CAT 6060/6060FS Hydraulic Shovel, Operation and Maintenance Manual

CAT 6060/6060FS Hydraulic Shovel, Operation and Maintenance Manual
DH360148
DH360180
DH360183 – up
DHN60177 – up

Print No: EM024061-1, July 2017
Type of machine: Hydraulic Shovel
Language and Format: English/PDF
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Operation and Maintenance Manual CAT 6060/6060FS Hydraulic Shovel provides you all the information necessary for the operation in optimal parameters of the machine, according to the manufacturer’s instructions. It contains all the necessary information regarding the intervals and maintenance procedures, the fluid change recommendations, the exact technical guidance for maximum performance, reliability and durability of the machine.

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Table of contents:
1. INTRODUCTION
ALL PRODUCTS FOREWORD
Literature Information
Safety
Operation
Product Information
Maintenance
Maintenance Intervals
Product Capacity
PREFACE
About this Operation and Maintenance Manual
Further machine documentation
WARRANTY
FUNDAMENTAL SAFETY INSTRUCTIONS
Warnings and symbols
Declaration of Conformity
Noise emission information
Vibration information
Visibility Information
Restricted Visibility
DESIGNATED USE
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
Warning of special dangers
Gas, dust, steam and smoke
Hydraulic equipment
FIRE AND EXPLOSION HAZARD
NOTES

2. OPERATION
OPERATION – SAFETY INSTRUCTIONS
Visibility aids
Operation and Maintenance Manual, where to store it in the operator’s cab
FIRE AND EXPLOSION HAZARD
DESCRIPTION OF THE HYDRAULIC SHOVEL
Hydraulic shovel layout
Undercarriage
Upper structure
Drive unit
Hydraulic system
Control and Monitoring Platform (CAMP)
Board-Control-System (BCS)
Demand control / Zero-flow regulation
Automatic reset to idling
Electrical system
Safety films and warning messages – Overview and Description
ISO – compliant safety messages set
Safety messages (ISO) – Description
Additional messages (ISO) – Description
ANSI – compliant safety messages set
Safety messages (ANSI) – Description
Additional messages (ANSI) – Description
Entering and leaving the machine – Safety instructions
Access ladder – Lighting
Swinging ladder – Function
Folding ladder (optional) – Function
Emergency exit in operator’s cab and escape ladder
Cab interior lighting – Switch on and off
Maintenance lights – Switch on and off
Emergency shut-off – Function
Putting the machine back into operation, reset of emergency shut off function
Battery isolator switch – Shut off supply voltage
Starter isolator switch – Shut off starter voltage
Operator’s seat
Reducing operators exposure to vibrations
Trainer’s / instructor’s seat
Windscreen washer
Operating hours meter (if equipped)
Fire extinguisher
Automatic fire-extinguishing system
MONITORING, WARNING AND CONTROL ELEMENTS
Engine 1 (LH), control and monitoring
Engine 2 (RH), control and monitoring
PUTTING THE MACHINE INTO OPERATION
Electrical Storm Injury Prevention
Reducing the operator’s exposure to noise
Refuelling
Diesel fuel – Recommendations
Back-up heating (option) – Fill in fuel
Service Station (fast fill arm)
Emergency off switch
Electrical system – Switch on and off
Engines – Emergency shut-off
Preheating system for engine and hydraulic oil (if equipped)
Fuel preheating system (if equipped)
ENGINES – STARTING AND STOPPING
Engines – Start
Starting the left-hand engine
Starting the right-hand engine
Engines – Adjust speed
Engines – Start at low temperatures
Engines – Shut off
Shutting off the left-hand engine
Shutting off the right-hand engine
AIR CONDITIONER (OPTIONAL)
Back-up heating operator’s cab (optional)
Back-up heating (optional)
OPERATIONAL PRACTICES
Working operation – Safety instructions
Before starting work
Machine Operating Temperature Range
Warming up the hydraulic system
Electronic hydraulic shovel control (pilot control) – activate
Working operation – basics
OPERATION TECHNIQUES
Machine operation with backhoe attachment, Best Practices
Backhoe Operation – Restricted Operation
Machine operation with face shovel attachment – Best Practices
Face Shovel Operation – Restricted Operation
TRAVELING
Traveling – Safety Instructions
Before starting traveling
Traveling – Basic Movements
Counter-rotation turns / Turning on the spot
Track Parking Brake – set/release
Traveling speed – adjust
Traveling uphill and downhill on ramps and steep slopes
Traveling over long distances
Traveling – Best Practices
Traveling – Restricted Operation
Maximum Machine Inclinations
TRANSPORTING THE MACHINE
Transport – Safety instructions
Engine-off lowering of the attachment
After daily operation
ASSEMBLING ATTACHMENT – SAFETY INSTRUCTIONS
Safety line on boom
Main control valves – attach/remove the handrail
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 – Check
Monitoring cameras – Function
Operator Assist System (if equipped)
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 oil
Refer to chapter “Engine oil service interval table” for more information. Also refer to SEBU6250 Caterpillar
Machine Fluid Recommendations
Air-intake system
Oils / Greases
Cleaning jobs
Components
3500 Engine Maintenance Interval Schedule – Notes
Plan V
Plan N
Plan T and Plan W
Plan A – E
LUBRICATING CHART – GREASE
Lubricating chart – Grease (legend)
Refill Capacities – Grease
INSPECTION PLAN – OIL
Inspection plan – Oil (legend)
Engine oil service interval table
Refill Capacities – Oil
Refill Capacities – Other
LUBRICANTS / CONSUMABLES
Notes on the selection of oils and greases
I. Oils for combustion engines
II. Fluids for hydraulic system
III.a Oils for pump distribution gearboxes and travel gearboxes
III.b Oils for swing gearboxes
V. Grease for bearings, slew rings and track system (Central lubrication system)
Grease for idlers, track rollers and upper rollers (Lifetime lubrication)
Coolant for use on all combustion engines
SERVICING WORK
Hose line for oil and cooling liquid changes
ENGINE
Engine – Safety instructions
Walk-Around Inspection
Belts – Inspect/Replace
Fuel Injector – Inspect/Adjust
Engine Oil Sample – Obtain
Engine Valve Lash – Check/Adjust
Water Pump – Inspect
Engine oil level – Check level / top up
Engine oil reservoir (if equipped) – Check oil level / top up
Engine oil – Change
Engine oil reservoir (if equipped) – Drain / Fill oil
Engine oil reservoir (if equipped) – Replace oil filters
Engine oil reservoir (if equipped) – Replace breather filters
Engine oil filter – Replace
Engine crankcase breather – Clean
Cold-starting fluid (ether) – Replace the pressure vessel
COOLING SYSTEM
Temperature
Cooling liquid radiators – Check / clean
Cooling liquid level – Check
Cooling liquid – Top up
Cooling liquid – Change
Cooling liquid composition – Test
Cooling System Supplemental Coolant Additive (SCA) – Add
Cooling System Water Temperature Regulator – Replace
Cooling System Coolant Sample (Level 1) – Obtain
Cooling System Coolant Sample (Level 2) – Obtain
AIR-INTAKE SYSTEM
Engine air pre cleaner – Inspect / clean
Primary air filter element – Inspect / replace
Secondary air filter element – Replace
Air-intake lines – Inspect
FUEL SYSTEM
Fuel system – Safety instructions
Fuel tank supply valve – Function
Fuel System – Prime
Fuel filter – Replace
Fuel system – Vent
Breather filter fuel tanks – Replace
Fuel tanks – Clean
Water trap (option) – Clean / replace
Hoses and Clamps – Inspect/Replace
ELECTRICAL SYSTEM
Electrical system – Safety instructions
Alternator – Instructions
Electrical circuit diagrams
Electrical system switch-cabinets
Lamps and bulbs – Replace
Xenon floodlight projector (optional) – Replace the lamp
Lighting systems in LED technology – Instructions
Battery- Check the state of charge
Battery – Remove and install
Battery charge inside the machine – Safety instructions
Switchgear cabinet filter – Clean
CAN-Bus wiring connections – Inspect
HYDRAULIC SYSTEM
Hydraulic system – Safety instructions
Hydraulic system – Depressurize
Attachment circuits – Depressurize
Hydraulic system sections – Depressurize
Hydraulic oil level – Check
Hydraulic Oil Analysis – Understand Particle Count Results
Hydraulic oil return-flow filters, Replace
Hydraulic oil return-flow filters – Replace (from machine no. 340173 / DHN60173)
Bypass valves – Clean / replace
Hydraulic oil tank breather filters – Replace
Filters (pilot control circuit) – Check / replace
Hydraulic oil filters for working hydraulics – Check / replace
Filters for swing pump charge circuit – Check / replace
Filters for swing circuits – Replace
Bearing flushing for main pumps – Replace filter
Hydraulic oil – Change
Hydraulic oil tank- Clean
Hydraulic system – Vent
Hydraulic oil cooler – Clean
Electronic hydraulic shovel controls – Clean / lubricate
Pressure accumulator – Emergency lowering
PUMP DRIVE GEARBOX
Pump drive gearbox – Check oil level / Top up with oil
Pre-chambers – Check oil level / top up with oil
Pump drive gearbox oil sample – Obtain
Pump drive gearbox – Change gearbox oil
Pre-chambers – Change gearbox oil
Pump drive gearbox breather valve – Replace
Pre-chamber breather valve – Replace
Pump drive gearbox lube oil filters – Replace
SWING GEARBOX
Swing gearbox oil sample – Obtain
Swing gearbox – Check oil level / Top up with oil
Swing gearbox – Vent
Swing gearbox oil – Change
TRAVEL GEARBOX (GEARBOX P/N 3683483)
Travel gearbox – Check oil level / Top up with oil
Travel gearbox – Change oil
Travel gearbox breather filter – Replace
Travel gearbox oil sample – Obtain
TRAVEL GEARBOX (GEARBOX P/N 3683496)
Travel gearbox – Check oil level / Top up with oil
Travel gearbox oil sample – Obtain
Travel gearbox oil – Change
Travel gearbox breather filter – Replace
TRAVEL GEARBOX (GEARBOX P/N 3749598)
Travel gearbox – Check oil level / Top up with oil
Travel gearbox oil sample – Obtain
Travel gearbox oil – Change
Travel gearbox breather filter – Replace
CRAWLER TRACKS
Undercarriage – Check for leaks and free movement
Track roller – Lubricate
Track tensioning system
Pressure-accumulator inspection regulations
Checking the gas charging pressure in the pressure accumulator
SWING RING
Swing ring – Instructions
Bearing races
Swing ring grease filling – Check
Swing ring bolts – Check for tightness
CENTRAL LUBRICATING SYSTEM
Central lubrication system – Design
Central lubrication system – Function
Grease container – Fill up
Grease container breather filter – Check / replace
Greasing pressure – Check
Grease line – Unblock
Oil filter (hydraulic circuit grease pump) – Replace
Grease filter (filling the grease container) – Check / replace
Grease filter (grease lines) – Check / replace
OTHER MAINTENANCE WORK
Engine – Clean
Travel Alarm – Test
Radiator – Clean
Aftercooler Core – Clean/Test
Reservoirs for used grease at the A-frame – Empty
Air conditioning filter – Clean
Attachment – Check for cracks
Clam cylinder chamber – Check for soiling
Window panes – Clean
Mirror – Clean / adjust position
Seat belt – Inspect
Seat belt – Replace
Cameras – Check/Clean/Adjust (If equipped)
Horn – Inspect / Replace
Hydraulic ladder – pressure accumulator
Pressure-accumulator inspection regulations
Pressure accumulator – Checking the gas charging pressure
ON-BOARD CRANE, DRIVE UNIT (OPTIONAL)
On-board crane – Lubricate
On-Board crane fastening bolts – Check tightness
PUTTING THE HYDRAULIC SHOVEL OUT OF OPERATION AND RECOMMISSIONING
Putting the hydraulic shovel 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
Overhaul Considerations
Overhaul Recommendation
Cleaning of Components
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 fire
Disposing of the machine without polluting the environment
Further hazardous substances
Appropriate disposal of batteries
NOTES

5. ANNEX
BOARD-CONTROL-SYSTEM
BCS III, what’s that?
The keys on the front side
Other elements on the front side
BCSIII, 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
Emergency Stop, reset function
Swing circuit lock-out function
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
Slew brake test 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
BCSIII, cleaning
BCSIII, 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
PRODUCT SPECIFICATION SHEET
NOTES

6. INDEX