1523, 13:35 sis20 2022/09/16 Commissioning the Machine (M0132719-02) ‘SMCS - 7000 109005531 Introduction This commissioning procedure contains the instructions that are required to commission the 6015 Hydraulic Mining Shovel After the 6015 Hydraulic Mining Shovel has been assembled, refer to Operation and Maintenance Manual, M0120630 [/ for the recommended fluids, correct filling procedures, and correct system fluid level checks. Refer to General Testing and Adjusting Information, 1Vi0122523 [% to perform the calibration procedures. A WARNING Do not attempt to assemble this machine until you read and you understand the assembly instructions. Improper assembly procedures could result in injury or death. Personal injury or death can result from improper lifting or blocking. When a hoist or jack is used to lift any part or component, stand clear of the area. Be sure the hoist or jack has the correct capacity to lift a component. Install blocks or stands before performance of any work under a heavy component. Approximate weights of the components are shown. Clean all surfaces where parts are to be installed, NOTICE Do not allow any dirt or foreign material to get into the hydraulic system during assembly, connection of lines, when components are filled with fluid, or during any maintenance operation. itps:si2,cat.comvt print previewiservice/%257B%2522te%2522%253A%2522Commissioning%2520the%2520Machine%2520(MO132719-0... t/t‘15123, 1328, sis20 Do not perform any procedures in this publication or order any parts until you understand the information that is contained in this publication. Alter you complete the assembly, prepare the machine for use according to the Operation and Maintenance Manual. Commissioning Procedure Use the Service Manual and the Operation and Maintenance Manual to correct a problem with a system. After you complete the final check, sign your name and the name of the dealer. Make copies of the check procedure and submit a/report of the inspection data through SIMSi 1. Go to SIMSi at the following address. https://sims.cat.com/sims/simsilindex.jsp Note: CWS ID is required for SIMSi. itps:si2,cat.comvt print previewiservice/%257B%2522te%2522%253A%2522Commissioning%2520the%2520Machine%2520(M0132719-0. ana11523, 135 sis20 iS io Lee Muttiie Sera! Number Entry (Sandee Let) Report Service Dealer Code Work Order Segment [00 store number [bt Employee idetteaion [ saci ia] [serace Meter Tous © saies © Kirn ar Faihuce made product Inoperable?) [Serice ic presevery? | ||Fiats Commissioning of SN: 000000), [Nontalure serge intommatonall? Senice warren? LI ‘AadRecord [_Addimage lMlustration 1 06374021 2. Click "Service Reporting" on the top menu. 3. Click "Report Service" on the left side menu. 4, Complete the form for your specific machine and dealer. Also, input the following required information as shown in Illustration 1, © Durability: No © Service Meter: 0 © Part Causing Failures: SP0100 © Qty:1 © Desc Cd: 38 © Group number: 7961 hitpssi2.cat.comv print previewsservce!%257B%2522N6%2522%253A%2522Commissioning%2620%he%2520Machine%2520(M0132719-0.... 3111523, 13:35 sis20 © Check on check box for "Service is predelivery?" © Check on check box for "Non-Failure service (informational)?" © Comments: Field Commissioning of (S/N: XXXXXXXX) 5. Upload the Product Status Report through "Add Image", refer to Illustration 1. 6. Submit the inspection data. Dealer Information Date Dealer Machine Model Dealer Code Serial Number Customer smu Configuration ME__FS_ Persons that completed the machine Job Site Unit Number Check Fluid Levels Note: Refer to the Operation and Maintenance Manual for the correct oil viscosity and for the amount of oil. Coolant Final Drives Window Washer Reservoir Hydraulic Oil Auto Lube (Grease) ‘Swing Drives Engine Oil itps:si2,cat.comvt print previewiservice/%257B%2522te%2522%253A%2522Commissioning%2520the%2520Machine%2520(MO132719-0....A/té11523, 13:35 sis20 Idlers Checks Before Machine Operation Note: Ensure that the following items have been completed: 1, Ensure that the swing gear compartment is not contaminated with water. Refer to Operation and Maintenance Manual, 0120630 [%, Swing Gear Grease - Check. 2, Start the engine and perform the start procedure for the fuel system. 3. Visually Inspect the hydraulic system for leaks. 4, Purge the implement pumps and the swing pump of air to reduce the possibility of pump cavitation. Refer to Testing and Adjusting, 0122523, Main Hydraulic Pump Air - Purge. 5. To prevent compression of oil and air in the hydraulic cylinders, the cylinders must be cycled as slowly as possible to purge all the trapped air from the cylinders. Use the following procedure to purge the cylinders and prevent damage to the piston and to the piston seals: NOTICE Carefully purging the cylinders of air will aid the assembly of the bucket to the stick and bucket cylinders. This action prevents damage to the cylinder pistons and seals. NOTICE Initial cycling of the cylinders must be done at low idle (tortoise). Hydraulic system must not go into relief. Do not allow rods to bottom out during the first two extensions and retractions. Do not make sudden reversals in direction of cylinder stroke during the first ten cycles. Allow at least 4 seconds between changing the direction of cylinder stroke. a. Start the machine. Turn the engine throttle control to position 1 b. For two cycles, slowly extend and slowly retract the hydraulic cylinders through one-half to three-fourths of a full stroke. The cylinders must not bottom out. Wait for a minimum of 4 seconds before reversing the direction of cylinder travel. c. For an extra eight cycles, slowly cycle the hydraulic cylinders through the full stroke. Wait for a minimum of 4 seconds before reversing the direction of cylinder travel. itps:si2,cat.comv print previewiservice/%257B%2522te%2522%253A%2522Commissioning%2520the%2520Machine%2520(MO132719-0.... S/té‘15123, 1328, sis20 d. After all the cylinders have been cycled at low idle for a minimum of ten cycles, the machine can be operated with the engine at high idle. e. When the air has satisfactorily been removed from the hydraulic system, select the throttle position 10. Run the engine at high idle. Stall the implements several times to increase the temperature of the oil for testing. Maintain the oil at a minimum temperature of 50 °C (122 °F) while the Testing and Adjusting is performed. f. After the completion of the machine, perform the following items: * Clean any spillage of oil. = Check the hydraulic oil level. = Inspect the machine thoroughly for leaks, Automatic Lubrication Before releasing the machine for production, adjust the time for the lube cycle to an interval of 5 minutes. Observe the grease points during machine operation. Adjust the cycle timer for the conditions of the job site. Note: For detailed instructions, refer to Testing and Adjusting, IM0122523 [/, Automatic Lubrication System - Testing and Adjusting Operation of the Electronic Monitoring System Note: Refer to the appropriate manuals for operating instructions. Ensure that the correct configuration software is installed before the checks for the machine systems are performed, An error message will be shown,on the message center if the problem exists. If necessary, load the software configuration. During the assembly process, category 1, 2; and’3 warnings may have been activated. If necessary, the following faults must be cleared: * Event List * Event Recorder * Blue Service Light Checks of the Machine Systems For the components that require pressure adjustments, relief valve setting adjustments, and cycle time, refer to Testing and Adjusting, 0122523 %. Note: Maintain the temperature of the hydraulic oil at a minimum of 50 °C (122 °F) when the Test and Adjust procedure is performed. itps:si2,cat.comv print previewiservice/%257B%2522te%2522%253A%2522Commissioning%2520the%2520Machine%2520(MO132719-0... 6/té11523, 13:35 sis20 Table 1 Checks of the Machine Systems Adjusted Description Specification Yes or Actual No Engine high idle 1800 + 50 rpm Engine low idle 700 + 50 rpm Accumulator pre-charge pressure for the pilot Refer to the chart for the system ambient temperature. Accumulator pre-charge pressure for the left Refer to the chart for the track tension system ambient temperature. Accumulator pre-charge pressure for the Refer to the chart for the right track tension system ambient temperature. , Refer to the chart for the Hydraulic Oil Cooler Accumulator ambient temperature. aS Refer to the chart for the ig ACcUmUlatol ambient temperature. Pilot Relief Valve Implement pilot oil pressure at High Idle (taken using a manual gauge at the pilot manifold) 6700 + 2000 - 0 kPa (972 + 290 - 0 psi) Implement pilot oil pressure at Low Idle (taken using a manual gauge at the pilot e700rs end Oke (972 + 116 - 0 psi) manifold) Pilot Pressure Reducing Valve Implement pilot oil pressure at High Idle. 4000 +400 0 kPa (taken from display) (680 + 58 - 0 psi) Relief Valve for Load Signal at Engine High Idle 30000 + 350 kPa Implement (4351 4 51 psi) ‘Swing System Pressure - Check 35000 # 1000 kPa (6076 + 145 psi) 35000 « 1000 kPa (6076 + 145 psi) Hydraulic Cooling Fan Cooling Fan (RPM) Swing Circuit Pressure #1 Swing Circuit Pressure #2 Minimum 425 + 50 rpm Maximum 1185 + 50 rpm High Ambient Maximum" 1300 rpm Cooling Fan (Pressure) ps2 cat.comhprint prevowiseren%257B%2522tHe%2522%259A%62522Commissonng?2520be%2520Machine%2520(MO192718-0... THé11523, 13:35 Minimum Maximum High Ambient Maximum" Minimum Maximum (Tier 1) Maximum (Tier 2) Maximum (Tier 4) Minimum Maximum (Tier 1) Maximum (Tier 2) Maximum (Tier 4) Automatic Lubrication System ‘Swing Pump Charge sis20 2000 + 500 kPa (290 + 70 psi) 13500 + 500 kPa (1960 + 70 psi) 16500 500 kPa (2393 + 73 psi) Engine Cooling Fan Cooling Fan (RPM) 525 + 50 rpm 840 + 50 rpm 1100 + 50 rpm 900 + 50 rpm Cooling Fan (Pressure) 4500 # 500 kPa (650 = 70 psi) 12500 # 500 kPa (1815 # 70 psi) 17500 + 500 kPa (2538 + 70 psi) 12800 + 500 kPa (1855 + 70 psi) Automatic Lubrication System at High Idle 2400 + 200 kPa (348 + 29 psi) ‘Swing Pump Charge Relief Valve at High Idle 3500 # 100 kPa (508 = 15 psi) Electronic Technician (ET). Table 2 For ambient temperatures above 45° C (113° F), also change the Hydraulic Cooling Fan Map parameter in Cat Cycle Times and Drift Rates” Description High-Speed Travel Time with the Engine at High Idle® Low Speed Travel Time with the Engine at High Idle® Travel Drift on 12.5 + 2.5° Slope Left Forward (High Speed) Right Forward (High Speed) Left Forward (Low Speed) itps:si2,cat.comv print previewiservice/%257B%2522te%2522%253A%2522Commissioning%2520the%2520Machine%2520(M0132719-0. Adjusted Specification Yesor Actual No 20 m.(65.6 ft) in 20.0 = 1.5 seconds 20 m (65:6 ft) in 40.0 + 2.0 seconds O.mm (0.0 inch) in 3 minutes Alternate Check of Travel Times with the Engine at High Idle 45 +5 seconds in 3 revolutions 45 +5 seconds in 3 revolutions 65 + 5 seconds in 3 revolutions ana11523, 1985 sis20 Right Forward (Low Speed) 65 + 5 seconds in 3 revolutions Left Reverse (High Speed) 45 + 5 seconds in 3 revolutions Right Reverse (High Speed) 45 + 5 seconds in 3 revolutions Left Reverse (Low Speed) 65 +5 seconds in 3 revolutions Right Reverse (Low Speed) 65 +5 seconds in 3 revolutions Implement Cycle Times with the Engine at High Idle Boom Raise 6.1 + 1 seconds Boom Lower 3.8 + 1 seconds Stick In 5.7 + 1 seconds Stick Out 4.6 + 1 seconds Bucket Load 4.9 + 1 seconds Bucket Dump 3.3 +1 seconds ‘Swing Speed Set the Engine at High Idle and have the 3 revolutions are equal to 37.0 upper structure in motion.) 4.0 seconds. ‘Swing time for 180° 9.5 seconds Swing Drift ‘Swing on 12.5 *2.5° Slope 50 mm (1.97 inch) in 3 minutes Swing Bearing Movement Slew Bearing Tilting Play Average Drift Rates of Implements (Empty Bucket) Boom Cylinders 6 mm (0.23 inch) in 5 minutes Stick Cylinder (Retracted) 10 mm (0.39 inch) in 5 minutes Stick Cylinder (Extended) 25 mm (0.98 inch) in 5 minutes Bucket Cylinder (Retracted) 10 mm (0.39 inch) in 5 minutes Bucket Cylinder (Extended) 20 mm (0.79 inch) in 5 minutes Test the ability to lower the boom with a dead engine. 7 Note the attachment code here from the Factory Test Data Sheet. (Refer to the service manual for the specifications. Enter the specification in the columi for the specification. (@ Depress both pedals fully and travel on flat, level Ground. («Raise the track off the ground and cycle the track for thrée revolutions, {@ The boom cylinder extended, the stick cylinder retracted, and the bucket cylinder extended when this testis performed. Refer to M0122523 ©, Swing Bearing Movement - Measure, Comments itps:si2,cat.comvt print preview!servce/%257B%2522te%2522%253A%2522Commissioning%2520the%2520Machine%2520(MO132719-0.... 9/1411523, 13:35 sis20 Break-In Procedure for the Track Rollers The following procedure provides a break-in period for the track rollers, the carrier rollers, and the idlers. This procedure must be performed when the machine is first operated. This procedure must be performed when any of the following components have been replaced: the track rollers, the carrier rollers, and the idlers. Use the following tool to monitor temperatures when you are performing this procedure: 123-6700 Laser Infrared Thermometer. When you are moving the machine over a long distance, perform the following steps. Raise the boom to the maximum height. * Retract the stick. * Bucket curl in for the Mass Excavator. * Travel on a level surface. * Ifalevel surface is not available for 20 minutes, travel with the sprocket downhill. 1. Travel the machine in the forward direction for 20 minutes. The implements should be over the idlers when you are Traveling in the forward direction. Monitor the temperatures of the components several times while you are performing this procedure. The temperatures of the components should not exceed 70 °C (158 °F). Check the temperatures at the flanges on the rollers. Check the temperatures near the seals, Check the temperatures at the ends of the shafts. 2. Stop the machine after 20 minutes of travel. Check the temperatures of the components. Inspect the seals for oil leaks. 3. If necessary, allow the components to cool_before you proceed. 4, Travel the machine in the reverse direction for 20 minutes. The implements should be over the sprockets when you are moving in the reverse direction. Monitor the temperatures of the components several times while you are performing this procedure. The temperatures of the itps:si2,cat.comvt print previewiservce/%257B%2522te%2522%253A%2522Commissioning%2520the%2520Machine%2520(MO132719-.. 10/14‘15123, 1328, sis20 components should not exceed 70 °C (158 °F). Check the temperatures at the flanges on the rollers. Check the temperatures near the seals. Check the temperatures at the ends of the shafts. 5. Stop the machine after the machine has Traveled for 20 minutes. Check the temperatures of the components. Inspect the seals for oil leaks. 6. If necessary, allow the components to cool before you proceed 7. Repeat Steps 1 through 6. Procedure To Move The Machine This procedure prevents overheating of the track rollers, carrier rollers, and idlers when you are moving the machine over long distances. Use the following tool to monitor temperatures when you are performing this procedure: 123-6700 Laser Infrared Thermometer. When you are moving the machine over a long distance, perform the following steps. Raise the boom to the maximum height. * Retract the stick. * Bucket curl in for the Mass Excavator. 1. Travel in the forward direction except when you are Traveling downhill. When you are Traveling downhill, position the sprocket on the downhill side. The implements should be over the idlers when you are Traveling in the forward direction. 2. Monitor the temperatures of the components several times while the machine is Traveling. The temperatures of the components should not exceed 70 °C (158 °F). Check the temperatures at the flanges on the rollers. Check the temperatures near the seals. Check the temperatures at the ends of the shafts. 3, Stop the machine after the machine has Traveled for 20 minutes. Check the temperatures of the components. Inspect the seals for oil leaks. 4. If necessary, allow the components to cool before you proceed Final Checks Before Delivery of the Excavator The following list is the recommended assembly chetks and system functional checks before the delivery of the excavator to the customer. Do all the checks and verify that all the systems function properly. Use the Service Manuals and the Operation and Maintenance Manual if a malfunction happens before the delivery of the machine. itps:si2,cat.comv print previewiservice/%257B%2522t6%2522%253A%2522Commissioning%2520the%2520Machine%2520(MO132719-.. 11/411523, 13:35 sis20 1. Fluids: a. Before the engine is started, make sure that all the hydraulic systems are filled and that all the pumps are primed. Yes, No. b. Check all the fluid levels, including the swing drives and the final drives. Yes, No. 2, Check the system pressure settings. a. Implement system pressure b, Swing system pressure c. Pilot system pressure d. Travel system pressure 3. The break-in procedure is completed for the track rollers and the carrier rollers. 4, Check for proper operation of the machine lights. a. Operating lights b. Access Ladder c. Cab and Dash d. Engine Compartment 5. Checklist for the cab a. Check for proper operation of the door of the cab. b. Ensure that the Operation and Maintenance Manual is in the literature pouch on the back of the operator seat. c. Check for proper operation of the horn. 4d. Check for proper operation of the window wiper and of the window washer. e. Check for proper operation of the seat belt. f. Check for proper operation of the fan switch. g. Check for proper operation of the travel alarm. itps:si2,cat.comvt print previewiservice/%257B%2522t6%2522%253A%2522Commissioning%2520the%2520Machine%2520(MO132719-.. 12/1411523, 13:35 sis20 h. Check for proper operation of the heater. i. Check for proper operation of the air conditioner. j. Check for proper operation of the test light: Check for proper operation of the test light for the Caterpillar Monitoring System. k. Check for proper operation of the hour meter. |. Check for proper operation of the automatic engin speed control. m, Check for proper operation the hydraulic activation control valve, 6. Check the implement control system, a. Raise the boom and lower the boom, b. Open the bucket and close the bucket. ¢. Stick in and stick out. 4d. Swing right and swing left. e. Travel forward and travel reverse. 7. Check that the mirror is installed and adjusted. lilustration 2 907502835 Boom line clamps itps:si2,cat.comv print previewiservce/%257B%2522te%2522%253A%2522Commissioning%2520the%2520Machine%2520(MO132719-.. 19/1411523, 13:35 sis20 8. Ensure that the boom lines do not rub the boom tower cross tube or swing motor. If the lines are contacting the cross tube or swing motor, adjust the clamps as shown in Illustration 2 to provide proper clearance. 9. Check the automatic ether injection system. Refer to the Operation and Maintenance Manual for the correct procedure. 10. Recheck all the fluid levels. 11. Checks for leaks and for unusual noises. 12. Make sure that quality requirements were fulfilled. All variances were corrected prior to the delivery of the machine to the customer. 13, Ensure that the machine is repainted to the factory specifications. PSP-0005A09A, 2023/05/01 17:34:28-04:00 i09005531 © 2023 Caterpillar Inc. Iitps:si2,cat.comvt print previewiservice/%257B%2522te%2522%253A%2522Commissioning%2520the%2520Machine%2520(MO132719-.. 14/44