Cat 6060, 6060 FS Hydraulic Shovel Operation and Maintenance Manual EM024061 – PDF DOWNLOAD

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Cat 6060, 6060 FS Hydraulic Shovel Operation and Maintenance Manual EM024061 – PDF DOWNLOAD

FILE DETAILS:

Cat 6060, 6060 FS Hydraulic Shovel Operation and Maintenance Manual EM024061 – PDF DOWNLOAD

Language : English
Pages : 452
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Cat 6060, 6060 FS Hydraulic Shovel Operation and Maintenance Manual EM024061 – PDF DOWNLOAD

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Cat 6060, 6060 FS Hydraulic Shovel Operation and Maintenance Manual EM024061 – PDF DOWNLOAD

1 INTRODUCTION ___ 1-1
ALL PRODUCTS FOREWORD ___ 1-3
Literature Information 1-3
Safety __ 1-3
Operation __ 1-3
Product Information 1-3
Maintenance 1-3
Maintenance Intervals 1-3
Product Capacity __ 1-3
PREFACE 1-4
About this Operation and Maintenance Manual _ 1-4
Further machine documentation _ 1-4
WARRANTY _ 1-5
FUNDAMENTAL SAFETY INSTRUCTIONS 1-6
Warnings and symbols ___ 1-6
Declaration of Conformity _ 1-6
Noise emission information 1-7
Vibration information 1-7
Visibility Information 1-7
Restricted Visibility 1-8
DESIGNATED USE _ 1-9
ORGANIZATIONAL MEASURES 1-10
Selection and qualification of personnel; basic responsibilities 1-11
Safety instructions governing specific operational phases ___ 1-11
Special work in conjunction with utilization of the machine and maintenance and repairs as well as
troubleshooting during work; disposal of parts and consumables 1-12
Warning of special dangers 1-13
Gas, dust, steam and smoke __ 1-13
Hydraulic equipment 1-14
FIRE AND EXPLOSION HAZARD 1-15
NOTES 1-2
2 OPERATION _ 2-1
OPERATION – SAFETY INSTRUCTIONS __ 2-3
Visibility aids 2-4
Operation and Maintenance Manual, where to store it in the operator’s cab 2-4
FIRE AND EXPLOSION HAZARD _ 2-5
DESCRIPTION OF THE HYDRAULIC SHOVEL __ 2-6
Hydraulic shovel layout ___ 2-7
Undercarriage 2-8
Upper structure ___ 2-8
Drive unit 2-8
Hydraulic system __ 2-8
Control and Monitoring Platform (CAMP) _ 2-8
Board-Control-System (BCS) ___ 2-9
Demand control / Zero-flow regulation 2-9
Automatic reset to idling __ 2-9
Electrical system __ 2-9
Safety films and warning messages – Overview and Description 2-10
ISO – compliant safety messages set 2-11
Safety messages (ISO) – Description 2-17
Additional messages (ISO) – Description 2-21
ANSI – compliant safety messages set __ 2-26
Safety messages (ANSI) – Description __ 2-32
Additional messages (ANSI) – Description 2-36
Entering and leaving the machine – Safety instructions 2-40
Access ladder – Lighting _ 2-40
Swinging ladder – Function 2-41
Folding ladder (optional) – Function _ 2-42
Emergency exit in operator’s cab and escape ladder __ 2-43
Cab interior lighting – Switch on and off _ 2-44
Maintenance lights – Switch on and off __ 2-45
Emergency shut-off – Function _ 2-46
Putting the machine back into operation, reset of emergency shut off function 2-47
Battery isolator switch – Shut off supply voltage 2-48
Starter isolator switch – Shut off starter voltage _ 2-48
Operator’s seat __ 2-49
Reducing operators exposure to vibrations 2-51
Trainer’s / instructor’s seat 2-51
Windscreen washer 2-51
Operating hours meter (if equipped) _ 2-51
Fire extinguisher _ 2-52
Automatic fire-extinguishing system _ 2-52
MONITORING, WARNING AND CONTROL ELEMENTS 2-54
Engine 1 (LH), control and monitoring __ 2-61
Engine 2 (RH), control and monitoring __ 2-63
PUTTING THE MACHINE INTO OPERATION __ 2-82
Electrical Storm Injury Prevention ___ 2-82
Reducing the operator’s exposure to noise 2-82
Refuelling _ 2-83
Diesel fuel – Recommendations 2-83
Back-up heating (option) – Fill in fuel _ 2-83
Service Station (fast fill arm) ___ 2-84
Emergency off switch ___ 2-85
Electrical system – Switch on and off 2-90
Engines – Emergency shut-off __ 2-90
Preheating system for engine and hydraulic oil (if equipped) _ 2-91
Fuel preheating system (if equipped) 2-92
ENGINES – STARTING AND STOPPING _ 2-93
Engines – Start __ 2-93
Starting the left-hand engine ___ 2-93
Starting the right-hand engine __ 2-93
Engines – Adjust speed _ 2-94
OMM 6060, 6060FS(3 847 031.04)-EN
EM024061-03
TABLE OF CONTENTS
vii
Engines – Start at low temperatures _ 2-94
Engines – Shut off 2-95
Shutting off the left-hand engine 2-95
Shutting off the right-hand engine ___ 2-95
AIR CONDITIONER (OPTIONAL) 2-96
Back-up heating operator’s cab (optional) 2-97
Back-up heating (optional) 2-98
OPERATIONAL PRACTICES ___ 2-99
Working operation – Safety instructions __ 2-99
Before starting work ___ 2-100
Machine Operating Temperature Range 2-100
Warming up the hydraulic system __ 2-100
Electronic hydraulic shovel control (pilot control) – activate _ 2-101
Working operation – basics ___ 2-102
OPERATION TECHNIQUES ___ 2-108
Machine operation with backhoe attachment, Best Practices __ 108
Backhoe Operation – Restricted Operation ___ 2-118
Machine operation with face shovel attachment – Best Practices __ 2-129
Face Shovel Operation – Restricted Operation 2-143
TRAVELING 2-158
Traveling – Safety Instructions _ 2-158
Before starting traveling 2-159
Traveling – Basic Movements _ 2-161
Counter-rotation turns / Turning on the spot __ 2-164
Track Parking Brake – set/release _ 2-165
Traveling speed – adjust 2-165
Traveling uphill and downhill on ramps and steep slopes ___ 2-166
Traveling over long distances _ 2-168
Traveling – Best Practices ___ 2-170
Traveling – Restricted Operation __ 2-171
Maximum Machine Inclinations 2-174
TRANSPORTING THE MACHINE ___ 2-175
Transport – Safety instructions 2-175
Engine-off lowering of the attachment __ 2-176
After daily operation ___ 2-177
ASSEMBLING ATTACHMENT – SAFETY INSTRUCTIONS __ 2-178
Safety line on boom ___ 2-178
Main control valves – attach/remove the handrail 2-179
Securing the machine __ 2-179
CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS) ___________ 2-180
ON-BOARD CRANE (OPTIONAL) ___ 2-181
On-board crane – Monitoring, warning and control elements 2-181
On-board crane- Putting into operation _ 2-182
On-board crane – Drive unit ___ 2-182
On-Board crane – Blocking the boom in position of rest 2-183
On-board crane – Check 2-183
Monitoring cameras – Function 2-184
Operator Assist System (if equipped) __ 2-184
NOTES _ 2-185
3 INSPECTION AND SERVICING __ 3-1
INSPECTION AND SERVICING – SAFETY INSTRUCTIONS ___ 3-3
INSPECTION AND SERVICING WORK, FIRE AND EXPLOSION HAZARD _ 3-7
INSPECTION AND SERVICING PLANS – INSTRUCTIONS 3-9
Intervals _ 3-9
Change of engine oil 3-9
Refer to chapter “Engine oil service interval table” for more information. Also refer to SEBU6250 Caterpillar
Machine Fluid Recommendations. 3-9
Air-intake system __ 3-9
Oils / Greases 3-9
Cleaning jobs 3-9
Components 3-9
3500 Engine Maintenance Interval Schedule – Notes _ 3-10
Plan V _ 3-11
Plan N _ 3-13
Plan T and Plan W 3-15
Plan A – E _ 3-19
LUBRICATING CHART – GREASE ___ 3-26
Lubricating chart – Grease (legend) _ 3-27
Refill Capacities – Grease 3-27
INSPECTION PLAN – OIL _ 3-28
Inspection plan – Oil (legend) __ 3-29
Engine oil service interval table _ 3-30
Refill Capacities – Oil 3-31
Refill Capacities – Other _ 3-31
LUBRICANTS / CONSUMABLES 3-32
Notes on the selection of oils and greases 3-32
I. Oils for combustion engines 3-33
II. Fluids for hydraulic system ___ 3-34
III.a Oils for pump distribution gearboxes and travel gearboxes __ 3-35
III.b Oils for swing gearboxes _ 3-36
V. Grease for bearings, slew rings and track system (Central lubrication system) ___________ 3-37
Grease for idlers, track rollers and upper rollers (Lifetime lubrication) 3-38
Coolant for use on all combustion engines 3-39
SERVICING WORK 3-40
Hose line for oil and cooling liquid changes ___ 3-40
ENGINE _ 3-41
Engine – Safety instructions ___ 3-41
Walk-Around Inspection _ 3-42
Belts – Inspect/Replace __ 3-43
Fuel Injector – Inspect/Adjust ___ 3-43
Engine Oil Sample – Obtain ___ 3-44
Engine Valve Lash – Check/Adjust __ 3-45
Water Pump – Inspect ___ 3-45
Engine oil level – Check level / top up 3-46
Engine oil reservoir (if equipped) – Check oil level / top up __ 3-47
Engine oil – Change 3-48
Engine oil reservoir (if equipped) – Drain / Fill oil 3-50
Engine oil reservoir (if equipped) – Replace oil filters __ 3-52
Engine oil reservoir (if equipped) – Replace breather filters __ 3-52
Engine oil filter – Replace 3-53
Engine crankcase breather – Clean _ 3-53
Cold-starting fluid (ether) – Replace the pressure vessel 3-54
COOLING SYSTEM 3-55
Temperature 3-55
Cooling liquid radiators – Check / clean __ 3-56
Cooling liquid level – Check 3-56
Cooling liquid – Top up __ 3-57
Cooling liquid – Change __ 3-59
Cooling liquid composition – Test ___ 3-60
Cooling System Supplemental Coolant Additive (SCA) – Add 3-61
Cooling System Water Temperature Regulator –Replace ___ 3-62
Cooling System Coolant Sample (Level 1) – Obtain ___ 3-63
Cooling System Coolant Sample (Level 2) – Obtain ___ 3-63
AIR-INTAKE SYSTEM 3-64
Engine air pre cleaner – Inspect / clean __ 3-65
Primary air filter element – Inspect / replace ___ 3-66
Secondary air filter element – Replace __ 3-67
Air-intake lines – Inspect _ 3-67
FUEL SYSTEM ___ 3-68
Fuel system – Safety instructions ___ 3-68
Fuel tank supply valve – Function ___ 3-68
Fuel System – Prime 3-68
Fuel filter – Replace 3-69
Fuel system – Vent 3-69
Breather filter fuel tanks – Replace __ 3-69
Fuel tanks – Clean 3-70
Water trap (option) – Clean / replace _ 3-72
Hoses and Clamps – Inspect/Replace 3-74
ELECTRICAL SYSTEM ___ 3-77
Electrical system – Safety instructions 3-77
Alternator – Instructions __ 3-77
Electrical circuit diagrams 3-77
Electrical system switch-cabinets ___ 3-77
Lamps and bulbs – Replace ___ 3-77
Xenon floodlight projector (optional) – Replace the lamp 3-78
Lighting systems in LED technology – Instructions 3-80
Battery- Check the state of charge __ 3-81
Battery – Remove and install ___ 3-82
Battery charge inside the machine – Safety instructions 3-83
Switchgear cabinet filter – Clean 3-84
CAN-Bus wiring connections – Inspect __ 3-86
HYDRAULIC SYSTEM ___ 3-87
Hydraulic system – Safety instructions 3-87
Hydraulic system – Depressurize ___ 3-87
Attachment circuits – Depressurize __ 3-88
Hydraulic system sections – Depressurize 3-89
Hydraulic oil level – Check 3-89
Hydraulic Oil Analysis – Understand Particle Count Results _ 3-91
Hydraulic oil return-flow filters, Replace _ 3-92
Hydraulic oil return-flow filters – Replace (from machine no. 340173 / DHN60173) _____________ 3-94
Bypass valves – Clean / replace 3-96
Hydraulic oil tank breather filters – Replace 3-97
Filters (pilot control circuit) – Check / replace __ 3-98
Hydraulic oil filters for working hydraulics – Check / replace _ 3-99
Filters for swing pump charge circuit – Check / replace 3-100
Filters for swing circuits – Replace _ 3-101
Bearing flushing for main pumps – Replace filter 3-102
Hydraulic oil – Change _ 3-103
Hydraulic oil tank- Clean 3-105
Hydraulic system – Vent 3-107
Hydraulic oil cooler – Clean __ 3-108
Electronic hydraulic shovel controls – Clean / lubricate 3-109
Pressure accumulator – Emergency lowering _ 3-110
PUMP DRIVE GEARBOX 3-111
Pump drive gearbox – Check oil level / Top up with oil 3-111
Pre-chambers – Check oil level / top up with oil 3-112
Pump drive gearbox oil sample – Obtain 3-112
Pump drive gearbox – Change gearbox oil ___ 3-113
Pre-chambers – Change gearbox oil 3-114
Pump drive gearbox breather valve – Replace 3-114
Pre-chamber breather valve – Replace _ 3-115
Pump drive gearbox lube oil filters – Replace _ 3-116
SWING GEARBOX 3-117
Swing gearbox oil sample – Obtain _ 3-117
Swing gearbox – Check oil level / Top up with oil 3-117
Swing gearbox – Vent __ 3-117
Swing gearbox oil – Change __ 3-118
TRAVEL GEARBOX (GEARBOX P/N 3683483) 3-120
Travel gearbox – Check oil level / Top up with oil 3-120
Travel gearbox – Change oil __ 3-121
Travel gearbox breather filter – Replace 3-122
Travel gearbox oil sample – Obtain 3-122
TRAVEL GEARBOX (GEARBOX P/N 3683496) 3-123
Travel gearbox – Check oil level / Top up with oil 3-123
Travel gearbox oil sample – Obtain 3-124
Travel gearbox oil – Change __ 3-125
Travel gearbox breather filter – Replace 3-126
TRAVEL GEARBOX (GEARBOX P/N 3749598) 3-127
Travel gearbox – Check oil level / Top up with oil 3-127
Travel gearbox oil sample – Obtain 3-128
Travel gearbox oil – Change __ 3-129
Travel gearbox breather filter – Replace 3-130
CRAWLER TRACKS 3-131
Undercarriage – Check for leaks and free movement _ 3-131
Track roller – Lubricate _ 3-132
Track tensioning system 3-133
Pressure-accumulator inspection regulations _ 3-134
Checking the gas charging pressure in the pressure accumulator _ 3-134
SWING RING 3-135
Swing ring – Instructions 3-135
Bearing races __ 3-135
Swing ring grease filling – Check __ 3-136
Swing ring bolts – Check for tightness _ 3-136
CENTRAL LUBRICATING SYSTEM _ 3-137
Central lubrication system – Design 3-137
Central lubrication system – Function __ 3-138
Grease container – Fill up 3-139
Grease container breather filter – Check / replace ___ 3-139
Greasing pressure – Check ___ 3-140
Grease line – Unblock __ 3-140
Oil filter (hydraulic circuit grease pump) – Replace ___ 3-141
Grease filter (filling the grease container) – Check / replace _ 3-142
Grease filter (grease lines) – Check / replace _ 3-143
OTHER MAINTENANCE WORK 3-144
Engine – Clean _ 3-144
Travel Alarm – Test 3-144
Radiator – Clean 3-145
Aftercooler Core – Clean/Test _ 3-146
Reservoirs for used grease at the A-frame – Empty __ 3-146
Air conditioning filter – Clean _ 3-147
Attachment – Check for cracks 3-147
Clam cylinder chamber – Check for soiling ___ 3-148
Window panes – Clean _ 3-148
Mirror – Clean / adjust position 3-149
Seat belt – Inspect 3-150
Seat belt – Replace 3-150
Cameras – Check/Clean/Adjust (If equipped) _ 3-151
Horn – Inspect / Replace 3-152
Hydraulic ladder – pressure accumulator 3-153
Pressure-accumulator inspection regulations _ 3-154
Pressure accumulator – Checking the gas charging pressure 3-154
ON-BOARD CRANE, DRIVE UNIT (OPTIONAL) 3-155
On-board crane – Lubricate ___ 3-156
On-Board crane fastening bolts – Check tightness ___ 3-156
PUTTING THE HYDRAULIC SHOVEL OUT OF OPERATION AND RECOMMISSIONING _______ 3-157
Putting the hydraulic shovel out of operation _ 3-157
Battery storage _ 3-157
Recommissioning 3-157
NOTES _ 3-159
4 REPAIR WORK 4-1
REPAIR WORK – SAFETY INSTRUCTIONS 4-3
CONFINED SPACES – SAFETY INSTRUCTIONS 4-4
REPAIR WORK, FIRE AND EXPLOSION HAZARD 4-5
REPAIR WORK, ENGINE __ 4-6
Overhaul Considerations __ 4-6
Overhaul Recommendation 4-7
Cleaning of Components _ 4-10
HYDRAULIC SYSTEM ___ 4-11
Repair instructions 4-11
Hydraulic hoses – Instructions _ 4-11
PRESSURE ACCUMULATORS – SAFETY INSTRUCTIONS __ 4-12
WELDING AND FLAME CUTTING WORKS – SAFETY INSTRUCTIONS __ 4-13
DISPOSAL AT THE END OF THE SERVICE LIFE 4-16
Dismantling and removal instructions 4-16
Risk of deflagrations 4-16
Risk of fire _ 4-16
Disposing of the machine without polluting the environment _ 4-17
Further hazardous substances _ 4-17
Appropriate disposal of batteries 4-18
NOTES 4-1
5 ANNEX __ 5-1
BOARD-CONTROL-SYSTEM 5-3
BCS III, what’s that? 5-3
The keys on the front side _ 5-4
Other elements on the front side _ 5-4
BCSIII, the start screen ___ 5-5
Information given on the start screen, top section 5-6
Information given on the start screen, central section ___ 5-7
Information given on the start screen, lower section 5-8
Emergency Stop, reset function _ 5-9
Swing circuit lock-out function __ 5-10
Information given on the “Service” screen 5-11
Engine data screen 5-12
Hydraulic data screen ___ 5-13
Lubrication data screen __ 5-14
Controls adjustment data screen ___ 5-15
View documents screen _ 5-16
Signal table screen 5-17
Signal table screen, location ___ 5-18
Signal table screen, diagram ___ 5-19
Signal table screen, diagram configuration 5-20
Code table screen 5-21
Slew brake test screen __ 5-22
BCS III, interfaces 5-23
USB interface, data storage ___ 5-23
Saving data to a USB stick 5-24
Saving data to a USB stick, continued __ 5-25
Saving data to a USB stick, continued __ 5-26
BCSIII, cleaning _ 5-27
BCSIII, disposal __ 5-27
TROUBLESHOOTING 5-28
Instructions on troubleshooting _ 5-28
Layout of the fault table __ 5-28
Possible causes _ 5-28
Measures _ 5-28
Section 5-28
FAULT TABLES ___ 5-29
Combustion engine – Fault table 5-29
Working hydraulics – Fault table 5-30
Track drive – Fault table _ 5-31
Swing mechnism – Fault table _ 5-32
Central lubricating system – Fault table _ 5-33
HYDRAULIC CIRCUIT DIAGRAM 5-34
Vibration data ___ 5-34
ABBREVIATIONS _ 5-35
ABBREVIATIONS 5-36
PRODUCT SPECIFICATION SHEET _ 5-37
NOTES __ 5-39
6 INDEX 6-1

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