Cat 6060 AC 6060 AC FS Hydraulic Shovel Operation and Maintenance Manual EM029999 – PDF DOWNLOAD

Description

Cat 6060 AC, 6060 AC FS Hydraulic Shovel Operation and Maintenance Manual EM029999 – PDF DOWNLOAD

FILE DETAILS:

Cat 6060 AC 6060 AC FS Hydraulic Shovel Operation and Maintenance Manual EM029999 – PDF DOWNLOAD

Language : English
Pages : 362
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Cat 6060 AC 6060 AC FS Hydraulic Shovel Operation and Maintenance Manual EM029999 – PDF DOWNLOAD

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Cat 6060 AC 6060 AC FS Hydraulic Shovel Operation and Maintenance Manual EM029999 – PDF DOWNLOAD

TABLE OF CONTENTS
1 INTRODUCTION 1-1
ALL PRODUCTS FOREWORD _ 1-2
Literature Information 1-2
Safety 1-2
Operation 1-2
Product Information 1-2
Maintenance __ 1-2
Maintenance Intervals 1-2
Product Capacity __ 1-2
CALIFORNIA PROPOSITION 65 WARNING 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
Sound Level Information for Machines in Eurasian Economic Union Countries 1-6
Visibility Information _ 1-6
Restricted Visibility 1-7
DESIGNATED USE _ 1-8
Useful Life 1-8
ORGANIZATIONAL MEASURES 1-9
Restricted Visibility 1-9
Selection and qualification of personnel; basic responsibilities 1-10
Safety instructions governing specific operational phases __ 1-10
Special work in conjunction with utilization of the machine and maintenance and repairs as well as
troubleshooting during work; disposal of parts and consumables _ 1-11
Warning of special dangers 1-12
Gas, dust, steam and smoke _ 1-13
Hydraulic equipment 1-13
Noise 1-13
Oil, grease and other chemical substances _ 1-13
Transporting and recommissioning _____ 1-13
ACCIDENT PREVENTION REGULATIONS FOR ELECTRICALLY POWERED HYDRAULIC SHOVELS1-14
Safety instructions for hydraulic shovels with electric motor 1-15
FIRE AND EXPLOSION HAZARD 1-16
NOTES 1-17
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
Demand control / Zero-flow regulation ____ 2-9
Board-Control-System (BCS) 2-9
Electrical system __ 2-9
Power supply 2-10
Operation with cable reel (if equipped) ___ 2-11
Safety films and warning messages – Overview and Description _ 2-12
Safety messages (ANSI) – Description __ 2-20
Additional messages (ANSI) – Description _ 2-24
Machine identification plate 2-27
Motor number plate 2-27
Eurasian Economic Union _ 2-28
CE-Plate, European Union _ 2-28
Entering and leaving the machine – Safety instructions _ 2-29
Access ladder – Lighting 2-29
Swinging ladder – Function _ 2-30
Emergency exit in operator’s cab and escape ladder __ 2-31
Cab interior lighting – Switch on and off __ 2-32
Maintenance lights – Switch on and off __ 2-33
Emergency shut off – Function 2-34
Servicing switch – Function 2-35
Windscreen washer – Reservoir 2-35
Reducing operators exposure to vibrations _ 2-35
Trainer’s / instructor’s seat _ 2-35
Operator’s seat __ 2-36
Fire extinguisher _ 2-38
Automatic fire-extinguishing system _____ 2-38
MONITORING, WARNING AND CONTROL ELEMENTS 2-40
PUTTING THE MACHINE INTO OPERATION 2-58
Electrical Storm Injury Prevention 2-58
Reducing the operator’s exposure to noise _ 2-58
Service station __ 2-58
Battery main switch – Switch on and off __ 2-61
Electrical system (24V) – Switch on and off _ 2-61
Electric motor – Switch on and off 2-62
Time-out before restart _ 2-63
Electric motor can not be switched on ___ 2-64
Circuit breaker – Switch on and off 2-65
Motor protection relay – Function 2-66
Active-power transducer – Function _____ 2-68
Preheating system for hydraulic oil reservoir and pump gearbox, switching on and off (if equipped) 2-69
Air conditioner (if equipped) 2-70
Back-up heating operator’s cab (if equipped) 2-70
OMM 6060AC, 6060ACFS(3 847 043 00)-EN
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TABLE OF CONTENTS
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OPERATIONAL PRACTICES 2-71
Working operation – Safety instructions __ 2-71
Before starting work 2-72
Machine Operating Temperature Range _ 2-72
Warm-up procedure for electric driven shovel __ 2-73
Electronic hydraulic shovel control (pilot control) – activate _ 2-74
Working operation – basics 2-75
OPERATION TECHNIQUES _ 2-81
Machine operation with backhoe attachment, Best Practices _ 81
Loading setups __ 2-85
Machine operation with face shovel attachment – Best Practices _ 2-91
Face Shovel Operation – Restricted Operation 2-105
TRAVELING _ 2-120
Traveling – Safety Instructions _ 2-120
Before starting traveling __ 2-122
Traveling – Basic Movements _ 2-124
Counter-rotation turns / Turning on the spot 2-127
Track Parking Brake – set/release _____ 2-128
Traveling speed – adjust __ 2-128
Traveling uphill and downhill on ramps and steep slopes _ 2-129
Traveling over long distances 2-131
Traveling – Best Practices 2-133
Traveling – Restricted Operation 2-134
Maximum Machine Inclinations 2-137
TRANSPORTING THE MACHINE 2-138
Transport – Safety instructions _ 2-138
RUNNING-IN INSTRUCTIONS FOR HYDRAULIC CYLINDERS _ 2-139
EMERGENCY LOWERING OF THE WORKING EQUIPMENT 2-140
AFTER DAILY OPERATION 2-141
ASSEMBLING WORKING EQUIPMENT – SAFETY INSTRUCTIONS _ 2-142
Securing the machine _ 2-143
CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS) 2-144
ON-BOARD CRANE (IF EQUIPPED) ____ 2-145
On-board crane, monitoring, warning and control elements _ 2-145
On-board crane, putting into operation __ 2-146
On-board crane, drive unit 2-146
On-Board crane, – blocking the boom in position of rest __ 2-147
On-board crane, checking 2-147
Monitoring cameras (if equipped) 2-148
NOTES _ 2-149
3 INSPECTION AND SERVICING _ 3-1
SAFETY INSTRUCTIONS FOR HYDRAULIC SHOVELS WITH ELECTRIC MOTOR __ 3-3
INSPECTION AND SERVICING – SAFETY INSTRUCTIONS _ 3-4
FIRE AND EXPLOSION HAZARD _ 3-8
INSPECTION AND SERVICING PLANS – INSTRUCTIONS __ 3-9
Servicing Intervals 3-9
Oils / Lubricants __ 3-9
Cleaning jobs _ 3-9
Components __ 3-9
Plan V 3-11
Plan N 3-13
Plan T and W 3-15
Plan A – E ___ 3-17
LUBRICATING CHART – LUBRICANT ___ 3-24
Lubricating chart – Lubricant (legend) ___ 3-25
Filling quantities – Lubricant 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 lubricants 3-29
LUBRICANTS / CONSUMABLES _ 3-30
I Oil for combustion engines (On-Board Crane, if equipped) 3-30
II Oil for hydraulic system (selection) _ 3-31
III a Oil for pump gearboxes and travel gearboxes ___ 3-32
III b Oil for swing gearboxes 3-33
V Lubricant for bearings, swing rings and track system (Central lubrication system) 3-34
Lubricants for idlers, track rollers and upper rollers (Lifetime lubrication) __ 3-35
SERVICING WORK _ 3-36
Hose line for oil changes __ 3-36
ELECTRIC MOTOR _ 3-37
Electric motor – Safety instructions 3-37
Electric motor – Clean _ 3-37
Electric motor (SIEMENS) – Lubricate ___ 3-38
Electric motor (ABB) – Initial Lubrication of Motor Bearings _ 3-39
Electric motor (ABB) – Lubrication at Regular Intervals _ 3-40
ELECTRICAL SYSTEM _ 3-41
Electrical system – Safety instructions ___ 3-41
Battery, checking state of charge 3-42
Electrical system, control cabinets 3-44
Slip ring assembly, servicing work 3-46
Electrical circuit diagrams __ 3-46
OMM 6060AC, 6060ACFS(3 847 043 00)-EN
EM029999-01
TABLE OF CONTENTS
ix
Replacing fuses _ 3-46
Replacing lamps and bulbs 3-46
Xenon floodlight projector (if equipped), replacing the lamp 3-47
Lighting systems in LED technonogy, instructions _ 3-49
HYDRAULIC SYSTEM 3-50
Hydraulic system – Safety instructions ___ 3-50
Depressurizing the hydraulic system ____ 3-50
Checking the hydraulic oil level _ 3-51
Hydraulic oil return-flow filters, replace __ 3-53
Hydraulic oil return-flow filters, replace (from machine no 340169) ___ 3-55
Bypass valves, clean / replace 3-57
Hydraulic oil tank breather filters, replace 3-58
Filter (servo control circuit), replace _____ 3-59
High-pressure filter for working hydraulics, replace 3-60
Filters for swing charge pump, replace __ 3-61
Changing the hydraulic oil _ 3-62
Avoid mixing of different hydraulic fluids _ 3-62
Venting the hydraulic system _ 3-66
Cleaning the hydraulic oil cooler 3-67
Electronic hydraulic shovel control 3-68
Pressure accumulator – Emergency lowering 3-69
PUMP DRIVE GEARBOX 3-70
Pump drive gearbox, checking oil level / Topping up with oil 3-70
Pump drive gearbox, changing oil 3-72
Pump drive gearbox, pre-chamber 3-73
Pump drive gearbox, venting _ 3-73
Pre-chambers working pumps, draining oil, changing oil 3-74
Pre-chambers swing pumps, draining oil, changing oil _ 3-74
Pump gearbox, oil filter _ 3-75
SWING GEARBOX 3-76
Swing gearbox – Checking the oil level / Topping up with oil 3-76
Changing the gearbox oil __ 3-76
Swing gearbox, venting 3-77
TRAVEL GEARBOX (GEARBOX P/N 3683483) _ 3-78
Travel gearbox – Checking the oil level / Topping up with oil 3-78
Travel gearbox – Changing oil 3-79
Travel gearbox – Breather filter 3-80
TRAVEL GEARBOX (GEARBOX P/N 3683496) _ 3-81
Travel gearbox – Checking the oil level / Topping up with oil 3-81
Travel gearbox – Changing oil 3-83
Travel gearbox -Breather filter 3-84
TRAVEL GEARBOX (GEARBOX P/N 3749598) _ 3-85
Travel gearbox – Checking the oil level / Topping up with oil 3-85
Travel gearbox – Changing oil 3-87
Travel gearbox – Breather filter 3-88
CRAWLER TRACKS _ 3-89
Track rollers _ 3-90
Track tensioner __ 3-91
Pressure-accumulator inspection regulations 3-92
Checking the gas charging pressure in the pressure accumulator 3-92
SWING RING __ 3-93
Swing ring – Instructions 3-93
Bearing races 3-93
CENTRAL LUBRICATING SYSTEM _____ 3-95
Design and function 3-95
Function 3-96
Filling up the lubricant container _ 3-97
Breather filter 3-97
Checking the greasing pressure _ 3-98
Checking the greasing pressure _ 3-99
Unblocking a lubricating line _ 3-100
Unblocking a lubricant line 3-100
Oilfilter (hydraulic circuit lubricant pump) ) _ 3-101
Lubricant filter (Filling the lubricant container) _ 3-102
Lubricant filter (Lubricating lines) 3-103
OTHER MAINTENANCE 3-104
Heating and air conditioning _ 3-104
Attachment – Check for cracks _ 3-104
Reservoirs for used lubricant at the A-frame – Empty _ 3-105
Hydraulic ladder – Pressure accumulator 3-105
Pressure-accumulator inspection regulations__ 3-106
Extract from the regulations _ 3-106
Checking the gas charging pressure in the pressure accumulator ___ 3-106
ON-BOARD CRANE – DRIVE UNIT _____ 3-107
On-board crane – Lubricate _ 3-108
On-Board crane – Check tightness of fastening bolts __ 3-108
PUTTING THE HYDRAULIC SHOVEL OUT OF OPERATION AND RECOMMISSIONING 3-109
Putting the hydraulic shovel out of operation __ 3-109
Battery storage _ 3-109
Recommissioning _ 3-109
NOTES _ 3-110
4 REPAIR WORK _ 4-1
SAFETY INSTRUCTIONS FOR HYDRAULIC SHOVELS WITH ELECTRIC MOTOR __ 4-3
REPAIR WORK – SAFETY INSTRUCTIONS 4-4
FIRE AND EXPLOSION HAZARD _ 4-5
HYDRAULIC SYSTEM 4-6
Repair 4-6
Hydraulic hoses – Instructions _ 4-6
OMM 6060AC, 6060ACFS(3 847 043 00)-EN
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TABLE OF CONTENTS
xi
PRESSURE ACCUMULATORS – SAFETY INSTRUCTIONS _ 4-7
WELDING AND FLAME CUTTING WORKS – SAFETY INSTRUCTIONS _ 4-8
DISPOSAL AT THE END OF THE SERVICE LIFE _ 4-11
Appropriate disposal of batteries 4-12
NOTES 4-13
5 ANNEX 5-1
BOARD-CONTROL-SYSTEM _ 5-3
BCS3e, what’s that? _ 5-3
What it is _ 5-3
What it does __ 5-3
Benefits for the operator _ 5-3
Want more information? _ 5-3
The keys on the front side __ 5-4
Other Elements on the Front Side 5-4
BCS3e, 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
Information Given on the “Service” Screen – continued 5-12
Electric Motor Data Screen _ 5-13
Electric Motor Data Screen – continued __ 5-14
Hydraulic Data Screen _ 5-15
Lubrication Data Screen 5-16
Controls Adjustment Data Screen 5-17
Slew Brake Test Data Screen 5-18
Signal Table Screen 5-19
Signal Table Screen – Diagram _ 5-20
Signal Table Screen – Diagram Configuration __ 5-21
Fault Storage / Fault Table – Screen ____ 5-22
Fault Storage – Save to USB-Stick _____ 5-23
Fault Storage – Fault Detail 5-24
BCS files – Copy to USB-Stick 5-25
BCS3e – Interfaces _ 5-26
USB Interface – Data Storage _ 5-26
Store Screenshot Screen __ 5-27
BCS3e – Cleaning 5-28
BCS3e – Disposal 5-28
TROUBLESHOOTING 5-29
Instructions on troubleshooting _ 5-29
Layout of the fault table 5-29
Possible causes _ 5-29
Measures ___ 5-29
Section _ 5-29
FAULT TABLES __ 5-30
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
ABBREVIATIONS _ 5-35
NOISE AND VIBRATION INFORMATION _ 5-37
Noise emission information _ 5-37
Vibration information 5-37
PRODUCT SPECIFICATION SHEET _____ 5-38
NOTES 5-40
6 INDEX _ 6-1

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