PDF Operation & Maintenance Manual Cat 6060 AC 6060 AC FS Hydraulic Shovel - 999 KB
This is the official Operation and Maintenance Manual for the Caterpillar 6060 AC and 6060 AC FS Hydraulic Shovels.
It provides operators and maintenance personnel with essential information on safety, machine operation, lubrication, and maintenance schedules.
Following the guidelines in this manual is key to the reliability and long life of your mining equipment.
PDF Viewer
Viewer loads when you scroll here
SHARE THIS MANUAL
Download the PDF Manual
PDF viewer loading area
Text Preview from This Manual
The text below was extracted from the visible preview pages to help you confirm the manual contents before download.
--- Page 1 ---
BA 6060(3 847 011.02)-EN
01 / 2014
Operation and
Maintenance
Manual
6060 AC, 6060 AC FS
Hydraulic Shovel No.
--- Page 3 ---
BA 6060(3 847 011.02)-EN
Introduction
1 INTRODUCTION
Operation and Maintenance Manual Target group
Part 1 INTRODUCTION Operating personnel
+
FUNDAMENTAL Inspection and
SAFETY INSTRUCTIONS servicing personnel
+
Repair personnel
Part 2 OPERATION Operating personnel
The operating personnel must have know-
how relevant to the operation and the appli-
cation of this or comparable machines.
Part 3 INSPECTION AND Inspection and servicing personnel
The inspection and servicing personnel must
SERVICING have know-how relevant to the inspection
and servicing of this or comparable ma-
chines.
Part 4 REPAIR WORK Repair personnel
The repair personnel must have know-how
and experience relevant to the repair of this
or comparable machines.
Part 5 ANNEX Operating personnel
+
Inspection and servicing personnel
+
Repair personnel
Part 6 INDEX Operating personnel
+
Inspection and servicing personnel
+
Repair personnel
1-1
--- Page 4 ---
BA 6060(3 847 011.02)-EN
Introduction
Gas, dust, steam and smoke Noise
Always start and operate the engine in a well- During operation, all sound baffles of the machine
vented area; must be closed.
If in an enclosed area, vent the exhaust to the out- Always wear the prescribed ear protectors.
side;
Do not modify or tamper with the exhaust system
Oil, grease and other chemical
Diesel engine exhaust and some of its constituents
are known to cause cancer, birth defects, and other substances
reproductive harm When handling oil, grease or other chemical sub-
Operate fuel-operated heating systems only on stances, observe the product-related safety regula-
adequately ventilated premises. Before starting the tions (see safety specifications).
machine on enclosed premises, make sure that Be careful when handling hot consumables (risk of
there is sufficient ventilation. burning or scalding).
Observe the regulations in force at the respective
site.
Transporting and recommission-
Carry out welding, flame-cutting and grinding work
on the machine only if this has been expressly au- ing
thorized, as there may be a risk of explosion and The machine must be loaded and transported only
fire. in accordance with the Operation and Maintenance
Before carrying out welding, flame-cutting and Manual.
grinding operations, clean the machine and its sur- Use only appropriate means of transport and lifting
roundings from dust and other inflammable sub- gear of adequate capacity.
stances and make sure that the premises are ade-
The recommisioning procedure must be strictly in
quately ventilated (risk of explosion).
accordance with the Operation and Maintenance
Manual.
Hydraulic / pneumatc equipment
Check all lines, hoses and screwed connections
regularly for leaks and obvious damage. Repair
damage immediately. Splashed oil may cause injury
and fire.
Depressurize all system sections and pressure
pipes (hydraulic / pneumatic system) to be removed
in accordance with the specific instructions for the
unit concerned before carrying out any repair work.
Hydraulic- and pneumatic lines must be laid and
fitted properly. Ensure that no connections are in-
terchanged. The fittings, lengths and quality of the
hoses must comply with the technical requirements.
1-11
--- Page 5 ---
BA 6060(3 847 011.02)-EN
OPeration
FIRE AND EXPLOSION HAZARD
Safety instructions
Avoid smoking and open fire on, next
to and below the machine.
Combustible and easily flammable substances or
liquids increase the fire and explosion hazard.
Do not store such substances on the excavator.
Clean the excavator thoroughly, if possible, with a
steam jet (rubber parts and electric components
with compressed air - refer to information label),
when, for example, oil, grease, fuel or cleaner was
spilled.
Such substances may spontaneously ignite if they
get into the vicinity of hot units.
Even battery gases can ignite in open flames or
fire.
Avoid parking the excavator in places where
– combustible substances such as coal dust or tar
are present,
– open or smouldering fire may occur.
Remove the excavator from such an area where
combustible or easily flammable liquids have
spilled from the excavator onto the ground.
Flying sparks may cause fire on the ground that can
spread to the excavator.
2-5
--- Page 6 ---
BA 6060(3 847 011.02)-EN
OPeration
Fig. 2-9:
2-15
--- Page 7 ---
BA 6060(3 847 011.02)-EN
OPeration
Switching the cab interior lighting
on and off
The cab interior lighting can be switched on and off
with the switches (arrow, Fig. 2-31:), (96, Fig. 2-32:)
and (arrow, Fig. 2-33:)
The cab interior light is supplied with power even
when the electrical system is shut down.
When leaving the machine, the interior light must
therefore be switched off. The batteries could be
discharged if the interior light is allowed to remain
on for a prolonged period.
Fig. 2-31:
Fig. 2-32:
Fig. 2-33:
2-25
--- Page 8 ---
BA 6060(3 847 011.02)-EN
OPeration
Hang up loop (4, Fig. Fig. 2-55:) into snap hook If you have the harness put on in such a way in
(16). case of danger you can escape from the excavator
(Fig. Fig. 2-57:).
Fig. 2-55:
Fig. 2-57:
Release hooking safety device (17, Fig. 2-56:).
Fig. 2-56:
2-35
--- Page 9 ---
BA 6060(3 847 011.02)-EN
OPeration
(Fig. 2-62:)
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 Superstructure hold- Blocks the superstructure.
61
ing brake
Press this button when the
superstructure is stationary.
Do not use this button while
the superstructure is still in
motion. Risk of damage to the
brake and the swing gear-
boxes.
Push-button Hydraulic shovel Press the switch face with the symbol:
63
parking brake, for The parking brake is applied permanently.
Service and Mainte- The hydraulic shovel cannot be moved.
nance purposes only For more information refer to chapter
“Track parking brake”.
Actuate this switch only
when the hydraulic shovel is
stationary.
Do not use this switch while
the hydraulic shovel is still in
motion. Risk of damage to the
brakes and the travel gear-
boxes.
Push-button Central greasing Reset function of the central greasing
64
system reset system control (Press for at least 3 sec.).
Press switch face without symbol:
Resets the control of the superstructure.
Press the switch face with the symbol:
Resets the control of the undercarriage.
Push-button Emergency lowering Lowering of the working equipment in an
65
emergency situation. For instance, if the
electric motor has failed.
For more information refer to chapter
“Emergency lowering of the working
equipment”.
2-45
--- Page 10 ---
BA 6060(3 847 011.02)-EN
OPeration
Assemblies resp. Measuring device Remarks
reservoirs
Pump drive gear- Dipstick (1, Fig. 2-68:) Stop filling when the oil reaches the "max" mark on the
box dipstick (see Part 3, chapter "Pump drive gearbox -
Checking the gearbox oil level/Filling in oil").
Hydraulic oil tank BCS monitor (Fig. 2-71:), Checking the oil level:
Inspection glass (1, Fig. Extend the piston rods of stick and bucket cylinders
2-69:), sign (2. Fig. 2-69: halfway and stand working equipment on the ground
and Fig. 2-70:) (as shown on sign 2, Fig. 2-70:).
Check oil level at an oil temperature of ca. 50 °C
(122°F), with the electric motor shut off.
Fill in oil when the oil level in the inspection glass has-
dropped below the "min" mark. Stop filling if the oil rea-
ches the "max" mark on the inspection glass or the
acoustic warning signal "Travel alarm" sounds (see
chapter "Hydraulic system - Checking the hydraulic oil
level / Refilling hydraulic oil").
Fig. 2-68:
Fig. 2-70:
Fig. 2-69:
2-55
--- Page 11 ---
BA 6060(3 847 011.02)-EN
OPeration
TRAVELLING, SAFETY INSTRUC-
TIONS
Have the attachment raised only so far as to permit
the machine to be driven under overhead power
lines without any risk.
Close the cab door.
If the machine is fitted with a safety belt for the
operator, fasten the belt.
If the superstructure is turned by more than 90°
from the BASIC POSITION, the excavator travels
in the opposite direction to that selected.
If the position of the superstructure in relation to
the undercarriage is not exactly known, touch the
accelerator lightly to see which direction the ma- Fig. 2-88:
chine takes, before initiating the full travelling mo-
vement.
Warn persons in the immediate vicinity by sound- Running-in specifications for components of
ing the horn before setting off. the crawler tracks
Never drive across slopes. Prior to initial commissioning and/or after repair
Take the utmost care on slippery, greasy ground. work, run in the idlers, track rollers and support
rollers as follow:
If the machine is to be driven a longer distance, the
Raise the equipment (Fig. 2-87:) or (Fig.
superstructure must be secured against turning by
2-88:).
means of the superstructure holding brake.
Drive the excavator in revers
approx. 50 m / 164ft.
Drive the excavator in forwards
approx. 50 m / 164ft.
Stop the excavator.
Measure the temperature at each dler, track
roller and support roller with an infrared ther-
mometer (at a temperature of approx. 100° C /
212°F wait for idlers, track rollers and support
rollers to cool down).
Repeat this running-in procedure up to 10x.
Fig. 2-87:
Check all idlers, track rollers and
support rollers for leaks.
Trailing cable
Never touch the trailing cable.
Risk of voltage drive, if the trailing
cable insulation is defective!
Change the position of the trailing
cable only by means of a cable hook.
2-65
--- Page 12 ---
BA 6060(3 847 011.02)-EN
OPeration
Swinging the superstructure
Swinging of the superstructure is possible only-
when:
the superstructure holding brake is released
and
the hydraulic shovel operator is sitting on his
seat and
the hydraulic ladder is raised and
the servicestation (tanklift) is raised and
the BCS swing circuit test was successful.
To swing the superstructure to the right -
move control lever to the right (115, Fig.
2-108:).
To swing the superstructure to the left -
move control lever to the left (115).
After releasing, the control lever returns automati-
cally to position “0”.
Fig. 2-108:
Releasing the control lever (115) is not sufficient to
brake the superstructure automatically. In order to
brake the superstructure, the control lever must be
moved in the direction opposite the swinging
movement (reversing).
Braking the superstructure
The superstructure can only be braked by moving
control lever (115) in the direction opposite the
swinging movement (reversing).
The superstructure does not stop
automatically by simply releasing the
swing control lever (115).
To brake the superstructure, the sw-
ing control lever (115) must be moved
in opposite direction.
In an emergency, activate the holding
brake by pressing switch (61, Fig.
2-109:).
Fig. 2-109:
2-75
--- Page 13 ---
BA 6060(3 847 011.02)-EN
OPeration
Monitoring cameras
This excavator is equipped with two monitoring
cameras:
one mounted on the counterweight, looking
backwards;
one mounted on the hydraulic oil cooler mod-
ule, looking to the right.
The two cameras and the belonging LCD-diplay
are operational after the electrical system of the
machine has been activated with the key operated
switch.
Both cameras transmit their images to the same
LCD-display. The display is mounted near the con-
trol column.
For toggling between the camera images beeing
displayed, press the key in the left joystick (arrow, Fig. 2-118:
Fig. 2-118:).
Additional information can be found in the manuals
of the camera manufacturer (see Volume 5 of the
Technical Documentation “Components”).
2-85
--- Page 14 ---
BA 6060(3 847 011.02)-EN
Inspection and servicing
Selecting oils and greases Oil-level check and oil change
Use the recommended qualities only, matching Position the machine horizontally.
viscosities with the temperature level.
Change the oil when the machine is at operating
temperature. Warm oil flows better and carries
suspended particles (carbon or abraded matter)
Filters better.
Replace / clean all filter elements or filter car-
tridges within the specified periods.
Lubricating
All filters are coordinated carefully with the equip-
ment. Original CGM HMS GmbH parts must be Clean the lubricating nipple, then lubricate as
used to ensure smooth running and a long ser- scheduled.
vice life of the engine and the hydraulic units.
After servicing
Sealing elements
To prevent corrosion, coat all bright metal parts
When dismantling parts, watch for sealing ele- with a grease film.
ments.
On completing work, re-install all protective de-
Check sealing elements prior to installation and vices.
replace any that are even slightly damaged.
Never switch on the electric motor while work is
When assembling, ensure a perfect fit. being done on the machine.
Carry out performance tests with the machine.
3-7
--- Page 16 ---
BA 6060(3 847 011.02)-EN
Inspection and servicing
Plan A – E
Plan A - after every 250 OH Plan B - after every 500 OH
(at 250, 750, 1250 ... OH) (at 500, 1500, 2500 ... OH)
Plan C - after every 1000 OH Plan D - after every 5000 OH
(at 1000, 2000, 3000, 4000 ... OH) (at 5000, 15000, 25000 ... OH)
Plan E - after every 10000 OH
(at 10000, 20000, 30000, ... OH)
Page 1 of 6
Location Servicing work Menge / Plan Plan Plan Plan Plan
No. A B C D E
Servicing in acc.
with W or T
Monitoring, warning and
control elements
- Joysticks
- Control spool, Grease lightly 2x45
plate, cardan joint
- Pedals
- Control spool Grease lightly 3x25
(machine with loading
shovel)
Electric motor Grease bearings 2
(see plate with lubricating
instructions at the electric
motor for detailed information)
Check for vibration
(See Electric motor manufac- Visual inspect interior of ma-
turer´s servicing instructions chine for degree of dirt depos-
for further details.) its
Rotor (inside and outside of Visual inspect all accessible
machine) places for rust
Terminals Check tightness
Check for degree of dirt de-
posits
Coupling Check for alignment and re-
cord measurements 6
Screwed / bolted connections Check condition and tightness
Operator’s cab
- Fastening bolts to cab mo- Check for tightness (see Ser-
dule vice Manual for tightening
torques)
5
apply a thin layer of low temperature grease
6
Check for alignment after every 2000 OH (refer to electric motor manufacturers servicing instructions)
3-17
--- Page 17 ---
BA 6060(3 847 011.02)-EN
Inspection and servicing
Inspection plan – Oil (legend)
No. Location Number Lubricant Check oil level Change oil
properties 15 every ... OH every ... OH
1 Hydraulic system 1 10 10000 16
II
2 Pump drive gearbox and cooling 1 60 1000
2
circuit
Pre-chambers, expansion reser- 1
III.a 10 1000
voir
3 Swing gearbox 4 10 1000
III.b
4 Travel gearbox 2 500 5000
- Pre-chamber (only at gearbox 2x1 500 5000
PN 3783483)
III.a
- Brake-chambers 2x2 500 5000
5 On-board crane (optional)
- Crane drive engine 1 10 250 17
I
- Hydraulic oil reservoir 1 10 1000 18
II
15
see "LUBRICANTS" section
16
Change hydraulic oil every 5000 OH unless the oil is analyzed at regular intervals, but not later than every
3 years.
17
Change oil at least once a year.
18
Change hydraulic oil at least once a year.
3-27
--- Page 18 ---
BA 6060(3 847 011.02)-EN
Inspection and servicing
ELECTRIC MOTOR
Electric motor - Safety instruc-
tions
Read and observe: "Inspection and
Servicing – Safety Instructions" and
the electric motor Operation and
Maintenance Manual.
Secure the machine as described in the "Securing
the machine" section.
Wear protective gloves and firm working clothing.
Switch off electric motor, to do so actuate
switch (42, Fig. 3-11:).
Set servicing switch (4, Fig. 3-12:) to locked
position and secure in this position with a pad-
lock.
Fig. 3-11:
Cleaning the electric motor
Clean the electric motor, the cooling fins, bearing
shields and ventilators from dust with compressed
air, brushes and clothes only.
Remove the fan guard before cleaning the ventila-
tor fan. Install it after cleaning.
Don't damage the protective coating while cleaning
the electric-motor.
For more information see the manufacturers man-
ual for the electric motor.
It is not permissible to clean the elec-
tric motor or any live excavator com-
ponents with a steam cleaner and
steam jet.
After finishing work on the electric motor re-
move the padlock from servicing switch (4, Fig.
3-12:) and unlock.
Fig. 3-12:
3-37
--- Page 19 ---
BA 6060(3 847 011.02)-EN
Inspection and servicing
Lighting systems in LED tech-
nonogy, instructions
The lights of the maintenance lighting system (Fig.
3-25) as well as the working floodlights (Fig. 3-26)
are equipped with lamps in LED technology (light-
emitting diodes).
High-performance LEDs ensure the emission of
light with high luminance. If the light is allowed to
shine directly into the eyes from a short distance
and over prolonged periods, there is a risk of injury
to the retina.
Do not look for a prolonged period into the light
cones of the LEDs.
Adjust the lights in such way that they do not shine
directly into the eyes and that you are not blinded
by the glare.
The lights become hot in operation.
The heat is dispersed via the ribbed
metal housing. Fig. 3-25
For this reason, the housings must
not be covered up and cleaning rags
or similar things placed over them.
The high-performance LEDs in these lights have a
very long service life and can therefore not be re-
placed. If one or more of these LEDs fail, the light
can remain in service if the remaining luminance is
still sufficient.
Fig. 3-26
3-47
--- Page 20 ---
BA 6060(3 847 011.02)-EN
Inspection and servicing
Filter (servo control circuit), Replacing the filter element
replace To filter the hydraulic oil in the control circuit, the
machine is equipped with a high-pressure filter
(arrow, Fig. 3-49:).
Risk of scalding caused by hot hy-
draulic oil. Change filter element regulary and when the BCS
indicates a contamination.
The filter housings themselves may
Place a suitable collecting recipient under the
also be hot.
filter housing (Fig. 3-49:).
Wear protective gloves and firm
Collect escaping hydraulic oil and used filter
working clothing.
elements. Discard without polluting the envi-
Skin contact with hydraulic oil may ronment.
cause skin injury. Avoid skin contact.
Unscrew filter housing (5, Fig. 3-50:) by coun-
Read and observe the "Inspection terclockwise rotation. Pour out the oil.
and servicing – Safety instructions"
Withdraw filter element (6) from filter housing
chapter.
(5).
Check filter housing (5) as well as used filter
Shut off the electric motor. surface for debris.
Depressurize the hydraulic system. Clean filter housing (5) and the sealing face at
the filter head with white spirit or paraffin oil.
Clean the filter housings as well as the imme-
diate vicinity carefully. Check seals (8) and replace, if required.
Dispose of waste oil, used filters and oil- Screw in the filter housing (5) to stop. Then
stained cleaning rags properly and separated turn out the filter housing by an 1/8 turn so that
from other waste. the filter housing is not stuck due to pressure
pulsation and can be easily loosened in case
of maintenance works.
Check high-pressure filters for leaks after put-
ting the hydraulic system back into operation.
Fig. 3-50:
Fig. 3-49:
3-57
--- Page 21 ---
BA 6060(3 847 011.02)-EN
Inspection and servicing
Pressure accumulator - Emer- Extract from the German regulations
gency lowering The accumulator vessel must not be subjected to
welding, soldering or any other mechanical work.
To permit the working equipment to be lowered in Work on systems containing accumulators (re-
an emergency, the machine is equipped with a pairs, connection of pressure gauges or similar
pressure accumulator (1, Fig. 3-67:). work) may be carried out only when the fluid pres-
The pressure accumulator (1) is located in the sure has been released
superstructure and is accessible from the ground.
Extract from the German acceptance
regulations
Hydraulic accumulators are pressure vessels and
are therefore subject to the "Druckbehälterverord-
nung (DruckbehV)" [Pressure Vessel Regulations].
Their installation, equipment and operation are
governed by the "Technische Regeln Druckbe-
hälter (TRB)" [Technical Rules for Pressure Ves-