CAT 6060 AC 6060 ACFS Hydraulic Shovel Operation & Maintenance Manual EM028480-0 – PDF DOWNLOAD

Description

CAT 6060 AC 6060 ACFS Hydraulic Shovel Operation & Maintenance Manual EM028480-0 – PDF DOWNLOAD

FILE DETAILS:

CAT 6060 AC 6060 ACFS Hydraulic Shovel Operation & Maintenance Manual EM028480-0 – PDF DOWNLOAD

Language : English
Pages : 350
Downloadable : Yes
File Type : PDF

DESCRIPTION:

CAT 6060 AC 6060 ACFS Hydraulic Shovel Operation & Maintenance Manual EM028480-0 – PDF DOWNLOAD

DH360194

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 protection.
• 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 .

• 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 Maintenance Manual.
• The Operation and Maintenance Manual does not contain work instructions for carrying out
  major re- pairs. 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 AC 6060 ACFS Hydraulic Shovel Operation & Maintenance Manual EM028480-0 – PDF DOWNLOAD

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
PREFACE 1-3
About this Operation and Maintenance Manual 1-3
Further machine documentation 1-3
WARRANTY 1-4
FUNDAMENTAL SAFETY INSTRUCTIONS 1-5
Warnings and symbols 1-5
DESIGNATED USE 1-6
ORGANIZATIONAL MEASURES 1-7
Selection and qualification of personnel; basic responsibilities 1-8
Safety instructions governing specific operational phases 1-8
Special work in conjunction with utilization of the machine and maintenance and repairs as well as
troubleshooting during work; disposal of parts and consumables 1-9
Warning of special dangers 1-10
Gas, dust, steam and smoke 1-11
Hydraulic / pneumatc equipment 1-11
Noise 1-11
Oil, grease and other chemical substances 1-11
Transporting and recommissioning 1-11
ACCIDENT PREVENTION REGULATIONS FOR ELECTRICALLY POWERED HYDRAULIC SHOVELS1-12
Safety instructions for hydraulic shovels with electric motor 1-13
FIRE AND EXPLOSION HAZARD 1-14
NOTES 1-15
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
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Control and Monitoring Platform (CAMP) 2-8
Demand control / Zero-flow regulation 2-9
Automatic reset to idling 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 number 2-27
Motor number 2-27
Entering and leaving the machine – Safety instructions 2-28
Access ladder – Lighting 2-28
Swinging ladder – Function 2-29
Emergency exit in operator’s cab and escape ladder 2-30
Cab interior lighting – Switch on and off 2-31
Maintenance lights – Switch on and off 2-32
Emergency shut off – Function 2-33
Servicing switch – Function 2-34
Windscreen washer – Reservoir 2-34
Reducing operators exposure to vibrations 2-34
Trainer’s / instructor’s seat 2-34
Operator’s seat 2-35
Fire extinguisher 2-37
Automatic fire-extinguishing system 2-37
MONITORING, WARNING AND CONTROL ELEMENTS 2-38
PUTTING THE MACHINE INTO OPERATION 2-56
Electrical Storm Injury Prevention 2-56
Reducing the operator’s exposure to noise 2-56
Service station 2-56
Battery main switch – Switch on and off 2-59
Electrical system (24V) – Switch on and off 2-59
Electric motor – Switch on and off 2-60
Time-out before restart 2-61
Electric motor can not be switched on 2-62
In case of failure 2-62
Circuit breaker – Switch on and off 2-63
Motor protection relay – Function 2-64
Active-power transducer – Function 2-66
Warm-up procedure for electric driven shovel 2-67
Preheating system for hydraulic oil reservoir and pump gearbox, switching on and off 2-68
Air conditioner (optional) 2-69
Back-up heating operator’s cab (optional) 2-69
OPERATIONAL PRACTICES 2-70
Working operation – Safety instructions 2-70
Before starting work 2-71
Machine Operating Temperature Range 2-71
Warm-up procedure for electric driven shovel 2-72
Electronic hydraulic shovel control (pilot control) – activate 2-73
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Working operation – basics 2-74
OPERATION TECHNIQUES 2-80
Machine operation with backhoe attachment, Best Practices 80
Loading setups 2-84
Machine operation with face shovel attachment – Best Practices 2-90
Face Shovel Operation – Restricted Operation 2-104
TRAVELING 2-119
Traveling – Safety Instructions 2-119
Before starting traveling 2-120
Traveling – Basic Movements 2-122
Counter-rotation turns / Turning on the spot 2-125
Track Parking Brake – set/release 2-126
Traveling speed – adjust 2-126
Traveling uphill and downhill on ramps and steep slopes 2-127
Traveling over long distances 2-129
Traveling – Best Practices 2-131
Traveling – Restricted Operation 2-132
Maximum Machine Inclinations 2-135
TRANSPORTING THE MACHINE 2-136
Transport – Safety instructions 2-136
RUNNING-IN INSTRUCTIONS FOR HYDRAULIC CYLINDERS 2-137
EMERGENCY LOWERING OF THE WORKING EQUIPMENT 2-138
AFTER DAILY OPERATION 2-139
ASSEMBLING WORKING EQUIPMENT – SAFETY INSTRUCTIONS 2-140
Securing the machine 2-141
CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS) 2-142
ON-BOARD CRANE (OPTIONAL) 2-143
On-board crane, monitoring, warning and control elements 2-143
On-board crane, putting into operation 2-144
On-board crane, drive unit 2-144
On-Board crane, – blocking the boom in position of rest 2-145
On-board crane, checking 2-145
Monitoring cameras 2-146
NOTES 2-148
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
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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, option) 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
Cleaning the electric motor 3-37
Electric motor, greasing 3-38
ELECTRICAL SYSTEM 3-39
Electrical system – Safety instructions 3-39
Battery, checking state of charge 3-40
Electrical system, control cabinets 3-42
Slip ring assembly, servicing work 3-44
Electrical circuit diagrams 3-44
Replacing fuses 3-44
Replacing lamps and bulbs 3-44
Xenon floodlight projector (if equipped), replacing the lamp 3-45
Lighting systems in LED technonogy, instructions 3-47
HYDRAULIC SYSTEM 3-48
Hydraulic system – Safety instructions 3-48
Depressurizing the hydraulic system 3-48
Checking the hydraulic oil level 3-49
Hydraulic oil return-flow filters, replace 3-51
Hydraulic oil return-flow filters, replace (from machine no. 340169) 3-53
Bypass valves, clean / replace 3-55
Hydraulic oil tank breather filters, replace 3-56
Filter (servo control circuit), replace 3-57
High-pressure filter for working hydraulics, replace 3-58
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Filters for swing charge pump, replace 3-59
Changing the hydraulic oil 3-60
Avoid mixing of different hydraulic fluids 3-60
Venting the hydraulic system 3-64
Cleaning the hydraulic oil cooler 3-65
Electronic hydraulic shovel control 3-66
Pressure accumulator – Emergency lowering 3-67
PUMP DRIVE GEARBOX 3-68
Pump drive gearbox, checking oil level / Topping up with oil 3-68
Pump drive gearbox, changing oil 3-70
Pump drive gearbox, pre-chamber 3-71
Pump drive gearbox, venting 3-71
Pre-chambers working pumps, draining oil, changing oil 3-72
Pre-chambers swing pumps, draining oil, changing oil 3-72
Pump gearbox, oil filter 3-73
SWING GEARBOX 3-74
Swing gearbox – Checking the oil level / Topping up with oil 3-74
Changing the gearbox oil 3-74
Swing gearbox, venting 3-75
TRAVEL GEARBOX (GEARBOX P/N 3683483) 3-76
Travel gearbox – Checking the oil level / Topping up with oil 3-76
Travel gearbox – Changing oil 3-77
Travel gearbox – Breather filter 3-78
TRAVEL GEARBOX (GEARBOX P/N 3683496) 3-79
Travel gearbox – Checking the oil level / Topping up with oil 3-79
Travel gearbox – Changing oil 3-81
Travel gearbox -Breather filter 3-82
TRAVEL GEARBOX (GEARBOX P/N 3749598) 3-83
Travel gearbox – Checking the oil level / Topping up with oil 3-83
Travel gearbox – Changing oil 3-85
Travel gearbox – Breather filter 3-86
CRAWLER TRACKS 3-87
Track rollers 3-88
Track tensioner 3-89
Pressure-accumulator inspection regulations 3-90
Checking the gas charging pressure in the pressure accumulator 3-90
SWING RING 3-91
Swing ring – Instructions 3-91
Bearing races 3-91
CENTRAL LUBRICATING SYSTEM 3-93
Design and function 3-93
Function 3-94
Filling up the lubricant container 3-95
Breather filter 3-95
Checking the greasing pressure 3-96
Checking the greasing pressure 3-97
Unblocking a lubricating line 3-98
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Unblocking a lubricant line 3-98
Oilfilter (hydraulic circuit lubricant pump) ) 3-99
Lubricant filter (Filling the lubricant container) 3-100
Lubricant filter (Lubricating lines) 3-101
OTHER MAINTENANCE 3-102
Heating and air conditioning 3-102
Attachment – Check for cracks 3-102
Reservoirs for used lubricant at the A-frame – Empty 3-103
Hydraulic ladder – Pressure accumulator 3-103
Pressure-accumulator inspection regulations 3-104
Extract from the regulations 3-104
Checking the gas charging pressure in the pressure accumulator 3-104
ON-BOARD CRANE – DRIVE UNIT 3-105
On-board crane – Lubricate 3-106
On-Board crane – Check tightness of fastening bolts 3-106
PUTTING THE HYDRAULIC SHOVEL OUT OF OPERATION AND RECOMMISSIONING 3-107
Putting the hydraulic shovel out of operation 3-107
Battery storage 3-107
Recommissioning 3-107
NOTES 3-108
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
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
BCS IV, 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
Sitemap of available screens 5-5
Sitemap of available screens, continued 5-6
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BCS IV, the start screen 5-7
Often used symbols and graphical buttons 5-8
Information given on the start screen, top section 5-9
Information given on the start screen, central section 5-10
Information given on the start screen, lower section 5-11
Information given on the “System Status” screen 5-12
Electric motor data screen (Service – Motor) 5-13
Hydraulic data screen (Service – Hydraulics I) 5-14
Lubrication data screen (Service – Lubrication Lincoln) 5-15
Controls adjustment data screen (Service – Servosystem) 5-16
More details data screen (Service – Servosystem) 5-17
Slew brake test data screen 5-18
Help / view documents screen 5-19
Software versions screen 5-20
Signal table screen 5-21
BCS IV, interfaces 5-22
USB interface, data storage 5-22
Saving data as a screenshot 5-23
BCS IV, cleaning 5-24
BCS IV, 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
Working hydraulics – Fault table 5-26
Track drive – Fault table 5-27
Swing mechnism – Fault table 5-28
Central lubricating system – Fault table 5-29
HYDRAULIC CIRCUIT DIAGRAM 5-30
ABBREVIATIONS 5-31
NOISE AND VIBRATION INFORMATION 5-33
Noise emission information 5-33
Vibration information 5-33
PRODUCT SPECIFICATION SHEET 5-34
NOTES 5-36
6 INDEX 6-1

Customer Support: [email protected]

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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