 10.5 m³ 13.8 yd³ 9 m³ 11.8 yd³ 3410 mm 11 ft 2 in 3000 mm 9 ft 10 in 6 12 400 kg 27,340 lb 1.8 t/m³ 3,030 lb/yd³

6020B Hydraulic Shovel 1

9 10

2

13

6

3

4

5

11 12 14

7

16 15

8

17

Dimensions (All dimensions are approximate.)

1

6045 mm

19 ft 10 in

10

7414 mm

24 ft 4 in

2

5907 mm

19 ft 4 in

11

1925 mm

6 ft 4 in

3

5500 mm

18 ft 0 in

12

880 mm

2 ft 10 in

4

2085 mm

6 ft 10 in

13

6430 mm

27 ft 1 in

5

1825 mm

5 ft 11 in

14

800 mm

2 ft 7 in

6

5735 mm

18 ft 9 in

15

5500 mm

18 ft 0 in

7

5720 mm

18 ft 9 in

16

1370 mm

4 ft 6 in

17

6240 mm

20 ft 6 in

8

7445 mm

24 ft 5 in

9

7950 mm

26 ft 1 in

OPTIONAL EQUIPMENT SUPERSTRUCTURE Oil change interval extension for engine oil up to 1,000 hours Cold-weather package 45 degree boarding ladder

CAB Dual HVAC system Camera system

ATTACHMENT Work lights on boom High-abrasive wear package

UNDERCARRIAGE Track pad width 1000 mm (3 ft 3 in) Carbody protection kit including belly plate and rear plumbing guard

For more complete information on Cat products, dealer services, and industry solutions, visit us on the web at www.cat.com © 2013 Caterpillar Inc. All Rights Reserved Printed in U.S.A. Materials and specifications are subject to change without notice. Featured machines in photos may include additional equipment. See your Cat dealer for available options.

CAT, CATERPILLAR, SAFETY.CAT.COM, 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.

AEHQ7001 (02-13)

BA 6020B(3 847 000.00)-EN

Annex

5-48

BA 6020B(3 847 000.00)-EN

Annex NOTES .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. ..............................................................................................................................................................................

5-49

BA 6020B(3 847 000.00)-EN

Annex

5-50

BA 6020B(3 847 000.00)-EN

Index 6 INDEX Operating instructions

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 6020B(3 847 000.00)-EN

Index

6-2

BA 6020B(3 847 000.00)-EN

Index

A ABBREVIATIONS............................................. 5-43 About this Operation and Maintenance Manual . 1-3 Additional messages ........................................ 2-23 Additional silencers - check / clean ................ 3-121 Additional silencers - function........................... 2-96 After daily operation.......................................... 2-95 AIR-INTAKE SYSTEM - information................. 3-53 Alternator - Instructions .................................... 3-66 Appropriate disposal of batteries ...................... 4-16 ASSEMBLING WORKING EQUIPMENT SAFETY INSTRUCTIONS ............................ 2-97 Automatic reset to idling ..................................... 2-9 Avoid mixing of different hydraulic fluids .3-31, 3-83

B Backhoe operation – digging and loading ........ 2-93 Battery – maintenance...................................... 3-68 Battery - removing and installing ...................... 3-69 Battery isolator switch – shutting off supply voltage2-36 Battery main switch – switching on / off ........... 2-31 Battery storage ............................................... 3-125 BCS display monitor – adjusting position ......... 2-43 BCS III - interfaces............................................ 5-34 BCS III, what’s that? ........................................... 5-3 BCSIII - cleaning............................................... 5-35 BCSIII - disposal ............................................... 5-35 BCSIII – replace battery ................................... 5-35 BCSIII screens - Sitemap 1 ................................ 5-4 BCSIII screens - Sitemap 2 ................................ 5-5 BCSIII, the first screen screen after startup ....... 5-7 BCSIII, the start screen ...................................... 5-8 Before starting work.......................................... 2-89 Bench – climbing and leaving........................... 2-94 Board-control-system ......................................... 5-3 Board-Control-System (BCS) – information ....... 2-9 Boarding ladder lighting – switching on / off..... 2-27 Bucket lip shroud – replace .............................. 4-11 Bucket tip – replace .......................................... 4-10 Bucket wing shroud – replace .......................... 4-11 Bypass valves (hydraulic oil tank) – clean / replace3-79

C Cab interior lights – switching on / off............... 2-30 CENTRAL LUBRICATING system ................. 3-111 Central lubricating system – Fault table ........... 5-41 Central lubricating system - function .............. 3-111 Charging batteries inside the machine – safety instructions .................................................... 3-67 Clean-air lines and hoses – inspect ................. 3-56 Cold-starting fluid (ether) – Replacing the pressure vessel ............................................................ 3-44 Combustion engine - Fault table....................... 5-37 Component numbers – location ....................... 2-25 confined spaces - Safety instructions................. 4-4

Contents of the Declaration of Conformity ....... 5-45 Control and Monitoring Platform (CAMP) .......... 2-8 Coolant for use on all combustion engines ...... 3-37 Cooling liquid – change.................................... 3-49 Cooling liquid - Testing the composition .......... 3-51 Cooling-liquid – Checking level........................ 3-46 Cornering.......................................................... 2-81 Corrosion protection for pins and bearings (bushings and hubs) .............................................. 2-99 CRAWLER TRACKS...................................... 3-105

D Demand control / Zero-flow regulation............... 2-9 DESCRIPTION OF THE hydraulic shovel ......... 2-6 Designated use, unauthorized use .................... 1-6 Diesel fuel - recommendations ........................ 2-63 Diesel fuel tank - refilling .................................. 2-63 Disposal at the end of the service life .............. 4-15 Dust trap - Cleaning ......................................... 3-53

E Electrical circuit diagrams ................................ 3-66 Electrical system ................................................ 2-9 ELECTRICAL SYSTEM ................................... 3-66 Electrical system - Safety instructions ............. 3-66 Electrical system – switching on and off .......... 2-69 Electrical system switch-cabinets .................... 3-66 Emergency exit in operator’s cab and escape ladder................................................................. 2-32 Emergency ladder on the righthand side of superstructure........................................................ 2-33 Emergency lowering of the working equipment 2-95 Emergency lowering the boarding ladder from the ground........................................................... 2-33 Emergency shut-off – function ......................... 2-34 ENGINE............................................................ 3-39 Engine – adjusting the speed........................... 2-71 Engine – emergency shut-off ........................... 2-69 Engine – other maintenance .......................... 3-119 Engine - Safety instructions ............................. 3-39 Engine – shutting off ........................................ 2-72 Engine – starting .............................................. 2-70 engine – Starting and stopping ........................ 2-70 Engine – starting at low temperatures ............. 2-71 Engine bearings – inspect................................ 3-51 engine COOLING SYSTEM - information........ 3-45 Engine crankcase breather – clean ................. 3-52 Engine information plate – location.................. 2-25 Engine monitoring, Control lamps.................... 5-42 Engine number plate – location ....................... 2-25 Engine oil – Changing ...................................... 3-41 Engine oil filters – Replacing............................ 3-43 Engine oil level – Checking / Topping up......... 3-40 Engine, control and monitoring ........................ 2-51 Entering and leaving the machine.................... 2-26 Equipotential bonding – inspect ....................... 3-70 Event list screen ............................................... 5-30 6-3

BA 6020B(3 847 000.00)-EN

Index Event list screen - location................................ 5-31 Excavator controls – clean, lubricate.............. 3-122

F FAULT TABLES................................................ 5-37 Filling quantities - Grease................................. 3-25 Filling quantities - oil ......................................... 3-30 Filling quantities - other .................................... 3-30 Filter (pilot hydraulic circuit) - replace............... 3-81 Fire and explosion hazard .........................1-12, 2-5 Fire extinguisher – location............................... 2-40 Floor window pane - cleaning......................... 3-123 Fluid for hydraulic system................................. 3-33 Fuel filters – information ................................... 3-57 FUEL SYSTEM................................................. 3-57 Fuel system - Safety instructions...................... 3-57 Fuel system – venting....................................... 3-61 Fuel tank – cleaning ......................................... 3-62 Fuel tank – drain water and sediment .............. 3-63 Fuel tank breather filter – replace..................... 3-61 Fuel tank supply valve – function ..................... 3-58 Further machine documentation......................... 1-3 Fuses - information ........................................... 3-66

G Grease drum – check filling level ................... 3-116 Grease drum - replace.................................... 3-113 Grease drum breather – replace .................... 3-116 Grease filter – check / clean ........................... 3-117 Grease for bearings and swing rings (Central lubrication system) ............................................... 3-35 Grease for idlers, track rollers and support rollers (Lifetime lubrication)...................................... 3-36 Grease lines - checking greasing pressure.... 3-115 Grease pump – changing oil........................... 3-118 Grease pump – checking hydraulic pressure. 3-115 Grease pump – checking oil level .................. 3-118

HYDRAULIC SYSTEM..................................... 3-73 Hydraulic system - depressurize...................... 3-73 Hydraulic system - Safety instructions ............. 3-73 Hydraulic system - venting ............................... 3-87 Hydraulic system – Warming up ...................... 2-87 Hydraulic tank angled screens - inspect .......... 3-80 Hydraulic tank breather filter - replace ............. 3-80

I Important Safety Information.................................. ii Inspection and servicing - Safety instructions.... 3-3 Inspection and Servicing plans - Instructions .... 3-9 inspection and servicing work, Fire and Explosion Hazard ............................................................ 3-7 INSPECTION PLAN - OIL................................ 3-28 Inspection plan – Oil (legend) .......................... 3-29 Instructions on troubleshooting ........................ 5-36

J Jump seat – use ............................................... 2-39

L Lamps and bulbs – replace .............................. 3-66 Layout of the fault table.................................... 5-36 Lighting systems in LED technonogy - instructions3-72 LUBRICANTS / CONSUMABLES.................... 3-31 LUBRICATING CHART – GREASE ................ 3-24 Lubricating chart – Grease (legend) ................ 3-25 LUBRICATING CHART – GREASE, working equipment ..................................................... 3-26 Lubricating chart – Grease, working equipment (legend)......................................................... 3-27

M

MACHINE – PUTTING INTO OPERATION..... 2-62 Machine number plate – location ..................... 2-25 Maintenance access – doors and cover locations3-38 H Maintenance lights – switching on / off ............ 2-31 Maximum machine inclinations – information .. 2-76 Help - Viewing PDF™ documents screen ........ 5-25 High-pressure filter for working hydraulics - replace3-82 Measures.......................................................... 5-36 Mirror– adjusting position ................................. 2-42 HVAC – unit, controls ....................................... 2-74 MONITORING, WARNING AND CONTROL ELEHVAC – unit, function ....................................... 2-73 MENTS in cab............................................... 2-46 HVAC, filter element inside cab – check / clean3-121 HVAC, filter elements fresh air (outside) – replace3-120 Hydraulic boarding ladder – raising / lowering . 2-28 N Hydraulic cylinders – running-in instructions .... 2-87 Noise emissions ............................................... 5-46 Hydraulic hoses – Instructions ........................... 4-7 Noise emissions and vibration data ................. 5-46 Hydraulic oil - change ....................................... 3-83 Notes ................................ 1-13, 2-101, 3-127, 5-49 Hydraulic oil cooler - clean ............................... 3-88 NOTES ............................................................. 4-17 Hydraulic oil level - check ................................. 3-74 Notes on the selection of oils and greases ...... 3-31 Hydraulic oil return-flow filters (filter housing) replace .......................................................... 3-78 Hydraulic oil return-flow filters (hydraulic oil reserO voir - replace ................................................. 3-76 Often used symbols and buttons ....................... 5-9 Hydraulic shovel layout....................................... 2-7 Oils for combustion engines............................. 3-32 Hydraulic system ................................................ 2-8

6-4

BA 6020B(3 847 000.00)-EN

Index Oils for pump drive gearboxes, swing gearboxes and travel gearboxes ............................. 3-34 Operating hours meter – location ..................... 2-43 Operation - Safety instructions ........................... 2-3 Operation and Maintenance Manual – where to store it in the operator’s cab............................ 2-4 Operator’s cab – lock / unlock the door............ 2-29 Operator’s cab – open the door from inside ..... 2-29 Operator’s seat – adjustment ........................... 2-37 Operator’s seat belt – use ................................ 2-38 Operator's exposure to noise - reducing .......... 2-62 Operators exposure to vibrations – reducing ... 2-38 Optional equipment .......................................... 2-96 Organizational measures.................................... 1-7 OTHER MAINTENANCE................................ 3-119 Other maintenance work .................................... 4-9

P PDF™ reader - functions.................................. 5-26 PDF™ reader - search screen ......................... 5-28 PDF™ reader - settings screen ........................ 5-27 Pilot hydraulic circuit – activating...................... 2-89 Plan A – E......................................................... 3-17 Plan N ............................................................... 3-13 Plan T and W .................................................... 3-15 Plan V ............................................................... 3-11 Possible causes................................................ 5-36 Power module..................................................... 2-8 Power receptacle inside cab – use................... 2-44 Preface ............................................................... 1-3 Pressure accumulator - emergency lowering and pilot circuit ..................................................... 3-89 Pressure accumulator – track tensioner......... 3-108 PRESSURE ACCUMULATORS - SAFETY INSTRUCTIONS................................................. 4-8 Primary filter elements – Check, clean, replace3-54 Primary fuel filter - drain water.......................... 3-58 Primary fuel filter – replace............................... 3-59 Product specification sheet............................... 5-47 Pump drive gearbox - change oil...................... 3-91 Pump drive gearbox - change oil...................... 3-94 Pump drive gearbox - checking the oil level / Topping up with oil .....................................3-90, 3-93 Pump drive gearbox breather - replace............ 3-95 Pump drive gearbox breather – replace ........... 3-92 Pump drive gearbox oil filter – replace ............. 3-96 PUMP drive GEARBOX P/N 3855121 ............. 3-93 PUMP drive GEARBOX P/N 3855122 ............. 3-90 Putting the hydraulic shovel out of operation . 3-125 PUTTING THE hydraulic shovel OUT OF OPERATION AND RECOMMISSIONING............... 3-125 Putting the machine back into operation – reset of emergency shut-off function.......................... 2-35

R Radiator core – clean ....................................... 3-46 Recommissioning ........................................... 3-125 Refuelling.......................................................... 2-63

Refuelling using the Service Station ................ 2-64 Repair instructions ............................................. 4-7 repair work - ENGINE ........................................ 4-6 repair work - Fire and Explosion Hazard............ 4-5 repair work - HYDRAULIC SYSTEM ................. 4-7 Repair work - Safety instructions ....................... 4-3 Restricted operation ......................................... 2-92 Roller blinds – adjusting position ..................... 2-44 Rotary beacon – switching on / off................... 2-96

S Safety films and warning messages – overview and description ............................................. 2-10 Safety instructions governing specific operational phases ............................................................ 1-8 Safety messages.............................................. 2-16 Screenshot - making and storing ..................... 5-32 Seat belt - inspect .......................................... 3-124 Seat belt – replace ............................................. 4-9 Secondary filter element – replace .................. 3-56 Secondary fuel filter – replace.......................... 3-60 Section ............................................................. 5-36 Securing the machine ...................................... 2-98 Selection and qualification of personnel; basic responsibilities ................................................ 1-8 Service – More details screen.......................... 5-23 Service – Servosystem screen ........................ 5-22 Service – Slew brake test screen..................... 5-24 SERVICING WORK ......................................... 3-38 Setup menu - login screen ............................... 5-33 Software version screen................................... 5-29 Special work in conjunction with utilization of the machine and maintenance and repairs as well as troubleshooting during work; disposal of parts and consumables ........................................... 1-9 Start screen – Help section .............................. 5-13 Start screen - Information given in the central section ................................................................ 5-11 Start screen - Information given in the lower section ................................................................ 5-12 Start screen - Information given in the top section5-10 Starter isolator switch – shutting off starter voltage2-36 Superstructure.................................................... 2-8 Superstructure basic position........................... 2-79 Swing gearbox – change oil ............................. 3-98 Swing gearbox – checking the oil level / Topping up with oil...................................................... 3-97 Swing gearbox breather – replace ................... 3-99 SWING GEARBOX P/N 3857027 .................... 3-97 Swing mechnism – Fault table ......................... 5-40 SWING RING ................................................. 3-109 Swing ring - Checking the grease filling......... 3-110 Swing ring - Instructions................................. 3-109 System status – Engine, Information given on the screen ........................................................... 5-15 System status – Grease, Progressive grease system screen .................................................... 5-21 System status – Hydraulics, Attachment screen5-17

6-5

BA 6020B(3 847 000.00)-EN

Index System status – Hydraulics, Main pump pressure screen ........................................................... 5-16 System status – Hydraulics, Oil tank screen .... 5-19 System status – Hydraulics, Slewing screen.... 5-18 System status – Hydraulics, Travel screen ...... 5-20 System status screen - Information given on the screen ........................................................... 5-14

T The BCS housing – overview ............................. 5-6 Track drive – Fault table ................................... 5-39 Track parking brake – function ......................... 2-84 Track roller, Support roller – Check tightening of bolts............................................................. 3-106 Track tensioner – Checking............................ 3-107 Tracks - Cleaning ........................................... 3-105 Trainer's / instructor's seat – use...................... 2-39 Transport - Safety instructions.......................... 2-85 Transporting the machine................................. 2-85 TRAVEL GEARBOX ....................................... 3-100 Travel gearbox brake housing - Changing oil 3-104 Travel gearbox brake housing - Checking the oil level / Topping up with oil............................ 3-101 Travel gearbox breather - replace .................. 3-104 Travel gearbox main stage - Changing oil...... 3-102 Travel gearbox main stage - Checking the oil level / Topping up with oil .................................... 3-100 Travel gearbox pre-stage - Changing oil ........ 3-103 Travel gearbox pre-stage - Checking the oil level / Topping up with oil ...................................... 3-101 Travel motor coupling housing - Changing oil 3-103 Travel motor coupling housing - Checking the oil level / Topping up with oil............................ 3-102 TRAVELLING ................................................... 2-79 TRAVELLING – SAFETY INSTRUCTIONS ..... 2-78 Travelling forwards / backwards....................... 2-79

6-6

Travelling in water or mud................................ 2-83 Travelling over long distances ......................... 2-82 Travelling speed – adjust ................................. 2-80 Travelling uphill and downhill ........................... 2-80 TROUBLESHOOTING ..................................... 5-36 Turning ............................................................. 2-81

U Undercarriage .................................................... 2-8 Upper structure – swinging .............................. 2-90 Upper structure holding brake – function ......... 2-84

V Vibration data ................................................... 5-46

W Warning of special dangers ............................. 1-10 Warnings and symbols....................................... 1-5 Warranty............................................................. 1-4 Water trap (optional) – check ........................... 3-64 Welding and flame cutting works - Safety instructions .............................................................. 4-12 Window panes - cleaning ............................... 3-123 Windscreen washer nozzles– adjust................ 2-41 Windscreen washer reservoir – refill................ 2-42 Windscreen wiper / washer – function ............. 2-41 Windscreen wiper blade – replace..................... 4-9 Working hydraulics – Fault table...................... 5-38 Working movements ........................................ 2-91 WORKING OPERATION ................................. 2-89 Working operation - Safety instructions ........... 2-86 Working techniques.......................................... 2-92

BA 6020B(3 847 000.00)-EN

Index

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