Caterpillar Bucyrus 6060 Hydraulic Excavator INSTRUCTIONS MANUAL BI651391 – PDF DOWNLOAD

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Caterpillar Bucyrus 6060 Hydraulic Excavator INSTRUCTIONS MANUAL BI651391 – PDF DOWNLOAD

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Caterpillar Bucyrus 6060 Hydraulic Excavator INSTRUCTIONS MANUAL BI651391 – PDF DOWNLOAD

Language : English
Pages : 266
Downloadable : Yes
File Type : PDF

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Caterpillar Bucyrus 6060 Hydraulic Excavator INSTRUCTIONS MANUAL BI651391 – PDF DOWNLOAD

1. INTRODUCTION
1.1 Foreword

• These operating instructions are designed to familiarize the operator with the machine and its designated use. The operating instructions 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 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 available 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

• In addition to the operating instructions 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 1 The operating instructions are directed to the construction- machine specialist. They cannot provide basic know-how.
• This can be acquired, for example, in several days’ instruction by a qualified mechanic or by attending an Terex|O&K training course for operators or maintenance 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 translation may give rise to questions which Terex|O&K will be pleased to answer. The operating instructions are not work instructions for carrying out major repairs. Such work is willingly done for you by the Terex|O&K aftersales 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 covering 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.

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TABLE OF CONTENTS:

Caterpillar Bucyrus 6060 Hydraulic Excavator INSTRUCTIONS MANUAL BI651391 – PDF DOWNLOAD

TITLEPAGE.....................................................................................................................................................................  1
1 INTRODUCTION................................................................................................................................................................ 11
	PREFACE .................................................................................................................................................................. 13
	WARRANTY ................................................................................................................................................................. 14
	FUNDAMENTAL SAFETY INSTRUCTIONS........................................................................................................................................... 15
		Warnings and symbols.................................................................................................................................................. 15
	DESIGNATED USE............................................................................................................................................................ 16
	ORGANIZATIONAL MEASURES .................................................................................................................................................. 17
		Selection and qualification of personnel; basic responsibilities...................................................................................................... 18
		Safety instructions governing specific operational phases............................................................................................................. 18
		Special work in conjunction with utilization of the machine and maintenance and repairs as well as troubleshooting during work; disposal of parts and consumables .... 19
		Warning of special dangers ........................................................................................................................................... 20
		Gas, dust, steam and smoke ........................................................................................................................................... 21
		Hydraulic / pneumatc equipment ....................................................................................................................................... 21
		Noise ................................................................................................................................................................ 21
		Oil, grease and other chemical substances ............................................................................................................................ 21
		Transporting and recommissioning ..................................................................................................................................... 21
	ACCIDENT PREVENTION REGULATIONS FOR ELECTRICALLY POWERED EXCAVATORS ...................................................................................................... 22
		Safety instructions for excavators with electric motor ............................................................................................................... 23
	FIRE AND EXPLOSION HAZARD ................................................................................................................................................ 24
	NOTES .................................................................................................................................................................... 25
2 OPERATION................................................................................................................................................................... 27
	OPERATION - SAFETY INSTRUCTIONS........................................................................................................................................... 29
		Operating Instructions, where to store it in the driver’s cab ........................................................................................................ 30
	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
		Control Management System (CMS) ...................................................................................................................................... 34
		Demand control / Zero-flow regulation ................................................................................................................................ 35
		Board-Control-System (BCS) ........................................................................................................................................... 35
		Electrical system .................................................................................................................................................... 35
		Power supply ......................................................................................................................................................... 36
		Operation with cable reel (optional) ................................................................................................................................. 37
		Signs ................................................................................................................................................................ 38
		Entering and leaving the machine Safety instructions ................................................................................................................. 47
		Ramp-type ladder ..................................................................................................................................................... 48
		Swinging ladder (optional) ........................................................................................................................................... 49
		Escape ladder ........................................................................................................................................................ 50
		Cab interior lamp .................................................................................................................................................... 51
		Servicing lighting ................................................................................................................................................... 52
		Illuminating the control column ...................................................................................................................................... 52
		EMERGENCY STOP switch ................................................................................................................................................ 53
		Servicing switch ..................................................................................................................................................... 54
		Windscreen washer .................................................................................................................................................... 54
		Driver's seat  ....................................................................................................................................................... 55
		Fire extinguisher .................................................................................................................................................... 57
		Automatic fire-extinguishing system (optional) ....................................................................................................................... 58
		Trainer's / instructor's seat ........................................................................................................................................ 58
		Emergency escape device (optional) ................................................................................................................................... 59
	MONITORING, WARNING AND CONTROL ELEMENTS ................................................................................................................................. 62
	PUTTING THE MACHINE INTO OPERATION ....................................................................................................................................... 84
		Service station (tanklift) ........................................................................................................................................... 84
		Battery main switch, switching on and off ............................................................................................................................ 87
		Electrical system (24V), switching on and off ........................................................................................................................ 87
		Switching the electric motor on and off .............................................................................................................................. 88
		Time-out before restart .............................................................................................................................................. 89
		Electric motor can not be switched on ................................................................................................................................ 90
		In case of failure ................................................................................................................................................... 90
		Circuit breaker, switching on and off ................................................................................................................................ 91
		Motor protection relay, functions .................................................................................................................................... 93
		Warm-up procedure for electric excavators ............................................................................................................................ 95
		Air conditioner (option) ............................................................................................................................................. 96
	TRAVELLING, SAFETY INSTRUCTIONS .......................................................................................................................................... 97
	TRAVELLING ............................................................................................................................................................... 98
		Superstructure basic position ........................................................................................................................................ 98
		Travelling forwards/backwards ........................................................................................................................................ 98
		Superstructure holding brake .........................................................................................................................................102
		Track parking brake ..................................................................................................................................................102
	TRANSPORTING THE MACHINE .................................................................................................................................................103
		Transport - Safety instructions ......................................................................................................................................103
	WORKING OPERATION - SAFETY INSTRUCTIONS ..................................................................................................................................104
	WORKING OPERATION ........................................................................................................................................................106
		Before starting work .................................................................................................................................................106
		Swinging the superstructure ..........................................................................................................................................106
		Braking the superstructure ...........................................................................................................................................106
		Working ..............................................................................................................................................................107
		Emergency lowering of the working equipment ..........................................................................................................................108
		 After daily operation ...............................................................................................................................................108
	ASSEMBLING WORKING EQUIPMENT - SAFETY INSTRUCTIONS .......................................................................................................................109
		Securing the machine .................................................................................................................................................110
	CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS) ...........................................................................................................111
	NOTES  ...................................................................................................................................................................113
3 INSPECTION AND SERVICING....................................................................................................................................................115
	SAFETY INSTRUCTIONS FOR EXCAVATORS WITH ELECTRIC MOTOR ...................................................................................................................117
	INSPECTION AND SERVICING - SAFETY INSTRUCTIONS ...........................................................................................................................119
	FIRE AND EXPLOSION HAZARD ................................................................................................................................................123
	INSPECTION AND SERVICING PLANS - INSTRUCTIONS ............................................................................................................................125
		Intervals.............................................................................................................................................................125
		Oils / Greases .......................................................................................................................................................125
		Cleaning jobs ........................................................................................................................................................125
		Components ...........................................................................................................................................................125
		Plan V ...............................................................................................................................................................127
		Plan N ...............................................................................................................................................................129
		Plan T and W .........................................................................................................................................................131
		Plan A – E ...........................................................................................................................................................133
	LUBRICATING CHART – GREASE ...............................................................................................................................................140
		Lubricating chart – Grease (legend) ..................................................................................................................................140
		Filling quantities – Grease ..........................................................................................................................................141
	INSPECTION PLAN - OIL ....................................................................................................................................................142
		Inspection plan – Oil (legend) .......................................................................................................................................143
		Filling quantities - oil .............................................................................................................................................144
		Filling quantities - other............................................................................................................................................144
	LUBRICANTS ...............................................................................................................................................................145
		Notes on the selection of oils and greases ...........................................................................................................................145
		Avoid mixing of different hydraulic fluids ...........................................................................................................................145
	LUBRICANTS ...............................................................................................................................................................146
		I. Oils for combustion engines (On-Board Crane, option) ..............................................................................................................146
		II. Oils for hydraulic system (selection) ............................................................................................................................147
		III.a Oils for pump gearboxes ........................................................................................................................................148
		III.b Oils for swing gearboxes .......................................................................................................................................149
		III.c Oils for drive gearboxes .......................................................................................................................................150
		V. Greases for bearings and swing rings ..............................................................................................................................151
	SERVICING WORK ...........................................................................................................................................................152
		Hose line for oil changes ............................................................................................................................................152
	ELECTRIC MOTOR ...........................................................................................................................................................153
		Electric motor - Safety instructions .................................................................................................................................153
		Cleaning the electric motor  .........................................................................................................................................153
		Electric motor, greasing .............................................................................................................................................154
	ELECTRICAL SYSTEM  .......................................................................................................................................................155
		Electrical system - Safety instructions ..............................................................................................................................155
		Battery ..............................................................................................................................................................156
		Control cabinets .....................................................................................................................................................158
		Slip ring assembly, servicing work ...................................................................................................................................160
		Floodlight projector, replacing the lamp .............................................................................................................................161
		Lighting systems in LED technonogy, instructions .....................................................................................................................163
	HYDRAULIC SYSTEM .........................................................................................................................................................164
		Hydraulic system - Safety instructions ...............................................................................................................................164
		Depressurizing the hydraulic system ..................................................................................................................................164
		Checking the hydraulic oil level .....................................................................................................................................165
		Changing the hydraulic oil return-flow filter (hydraulic oil reservoir) ..............................................................................................167
		Bypass valves (hydraulic oil reservoir) ..............................................................................................................................169
		Breather filter ......................................................................................................................................................170
		Filter (servo control circuit), replace ..............................................................................................................................171
		High-pressure filter for working hydraulics, replace .................................................................................................................172
		Filters for swing charge pump, replace ...............................................................................................................................173
		Bearing flushing of the main pumps, filter replacement Bearing flushing of the main pumps, filter replacement.........................................................174
		Changing the hydraulic oil ...........................................................................................................................................175
		Venting the hydraulic system..........................................................................................................................................179
		Cleaning the hydraulic oil cooler.....................................................................................................................................180
		Electronic excavator control..........................................................................................................................................181
		Pressure accumulator - Emergency lowering.............................................................................................................................182
	PUMP TRANSFER GEARBOX ....................................................................................................................................................183
		Pump gearbox, checking oil level / Topping up with oil ...............................................................................................................183
		Pump gearbox, pre-chamber ............................................................................................................................................185
		Pump gearbox, venting ................................................................................................................................................185
		Pre-chambers working pumps, draining oil, changing oil ...............................................................................................................186
		Pre-chambers swing pumps, draining oil, changing oil .................................................................................................................186
		Pump gearbox, oil filter .............................................................................................................................................187
	SWING GEARBOX ............................................................................................................................................................188
		Swing gearbox - Checking the oil level / Topping up with oil .........................................................................................................188
		Changing the gearbox oil .............................................................................................................................................188
		Swing gearbox, venting ,..............................................................................................................................................189
	TRAVEL GEARBOX (GEARBOX P/N 3683483)  ....................................................................................................................................190
		Travel gearbox - Checking the oil level / Topping up with oil ........................................................................................................190
		Travel gearbox - Changing oil ........................................................................................................................................191
		Travel gearbox - Breather filter .....................................................................................................................................192
	TRAVEL GEARBOX(GEARBOX P/N 3683496)  .....................................................................................................................................193
		Travel gearbox - Checking the oil level / Topping up with oil ........................................................................................................193
		Travel gearbox - Changing oil ........................................................................................................................................195
		Travel gearbox -Breather filter ......................................................................................................................................196
	CRAWLER TRACKS ...........................................................................................................................................................197
		Track rollers ........................................................................................................................................................198
		Track tensioner ......................................................................................................................................................199
		Pressure-accumulator inspection regulations ..........................................................................................................................200
		Checking the gas charging pressure in the pressure accumulator........................................................................................................200
	SWING RING ...............................................................................................................................................................201
		Swing ring - Instructions.............................................................................................................................................201
		Bearing races.........................................................................................................................................................201
	CENTRAL LUBRICATING ......................................................................................................................................................203
		Design and function ..................................................................................................................................................203
		Function .............................................................................................................................................................204
		Filling up the grease container ......................................................................................................................................205
		Breather filter ......................................................................................................................................................205
		Checking the greasing pressure .......................................................................................................................................206
		Checking the greasing pressure .......................................................................................................................................207
		Unblocking a grease line..............................................................................................................................................208
		Unblocking a grease line..............................................................................................................................................208
		Oilfilter (hydraulic circuit grease pump) )...........................................................................................................................209
		Grease filter (Filling the grease container) .........................................................................................................................210
		Grease filter (Grease lines) .........................................................................................................................................211
	OTHER MAINTENANCE ........................................................................................................................................................212
		Heating and air conditioning .........................................................................................................................................212
		Equipment, check for cracks ..........................................................................................................................................212
		Reservoirs for used grease at the A-frame, emptying ..................................................................................................................213
		Hydraulic ladder, pressure accumulator ...............................................................................................................................213
		Pressure-accumulator inspection regulations ..........................................................................................................................214
		Extract from the regulations..........................................................................................................................................214
		Checking the gas charging pressure in the pressure accumulator........................................................................................................214
	ON-BOARD CRANE (OPTIONAL) ................................................................................................................................................215
		Crane, monitoring, warning and control elements ......................................................................................................................215
		Checking the on-board crane...........................................................................................................................................215
		Crane, drive unit ....................................................................................................................................................216
		On-board crane, servicing ............................................................................................................................................216
		On-Board crane, checking tightness of fastening bolts ................................................................................................................217
	PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING ...............................................................................................................218
		Putting the excavator out of operation................................................................................................................................218
		Battery storage.......................................................................................................................................................218
		Recommissioning.......................................................................................................................................................218
	NOTES ....................................................................................................................................................................219
4 REPAIR WORK.................................................................................................................................................................221
	SAFETY INSTRUCTIONS FOR EXCAVATORS WITH ELECTRIC MOTOR ...................................................................................................................223
	REPAIR WORK - SAFETY INSTRUCTIONS.........................................................................................................................................225
	FIRE AND EXPLOSION HAZARD ................................................................................................................................................227
	HYDRAULIC SYSTEM..........................................................................................................................................................228
		Repair ...............................................................................................................................................................228
		Hydraulic hoses – Instructions  ......................................................................................................................................228
	PRESSURE ACCUMULATORS - SAFETY INSTRUCTIONS...............................................................................................................................229
	WELDING AND FLAME CUTTING WORKS - SAFETY INSTRUCTIONS ....................................................................................................................230
	DISPOSAL AT THE END OF THE SERVICE LIFE ..................................................................................................................................233
		Appropriate disposal of batteries ....................................................................................................................................234
	NOTES ....................................................................................................................................................................235
5 ANNEX.......................................................................................................................................................................237
	TROUBLESHOOTING ..........................................................................................................................................................239
		Instructions on troubleshooting ......................................................................................................................................239
		Layout of the fault table ............................................................................................................................................239
		Possible causes ......................................................................................................................................................239
		Measures .............................................................................................................................................................239
		Section ..............................................................................................................................................................239
	FAULT TABLES .............................................................................................................................................................240
		Working hydraulics – Fault table .....................................................................................................................................240
		Track drive – Fault table ............................................................................................................................................241
		Swing mechnism – Fault table .........................................................................................................................................242
		Central lubricating system – Fault table .............................................................................................................................243
	HYDRAULIC CIRCUIT DIAGRAM ................................................................................................................................................244
	ABBREVIATIONS ............................................................................................................................................................245
	TECHNICAL DATA ...........................................................................................................................................................247
		Product Specification Sheet...........................................................................................................................................249
	NOTES  ...................................................................................................................................................................259
6 INDEX.......................................................................................................................................................................261

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