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CAT 6050, 6050 FS Hydraulic Shovel Operation & Maintenance Manual EM027997-0 – PDF DOWNLOAD
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CAT 6050, 6050 FS Hydraulic Shovel Operation & Maintenance Manual EM027997-0 – PDF DOWNLOAD
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DHM50164 –UP
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Description
CAT 6050, 6050 FS Hydraulic Shovel Operation & Maintenance Manual EM027997-0 – PDF DOWNLOAD
FILE DETAILS:
CAT 6050, 6050 FS Hydraulic Shovel Operation & Maintenance Manual EM027997-0 – PDF DOWNLOAD
Language : English
Pages : 334
Downloadable : Yes
File Type : PDF
DESCRIPTION:
CAT 6050, 6050 FS Hydraulic Shovel Operation & Maintenance Manual EM027997-0 – PDF DOWNLOAD
DH250157 –UP
DHM50164 –UP
PREFACE:
- These operating instructions are designed to fa- miliarize the operator with the machine
and its designated use. - The operating instructions contain important in- formation 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 operating instructions must be supplemented by the respective national rules and regulations
for accident prevention and environmental protection. - The operating instructions must always be avail- able in the driver’s cab of the machine.
- The operating instructions must be read and put into practice by any person in charge
of carrying out work with or on the machine, such as
■ operation, including setting-up, troubleshoot- ing in the course of work, care,
evacuation of production waste and disposal of fuels and consumables,
■ maintenance (inspection, servicing, repair) and / or
■ transport.
In addition to the operating instructions and the mandatory rules and regulations for
accident pre- vention and environmental protection in the user’s country and at the place where the
machine is to be used, the generally recognized technical rules for safe and proper working must
be observed .
- The Operation and Maintenance Manual is di- rected 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 HMS GmbH mechanic or by attending an CGM HMS training course
for op- erators or maintenance personnel. - The CGM HMS after-sales service will be pleased to deal with any queries you may have after read-
ing through the operating instructions. - 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 operating instructions are not work instruc- tions for carrying out major repairs.
Such work is willingly done for you by the CGM HMS after-sales
service.
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
CAT 6050, 6050 FS Hydraulic Shovel Operation & Maintenance Manual EM027997-0 – PDF DOWNLOAD
TITLEPAGE.................................................................................................................................................................... 3 1 INTRODUCTION............................................................................................................................................................... 15 PREFACE ................................................................................................................................................................. 17 About this Operating Instructions ................................................................................................................................... 17 Further machine documentation ....................................................................................................................................... 17 WARRANTY ................................................................................................................................................................ 18 FUNDAMENTAL SAFETY INSTRUCTIONS ......................................................................................................................................... 19 Warnings and symbols ................................................................................................................................................ 19 DESIGNATED USE, UNAUTHORIZED USE ........................................................................................................................................ 20 ORGANIZATIONAL MEASURES ................................................................................................................................................. 21 Selection and qualification of personnel; basic responsibilities .................................................................................................... 22 Safety instructions governing specific operational phases ........................................................................................................... 22 Special work in conjunction with utilization of the machine and maintenance and repairs as well as troubleshooting during work; disposal of parts and consumables.... 23 Warning of special dangers........................................................................................................................................... 24 FIRE AND EXPLOSION HAZARD ............................................................................................................................................... 26 NOTES ................................................................................................................................................................... 27 2 OPERATION.................................................................................................................................................................. 29 OPERATION - SAFETY INSTRUCTIONS.......................................................................................................................................... 31 Operating Instructions, where to store it in the driver’s cab ....................................................................................................... 32 OPERATION, FIRE AND EXPLOSION HAZARD .................................................................................................................................... 33 DESCRIPTION OF THE EXCAVATOR............................................................................................................................................. 34 Excavator layout .................................................................................................................................................... 35 Undercarriage........................................................................................................................................................ 36 Superstructure....................................................................................................................................................... 36 Drive................................................................................................................................................................ 36 Hydraulic system..................................................................................................................................................... 36 Pump Managing System (PMS)........................................................................................................................................... 36 Stored Program Control (SPC) ........................................................................................................................................ 36 Central Management System (CMS) ..................................................................................................................................... 36 Demand control / Zero-flow regulation................................................................................................................................ 37 Automatic engine speed reduction .................................................................................................................................... 37 Board-Control-System (BCS) .......................................................................................................................................... 37 Electrical system ................................................................................................................................................... 37 Signs ............................................................................................................................................................... 38 Entering and leaving the machine, Safety instructions................................................................................................................ 46 Access lighting ..................................................................................................................................................... 46 Folding ladder (optional) ........................................................................................................................................... 47 Swinging ladder (optional) .......................................................................................................................................... 48 Cab interior lamp ................................................................................................................................................... 49 Servicing lighting .................................................................................................................................................. 50 Illuminating the control column ..................................................................................................................................... 50 EMERGENCY STOP switch ............................................................................................................................................... 51 Escape ladder ....................................................................................................................................................... 52 Trainer's / instructor's seat ....................................................................................................................................... 53 Windscreen washer ................................................................................................................................................... 53 Driver's seat ....................................................................................................................................................... 54 Fire extinguisher ................................................................................................................................................... 56 Automatic fire-extinguishing system (optional) ...................................................................................................................... 57 Harness (optional) .................................................................................................................................................. 58 MONITORING, WARNING AND CONTROL ELEMENTS ................................................................................................................................ 62 PUTTING THE MACHINE INTO OPERATION ...................................................................................................................................... 92 Refuelling .......................................................................................................................................................... 92 Service station (tanklift) .......................................................................................................................................... 92 Switching the electrical system on and off .......................................................................................................................... 98 STARTING AND STOPPING THE ENGINES ....................................................................................................................................... 99 Starting the engines ................................................................................................................................................ 99 Starting the engines at low temperatures ............................................................................................................................100 Shutting off the engines ............................................................................................................................................101 Emergency - stop ....................................................................................................................................................101 AIR CONDITIONER (OPTION) ................................................................................................................................................102 Back-up heating (option) ............................................................................................................................................103 MAXIMUM MACHINE INCLINATIONS, INFORMATION ...............................................................................................................................105 TRAVELLING, SAFETY INSTRUCTIONS .........................................................................................................................................106 Superstructure basic position .......................................................................................................................................107 Travel forwards/backwards ...........................................................................................................................................107 Emergency machine drive .............................................................................................................................................111 Superstructure holding brakes .......................................................................................................................................113 Track parking brake .................................................................................................................................................113 TRANSPORTING THE MACHINE ................................................................................................................................................114 Transport - Safety instructions .....................................................................................................................................114 WORKING OPERATION - SAFETY INSTRUCTIONS .................................................................................................................................115 WORKING OPERATION .......................................................................................................................................................117 Before starting work ................................................................................................................................................117 Swing the superstructure ............................................................................................................................................117 Braking the superstructure ..........................................................................................................................................117 Working movements ...................................................................................................................................................118 After daily operation ...............................................................................................................................................119 ASSEMBLING WORKING EQUIPMENT - SAFETY INSTRUCTIONS ......................................................................................................................120 Securing the machine ................................................................................................................................................121 CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS) ..........................................................................................................122 ON-BOARD CRANE (OPTIONAL) ...............................................................................................................................................123 On-board crane, monitoring, warning and control elements ............................................................................................................123 On-board crane, putting into operation ..............................................................................................................................124 On-board crane, drive unit ..........................................................................................................................................124 On-Board crane, – blocking the boom in position of rest .............................................................................................................125 On-board crane, checking ............................................................................................................................................125 OPTIONAL EQUIPMENT ......................................................................................................................................................126 Monitoring cameras...................................................................................................................................................126 NOTES ...................................................................................................................................................................127 3 INSPECTION AND SERVICING...................................................................................................................................................129 INSPECTION AND SERVICING - SAFETY INSTRUCTIONS ..........................................................................................................................131 INSPECTION AND SERVICING WORK, FIRE AND EXPLOSION HAZARD ................................................................................................................136 INSPECTION AND SERVICING PLANS - INSTRUCTIONS ...........................................................................................................................137 Intervals............................................................................................................................................................137 Change of engine oil ................................................................................................................................................137 Air-intake system ...................................................................................................................................................137 Oils / Greases ......................................................................................................................................................137 Cleaning jobs .......................................................................................................................................................137 Components ..........................................................................................................................................................137 Plan V ..............................................................................................................................................................139 Plan N ..............................................................................................................................................................141 Plan T and W ........................................................................................................................................................143 Plan A – E ..........................................................................................................................................................145 LUBRICATING CHART – GREASE ..............................................................................................................................................154 Lubricating chart – Grease (legend) .................................................................................................................................155 Filling quantities – Grease .........................................................................................................................................155 INSPECTION PLAN - OIL ...................................................................................................................................................156 Inspection plan – Oil (legend) ......................................................................................................................................157 Filling quantities - oil ............................................................................................................................................158 Filling quantities – other ..........................................................................................................................................158 LUBRICANTS ..............................................................................................................................................................159 Notes on the selection of oils and greases ..........................................................................................................................159 Avoid mixing of different hydraulic fluids ..........................................................................................................................159 I. Oils for combustion engines ......................................................................................................................................160 II. Oils for hydraulic system .......................................................................................................................................161 III.a Oils for pump gearboxes and travel gearboxes ..................................................................................................................162 III.b Oils for swing gearboxes ......................................................................................................................................163 V. Greases for bearings, swing rings and track system (Central lubrication system) ..................................................................................164 Grease for idlers, track rollers and support rollers (Lifetime lubrication) .........................................................................................165 Coolant for use on all combustion engines ...........................................................................................................................166 SERVICING WORK ..........................................................................................................................................................167 Hose line for oil and cooling liquid changes ........................................................................................................................167 ENGINE ..................................................................................................................................................................168 Engine - Safety instructions ........................................................................................................................................168 Engine oil, checking the level / topping up .........................................................................................................................169 Engine oil reservoir, checking the oil level / topping up ...........................................................................................................170 Engine oil, change ..................................................................................................................................................171 Engine oil reservoir (optional), draining the oil off ...............................................................................................................173 Oil change prolongation system, replacing the oil filter ............................................................................................................175 Eliminator filter and centrifuge (optional) .........................................................................................................................176 Cold-starting fluid (ether) - Replacing the pressure vessel .........................................................................................................178 COOLING SYSTEM ..........................................................................................................................................................179 Cooling liquid, change ..............................................................................................................................................182 Water filter, change ................................................................................................................................................184 AIR-INTAKE SYSTEM .......................................................................................................................................................185 Main filter elements, removal and installation ......................................................................................................................186 Main filter elements, checking and cleaning .........................................................................................................................187 Safety filter element, replace ......................................................................................................................................188 Air-intake lines ....................................................................................................................................................189 Dust collection .....................................................................................................................................................189 FUEL SYSTEM .............................................................................................................................................................190 Fuel system, Safety instructions ....................................................................................................................................190 Fuel filter, replace ................................................................................................................................................190 Fuel system, venting ................................................................................................................................................191 Cleaning the fuel tanks .............................................................................................................................................191 Water trap (option) .................................................................................................................................................193 ELECTRICAL SYSTEM ......................................................................................................................................................195 Electrical system - Safety instructions .............................................................................................................................195 Alternator - Instructions ...........................................................................................................................................195 Battery .............................................................................................................................................................196 Switchgear cabinet ..................................................................................................................................................198 Floodlight projector, replacing the lamp ............................................................................................................................200 HYDRAULIC SYSTEM ........................................................................................................................................................202 Hydraulic system - Safety instructions ..............................................................................................................................202 Depressurizing the hydraulic system .................................................................................................................................202 Checking the hydraulic oil level ....................................................................................................................................203 Changing the hydraulic oil return-flow filters (hydraulic oil reservoir) ............................................................................................205 Bypass valves (hydraulic oil reservoir) .............................................................................................................................207 Replacing the bypass valves and sealing rings .......................................................................................................................207 Breather filter .....................................................................................................................................................208 Filter (control circuit).............................................................................................................................................209 High-pressure filter for working hydraulics .........................................................................................................................210 High-pressure filters for the servo circuit .........................................................................................................................211 High-pressure filters for feeding circuits and slewing pumps ........................................................................................................212 High-pressure filters for slewing circuit ...........................................................................................................................213 Changing the hydraulic oil ..........................................................................................................................................214 Avoid mixing of different hydraulic fluids ..........................................................................................................................214 Venting the hydraulic system.........................................................................................................................................218 Cleaning the hydraulic oil cooler....................................................................................................................................219 Electronic excavator control.........................................................................................................................................220 Pressure accumulator - Emergency lowering............................................................................................................................221 PUMP TRANSFER GEARBOX ...................................................................................................................................................222 Checking the gearbox oil level / Topping up with oil ................................................................................................................222 Changing the gearbox oil ............................................................................................................................................223 Gearbox, breather valve .............................................................................................................................................224 Pre-chamber, breather valve .........................................................................................................................................225 Pump transfer gearbox lube oil filters ..............................................................................................................................226 SWING GEARBOX ...........................................................................................................................................................227 Gearbox - Checking the oil level / Topping up with oil ..............................................................................................................227 Changing the gearbox oil ............................................................................................................................................227 Gearbox venting .....................................................................................................................................................228 TRAVEL GEARBOX (VALID FOR GEARBOX PN 3673978) ...........................................................................................................................229 Travel gearbox - Checking the oil level / Topping up with oil .......................................................................................................229 Travel gearbox - Changing oil .......................................................................................................................................230 Breather filters, clean / replace ...................................................................................................................................231 TRAVEL GEARBOX (VALID FOR GEARBOX PN 2763214) ...........................................................................................................................232 Travel gearbox - Checking the oil level / Topping up with oil .......................................................................................................232 Travel gearbox - Changing oil .......................................................................................................................................233 Pre-stage - Changing the oil .......................................................................................................................................233 Brake chambers - Changing oil .......................................................................................................................................234 Breather filters, clean / replace ...................................................................................................................................234 CRAWLER TRACKS ..........................................................................................................................................................235 Track roller, Support roller ........................................................................................................................................236 Track tensioner .....................................................................................................................................................237 Pressure-accumulator inspection regulations .........................................................................................................................238 Checking the gas charging pressure in the pressure accumulator.......................................................................................................238 SWING RING ..............................................................................................................................................................239 Swing ring – Instructions ...........................................................................................................................................239 Bearing races .......................................................................................................................................................239 CENTRAL LUBRICATING .....................................................................................................................................................241 Design ..............................................................................................................................................................241 Function ............................................................................................................................................................242 Filling up the grease container .....................................................................................................................................243 Breather filter .....................................................................................................................................................243 Checking the greasing pressure ......................................................................................................................................244 Unblocking a grease line.............................................................................................................................................245 Oilfilter (hydraulic circuit grease pump) ...........................................................................................................................246 Grease filter (Filling the grease container) ........................................................................................................................247 Grease filter (Grease lines) ........................................................................................................................................248 OTHER MAINTENANCE .......................................................................................................................................................249 Engine ..............................................................................................................................................................249 Equipment, checking .................................................................................................................................................250 Hydraulic ladder (optional) .........................................................................................................................................250 Pressure-accumulator inspection regulations .........................................................................................................................251 Extract from the German regulations..................................................................................................................................251 Checking the gas charging pressure in the pressure accumulator.......................................................................................................251 ON-BOARD CRANE, DRIVE UNIT ..............................................................................................................................................252 On-board crane, lubricating .........................................................................................................................................253 On-Board crane, checking tightness of fastening bolts ...............................................................................................................253 PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING ..............................................................................................................254 Putting the excavator out of operation...............................................................................................................................254 Battery storage......................................................................................................................................................254 Recommissioning......................................................................................................................................................254 NOTES ..................................................................................................................................................................255 4 REPAIR WORK................................................................................................................................................................257 REPAIR WORK - SAFETY INSTRUCTIONS........................................................................................................................................259 REPAIR WORK, FIRE AND EXPLOSION HAZARD ..................................................................................................................................261 REPAIR WORK, ENGINE......................................................................................................................................................262 ELECTRICAL SYSTEM .......................................................................................................................................................263 Assisted starting (with jumper cables) – Safety instructions ........................................................................................................263 Assisted starting (with jumper cables)...............................................................................................................................263 Starting the engine with jumper cables (external batteries ..........................................................................................................263 HYDRAULIC SYSTEM.........................................................................................................................................................265 Repair instructions .................................................................................................................................................265 Hydraulic hoses – Instructions ......................................................................................................................................265 PRESSURE ACCUMULATORS - SAFETY INSTRUCTIONS..............................................................................................................................266 WELDING AND FLAME CUTTING WORKS - SAFETY INSTRUCTIONS ...................................................................................................................267 DISPOSAL AT THE END OF THE SERVICE LIFE ................................................................................................................................270 Dismantling and removal instructions ................................................................................................................................270 Risk of deflagrations ...............................................................................................................................................270 Risk of fire ........................................................................................................................................................270 Disposing of the machine without polluting the environment ..........................................................................................................271 Further hazardous substances ........................................................................................................................................271 Appropriate disposal of batteries ...................................................................................................................................272 NOTES ...................................................................................................................................................................273 5 ANNEX......................................................................................................................................................................275 TROUBLESHOOTING .........................................................................................................................................................277 Instructions on troubleshooting .....................................................................................................................................277 Layout of the fault table ...........................................................................................................................................277 Possible causes .....................................................................................................................................................277 Measures ............................................................................................................................................................277 Section .............................................................................................................................................................277 FAULT TABLES ............................................................................................................................................................278 Combustion engine - Fault table .....................................................................................................................................278 Working hydraulics – Fault table ....................................................................................................................................279 Track drive – Fault table ...........................................................................................................................................280 Swing mechnism – Fault table ........................................................................................................................................281 Central lubricating system – Fault table ............................................................................................................................282 Engine electronic unit, displaying stored fault codes ...............................................................................................................283 HYDRAULIC CIRCUIT DIAGRAM ...............................................................................................................................................284 ABBREVIATIONS ...........................................................................................................................................................285 ABBREVIATIONS........................................................................................................................................................286 TECHNICAL DATA ..........................................................................................................................................................287 Product Specification Sheet .........................................................................................................................................289 NOTES ...................................................................................................................................................................299 6 INDEX......................................................................................................................................................................301 02_operating_BCS_6050_FS_en_3847007_00_en.pdf................................................................................................................................ 0 Titlepage ...............................................................................................................................................................307 DESCRIPTION .........................................................................................................................................................311 Functions .......................................................................................................................................................311 Components ......................................................................................................................................................311 DISPLAYS : USING BCS.................................................................................................................................................312 Display and keyboard ............................................................................................................................................314 Indicator lights ............................................................................................................................................315 Buttons .....................................................................................................................................................315 Instruments .....................................................................................................................................................316 Service menu ....................................................................................................................................................316 Program 1: Oil change .......................................................................................................................................317 Program 2 to 6 ..............................................................................................................................................317 The programs (Fig. 15).......................................................................................................................................317 Program 2: Service ..........................................................................................................................................317 Program 3: Engine ...........................................................................................................................................318 Program 4: Hydraulics (Fig. 19)..............................................................................................................................318 Program 5: Excavator .......................................................................................................................................319 Program 6: Operating hours ..................................................................................................................................319 HOLD function ...............................................................................................................................................320 Program 7: Setting date and time ............................................................................................................................321 Program 8: Complete fault list ..............................................................................................................................322 Program 9: Service Bucyrus HEX ..............................................................................................................................322 Fault reports ...................................................................................................................................................323 Service data & fault storage: print-out or transfer into Buffer .................................................................................................324 APPENDIX ............................................................................................................................................................325 Print-out .......................................................................................................................................................325 DATA ACQUISITION COMPUTER DER 1......................................................................................................................................327 Sensor analogue inputs...........................................................................................................................................327 DATA ACQUISITION COMPUTER DER 1......................................................................................................................................328 Sensor digital inputs............................................................................................................................................328 DATA ACQUISITION COMPUTER DER 2......................................................................................................................................329 Sensor analogue inputs...........................................................................................................................................329 DATA ACQUISITION COMPUTER DER 2......................................................................................................................................330 Sensor digital inputs............................................................................................................................................330 DATA ACQUISITION COMPUTER DER 3......................................................................................................................................331 Sensor analogue inputs...........................................................................................................................................331 DATA ACQUISITION COMPUTER DER 3......................................................................................................................................332 Sensor digital inputs............................................................................................................................................332 CAT_Rueckseite.pdf........................................................................................................................................................... 0 Leere 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