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Cat 6060, 6060 FS Hydraulic Shovel Operation and Maintenance Manual BI651403 – PDF DOWNLOAD
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Description
Cat 6060, 6060 FS Hydraulic Shovel Operation and Maintenance Manual BI651403 – PDF DOWNLOAD
FILE DETAILS:
Cat 6060 6060 FS Hydraulic Shovel Operation and Maintenance Manual BI651403 – PDF DOWNLOAD
Language : English
Pages : 338
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Cat 6060 6060 FS Hydraulic Shovel Operation and Maintenance Manual BI651403 – PDF DOWNLOAD
PREFACE
About this Operating Instructions
- These operating instructions are designed to familiarize the operator with the machine and its designated use. The operating instructions 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 operating instructions must be supplemented by the respective national rules and regulations for accident prevention and environmental protection.
- The operating instructions must always be available 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, troubleshooting 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 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 be observed 1. The operating instructions are directed to the mining- machine specialist. They cannot provide basic know-how. This can be acquired, for example, in several days’ instruction by a qualified Bucyrus HEX mechanic or by attending an Bucyrus HEX training course for operators or maintenance personnel
- The Bucyrus HEX after-sales service will be pleased to deal with any queries you may have after reading through the operating instructions.
- All Bucyrus HEX operating manuals are issued in German and then translated. Even a good translation may give rise to questions which Bucyrus HEX will be pleased to answer.
- The operating instructions are not work instructions for carrying out major repairs. Such work is willingly done for you by the Bucyrus HEX aftersales service
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Cat 6060 6060 FS Hydraulic Shovel Operation and Maintenance Manual BI651403 – PDF DOWNLOAD
TITLEPAGE..................................................................................................................................................................... 1 1 INTRODUCTION................................................................................................................................................................ 13 PREFACE .................................................................................................................................................................. 15 About this Operating Instructions .................................................................................................................................... 15 Further machine documentation ........................................................................................................................................ 15 WARRANTY ................................................................................................................................................................. 16 FUNDAMENTAL SAFETY INSTRUCTIONS .......................................................................................................................................... 17 Warnings and symbols ................................................................................................................................................. 17 DESIGNATED USE, UNAUTHORIZED USE ......................................................................................................................................... 18 Noise emission information ........................................................................................................................................... 19 Vibration information ................................................................................................................................................ 19 ORGANIZATIONAL MEASURES .................................................................................................................................................. 20 Selection and qualification of personnel; basic responsibilities ..................................................................................................... 21 Safety instructions governing specific operational phases ............................................................................................................ 21 Special work in conjunction with utilization of the machine and maintenance and repairs as well as troubleshooting during work; disposal of parts and consumables .... 22 Warning of special dangers ........................................................................................................................................... 23 Gas, dust, steam and smoke ........................................................................................................................................... 23 Hydraulic equipment .................................................................................................................................................. 24 FIRE AND EXPLOSION HAZARD ................................................................................................................................................ 25 NOTES .................................................................................................................................................................... 27 2 OPERATION................................................................................................................................................................... 29 OPERATION - SAFETY INSTRUCTIONS .......................................................................................................................................... 31 Operating Instructions, where to store it in the driver’s cab ........................................................................................................ 32 FIRE AND EXPLOSION HAZARD................................................................................................................................................. 33 DESCRIPTION OF THE HYDRAULIC SHOVEL ...................................................................................................................................... 34 Hydraulic shovel layout .............................................................................................................................................. 35 Undercarriage ........................................................................................................................................................ 36 Superstructure ....................................................................................................................................................... 36 Drive ................................................................................................................................................................ 36 Hydraulic system ..................................................................................................................................................... 36 Control and Monitoring Platform (CAMP) ............................................................................................................................... 36 Board-Control-System (BCS) ........................................................................................................................................... 37 Demand control / Zero-flow regulation................................................................................................................................. 37 Automatic reset to idling............................................................................................................................................. 37 Electrical system .................................................................................................................................................... 37 Signs ................................................................................................................................................................ 38 Entering and leaving the machine, Safety instructions ................................................................................................................ 46 Access ladder lighting ............................................................................................................................................... 46 Folding ladder ....................................................................................................................................................... 47 Swinging ladder (optional) .......................................................................................................................................... 48 Emergency exit in driver’s cab and escape ladder ..................................................................................................................... 49 Switching the cab interior lighting on and off ....................................................................................................................... 50 Switching the maintenance lights on and off .......................................................................................................................... 51 Emergency shut-off function .......................................................................................................................................... 52 Putting the machine back into operation, reset of emergency shut off function ........................................................................................ 53 Battery isolator switch, shutting off supply voltage ................................................................................................................. 54 Starter isolator switch, shutting off starter voltage ................................................................................................................ 54 Driver’s seat ....................................................................................................................................................... 55 Reducing operators exposure to vibrations ............................................................................................................................ 57 Trainer's / instructor's seat ........................................................................................................................................ 57 Windscreen washer .................................................................................................................................................... 57 Operating hours meter ................................................................................................................................................ 57 Fire extinguisher .................................................................................................................................................... 58 Automatic fire-extinguishing system (optional) ....................................................................................................................... 59 Harness (optional) ................................................................................................................................................... 60 MONITORING, WARNING AND CONTROL ELEMENTS ................................................................................................................................. 64 Engine 1 (LH), control and monitoring ................................................................................................................................ 71 Engine 2 (RH), control and monitoring ................................................................................................................................ 73 PUTTING THE MACHINE INTO OPERATION ....................................................................................................................................... 92 Reducing the operator's exposure to noise ............................................................................................................................ 92 Refuelling ........................................................................................................................................................... 93 Back-up heating (option), filling in fuel ............................................................................................................................ 93 Service station (tanklift) ........................................................................................................................................... 94 Emergency off switch ................................................................................................................................................. 95 Switching the electrical system on and off ...........................................................................................................................100 Engines, emergency shut-off ..........................................................................................................................................100 STARTING AND STOPPING THE ENGINES ........................................................................................................................................102 Starting the engines .................................................................................................................................................102 Starting the left-hand engine.........................................................................................................................................102 Starting the right-hand engine........................................................................................................................................102 Engines – adjusting the speed ........................................................................................................................................103 Starting the engines at low temperatures .............................................................................................................................103 Shutting off the engines .............................................................................................................................................104 Shutting off the left-hand engine.....................................................................................................................................104 Shutting off the right-hand engine....................................................................................................................................104 AIR CONDITIONER (OPTIONAL) ...............................................................................................................................................105 Back-up heating driver’s cab (optional) ..............................................................................................................................106 Back-up heating (optional) ...........................................................................................................................................107 MAXIMUM MACHINE INCLINATIONS, INFORMATION ................................................................................................................................108 TRAVELLING, SAFETY INSTRUCTIONS ..........................................................................................................................................110 TRAVELLING ...............................................................................................................................................................111 Superstructure basic position ........................................................................................................................................111 Travelling forwards/backwards ........................................................................................................................................111 Superstructure holding brake .........................................................................................................................................115 Track parking brake ..................................................................................................................................................115 TRANSPORTING THE MACHINE .................................................................................................................................................116 Transport - Safety instructions ......................................................................................................................................116 WORKING OPERATION - SAFETY INSTRUCTIONS ..................................................................................................................................117 WORKING OPERATION ........................................................................................................................................................119 Before starting work .................................................................................................................................................119 Activating the electronic excavator control ..........................................................................................................................119 Swinging the superstructure ..........................................................................................................................................120 Braking the superstructure ...........................................................................................................................................120 Working ..............................................................................................................................................................121 Emergency lowering of the equipment ..................................................................................................................................122 After daily operation ................................................................................................................................................123 ASSEMBLING WORKING EQUIPMENT - SAFETY INSTRUCTIONS .......................................................................................................................124 Securing the machine .................................................................................................................................................125 CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS) ...........................................................................................................126 ON-BOARD CRANE (OPTIONAL) ................................................................................................................................................127 On-board crane, monitoring, warning and control elements .............................................................................................................127 On-board crane, putting into operation ...............................................................................................................................128 On-board crane, drive unit ...........................................................................................................................................128 On-Board crane, – blocking the boom in position of rest ..............................................................................................................129 On-board crane, checking .............................................................................................................................................129 NOTES ....................................................................................................................................................................130 3 INSPECTION AND SERVICING....................................................................................................................................................131 INSPECTION AND SERVICING - SAFETY INSTRUCTIONS ...........................................................................................................................133 INSPECTION AND SERVICING WORK, FIRE AND EXPLOSION HAZARD .................................................................................................................137 INSPECTION AND SERVICING PLANS - INSTRUCTIONS ............................................................................................................................139 Plan V ...............................................................................................................................................................141 Plan N ...............................................................................................................................................................143 Plan T ...............................................................................................................................................................145 Plan A – E ...........................................................................................................................................................147 LUBRICATING CHART ........................................................................................................................................................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. Oil for combustion engines ........................................................................................................................................160 II. Oil for hydraulic system .........................................................................................................................................161 III.a Oil for pump distribution gearboxes ............................................................................................................................162 III.b Oil for swing gearboxes ........................................................................................................................................163 III.c Oil for travel gearboxes .......................................................................................................................................164 V. Grease for bearings,slew rings and track system (Central lubrication system) ......................................................................................165 VI. Grease for idlers, track rollers and support rollers (Lifetime lubrication) ......................................................................................166 SERVICING WORK ...........................................................................................................................................................167 Hose line for oil and cooling liquid changes .........................................................................................................................167 ENGINE ...................................................................................................................................................................168 Engine - Safety instructions .........................................................................................................................................168 Checking the engine oil level / Topping up ..........................................................................................................................169 Engine oil reservoir, checking the oil level / topping up ............................................................................................................170 Engine oil, change ...................................................................................................................................................171 Engine oil reservoir, filling in /draining off the oil ...............................................................................................................173 Filters oil change prolongation, replace .............................................................................................................................175 EliminatorTM filter and centrifuge ...................................................................................................................................176 COOLING SYSTEM ...........................................................................................................................................................178 Radiators ............................................................................................................................................................179 Cooling-liquid level, check ..........................................................................................................................................179 Cooling-liquid, topping up ...........................................................................................................................................180 Cooling-liquid, topping up using the Service-Station .................................................................................................................181 Cooling liquid change ................................................................................................................................................182 Water filter, replace ................................................................................................................................................184 Cold-starting fluid (ether) - Replacing the pressure vessel ..........................................................................................................185 AIR-INTAKE SYSTEM ........................................................................................................................................................186 Main filter elements, removal and installation .......................................................................................................................187 Main filter elements, checking and cleaning ..........................................................................................................................188 Safety filter element, replace .......................................................................................................................................189 Air-intake lines .....................................................................................................................................................190 Dust collection ......................................................................................................................................................190 FUEL SYSTEM ..............................................................................................................................................................191 Fuel system - Safety instructions ....................................................................................................................................191 Fuel filter, replace .................................................................................................................................................191 Fuel tank, replace breather filter ...................................................................................................................................192 Fuel tanks, cleaning .................................................................................................................................................192 Water trap (option) ..................................................................................................................................................194 ELECTRICAL SYSTEM .......................................................................................................................................................196 Electrical system - Safety instructions ..............................................................................................................................196 Alternator - Instructions ............................................................................................................................................196 Electrical circuit diagrams ..........................................................................................................................................196 Electrical system switch-cabinets ....................................................................................................................................196 Replacing lamps and bulbs ............................................................................................................................................196 Battery ..............................................................................................................................................................197 Switchgear cabinet, breather .........................................................................................................................................199 Floodlight projector, replacing the lamp .............................................................................................................................201 Lighting systems in LED technonogy, instructions .....................................................................................................................203 Charging batteries inside the machine, safety instructions ...........................................................................................................204 HYDRAULIC SYSTEM .........................................................................................................................................................205 Hydraulic system - Safety instructions ...............................................................................................................................205 Depressurizing the hydraulic system ..................................................................................................................................205 Checking the hydraulic oil level .....................................................................................................................................206 Changing the hydraulic oil return-flow (hydraulic oil reservoir) .....................................................................................................208 Bypass valves (hydraulic oil reservoir) ..............................................................................................................................210 Breather filter ......................................................................................................................................................211 Filter (control circuit)..............................................................................................................................................212 High-pressure filter for working hydraulics ..........................................................................................................................213 High-pressure filters for the servo circuit ..........................................................................................................................214 High-pressure filters for feeding circuits and swing pumps ...........................................................................................................215 High-pressure filters for swing circuit ..............................................................................................................................216 Bearing flushing for main pumps, replace filter ......................................................................................................................217 Changing the hydraulic oil ...........................................................................................................................................218 Avoid mixing of different hydraulic fluids ...........................................................................................................................218 Venting the hydraulic system..........................................................................................................................................222 Cleaning the hydraulic oil cooler.....................................................................................................................................223 Electronic controls...................................................................................................................................................224 Pressure accumulator - Emergency lowering.............................................................................................................................225 PUMP TRANSFER GEARBOX ....................................................................................................................................................226 Checking the gearbox oil level / Topping up with oil .................................................................................................................226 Pre-chambers, checking oil level, topping up with oil ................................................................................................................226 Changing the gearbox oil .............................................................................................................................................227 Pre-chambers, changing the gearbox oil ...............................................................................................................................228 Gearbox venting ......................................................................................................................................................228 Pre-chamber venting ..................................................................................................................................................229 Pump transfer gearbox lube oil filters ...............................................................................................................................230 SWING GEARBOX ............................................................................................................................................................231 Swing Gearbox - Checking the oil level / Topping up with oil .........................................................................................................231 Changing the gearbox oil .............................................................................................................................................232 Swing Gearbox venting ................................................................................................................................................232 TRAVEL GEARBOX (GEARBOX P/N 3683483) ....................................................................................................................................233 Travel gearbox - Checking the oil level / Topping up with oil ........................................................................................................233 Travel gearbox - Changing oil ........................................................................................................................................234 Travel gearbox - Breather filter .....................................................................................................................................235 TRAVEL GEARBOX(GEARBOX P/N 3683496) .....................................................................................................................................236 Travel gearbox - Checking the oil level / Topping up with oil ........................................................................................................236 Travel gearbox - Changing oil ........................................................................................................................................238 Travel gearbox -Breather filter ......................................................................................................................................239 CRAWLER TRACKS ...........................................................................................................................................................240 Track rollers ........................................................................................................................................................241 Track tensioner ......................................................................................................................................................242 Pressure-accumulator inspection regulations ..........................................................................................................................243 Checking the gas charging pressure in the pressure accumulator........................................................................................................243 SWING RING ...............................................................................................................................................................244 Swing ring - Instructions.............................................................................................................................................244 Bearing races.........................................................................................................................................................244 CENTRAL LUBRICATING ......................................................................................................................................................246 Design ...............................................................................................................................................................246 Function .............................................................................................................................................................247 Filling up the grease container ......................................................................................................................................248 Breather filter ......................................................................................................................................................248 Checking the greasing pressure .......................................................................................................................................249 Unblocking a grease line..............................................................................................................................................250 Oilfilter (hydraulic circuit grease pump) ............................................................................................................................251 Grease filter (Filling the grease container) .........................................................................................................................252 Grease filter (Grease lines) .........................................................................................................................................253 OTHER MAINTENANCE ........................................................................................................................................................254 Engine ...............................................................................................................................................................254 Reservoirs for used grease at the A-frame, emptying ..................................................................................................................255 Heating and air conditioning .........................................................................................................................................255 Equipment ............................................................................................................................................................256 HYDRAULIC LADDER (OPTIONAL) ..............................................................................................................................................257 Pressure-accumulator inspection regulations ..........................................................................................................................258 Extract from the German regulations...................................................................................................................................258 Checking the gas charging pressure in the pressure accumulator........................................................................................................258 ON-BOARD CRANE, DRIVE UNIT ...............................................................................................................................................259 On-board crane, lubricating ..........................................................................................................................................260 On-Board crane, checking tightness of fastening bolts ................................................................................................................260 PUTTING THE HYDRAULIC SHOVEL OUT OF OPERATION AND RECOMMISSIONING ........................................................................................................261 Putting the hydraulic shovel out of operation ........................................................................................................................261 Battery storage ......................................................................................................................................................261 Recommissioning ......................................................................................................................................................261 NOTES ....................................................................................................................................................................263 4 REPAIR WORK.................................................................................................................................................................265 REPAIR WORK - SAFETY INSTRUCTIONS ........................................................................................................................................267 CONFINED SPACES - SAFETY INSTRUCTIONS ....................................................................................................................................268 REPAIR WORK, FIRE AND EXPLOSION HAZARD ...................................................................................................................................269 REPAIR WORK, ENGINE ......................................................................................................................................................270 HYDRAULIC SYSTEM .........................................................................................................................................................271 Repair instructions ..................................................................................................................................................271 Hydraulic hoses – Instructions ......................................................................................................................................271 PRESSURE ACCUMULATORS - SAFETY INSTRUCTIONS...............................................................................................................................272 WELDING AND FLAME CUTTING WORKS - SAFETY INSTRUCTIONS ....................................................................................................................273 DISPOSAL AT THE END OF THE SERVICE LIFE .................................................................................................................................276 Dismantling and removal instructions .................................................................................................................................276 Risk of deflagrations ................................................................................................................................................276 Risk of fire .........................................................................................................................................................276 Disposing of the machine without polluting the environment ...........................................................................................................277 Further hazardous substances .........................................................................................................................................277 Appropriate disposal of batteries ....................................................................................................................................278 NOTES ....................................................................................................................................................................279 5 ANNEX.......................................................................................................................................................................281 BOARD-CONTROL-SYSTEM .....................................................................................................................................................283 BCS III, what’s that? ................................................................................................................................................283 The keys on the front side ...........................................................................................................................................284 Other elements on the front side .....................................................................................................................................284 BCSIII, the start screen .............................................................................................................................................285 Information given on the start screen, top section ...................................................................................................................286 Information given on the start screen, central section ...............................................................................................................287 Information given on the start screen, lower section .................................................................................................................288 Information given on the “Service” screen ............................................................................................................................289 Engine data screen ...................................................................................................................................................290 Hydraulic data screen ................................................................................................................................................291 Lubrication data screen ..............................................................................................................................................292 Controls adjustment data screen ......................................................................................................................................293 View documents screen ................................................................................................................................................294 Signal table screen ..................................................................................................................................................295 Signal table screen, location ........................................................................................................................................296 Signal table screen, diagram .........................................................................................................................................297 Signal table screen, diagram configuration ...........................................................................................................................298 Code table screen ....................................................................................................................................................299 BCS III, interfaces ..................................................................................................................................................300 USB interface, data storage ..........................................................................................................................................300 Saving data to a USB stick ...........................................................................................................................................301 Saving data to a USB stick, continued ................................................................................................................................302 Saving data to a USB stick, continued ................................................................................................................................303 BCSIII, cleaning .....................................................................................................................................................304 BCSIII, disposal .....................................................................................................................................................304 TROUBLESHOOTING ..........................................................................................................................................................305 Instructions on troubleshooting ......................................................................................................................................305 Layout of the fault table ............................................................................................................................................305 Possible causes ......................................................................................................................................................305 Measures .............................................................................................................................................................305 Section ..............................................................................................................................................................305 FAULT TABLES .............................................................................................................................................................306 Combustion engine - Fault table ......................................................................................................................................306 Working hydraulics – Fault table .....................................................................................................................................307 Track drive – Fault table ............................................................................................................................................308 Swing mechnism – Fault table .........................................................................................................................................309 Central lubricating system – Fault table .............................................................................................................................310 Engine control module, displaying stored fault codes .................................................................................................................311 HYDRAULIC CIRCUIT DIAGRAM ................................................................................................................................................313 Vibration data .......................................................................................................................................................313 ABBREVIATIONS ............................................................................................................................................................314 ABBREVIATIONS.........................................................................................................................................................315 TECHNICAL DATA ...........................................................................................................................................................317 Product Specification Sheet ..........................................................................................................................................319 NOTES ....................................................................................................................................................................329 6 INDEX.......................................................................................................................................................................331
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