CAT 6060 6060 FS Hydraulic Shovel Operation & Maintenance Manual – PDF DOWNLOAD

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CAT 6060 6060 FS Hydraulic Shovel Operation & Maintenance Manual – PDF DOWNLOAD

FILE DETAILS:

CAT 6060 6060 FS Hydraulic Shovel Operation & Maintenance Manual – PDF DOWNLOAD

Language : English
Pages : 337
Downloadable : Yes
File Type : PDF

DESCRIPTION:

CAT 6060 6060 FS Hydraulic Shovel Operation & Maintenance Manual – PDF DOWNLOAD

PREFACE:
About this Operating Instructions:

• These Operation and Maintenance Manual is de- signed to familiarize the operator with the
  machine and its designated use.
• The Operation and Maintenance Manual contains important information on how to operate
  the ma- chine safely, properly and with maximum effi- ciency. Observing these
  instructions helps to pre- vent hazardous situations, to reduce repair costs and downtimes
  and to increase the reliability and service life of the machine.
• The Operation and Maintenance Manual must be supplemented by the respective national rules
  and regulations for accident prevention and environ- mental protection.
• The Operation and Maintenance Manual must always be available in the driver’s cab of the
  ma- chine.

The Operation and Maintenance Manual must be read and put into practice by any person in
charge of carrying out work with or on the machine, such as
▪ operation, including setting-up, 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 Operation and Maintenance Man- ual 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 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 Manu- als 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 6060 6060 FS Hydraulic Shovel Operation & Maintenance Manual – PDF DOWNLOAD

1 INTRODUCTION 1-1
PREFACE 1-3
About this Operating Instructions 1-3
Further machine documentation 1-3
WARRANTY 1-4
FUNDAMENTAL SAFETY INSTRUCTIONS 1-5
Warnings and symbols 1-5
DESIGNATED USE, UNAUTHORIZED USE 1-6
Noise emission information 1-7
Vibration information 1-7
ORGANIZATIONAL MEASURES 1-8
Selection and qualification of personnel; basic responsibilities 1-9
Safety instructions governing specific operational phases 1-9
Special work in conjunction with utilization of the machine and maintenance and repairs as well as
troubleshooting during work; disposal of parts and consumables 1-10
Warning of special dangers 1-11
Gas, dust, steam and smoke 1-11
Hydraulic equipment 1-12
FIRE AND EXPLOSION HAZARD 1-13
NOTES 1-15
2 OPERATION 2-1
OPERATION – SAFETY INSTRUCTIONS 2-3
Operating Instructions, where to store it in the driver’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
Superstructure 2-8
Drive 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
Signs 2-10
Entering and leaving the machine, Safety instructions 2-18
Access ladder lighting 2-18
Folding ladder 2-19
Swinging ladder (optional) 2-20
Emergency exit in driver’s cab and escape ladder 2-21
Switching the cab interior lighting on and off 2-22
Switching the maintenance lights on and off 2-23
BA RH340B(3 847 009.00)-EN
TABLE OF CONTENTS
vi
Emergency shut-off function 2-24
Putting the machine back into operation, reset of emergency shut off function 2-25
Battery isolator switch, shutting off supply voltage 2-26
Starter isolator switch, shutting off starter voltage 2-26
Driver’s seat 2-27
Reducing operators exposure to vibrations 2-29
Trainer’s / instructor’s seat 2-29
Windscreen washer 2-29
Operating hours meter 2-29
Fire extinguisher 2-30
Automatic fire-extinguishing system (optional) 2-31
Harness (optional) 2-32
MONITORING, WARNING AND CONTROL ELEMENTS 2-36
Engine 1 (LH), control and monitoring 2-43
Engine 2 (RH), control and monitoring 2-45
PUTTING THE MACHINE INTO OPERATION 2-64
Reducing the operator’s exposure to noise 2-64
Refuelling 2-65
Back-up heating (option), filling in fuel 2-65
Service station (tanklift) 2-66
Emergency off switch 2-67
Switching the electrical system on and off 2-72
Engines, emergency shut-off 2-72
STARTING AND STOPPING THE ENGINES 2-74
Starting the engines 2-74
Starting the left-hand engine 2-74
Starting the right-hand engine 2-74
Engines – adjusting the speed 2-75
Starting the engines at low temperatures 2-75
Shutting off the engines 2-76
Shutting off the left-hand engine 2-76
Shutting off the right-hand engine 2-76
AIR CONDITIONER (OPTIONAL) 2-77
Back-up heating driver’s cab (optional) 2-78
Back-up heating (optional) 2-79
MAXIMUM MACHINE INCLINATIONS, INFORMATION 2-80
TRAVELLING, SAFETY INSTRUCTIONS 2-82
TRAVELLING 2-83
Superstructure basic position 2-83
Travelling forwards/backwards 2-83
Superstructure holding brake 2-87
Track parking brake 2-87
TRANSPORTING THE MACHINE 2-88
Transport – Safety instructions 2-88
BA RH340B(3 847 009.00)-EN
TABLE OF CONTENTS
vii
WORKING OPERATION – SAFETY INSTRUCTIONS 2-89
WORKING OPERATION 2-91
Before starting work 2-91
Activating the electronic excavator control 2-91
Swinging the superstructure 2-92
Braking the superstructure 2-92
Working 2-93
Emergency lowering of the equipment 2-94
After daily operation 2-95
ASSEMBLING WORKING EQUIPMENT – SAFETY INSTRUCTIONS 2-96
Securing the machine 2-97
CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS) 2-98
ON-BOARD CRANE (OPTIONAL) 2-99
On-board crane, monitoring, warning and control elements 2-99
On-board crane, putting into operation 2-100
On-board crane, drive unit 2-100
On-Board crane, – blocking the boom in position of rest 2-101
On-board crane, checking 2-101
NOTES 2-102
3 INSPECTION AND SERVICING 3-1
INSPECTION AND SERVICING – SAFETY INSTRUCTIONS 3-3
INSPECTION AND SERVICING WORK, FIRE AND EXPLOSION HAZARD 3-7
INSPECTION AND SERVICING PLANS – INSTRUCTIONS 3-9
Plan V 3-11
Plan N 3-13
Plan T 3-15
Plan A – E 3-17
LUBRICATING CHART 3-24
Lubricating chart – Grease (legend) 3-25
Filling quantities – Grease 3-25
INSPECTION PLAN – OIL 3-26
Inspection plan – Oil (legend) 3-27
Filling quantities – oil 3-28
Filling quantities – other 3-28
LUBRICANTS 3-29
Notes on the selection of oils and greases 3-29
Avoid mixing of different hydraulic fluids 3-29
I. Oil for combustion engines 3-30
II. Oil for hydraulic system 3-31
III.a Oil for pump distribution gearboxes and travel gearboxes 3-32
III.b Oil for swing gearboxes 3-33
V. Grease for bearings,slew rings and track system (Central lubrication system) 3-34
VI. Grease for idlers, track rollers and support rollers (Lifetime lubrication) 3-35
Coolant for use on all combustion engines 3-36
BA RH340B(3 847 009.00)-EN
TABLE OF CONTENTS
viii
SERVICING WORK 3-37
Hose line for oil and cooling liquid changes 3-37
ENGINE 3-38
Engine – Safety instructions 3-38
Checking the engine oil level / Topping up 3-39
Engine oil reservoir, checking the oil level / topping up 3-40
Engine oil, change 3-41
Engine oil reservoir, filling in /draining off the oil 3-43
Filters oil change prolongation, replace 3-45
EliminatorTM filter and centrifuge 3-46
COOLING SYSTEM 3-48
Radiators 3-49
Cooling-liquid level, check 3-49
Cooling-liquid, topping up 3-50
Cooling-liquid, topping up using the Service-Station 3-51
Cooling liquid change 3-52
Water filter, replace 3-54
Cold-starting fluid (ether) – Replacing the pressure vessel 3-55
AIR-INTAKE SYSTEM 3-56
Main filter elements, removal and installation 3-57
Main filter elements, checking and cleaning 3-58
Safety filter element, replace 3-59
Air-intake lines 3-60
Dust collection 3-60
FUEL SYSTEM 3-61
Fuel system – Safety instructions 3-61
Fuel filter, replace 3-61
Fuel tank, replace breather filter 3-62
Fuel tanks, cleaning 3-62
Water trap (option) 3-64
ELECTRICAL SYSTEM 3-66
Electrical system – Safety instructions 3-66
Alternator – Instructions 3-66
Electrical circuit diagrams 3-66
Electrical system switch-cabinets 3-66
Replacing lamps and bulbs 3-66
Battery 3-67
Switchgear cabinet, breather 3-69
Floodlight projector, replacing the lamp 3-71
Lighting systems in LED technonogy, instructions 3-73
Charging batteries inside the machine, safety instructions 3-74
HYDRAULIC SYSTEM 3-75
Hydraulic system – Safety instructions 3-75
Depressurizing the hydraulic system 3-75
Checking the hydraulic oil level 3-76
Changing the hydraulic oil return-flow (hydraulic oil reservoir) 3-78
Bypass valves (hydraulic oil reservoir) 3-80
Breather filter 3-81
BA RH340B(3 847 009.00)-EN
TABLE OF CONTENTS
ix
Filter (control circuit) 3-82
High-pressure filter for working hydraulics 3-83
High-pressure filters for the servo circuit 3-84
High-pressure filters for feeding circuits and swing pumps 3-85
High-pressure filters for swing circuit 3-86
Bearing flushing for main pumps, replace filter 3-87
Changing the hydraulic oil 3-88
Avoid mixing of different hydraulic fluids 3-88
Venting the hydraulic system 3-92
Cleaning the hydraulic oil cooler 3-93
Electronic controls 3-94
Pressure accumulator – Emergency lowering 3-95
PUMP TRANSFER GEARBOX 3-96
Checking the gearbox oil level / Topping up with oil 3-96
Pre-chambers, checking oil level, topping up with oil 3-96
Changing the gearbox oil 3-97
Pre-chambers, changing the gearbox oil 3-98
Gearbox venting 3-98
Pre-chamber venting 3-99
Pump transfer gearbox lube oil filters 3-100
SWING GEARBOX 3-101
Swing Gearbox – Checking the oil level / Topping up with oil 3-101
Changing the gearbox oil 3-102
Swing Gearbox venting 3-102
TRAVEL GEARBOX (GEARBOX P/N 3683483) 3-103
Travel gearbox – Checking the oil level / Topping up with oil 3-103
Travel gearbox – Changing oil 3-104
Travel gearbox – Breather filter 3-105
TRAVEL GEARBOX (GEARBOX P/N 3683496) 3-106
Travel gearbox – Checking the oil level / Topping up with oil 3-106
Travel gearbox – Changing oil 3-108
Travel gearbox -Breather filter 3-109
CRAWLER TRACKS 3-110
Track rollers 3-111
Track tensioner 3-112
Pressure-accumulator inspection regulations 3-113
Checking the gas charging pressure in the pressure accumulator 3-113
SWING RING 3-114
Swing ring – Instructions 3-114
Bearing races 3-114
CENTRAL LUBRICATING 3-116
Design 3-116
Function 3-117
Filling up the grease container 3-118
Breather filter 3-118
Checking the greasing pressure 3-119
Unblocking a grease line. 3-120
BA RH340B(3 847 009.00)-EN
TABLE OF CONTENTS
x
Oilfilter (hydraulic circuit grease pump) 3-121
Grease filter (Filling the grease container) 3-122
Grease filter (Grease lines) 3-123
OTHER MAINTENANCE 3-124
Engine 3-124
Reservoirs for used grease at the A-frame, emptying 3-125
Heating and air conditioning 3-125
Equipment 3-126
HYDRAULIC LADDER (OPTIONAL) 3-127
Pressure-accumulator inspection regulations 3-128
Extract from the German regulations 3-128
Checking the gas charging pressure in the pressure accumulator 3-128
ON-BOARD CRANE, DRIVE UNIT 3-129
On-board crane, lubricating 3-130
On-Board crane, checking tightness of fastening bolts 3-130
PUTTING THE HYDRAULIC SHOVEL OUT OF OPERATION AND RECOMMISSIONING 3-131
Putting the hydraulic shovel out of operation 3-131
Battery storage 3-131
Recommissioning 3-131
NOTES 3-133
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
HYDRAULIC SYSTEM 4-7
Repair instructions 4-7
Hydraulic hoses – Instructions 4-7
PRESSURE ACCUMULATORS – SAFETY INSTRUCTIONS 4-8
WELDING AND FLAME CUTTING WORKS – SAFETY INSTRUCTIONS 4-9
DISPOSAL AT THE END OF THE SERVICE LIFE 4-12
Dismantling and removal instructions 4-12
Risk of deflagrations 4-12
Risk of fire 4-12
Disposing of the machine without polluting the environment 4-13
Further hazardous substances 4-13
Appropriate disposal of batteries 4-14
NOTES 4-15
5 ANNEX 5-1
BOARD-CONTROL-SYSTEM 5-3
BCS III, what’s that? 5-3
BA RH340B(3 847 009.00)-EN
TABLE OF CONTENTS
xi
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
Information given on the “Service” screen 5-9
Engine data screen 5-10
Hydraulic data screen 5-11
Lubrication data screen 5-12
Controls adjustment data screen 5-13
View documents screen 5-14
Signal table screen 5-15
Signal table screen, location 5-16
Signal table screen, diagram 5-17
Signal table screen, diagram configuration 5-18
Code table screen 5-19
BCS III, interfaces 5-20
USB interface, data storage 5-20
Saving data to a USB stick 5-21
Saving data to a USB stick, continued 5-22
Saving data to a USB stick, continued 5-23
BCSIII, cleaning 5-24
BCSIII, disposal 5-24
TROUBLESHOOTING 5-25
Instructions on troubleshooting 5-25
Layout of the fault table 5-25
Possible causes 5-25
Measures 5-25
Section 5-25
FAULT TABLES 5-26
Combustion engine – Fault table 5-26
Working hydraulics – Fault table 5-27
Track drive – Fault table 5-28
Swing mechnism – Fault table 5-29
Central lubricating system – Fault table 5-30
Engine control module, displaying stored fault codes 5-31
HYDRAULIC CIRCUIT DIAGRAM 5-33
Vibration data 5-33
ABBREVIATIONS 5-34
TECHNICAL DATA 5-37
NOTES 5-39
6 INDEX 6-1
BA RH340B(3 847 009.00)-EN

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PLEASE NOTE:

• This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
• Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.

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