PDF Operation & Maintenance Manual CAT 6060 6060FS Hydraulic Shovel - 1 MB
Master the operation and maintenance of your CAT 6060 and 6060FS Hydraulic Shovel with this comprehensive manual.
It contains vital information on safe operating procedures, instrument panels, and daily maintenance schedules.
Following these guidelines will help prevent premature wear and ensure the machine performs reliably.
This is a must-have document for any operator or fleet manager responsible for this powerful equipment.
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--- Page 1 ---
BA RH340B(3 847 013.01)-EN
04 - 2013
Operation and
Maintenance
Manual
6060, 6060FS
Hydraulic Shovel No.
--- Page 3 ---
BA RH340B(3 847 013.01)-EN
TABLE OF CONTENTS
Risk of deflagrations _____________________________________________________________ 4-12
Risk of fire _____________________________________________________________________ 4-12
Disposing of the machine without polluting the environment ______________________________ 4-13
Further hazardous substances _____________________________________________________ 4-13
Appropriate disposal of batteries____________________________________________________ 4-14
NOTES_________________________________________________________________________ 4-15
5 ANNEX__________________________________________________________________________ 5-1
BOARD-CONTROL-SYSTEM ________________________________________________________ 5-3
BCS III, whatβs that? ______________________________________________________________ 5-3
The keys on the front side __________________________________________________________ 5-4
Other elements on the front side _____________________________________________________ 5-4
BCSIII, 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 βServiceβ screen_____________________________________________ 5-11
Engine data screen ______________________________________________________________ 5-12
Hydraulic data screen ____________________________________________________________ 5-13
Lubrication data screen ___________________________________________________________ 5-14
Controls adjustment data screen____________________________________________________ 5-15
View documents screen __________________________________________________________ 5-16
Signal table screen ______________________________________________________________ 5-17
Signal table screen, location _______________________________________________________ 5-18
Signal table screen, diagram_______________________________________________________ 5-19
Signal table screen, diagram configuration ____________________________________________ 5-20
Code table screen _______________________________________________________________ 5-21
Slew brake test screen ___________________________________________________________ 5-22
BCS III, interfaces _______________________________________________________________ 5-23
USB interface, data storage _______________________________________________________ 5-23
Saving data to a USB stick ________________________________________________________ 5-24
Saving data to a USB stick, continued _______________________________________________ 5-25
Saving data to a USB stick, continued _______________________________________________ 5-26
BCSIII, cleaning_________________________________________________________________ 5-27
BCSIII, disposal_________________________________________________________________ 5-27
TROUBLESHOOTING _____________________________________________________________ 5-28
Instructions on troubleshooting _____________________________________________________ 5-28
Layout of the fault table ___________________________________________________________ 5-28
Possible causes ________________________________________________________________ 5-28
Measures _____________________________________________________________________ 5-28
Section _______________________________________________________________________ 5-28
FAULT TABLES __________________________________________________________________ 5-29
Combustion engine - Fault table ____________________________________________________ 5-29
Working hydraulics β Fault table ____________________________________________________ 5-30
Track drive β Fault table __________________________________________________________ 5-31
Swing mechnism β Fault table _____________________________________________________ 5-32
Central lubricating system β Fault table ______________________________________________ 5-33
xi
--- Page 4 ---
BA RH340B(3 847 013.01)-EN
Introduction
Selection and qualification of per- In the event of malfunction, stop the machine im-
mediately and lock it. Have any defects rectified
sonnel; basic responsibilities immediately.
Any work on and with the machine must be exe- Start the machine from the operator's seat only.
cuted by reliable personnel only. Statutory mini-
During start-up and shut-down procedures always
mum age limits must be observed.
watch the indicators in accordance with the Opera-
Employ only trained or instructed staff and set out tion and Maintenance Manual.
clearly the individual responsibilities of the person-
Before setting the machine in motion, make sure
nel for operation, set-up, maintenance and repair.
that nobody is at risk.
Make sure that only authorized personnel works
Before starting work or travelling with the machine,
on or with the machine.
check that braking, signalling and lighting systems
Define the machine operator's responsibilities giv- are fully functional.
ing the operator the authority to refuse instructions
Before setting the machine in motion always check
by third parties that are contrary to safety.
that the accessories have been safely stowed
Do not allow persons to be trained or instructed or away.
persons taking part in a general training course to
In conditions of poor visibility and after dark always
work on or with the machine without being perma-
switch on the lighting system.
nently supervised by an experienced person.
Persons accopanying the operator must be seated
Work on the electrical system and equipment of
on the passenger seat provided for this purpose.
the machine must be carried out only by a skilled
electrician or by instructed persons under the su- When crossing underpasses and bridges or when
pervision and guidance of a skilled electrician and passing under overhead lines always make sure
in accordance with electrical engineering rules and that there is sufficient clearance.
regulations. Always keep a distance from the working face and
Work on chassis and brake systems must be per- from slopes.
formed by skilled personnel only, which has been Avoid any operation that might be a risk to ma-
specially trained for such work. chine stability.
Work on hydraulic systems must be carried out Never travel across slopes; always keep the work-
only by personnel with special knowledge and ing equipment and the load close to the ground,
experience of hydraulic equipment. especially when travelling downhill.
On sloping terrain always adapt your travelling
speed to the prevailing ground conditions.
Safety instructions governing
Before leaving the operator's seat always secure
specific operational phases the machine against inadvertent movement and
Standard operation unauthorized use. Shut off the engines.
Avoid any operational mode that might be prejudi-
cial to safety.
Before beginning work, familiarize yourself with the
surroundings and circumstances of the site, such
as obstacles in the working area and the bearing
capacity of the soil.
Take the necessary precautions to ensure that the
machine is in a safe and reliable state.
Operate the machine only if all protective and
safety-oriented devices, such as removable safety
devices, emergency shut-off equipment, sound-
proofing elements and exhausters, are in place
and fully functional.
Check the machine at least once per working shift
for obvious damage and defects. Report any
changes (incl. changes in the machine's working
behaviour) to the competent organization/person
immediately. If necessary, stop the machine im-
mediately and lock it.
1-7
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BA RH340B(3 847 013.01)-EN
Operation
OPERATION - SAFETY INSTRUC- Safety belt
TIONS For machines with a safety belt for operating per-
sonnel:
Operation and Maintenance Manual Check the safety belt attached to the operator's
Never operate the machine before seat. In the event of damage or after an accident,
having read and understood the Op- have it replaced immediately.
eration and Maintenance Manual. Apply the safety belt before starting work.
Pay special attention to:
the "Fundamental Safety Instructions" and to all State of the machine
warning and instruction signs attached to the ma-
chine. Operate the machine only in a safe state and only
in accordance with its designated use. Always
Familiarize yourself with the layout, the function- observe the safety instructions.
ing and the sense of actuation of the control ele-
ments prior to starting up the machine. Always have inspection and maintenance work
carried out on schedule.
Activate the control elements from the operator's
seat only. Operate the machine only with the equipment and
component combinations approved by CGM HMS
Keep the Operation and Maintenance Manual with GmbH. Clear-cut data are given in the technical
the machine at all times. specification.
Never install and commission other equipment
Operating personnel and component combinations without CGM HMS
GmbH having first inspected and approved the
The operating personnel must be fully informed of project.
the operation and application of this or compara-
ble machines. Before starting work or travelling with the ma-
chine, check that the braking, signalling and light-
The necessary know-how can be acquired in sev- ing systems are fully functional.
eral days' instruction, e.g. by an CGM HMS
GmbH mechanic or by attending an CGM HMS Poor visibility may result in accidents. Always
GmbH operator's training course. clean the windows and the glass covers of all
lamps before starting the machine.
Check that all warning and instruction signs at-
Personal protective gear and working tached to the machine are present and legible.
clothing
Wear a safety helmet and working footwear with
non-slip soles. Smooth soles may slip from steps Entering and leaving the machine
and pedals resulting in injury or incorrect opera- Always face the machine when entering or leaving
tion. it.
Wear closely fitting working clothing when operat- Use only the ladders, steps, platforms and grab
ing the machine. Loose, wide garments may result handles provided when entering and leaving the
in control levers being inadvertently activated machine.
Always maintain a three point contact with the
steps and grab handles.
Always keep ladders, steps and platforms in a
non-slip, safe state and remove any oil, grease,
soil, snow, ice and other foreign matter imme-
diately.
Hazard range
The hazard range is that zone around the ma-
chine in which persons are within reach of loads
or attachments falling as a result of operational
movements by the machine, of its equipment and
attachments or of swinging loads.
2-3
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BA RH340B(3 847 013.01)-EN
Operation
Fig. 2-5:
2-13
--- Page 7 ---
BA RH340B(3 847 013.01)-EN
Operation
Switching the maintenance lights
on and off
The maintenance lights in the various modules can
be activated from a central point with the switches
(arrow, Fig. 2-30:) or (95, Fig. 2-31:).
The invidual modules are also equipped with
switches, for example the engine module:
Switch at the switchgear cabinet behind the hy-
draulic oil reservoir (1, Fig. 2-32:).
Fig. 2-30:
Fig. 2-31:
Fig. 2-32:
2-23
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BA RH340B(3 847 013.01)-EN
Operation
Taking on harness ο Pull loop (6) of the back support (1) between
your legs to the front (Fig. 2-56:).
ο Take harness out of handbag (15, Fig. 2-54:).
ο Pull loop (5, Fig. 2-57:) through loop (6).
Fig. 2-54:
Fig. 2-57:
ο Take on shoulder belts (2 and 3, Fig. 2-55:).
ο Pull loop (4, Fig. 2-57:) through loop (5).
ο Press the hooking safety device (17, Fig.
2-57:) of the snap hook (16).
Fig. 2-55:
ο Pull back support (1, Fig. 2-55:) behind your
body (Fig. 2-56:).
The loops (4 and 5) are in front of your body. Fig. 2-58:
Fig. 2-56:
2-33
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BA RH340B(3 847 013.01)-EN
Operation
(Fig. 2-65:)
Engine 1 (LH), control and monitoring
All switches and pushbuttons have an illuminated symbol face.
The opposite side is equipped with an LED. The LED lights up when the switch / pushbutton is actuated.
No. Element Function Symbol
Push-button Start Starting of the engine. For starting, press the
41
push-button face with the symbol.
Push-button Stop Stopping of the engine. For stopping, press
42
the push-button face with the symbol.
Push-button Idle Stopping of the engine with an after-run de-
43
lay of 5 min. For delayed stopping, press the
push-button face with the symbol.
Warning lamp Engine oil pressure Lit up when the engine oil pressure is too
44
low.
Warning lamp Alternator Lit up when the batteries are not being
45
charged or in the event of an alternator de-
fect.
Warning lamp Engine oil tempera- Lit up when the engine oil temperature is too
46
ture high.
Warning lamp Cooling liquid tem- Lit up when the engine cooling liquid tem-
47
perature perature is too high.
Switch Engine speed Press switch face without symbol:
48
the speed of the engine increases.
Press the switch face with the symbol:
the speed of the engine reduces.
Warning lamp Engine monitoring STOP!
49
Lamp is lit up in the event of a critical
fault on the left engine 1.
Shut off engine immediately.
Check the BCS display for further fault
messages and give an information to the
responsible service personnel immedi-
ately.
Warning lamp Engine monitoring Not used on this machine.
50
2-43
--- Page 10 ---
BA RH340B(3 847 013.01)-EN
Operation
(Fig. 2-70:)
No. Element Function Symbol
101 Push-button (Free for options) Can be used as a push-to-speak button on a
radio, or to switch over from one camera to
another one.
102 Push-button Stick floating posi- Button is pressed:
tion (shovel equip- The stick cylinders are pressurized on re-
ment only) tracting.
Press button (102) only in posi-
tion "0" of control lever (115).
103 Push-button Boom floating posi- Button is pressed:
tion The boom cylinders are pressurized on re-
tracting.
Press button (103) only in posi-
tion "0" of control lever (116).
104 Push-button Warning signal Button is pressed:
Acoustic warning signal / horn is activated.
105 Push-button Electronic excavator Button in the seat.
inside the seat control (servo- The electronic excavator control (servo-
control) control) is activated when the operators sits
down on the seat.
The electronic excavator control (servo-
control) is deactivated when he leaves the
seat.
111 Pedal Shovel trap (shovel Forwards β shovel trap is opened;
equipment only) Backwards β shovel trap is closed.
112 Pedal Travel, left track Forwards β forward travel;
Backwards β backward travel.
113 Pedal Travel, right track Forwards β forward travel;
Backwards β backward travel.
114 Footrest
115 Control lever Forwards β raising the stick
Backwards β lowering the stick.
To the left / right β
swinging and braking of the superstructure.
116 Control lever Forwards β lowering the boom;
Backwards β raising the boom.
To the left β backwards tipping of shovel /
bucket;
To the right β dumping of shovel / bucket.
117 Push-button Not used on this machine.
118 Thumb wheel Shovel trap (shovel Turn Forwards β shovel trap is opened;
equipment only) Turn Backwards β shovel trap is closed.
Function can be overridden by Pedal 111.
(Thumb wheel is spring centered).
119 Push-button By-pass for the Lower half pushed β automatically stopped
automatically stick- and/or backhoe cylinders can be
switch off for stick- driven slowly to the limit stopps.
and /or backhoe Upper half pushed β Each press on the but-
cylinders (Option) ton increments the loaded dumper count for
by "1". (Count reset with button (91)).
120 Thumb wheel Not used on this machine.
2-53
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BA RH340B(3 847 013.01)-EN
Operation
(Fig. 2-75:)
Optional equipment: Air filter monitoring
(Depending on the options ordered with the machine, the described elements can be found on different posi-
tions on or near the control column).
No. Element Function Symbol
Underpressure Air filters (left en- Indicates the underpressure in the air filters.
191
gauge gine 1, outside) Underpressure must be less than 25 inches
(635 mm) water column.
Otherwise clean / replace the filterelement.
Underpressure Air filters (left en- Indicates the underpressure in the air filters.
192
gauge gine 1, inside) Underpressure must be less than 25 inches
(635 mm) water column.
Otherwise clean / replace the filterelement.
Underpressure Air filters (right en- Indicates the underpressure in the air filters.
193
gauge gine 2, outside) Underpressure must be less than 25 inches
(635 mm) water column.
Otherwise clean / replace the filterelement.
Underpressure Air filters (right en- Indicates the underpressure in the air filters.
194
gauge gine 2, inside) Underpressure must be less than 25 inches
(635 mm) water column.
Otherwise clean / replace the filterelement.
2-63
--- Page 12 ---
BA RH340B(3 847 013.01)-EN
Operation
Switching the electrical system Engines, emergency shut-off
on and off In an emergency, the engines can be stopped out
of full load.
The electrical system is switched on with key-
switch (32, Fig. 2-94:). To do so:
ο Insert key into key-switch and turn to the right. ο Depress the emergency shut-off switch (35,
Fig. 2-95:). The engines are stopped.
If the electrical system cannot be switched on, (see the chapter "Emergency shut-off func-
check first whether the battery main switch is on tion").
(see: "Battery isolator switch, shutting off supply
voltage"). ο Switch off the electrical system with key-switch
(32).
Fig. 2-95:
Fig. 2-94:
2-73
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BA RH340B(3 847 013.01)-EN
Operation
TRAVELLING Travelling forwards/backwards
Travelling forwards:
Superstructure basic position
ο depress pedals (112 and 113) forwards.
Travel direction and sense of actuation of pedals
(112 and 113, Fig. 2-112:) are identical only when The hydraulic shovel travels in the direction of the
the hydraulic shovel is in its BASIC POSITION idler (2, Fig. 2-111:).
(Fig. 2-111:). Travelling backwards:
ο depress pedals (112 and 113, Fig. 2-112:)
backwards.
The hydraulic shovel travels in the direction of the
drive sprocket (4, Fig. 2-111:).
ο During travelling, an acoustic warning signal
sounds (Travel Alarm).
Fig. 2-111:
If the superstructure is swung out of
its basic position by more than 90Β°
(Fig. 2-113:), the hydraulic shovel mo-
ves in a direction opposite to that ex-
pected when pedals (112 and 113, Fig.
2-112:) are depressed. Fig. 2-113:
The pedals return automatically to their "0" posi-
tions when released.
Reverse the hydraulic shovel only over short dis-
tances and with the assistance of marshallers be-
cause of restricted rear-view conditions.
Do not travel across slopes.
When travelling uphill or downhill, the
travel drive must always be at the rear.
Travel only in the basic position of the
hydraulic shovel and only forwards.
Be extremely careful on slippery and
greasy ground.
Do not exceed the maximum machine
inclination (see βMaximum machine
Fig. 2-112: inclinations, informationβ chapter).
If the operator is not completely sure of the posi-
tion of the superstructure with regard to the under-
All instructions with regard to travelling speed
carriage, pedals (112 and 113) should be de-
regulation and travel direction control are applica-
pressed slightly in order to find out which way the
ble only as long as the crawler tracks have suffi-
hydraulic shovel moves before initiating the full
cient grip and do not slip.
travelling movement.
2-83
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BA RH340B(3 847 013.01)-EN
Operation
Working
When released, all control levers for working op-
eration return automatically to position "0".
Sound the horn to warn persons in the
immediate vicinity before starting
work.
Do not exceed the maximum machine
inclination (see βMaximum machine
inclinations, informationβ chapter).
Level a surface only in the bucket's
digging direction. Never "beat" or
"sweep" with the bucket.
Do not level off a surface with the
front shell of the bucket open.
Close bucket completely before be-
ginning to dig.
Fig. 2-129:
Extending and retracting the bucket or
backhoe bucket stick
ο To extend the stick:
push control lever (115, Fig. 2-129:) forwards.
ο To retract the stick:
pull control lever (115) backwards.
ο To retract the stick with pressure:
(only on bottom-dump bucket equipment)
depress button (102) and push control lever
(115) backwards.
Opening and closing the bottom-dump
bucket
ο To open the bucket:
press pedal (111, Fig. 2-129:) forwards or turn
thumb wheel (118) forwards.
ο To close the bucket:
press pedal (111) backwards or turn thumb
wheel (118) backwards. Fig. 2-130:
Pressing pedal (111) overrides turning the
thumb wheel (118).
Filling and emptying the bucket or the
Raising and lowering the boom backhoe
ο To raise the boom: ο To fill/tip back the bucket:
pull control lever (116, Fig. 2-130:) backwards. shift control lever (116, Fig. 2-130:) to the left.
ο To lower the boom: ο To empty the bucket by dumping/tipping:
push control lever (116) forwards. shift control lever (116) to the right.
ο To lower the boom with pressure:
depress button (103) and
push control lever (116) forwards.
2-93
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BA RH340B(3 847 013.01)-EN
Operation
NOTES
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