CAT 6060, 6060FS Hydraulic Shovel Operation & Maintenance Manual BI015764 – PDF DOWNLOAD

Description

CAT 6060, 6060FS Hydraulic Shovel Operation & Maintenance Manual BI015764 – PDF DOWNLOAD

FILE DETAILS:

CAT 6060, 6060FS Hydraulic Shovel Operation & Maintenance Manual BI015764 – PDF DOWNLOAD

Language : English
Pages : 340
Downloadable : Yes
File Type : PDF

DESCRIPTION:

CAT 6060, 6060FS Hydraulic Shovel Operation & Maintenance Manual BI015764 – PDF DOWNLOAD

PREFACE:
About this Operation and Mainte- nance Manual:

• These Operation and Maintenance Manual are designed to familiarize the operator with the
  machine and its designated use.
• The Operation and Maintenance Manual 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 ser- vice 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 operator’s cab
  of the machine.

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 Manual and the mandatory rules and
  regulations for accident prevention and environmental protec- tion in the user’s country and
  at the place where the machine is to be used, the generally recog- nized technical
  rules for safe and proper working must be observed ¹
• The Operation and Maintenance Manual are di- rected to the mining-machine specialist. They
  can- not provide basic know-how. This can be acquired, for example, in several days’ instruction by
  a quali- fied CGM HMS GmbH (Caterpillar Global Mining Hydraulic Mining Shovels GmbH)
  mechanic or by attending an CGM HMS GmbH training course for operators or maintenance personnel.
• The CGM HMS GmbH after-sales service will be pleased to deal with any queries you may
  have after reading through the Operation and Mainte- nance Manual.
• The Operation and Maintenance Manual does not contain work instructions for carrying out
  major repairs. Such work is willingly done for you by the
  CGM HMS GmbH after-sales service.

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

CAT 6060, 6060FS Hydraulic Shovel Operation & Maintenance Manual BI015764 – PDF DOWNLOAD

1 INTRODUCTION 1-1
PREFACE 1-1
About this Operation and Maintenance Manual 1-1
Further machine documentation 1-1
WARRANTY 1-2
FUNDAMENTAL SAFETY INSTRUCTIONS 1-3
Warnings and symbols 1-3
DESIGNATED USE 1-4
Noise emission information 1-5
Vibration information 1-5
ORGANIZATIONAL MEASURES 1-6
Selection and qualification of personnel; basic responsibilities 1-7
Safety instructions governing specific operational phases 1-7
Special work in conjunction with utilization of the machine and maintenance and repairs as well as
troubleshooting during work; disposal of parts and consumables 1-8
Warning of special dangers 1-9
Gas, dust, steam and smoke 1-9
Hydraulic equipment 1-10
FIRE AND EXPLOSION HAZARD 1-11
NOTES 1-12
2 OPERATION 2-1
OPERATION – SAFETY INSTRUCTIONS 2-3
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
Upperstructure 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 2-10
Entering and leaving the machine, Safety instructions 2-18
Access ladder lighting 2-18
Swinging ladder 2-19
Folding ladder (optional) 2-20
Emergency exit in operator’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
BI015764
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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
Operator’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
Electrical Storm Injury Prevention 2-64
Reducing the operator’s exposure to noise 2-64
Refuelling 2-65
Diesel fuel – recommendations 2-65
Back-up heating (option), filling in fuel 2-65
Service station (tanklift) 2-66
Emergency off switch 2-68
Switching the electrical system on and off 2-73
Engines, emergency shut-off 2-73
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 operator’s cab (optional) 2-78
Back-up heating (optional) 2-79
MAXIMUM MACHINE INCLINATIONS, INFORMATION 2-80
TRAVELING, SAFETY INSTRUCTIONS 2-82
TRAVELING 2-83
Upperstructure basic position 2-83
Traveling forwards/backwards 2-83
Upperstructure holding brake 2-87
Track parking brake 2-87
TRANSPORTING THE MACHINE 2-88
Transport – Safety instructions 2-88
BI015764
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WORKING OPERATION – SAFETY INSTRUCTIONS 2-89
WORKING OPERATION 2-91
Before starting work 2-91
Activating the electronic hydraulic shovel control 2-91
Swinging the upperstructure 2-92
Braking the upperstructure 2-92
Working operations 2-93
Engine-off lowering of the attachment 2-94
After daily operation 2-95
ASSEMBLING ATTACHMENT – SAFETY INSTRUCTIONS 2-96
Safety line on boom 2-96
Main control valves – attach/remove the handrail 2-97
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
Monitoring cameras 2-102
NOTES 2-103
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
Air-intake system 3-9
Oils / Greases 3-9
Cleaning jobs 3-9
Components 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
BI015764
OMM 6060, 6060FS(3 847 013.02)-EN
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LUBRICANTS / CONSUMABLES 3-29
Notes on the selection of oils and greases 3-29
Avoid mixing of different hydraulic fluids 3-29
I. Oils for combustion engines and compressors 3-30
II. Oil for hydraulic system 3-31
III.a Oils for pump distribution gearboxes and travel gearboxes 3-32
III.b Oils for swing gearboxes 3-33
V. Grease for bearings, slew rings and track system (Central lubrication system) 3-34
Grease for idlers, track rollers and upper rollers (Lifetime lubrication) 3-35
Coolant for use on all combustion engines 3-36
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 3-40
Changing the engine oil 3-41
Engine oil reservoir, filling in / draining off the oil 3-43
Replacing the oil filter 3-46
Cold-starting fluid (ether) – Replacing the pressure vessel 3-47
COOLING SYSTEM 3-48
Temperature 3-48
Radiators, check / clean 3-49
Cooling-liquid level, check 3-49
Cooling liquid, change 3-52
Testing the cooling liquid composition 3-54
AIR-INTAKE SYSTEM 3-55
Dust trap, cleaning 3-55
Main filter elements 3-56
Secondary filter element 3-58
Air-intake lines 3-58
FUEL SYSTEM 3-59
Fuel system – Safety instructions 3-59
Fuel tank supply valve – function 3-59
Replacing the fuel filter 3-60
Venting the fuel system 3-60
Breather filter fuel tanks, replace 3-60
Cleaning the fuel tanks 3-61
Water trap (option), clean / replace 3-63
ELECTRICAL SYSTEM 3-65
Electrical system – Safety instructions 3-65
Alternator – Instructions 3-65
Electrical circuit diagrams 3-65
Electrical system switch-cabinets 3-65
Replacing lamps and bulbs 3-65
Xenon floodlight projector (optional), replacing the lamp 3-66
Lighting systems in LED technonogy, instructions 3-68
Battery, checking the state of charge 3-69
BI015764
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Battery, removing and installing 3-70
Charging batteries inside the machine, safety instructions 3-71
Switchgear cabinet 3-72
HYDRAULIC SYSTEM 3-74
Hydraulic system – Safety instructions 3-74
Depressurizing the hydraulic system 3-74
Checking the hydraulic oil level 3-75
Hydraulic oil return-flow filters, replace 3-77
Hydraulic oil return-flow filters, replace (from machine no. 340173) 3-79
Bypass valves, clean / replace 3-80
Hydraulic oil tank breather filters, replace 3-82
Filters (pilot control circuit), replace 3-83
Hydraulic oil filters for working hydraulics, replace 3-84
Filters for swing pump charge circuit, replace 3-85
Filters for swing circuits, replace 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 hydraulic shovel controls, clean / lubricate 3-94
Pressure accumulator – Emergency lowering 3-95
PUMP DRIVE GEARBOX 3-96
Pump drive gearbox, Checking the oil level / Topping up with oil 3-96
Pre-chambers, checking oil level / topping up with oil 3-97
Pump drive gearbox, changing the gearbox oil 3-98
Pre-chambers, changing the gearbox oil 3-99
Pump drive gearbox breather valve, replace 3-99
Pre-chamber breather valve, replace 3-100
Pump drive gearbox lube oil filters, replace 3-101
SWING GEARBOX 3-102
Swing gearbox – Checking the oil level / Topping up with oil 3-102
Gearbox venting 3-102
Changing the swing gearbox oil 3-103
TRAVEL GEARBOX (GEARBOX P/N 3683483) 3-105
Travel gearbox – Checking the oil level / Topping up with oil 3-105
Travel gearbox – Changing oil 3-106
Travel gearbox – Breather filter 3-107
TRAVEL GEARBOX (GEARBOX P/N 3683496) 3-108
Travel gearbox – Checking the oil level / Topping up with oil 3-108
Travel gearbox – Changing oil 3-110
Travel gearbox – Breather filter 3-111
TRAVEL GEARBOX (GEARBOX P/N 3749598) 3-112
Travel gearbox – Checking the oil level / Topping up with oil 3-112
Travel gearbox – Changing oil 3-114
Travel gearbox – Breather filter 3-115
BI015764
OMM 6060, 6060FS(3 847 013.02)-EN
TABLE OF CONTENTS
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CRAWLER TRACKS 3-116
Track roller, lubricating 3-117
Track tensioner 3-118
Pressure-accumulator inspection regulations 3-119
Checking the gas charging pressure in the pressure accumulator 3-119
SWING RING 3-120
Swing ring – Instructions 3-120
Bearing races 3-120
CENTRAL LUBRICATING SYSTEM 3-122
Design 3-122
Function 3-123
Filling up the grease container 3-124
Breather filter grease container, check / replace 3-124
Checking the greasing pressure 3-125
Unblocking a grease line 3-125
Oilfilter replace (hydraulic circuit grease pump) 3-126
Grease filter replace (filling the grease container) 3-127
Grease filter replace (Grease lines) 3-127
OTHER MAINTENANCE 3-128
Engine 3-128
Reservoirs for used grease at the A-frame, emptying 3-129
Heating and air conditioning 3-129
Attachment, check for cracks 3-130
Clam cylinder chamber, check for soiling 3-130
Window panes – cleaning 3-131
Mirror – cleaning / adjusting position 3-131
HYDRAULIC LADDER 3-132
Pressure-accumulator inspection regulations 3-133
Extract from the German regulations 3-133
Checking the gas charging pressure in the pressure accumulator 3-133
ON-BOARD CRANE, DRIVE UNIT 3-134
On-board crane, lubricating 3-135
On-Board crane, checking tightness of fastening bolts 3-135
PUTTING THE HYDRAULIC SHOVEL OUT OF OPERATION AND RECOMMISSIONING 3-136
Putting the hydraulic shovel out of operation 3-136
Battery storage 3-136
Recommissioning 3-136
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TABLE OF CONTENTS
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NOTES 3-137
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
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
BI015764
OMM 6060, 6060FS(3 847 013.02)-EN
TABLE OF CONTENTS
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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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