Cat 6060 6060FS Hydraulic shovel Operation & Maintenance Manual – PDF DOWNLOAD

Description

Cat 6060 6060FS Hydraulic shovel Operation & Maintenance Manual – PDF DOWNLOAD

FILE DETAILS:

Cat 6060 6060FS Hydraulic shovel Operation & Maintenance Manual – PDF DOWNLOAD

Language : English
Pages :334+
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Cat 6060 6060FS Hydraulic shovel Operation & Maintenance Manual – PDF DOWNLOAD

1 INTRODUCTION
PREFACE
About this Operation and Maintenance Manual Further machine documentation
WARRANTY
FUNDAMENTAL SAFETY INSTRUCTIONS
Wamings and symbols
DESIGNATED USE
Noise emission Information,
Vibration Information,
ORGANIZATIONAL MEASURES
Selection and qualification of personnel; basic responsibilities,
Safety Instructions governing specific operational phases
Special work in conjunction with utilization of the machine and maintenance and repairs as well as troubleshooting during work; disposal of parts and consumables
Waming of special dangers
Gas, dust, steam and smoke,
Hydraulic equipment
FIRE AND EXPLOSION HAZARD,
NOTES
2 OPERATION
OPERATION-SAFETY INSTRUCTIONS
Operation and Maintenance Manual, where to store it in the driver’s cab
FIRE AND EXPLOSION HAZARD
DESCRIPTION OF THE EXCAVATOR
Excavator layout
Undercamage.
Superstructure
Drive unit,
Hydraulic system
Control and Monitoring Platform (CAMP)
Board-Control-System (BCS)
Demand control/Zero-flow regulation
Automatic reset to idling,
Electrical system,
Signs,
Entering and leaving the machine, Safety Instructions
Access ladder lighting.
Swinging ladder,
Folding ladder (optional),
Emergency exit in driver’s cab and escape ladder
Switching the cab interior lighting on and off
Switching the maintenance lights on and off,
Emergency shut-off function
Putting the machine back into operation, reset of emergency shut off function
Battery Isolator switch, shutting off supply voltage
Starter Isolator switch, shutting off starter voltage,
Driver’s seat
Reducing operators exposure to vibrations,
Trainer’s/Instructor’s seat
Windscreen washer,
Operating hours meter
Fire extinguisher
Automatic fire-extinguishing system (optional)
Hamess (optional),
MONITORING, WARNING AND CONTROL ELEMENTS, Engine 1 (LH), control and monitoring_
Engine 2 (RH), control and monitoring
PUTTING THE MACHINE INTO OPERATION
Reducing the operator’s exposure to noise
Refueling
Back-up heating (option), filling in fuel
Service station (tankiift),
Emergency off switch
Switching the electrical system on and off
Engines, emergency shut-off
STARTING AND STOPPING THE ENGINES
Starting the engines
Starting the left-hand engine,
Starting the right-hand engine,
Engines-adjusting the speed
Starting the engines at low temperatures
Shutting off the engines
Shutting off the left-hand engine
Shutting off the right-hand engine
AIR CONDITIONER (OPTIONAL),
Back-up heating driver’s cab (optional),
Back-up heating (optional)
MAXIMUM MACHINE INCLINATIONS, INFORMATION,
TRAVELLING, SAFETY INSTRUCTIONS,
TRAVELLING
Superstructure basic position
Traveling forwards/backwards
Superstructure holding brake
Track parking brake
TRANSPORTING THE MACHINE
Transport-Safety Instructions
WORKING OPERATION-SAFETY INSTRUCTIONS
WORKING OPERATION
Before starting work
Activating the electronic excavator control
Swinging the superstructure
Braking the superstructure
Working.
Emergency lowering of the equipment
After daily operation
ASSEMBLING WORKING EQUIPMENT-SAFETY INSTRUCTIONS
Securing the machine
CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS),
ON-BOARD CRANE (OPTIONAL)___
On-board crane, monitoring, warning and control elements
On-board crane, putting into operation
On-board crane, drive unit
On-Board crane, -blocking the boom in position of rest On-board crane, checking,
NOTES
3 INSPECTION AND SERVICING
INSPECTION AND SERVICING-SAFETY INSTRUCTIONS
INSPECTION AND SERVICING WORK, FIRE AND EXPLOSION HAZARD
INSPECTION AND SERVICING PLANS – INSTRUCTIONS
Intervals
Change of engine oll
Air-intake system,
Olls/Greases
Cleaning jobs
Components
Plan V
Plan N
Plan T
Plan A-E
LUBRICATING CHART
Lubricating chart- Grease (legend)
Filing quanties-Grease
INSPECTION PLAN-OIL
Inspection plan – Oll (legend)
Filing quantities-oll
Filling quantities-other
LUBRICANTS/CONSUMABLES
Notes on the selection of oils and greases
Avold mixing of different hydraulic fulds
1. Olls for combustion engines and compressors
Olls for pump distribution gearboxes and travel gearboxes
Grease for bearings, slew rings and track system (Central lubrication system) Grease for idlers, track rollers and support rollers (Lifetime lubrication)__
Coolant for use on all combustion engines
SERVICING WORK
Hose line for ol and cooling liquid changes
ENGINE
Engine-Safety instructions
Checking the engine oil level/Topping up
Engine oil reservoir, checking the oil level Changing the engine oil
Engine oil reservoir, filing in/draining off the ol
Replacing the oil filter
Cold-starting fluid (ether) – Replacing the pressure vessel,
COOLING SYSTEM,
Temperature
Radiators
Cooling-liquid level check
Cooling liquid, change
Testing the cooling liquid composition,
AIR-INTAKE SYSTEM
Dust trap, cleaning
Main fer elements, Safety filter element Air-intake Ines
FUEL SYSTEM
Fuel system-Safety Instructions
Replacing the fuel filter
Venting the fuel system
Cleaning the fuel tanks Water trap (option)
ELECTRICAL SYSTEM,
Electrical system-Safety Instructions
Alterator-Instructions,
Electrical circuit diagrams
Electrical system switch-cabinets
Replacing lamps and bulbs,
Xenon floodlight projector, replacing the lamp
Lighting systems in LED technonogy, Instructions
Battery
Charging batteries Inside the machine, safety instructions Switchgear cabinet
HYDRAULIC SYSTEM,
Hydraulic system-Safety Instructions
Depressurizing the hydraulic system
Checking the hydraulic oil level
Changing the hydraulic oil retum-flow (hydraulic oil reservoir) Bypass valves (hydraulic oil reservoir)
Breather filter
Fiter (control circuit)
High-pressure filter for working hydraulics High-pressure filters for the servo circuit,
High-pressure fiters for feeding circuts and swing pumps
High-pressure fiters for swing circuit
Bearing flushing for main pumps, replace filter,
Changing the hydraulic oil
Avold mixing of different hydraulic fulds,
Venting the hydraulic system
Cleaning the hydraulic oil cooler
Electronic excavator controls
Pressure accumulator – Emergency lowering
PUMP TRANSFER GEARBOX
Checking the gearbox all level/Topping up with oll
Pre-chambers, checking oll level, topping up with oll Changing the gearbox oll
Pre-chambers, changing the gearbox oil,
Gearbox venting
Pre-chamber venting
Pump transfer gearbox lube oil filters
SWING GEARBOX
Swing Gearbox-Checking the oil level/Topping up with oll Changing the gearbox oll
Swing Gearbox venting.
TRAVEL GEARBOX (GEARBOX PIN 3683483)
Travel gearbox -Checking the oil level/Topping up with oil
Travel gearbox -Changing oll
Travel gearbox -Breather filter
TRAVEL GEARBOX (GEARBOX P/N 3683496)
Travel gearbox – Checking the oil level/Topping up with oil
Travel gearbox -Changing oll
Travel gearbox -Breather filter,
CRAWLER TRACKS
Track rollers
Track tensioner
Pressure-accumulator inspection regulations.
Checking the gas charging pressure in the pressure accumulator
SWING RING,
Swing ring-Instructions
Bearing races
CENTRAL LUBRICATING
Design
Function
Filing up the grease container Breather filter
Checking the greasing pressure
Unblocking a grease ine
Olifier (hydraulic circuit grease pump),
Grease filter (Filing the grease container)
Grease filter (Grease lines),
OTHER MAINTENANCE,
Engine
Reservoirs for used grease at the A-frame, emptying. Heating and air conditioning
Equipment
HYDRAULIC LADDER (OPTIONAL),
Pressure-accumulator inspection regulations
Extract from the German regulations
Checking the gas charging pressure in the pressure accumulator
ON-BOARD CRANE, DRIVE UNIT
On-board crane, lubricating
On-Board crane, checking tightness of fastening bolts
PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING
Putting the excavator out of operation
Battery storage
Recommissioning
NOTES,
4 REPAIR WORK
REPAIR WORK-SAFETY INSTRUCTIONS
CONFINED SPACES-SAFETY INSTRUCTIONS
REPAIR WORK, FIRE AND EXPLOSION HAZARD
REPAIR WORK, ENGINE
HYDRAULIC SYSTEM
Repair Instructions
Hydraulic hoses-instructions
PRESSURE ACCUMULATORS-SAFETY INSTRUCTIONS
WELDING AND FLAME CUTTING WORKS-SAFETY INSTRUCTIONS
DISPOSAL AT THE END OF THE SERVICE LIFE.
Dismantling and removal Instructions
Risk of deflagrations,
Risk of fre
Disposing of the machine without polluting the environment
Further hazardous substances
Appropriate disposal of batteries
NOTES
6 ANNEX
BOARD-CONTROL-SYSTEM
BCS III, what’s that?
The keys on the front side,
Other elements on the front side,
BCGI, the start screen,
Information given on the start screen, top section,
Information given on the start screen, central section,
Information given on the start screen, lower section,
Information given on the “Service” screen
Engine data screen.
Hydraulic data screen
Lubrication data screen,
Controls adjustment data screen
View documents screen
Signal table screen
Signal table screen, location,
Signal table screen, diagram,
Signal table screen, diagram configuration
Code table screen,
BCS III, Interfaces,
USB Interface, data storage
Saving data to a USB stick
Saving data to a USB stick, continued
Saving data to a USB stick, continued
BCGI, cleaning
BCO, disposal
TROUBLESHOOTING,
Instructions on troubleshooting
Layout of the fault table,
Possible causes
Measures
Section
FAULT TABLES,
Combustion engine-Fault table
Working hydraulics – Fault table
Track drive-Fault table
Swing mechnism-Fault table
Central lubricating system-Fault table
HYDRAULIC CIRCUIT DIAGRAM,
Vibration data
ABBREVIATIONS
ABBREVIATIONS
TECHNICAL DATA
NOTES,
6 INDEX

DESCRIPTION:

Cat 6060 6060FS Hydraulic shovel Operation & Maintenance Manual – PDF DOWNLOAD

PREFACE

• About this Operation and Mainte- nance Manual These Operation and Maintenance Manual are designed to familiarize the operator with the ma- chine and its designated use.
• The Operation and Maintenance Manual contain 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

• 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 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 HMB 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.

All CGM HMS GmbH Operation and Maintenance Manuals are issued in German and then trans- lated. Even a good translation may give rise to questions which CGM HMS GmbH will be pleased to answer. The Operation and Maintenance Manual are not work instructions for carrying out major repairs. Such work is willingly done for you by the CGM HMS GmbH after-sales service.

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