CAT 6060, 6060FS Hydraulic Shovel Operation & Maintenance Manual BI017744 – PDF DOWNLOAD

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CAT 6060, 6060FS Hydraulic Shovel Operation & Maintenance Manual BI017744 – PDF DOWNLOAD

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CAT 6060, 6060FS Hydraulic Shovel Operation & Maintenance Manual BI017744 – PDF DOWNLOAD

Language : English
Pages : 284
Downloadable : Yes
File Type : PDF

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DESCRIPTION:

CAT 6060, 6060FS Hydraulic Shovel Operation & Maintenance Manual BI017744 – PDF DOWNLOAD

PREFACE:
These operating instructions are designed to fa- miliarize the operator with the machine
and its designated use.

• The operating instructions contain important in- formation on how to operate the machine
  safely, properly and with maximum efficiency. Observing these instructions helps to prevent
  hazardous situations, to reduce repair costs and downtimes and to increase the
  reliability and service life of the machine.
• The operating instructions must be supplemented by the respective national rules and
  regulations for accident prevention and environmental protec- tion.
• The operating instructions must always be avail- able in the driver’s cab of the machine.

The operating instructions must be read and put into practice by any person in charge of
carrying out work with or on the machine, such as

▪ operation, including setting-up, troubleshoot- ing in the course of work, care,
evacuation of production waste and disposal of fuels and consumables,
▪ maintenance (inspection, servicing, repair) and / or
▪ transport.

• In addition to the operating instructions and the mandatory rules and regulations for
  accident pre- vention and environmental protection in the user’s country and at the place where the
  machine is to be used, the generally recognized technical rules for safe and proper working must be
  observed ¹
• The operating instructions are directed to the con- struction-machine specialist. They cannot
  provide basic know-how. This can be acquired, for exam- ple, in several days’ instruction by
  a qualified Terex O&K mechanic or by attending an Terex O&K training course for
  operators or main- tenance personnel.
• The Terex O&K after-sales service will be pleased to deal with any queries you may
  have after reading through the operating instructions.
• All Terex O&K operating manuals are issued in German and then translated. Even a good
  transla- tion may give rise to questions which Terex O&K 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 Terex O&K after- sales service.
• The documentation relating to the machine is listed according to scope, quantity and language in
  the shipping note of the machine or in the cov- ering letter if supplied separately. The operating
  instructions and spare-parts list are marked with the serial number of the machine.
• On taking receipt of the consignment, please check that the documentation is complete and in
  the language requested by you.

TABLE OF CONTENTS:

CAT 6060, 6060FS Hydraulic Shovel Operation & Maintenance Manual BI017744 – PDF DOWNLOAD

1 INTRODUCTION............................................................................................................................................................... 13
	PREFACE.................................................................................................................................................................. 15
	WARRANTY................................................................................................................................................................. 16
	FUNDAMENTAL SAFETY INSTRUCTIONS.......................................................................................................................................... 17
		Warnings and symbols................................................................................................................................................. 17
	DESIGNATED USE........................................................................................................................................................... 18
	ORGANIZATIONAL MEASURES.................................................................................................................................................. 19
		Selection and qualification of personnel; basic responsibilities..................................................................................................... 20
		Safety instructions governing specific operational phases............................................................................................................ 20
		Special work in conjunction with utilization of the machine and maintenance and repairs as well as troubleshooting during work; disposal of parts and consumables.... 21
		Warning of special dangers........................................................................................................................................... 22
		Gas, dust, steam and smoke........................................................................................................................................... 23
		Hydraulic equipment.................................................................................................................................................. 23
		Noise................................................................................................................................................................ 23
		Oil, grease and other chemical substances............................................................................................................................ 23
	FIRE AND EXPLOSION HAZARD................................................................................................................................................ 24
	NOTES ................................................................................................................................................................... 25
2 OPERATION.................................................................................................................................................................. 27
	OPERATION - SAFETY INSTRUCTIONS.......................................................................................................................................... 29
	OPERATION, FIRE AND EXPLOSION HAZARD..................................................................................................................................... 31
	DESCRIPTION OF THE EXCAVATOR............................................................................................................................................. 32
		Excavator layout..................................................................................................................................................... 33
		Undercarriage ....................................................................................................................................................... 34
		Superstructure....................................................................................................................................................... 34
		Drive................................................................................................................................................................ 34
		Hydraulic system..................................................................................................................................................... 34
		Pump Managing System (PMS)........................................................................................................................................... 34
		Programmable Logic Controller (PLC) ................................................................................................................................. 34
		Central Management System (CMS) ..................................................................................................................................... 34
		Demand control / Zero-flow regulation................................................................................................................................ 35
		Automatic engine speed reduction .................................................................................................................................... 35
		Board-Control-System (BCS) .......................................................................................................................................... 35
		Electrical system ................................................................................................................................................... 35
		Sign ................................................................................................................................................................ 37
		Entering and leaving the machine Safety instructions................................................................................................................. 38
		Ramp-type ladder (optional) ......................................................................................................................................... 39
		Ramp-type ladder (optional) ......................................................................................................................................... 40
		EMERGENCY STOP pushbuttons .......................................................................................................................................... 43
		Windscreen washer ................................................................................................................................................... 43
		Driver's seat ....................................................................................................................................................... 44
		Fire extinguisher.................................................................................................................................................... 46
		Automatic fire-extinguishing system (optional)....................................................................................................................... 47
		Harness (optional)................................................................................................................................................... 48
	MONITORING, WARNING AND CONTROL ELEMENTS ................................................................................................................................ 52
	PUTTING THE MACHINE INTO OPERATION ...................................................................................................................................... 83
		Refuelling .......................................................................................................................................................... 83
		Service station (tanklift) .......................................................................................................................................... 83
		Switching the electrical system on and off .......................................................................................................................... 89
	STARTING AND STOPPING THE ENGINES ....................................................................................................................................... 90
	AIR CONDITIONER (OPTION)................................................................................................................................................. 93
		Back-up heating (option) ............................................................................................................................................ 95
	DRIVING ................................................................................................................................................................. 97
		SAFETY INSTRUCTIONS ................................................................................................................................................. 97
		Superstructure basic position ....................................................................................................................................... 98
		Emergency machine drive .............................................................................................................................................102
		Locking the superstructure ..........................................................................................................................................104
		Track parking brake .................................................................................................................................................104
	TRANSPORTING THE MACHINE ................................................................................................................................................105
		Safety instructions .................................................................................................................................................105
	WORKING OPERATION .......................................................................................................................................................106
		Safety instructions .................................................................................................................................................106
		Before starting work ................................................................................................................................................108
		Slewing and braking the superstructure ..............................................................................................................................108
		Braking the superstructure ..........................................................................................................................................108
		Working .............................................................................................................................................................109
		After daily operation ...............................................................................................................................................110
	ASSEMBLING WORKING EQUIPMENT ............................................................................................................................................111
		Safety instructions .................................................................................................................................................111
		Securing the machine ................................................................................................................................................113
	CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS) ..........................................................................................................114
	NOTES ...................................................................................................................................................................115
3 INSPECTION AND SERVICING...................................................................................................................................................117
	INSPECTION AND SERVICING - SAFETY INSTRUCTIONS ..........................................................................................................................119
	INSPECTION AND SERVICING WORK, FIRE AND EXPLOSION HAZARD ................................................................................................................125
	INSPECTION AND SERVICING PLANS - INSTRUCTIONS ...........................................................................................................................127
		Intervals............................................................................................................................................................127
		Change of engine oil ................................................................................................................................................127
		Air-intake system ...................................................................................................................................................127
		Oils / Greases ......................................................................................................................................................127
		Cleaning jobs .......................................................................................................................................................127
		Components ..........................................................................................................................................................127
		Plan V ..............................................................................................................................................................129
		Plan N ..............................................................................................................................................................131
		Plan T ..............................................................................................................................................................133
		Plan A – E ..........................................................................................................................................................135
	LUBRICATING CHART .......................................................................................................................................................142
		Lubricating chart – Grease (legend) .................................................................................................................................143
		Filling quantities - Grease..........................................................................................................................................143
	INSPECTION PLAN - OIL ...................................................................................................................................................144
		Inspection plan – Oil (legend) ).....................................................................................................................................145
		Filling quantities - oil ............................................................................................................................................146
		Filling quantities - other...........................................................................................................................................146
	LUBRICANTS ..............................................................................................................................................................147
		Notes on the selection of oils and greases ..........................................................................................................................147
		I. Oils for combustion engines and compressors ......................................................................................................................148
		II. Oils for hydraulic system (selection) ...........................................................................................................................149
		III.a Oils for pump distribution gearboxes ..........................................................................................................................150
		III.b Oils for swing gearboxes ......................................................................................................................................151
		III.c Oils for travel gearboxes .....................................................................................................................................152
		V. Greases for bearings and slewing rings ...........................................................................................................................153
	SERVICING WORK ..........................................................................................................................................................154
		Hose line for oil and cooling liquid changes ........................................................................................................................154
	ENGINE ..................................................................................................................................................................155
		Engine - Safety instructions ........................................................................................................................................155
		Checking the engine oil level / Topping up  .........................................................................................................................156
		Checking the oil level in the engine oil reservoir / topping up (optional) ..........................................................................................157
		Changing the engine oil .............................................................................................................................................158
		Draining the oil off the engine oil reservoir (optional) ............................................................................................................160
		Replacing the oil filter ............................................................................................................................................162
		Eliminator filter and centrifuge ....................................................................................................................................163
	COOLING SYSTEM ..........................................................................................................................................................165
		Radiators ...........................................................................................................................................................166
		Cooling liquid ......................................................................................................................................................168
		Water filter ........................................................................................................................................................170
	AIR-INTAKE SYSTEM .......................................................................................................................................................171
		Main filter elements ................................................................................................................................................171
		Safety filter element ...............................................................................................................................................173
		Air-intake lines ....................................................................................................................................................174
		Dust collection .....................................................................................................................................................174
	FUEL SYSTEM .............................................................................................................................................................175
		Fuel system - Safety instructions ...................................................................................................................................175
		Replacing the fuel filter ...........................................................................................................................................175
		Venting the fuel system .............................................................................................................................................176
		Cleaning the fuel tanks .............................................................................................................................................176
		Water trap (option)..................................................................................................................................................178
	ELECTRICAL SYSTEM  ......................................................................................................................................................180
		Electrical system - Safety instructions .............................................................................................................................180
		Alternator - Instructions ...........................................................................................................................................180
		Battery .............................................................................................................................................................181
		Switchgear cabinet ..................................................................................................................................................183
		Floodlight projector, replacing the lamp ............................................................................................................................185
	HYDRAULIC SYSTEM ........................................................................................................................................................187
		Hydraulic system - Safety instructions ..............................................................................................................................187
		Depressurizing the hydraulic system .................................................................................................................................187
		Checking the hydraulic oil level ....................................................................................................................................188
		Changing the hydraulic oil return-flow (hydraulic oil reservoir) ....................................................................................................190
		Bypass valves (hydraulic oil reservoir) .............................................................................................................................192
		Breather filter .....................................................................................................................................................193
		Filter (control circuit).............................................................................................................................................194
		High-pressure filter for working hydraulics .........................................................................................................................195
		High-pressure filters for the servo circuit .........................................................................................................................196
		High-pressure filters for feeding circuits and slewing pumps ........................................................................................................197
		High-pressure filters for slewing circuit ...........................................................................................................................198
		Changing the hydraulic oil ..........................................................................................................................................199
		Venting the hydraulic system.........................................................................................................................................202
		Cleaning the hydraulic oil cooler....................................................................................................................................203
		Electronic excavator control.........................................................................................................................................204
		Pressure accumulator - Emergency lowering............................................................................................................................205
	PUMP TRANSFER GEARBOX ...................................................................................................................................................206
		Checking the gearbox oil level / Topping up with oil ................................................................................................................206
		Pre-chamber .........................................................................................................................................................206
		Changing the gearbox oil ............................................................................................................................................207
		Pre-chamber .........................................................................................................................................................208
		Gearbox venting .....................................................................................................................................................209
		Pump transfer gearbox lube oil filters ..............................................................................................................................210
	SLEWING GEARBOX .........................................................................................................................................................211
		Gearbox - Checking the oil level / Topping up with oil ..............................................................................................................211
		Changing the gearbox oil ............................................................................................................................................211
		Gearbox venting .....................................................................................................................................................212
	TRAVEL GAERBOX ..........................................................................................................................................................213
		Gearbox - Checking the oil level / Topping up with oil ..............................................................................................................213
		Travel gearbox - Changing oil .......................................................................................................................................214
		Pre-chamber - Changing the oil ......................................................................................................................................214
		Brake chamber - Changing oil ........................................................................................................................................215
		Breather filter .....................................................................................................................................................215
		Track rollers........................................................................................................................................................216
		Track tensioner .....................................................................................................................................................217
		Pressure-accumulator inspection regulations .........................................................................................................................218
		Checking the gas charging pressure in the pressure accumulator.......................................................................................................218
	SLEWING RING ............................................................................................................................................................219
		Slewing ring - Instructions..........................................................................................................................................219
		Bearing races........................................................................................................................................................219
	CENTRAL LUBRICATING .....................................................................................................................................................221
		Design ..............................................................................................................................................................221
		Function ............................................................................................................................................................222
		Filling up the grease container .....................................................................................................................................223
		Breather filter .....................................................................................................................................................223
		Checking the greasing pressure ......................................................................................................................................224
		Checking the greasing pressure ......................................................................................................................................225
		Unblocking a grease line.............................................................................................................................................226
		Unblocking a grease line.............................................................................................................................................226
		Oilfilter (hydraulic circuit grease pump) )..........................................................................................................................227
		Grease filter (Filling the grease container) ........................................................................................................................228
		Grease filter (Grease lines) ........................................................................................................................................229
	 OTHER MAINTENANCE ......................................................................................................................................................230
		Engine ..............................................................................................................................................................230
		Heating and air conditioning ........................................................................................................................................230
		Equipment ...........................................................................................................................................................231
	HYDRAULIC LADDER (OPTIONAL) .............................................................................................................................................232
		Pressure-accumulator inspection regulations .........................................................................................................................233
		Extract from the German regulations..................................................................................................................................233
		Checking the gas charging pressure in the pressure accumulator.......................................................................................................233
	ON-BOARD CRANE (OPTIONAL) ...............................................................................................................................................234
		Monitoring, warning and control elements ............................................................................................................................234
		Checking the on-board crane..........................................................................................................................................234
		Drive unit...........................................................................................................................................................235
		On-board crane.......................................................................................................................................................235
		On-Board crane, checking tightness of fastening bolts ...............................................................................................................236
	PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING ..............................................................................................................237
		Putting the excavator out of operation...............................................................................................................................237
		Battery storage......................................................................................................................................................237
		Recommissioning......................................................................................................................................................238
	NOTES ...................................................................................................................................................................239
4 REPAIR WORK................................................................................................................................................................241
	REPAIR WORK - SAFETY INSTRUCTIONS........................................................................................................................................243
	REPAIR WORK, FIRE AND EXPLOSION HAZARD ..................................................................................................................................245
	REPAIR WORK, ENGINE......................................................................................................................................................246
	ELECTRICAL SYSTEM .......................................................................................................................................................247
		Assisted starting (with jumper cables) – Safety instructions ........................................................................................................247
		Assisted starting (with jumper cables)...............................................................................................................................247
		Starting the engine with jumper cables (external batteries ..........................................................................................................247
	HYDRAULIC SYSTEM.........................................................................................................................................................250
		Repair instructions .................................................................................................................................................250
		Hydraulic hoses – Instructions  .....................................................................................................................................250
	PRESSURE ACCUMULATORS - SAFETY INSTRUCTIONS..............................................................................................................................251
	WELDING OPERATIONS - SAFETY INSTRUCTIONS ................................................................................................................................252
	NOTES ...................................................................................................................................................................253
5 ANNEX......................................................................................................................................................................255
	TROUBLESHOOTING .........................................................................................................................................................257
		Instructions on troubleshooting .....................................................................................................................................257
		Layout of the fault table ...........................................................................................................................................257
		Possible causes .....................................................................................................................................................257
		Measures ............................................................................................................................................................257
		Section .............................................................................................................................................................257
	FAULT TABLES ............................................................................................................................................................258
		Combustion engine - Fault table .....................................................................................................................................258
		Working hydraulics – Fault table ....................................................................................................................................259
		Track drive – Fault table ...........................................................................................................................................260
		Slewing mechnism – Fault table ......................................................................................................................................261
		Central lubricating system – Fault table ............................................................................................................................262
	HYDRAULIC CIRCUIT DIAGRAM ...............................................................................................................................................263
	ABBREVIATIONS ...........................................................................................................................................................265
	ABBREVIATIONS ...........................................................................................................................................................266
	TECHNICAL DATA ..........................................................................................................................................................267
	NOTES ...................................................................................................................................................................277
6 INDEX......................................................................................................................................................................279

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