CAT 6050, 6050 FS Hydraulic Shovel Operation and Maintenance Manual EM027997 – PDF DOWNLOAD
FILE DETAILS:
CAT 6050, 6050 FS Hydraulic Shovel Operation and Maintenance Manual EM027997 – PDF DOWNLOAD
Language : English
Pages :334
Downloadable : Yes
File Type : PDF
DESCRIPTION:
CAT 6050, 6050 FS Hydraulic Shovel Operation and Maintenance Manual EM027997 – PDF DOWNLOAD
DH250157 –UP
DHM50164 –UP
PREFACE
About this Operating Instructions
- These Operation and Maintenance Manual is designed to familiarize the operator with the machine and its designated use. The Operation and Maintenance Manual contains 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 Operation and Maintenance Manual must be supplemented by the respective national rules and regulations for accident prevention and environmental protection.
- The Operation and Maintenance Manual must always be available in the driver’s cab of the machine. The Operation and Maintenance Manual must be read and put into practice by any person in charge of carrying out work with or on the machine, such as
operation, including setting-up, troubleshooting in the course of work, care, evacuation of production waste and disposal of fuels and consumables,
maintenance (inspection, servicing, repair and / or
transport
- In addition to the Operation and Maintenance Manual 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 Operation and Maintenance Manual is directed to the mining-machine specialist. It cannot provide basic know-how. This can be acquired, for example, in several days’ instruction by a qualified Caterpillar Global Mining HMS GmbH mechanic or by attending an CGM HMS training course for operators or maintenance personnel.
- The CGM HMS after-sales service will be pleased to deal with any queries you may have after reading through the operating instructions. All CGM HMS Operation and Maintenance Manuals are issued in German and then translated. Even a good translation may give rise to questions which CGM HMS 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 CGM HMS after-sales service.
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
CAT 6050, 6050 FS Hydraulic Shovel Operation and Maintenance Manual EM027997 – PDF DOWNLOAD
TABLE OF CONTENTS
1 INTRODUCTION _ 1-1
PREFACE __ 1-3
About this Operating Instructions 1-3
Further machine documentation _ 1-3
WARRANTY _ 1-4
FUNDAMENTAL SAFETY INSTRUCTIONS ____ 1-5
Warnings and symbols ____ 1-5
DESIGNATED USE, UNAUTHORIZED USE ___ 1-6
ORGANIZATIONAL MEASURES _ 1-7
Selection and qualification of personnel; basic responsibilities __ 1-8
Safety instructions governing specific operational phases _ 1-8
Special work in conjunction with utilization of the machine and maintenance and repairs as well as
troubleshooting during work; disposal of parts and consumables 1-9
Warning of special dangers 1-10
FIRE AND EXPLOSION HAZARD 1-12
NOTES 1-13
2 OPERATION 2-1
OPERATION – SAFETY INSTRUCTIONS 2-3
Operating Instructions, where to store it in the driver’s cab 2-4
OPERATION, FIRE AND EXPLOSION HAZARD 2-5
DESCRIPTION OF THE EXCAVATOR 2-6
Excavator layout 2-7
Undercarriage __ 2-8
Superstructure __ 2-8
Drive 2-8
Hydraulic system 2-8
Pump Managing System (PMS) _ 2-8
Stored Program Control (SPC) __ 2-8
Central Management System (CMS) 2-8
Demand control / Zero-flow regulation _ 2-9
Automatic engine speed reduction __ 2-9
Board-Control-System (BCS) ___ 2-9
Electrical system 2-9
Signs 2-10
Entering and leaving the machine, Safety instructions ___ 2-18
Access lighting 2-18
Folding ladder (optional) __ 2-19
Swinging ladder (optional) _ 2-20
Cab interior lamp 2-21
Servicing lighting 2-22
Illuminating the control column _ 2-22
EMERGENCY STOP switch ___ 2-23
Escape ladder _ 2-24
Trainer’s / instructor’s seat 2-25
Windscreen washer 2-25
Driver’s seat __ 2-26
Fire extinguisher 2-28
Automatic fire-extinguishing system (optional) 2-29
Harness (optional) _ 2-30
MONITORING, WARNING AND CONTROL ELEMENTS __ 2-34
PUTTING THE MACHINE INTO OPERATION _ 2-64
Refuelling 2-64
Service station (tanklift) ___ 2-64
Switching the electrical system on and off ___ 2-70
STARTING AND STOPPING THE ENGINES __ 2-71
Starting the engines _____ 2-71
Starting the engines at low temperatures ____ 2-72
Shutting off the engines ___ 2-73
Emergency – stop _ 2-73
AIR CONDITIONER (OPTION) __ 2-74
Back-up heating (option) __ 2-75
MAXIMUM MACHINE INCLINATIONS, INFORMATION ___ 2-77
TRAVELLING, SAFETY INSTRUCTIONS _____ 2-78
Superstructure basic position __ 2-79
Travel forwards/backwards 2-79
Emergency machine drive _ 2-83
Superstructure holding brakes _ 2-85
Track parking brake _____ 2-85
TRANSPORTING THE MACHINE 2-86
Transport – Safety instructions _ 2-86
WORKING OPERATION – SAFETY INSTRUCTIONS 2-87
WORKING OPERATION ___ 2-89
Before starting work _____ 2-89
Swing the superstructure __ 2-89
Braking the superstructure 2-89
Working movements _____ 2-90
After daily operation _____ 2-91
ASSEMBLING WORKING EQUIPMENT – SAFETY INSTRUCTIONS _____ 2-92
Securing the machine ____ 2-93
CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS) 2-94
ON-BOARD CRANE (OPTIONAL) 2-95
On-board crane, monitoring, warning and control elements ___ 2-95
On-board crane, putting into operation 2-96
On-board crane, drive unit _ 2-96
On-Board crane, – blocking the boom in position of rest _ 2-97
On-board crane, checking _ 2-97
OPTIONAL EQUIPMENT ___ 2-98
Monitoring cameras 2-98
NOTES 2-99
3 INSPECTION AND SERVICING 3-101
INSPECTION AND SERVICING – SAFETY INSTRUCTIONS __ 3-103
INSPECTION AND SERVICING WORK, FIRE AND EXPLOSION HAZARD ___ 3-108
INSPECTION AND SERVICING PLANS – INSTRUCTIONS ___ 3-109
Intervals _ 3-109
Change of engine oil ____ 3-109
Air-intake system _ 3-109
Oils / Greases 3-109
Cleaning jobs 3-109
Components _ 3-109
Plan V __ 3-111
Plan N __ 3-113
Plan T and W _ 3-115
Plan A – E ___ 3-117
LUBRICATING CHART – GREASE _ 3-126
Lubricating chart – Grease (legend) _ 3-127
Filling quantities – Grease 3-127
INSPECTION PLAN – OIL _ 3-128
Inspection plan – Oil (legend) _ 3-129
Filling quantities – oil ____ 3-130
Filling quantities – other _ 3-130
LUBRICANTS _ 3-131
Notes on the selection of oils and greases __ 3-131
Avoid mixing of different hydraulic fluids ____ 3-131
I. Oils for combustion engines __ 3-132
II. Oils for hydraulic system 3-133
III.a Oils for pump gearboxes and travel gearboxes _ 3-134
III.b Oils for swing gearboxes _ 3-135
V. Greases for bearings, swing rings and track system (Central lubrication system) ____ 3-136
Grease for idlers, track rollers and support rollers (Lifetime lubrication) __ 3-137
Coolant for use on all combustion engines __ 3-138
SERVICING WORK 3-139
Hose line for oil and cooling liquid changes _ 3-139
ENGINE __ 3-140
Engine – Safety instructions ___ 3-140
Engine oil, checking the level / topping up __ 3-141
Engine oil reservoir, checking the oil level / topping up __ 3-142
Engine oil, change 3-143
Engine oil reservoir (optional), draining the oil off _ 3-145
Oil change prolongation system, replacing the oil filter __ 3-147
Eliminator filter and centrifuge (optional) ____ 3-148
Cold-starting fluid (ether) – Replacing the pressure vessel ___ 3-150
COOLING SYSTEM 3-151
Cooling liquid, change ___ 3-154
Water filter, change _____ 3-156
AIR-INTAKE SYSTEM ____ 3-157
Main filter elements, removal and installation 3-158
Main filter elements, checking and cleaning _ 3-159
Safety filter element, replace __ 3-160
Air-intake lines 3-161
Dust collection 3-161
FUEL SYSTEM 3-162
Fuel system, Safety instructions __ 3-162
Fuel filter, replace 3-162
Fuel system, venting ____ 3-163
Cleaning the fuel tanks __ 3-163
Water trap (option) _____ 3-165
ELECTRICAL SYSTEM ___ 3-167
Electrical system – Safety instructions 3-167
Alternator – Instructions __ 3-167
Battery __ 3-168
Switchgear cabinet _____ 3-170
Floodlight projector, replacing the lamp ____ 3-172
HYDRAULIC SYSTEM ____ 3-174
Hydraulic system – Safety instructions _____ 3-174
Depressurizing the hydraulic system _ 3-174
Checking the hydraulic oil level 3-175
Changing the hydraulic oil return-flow filters (hydraulic oil reservoir) ____ 3-177
Bypass valves (hydraulic oil reservoir) _____ 3-179
Replacing the bypass valves and sealing rings ___ 3-179
Breather filter _ 3-180
Filter (control circuit) ____ 3-181
High-pressure filter for working hydraulics __ 3-182
High-pressure filters for the servo circuit ____ 3-183
High-pressure filters for feeding circuits and slewing pumps _ 3-184
High-pressure filters for slewing circuit _____ 3-185
Changing the hydraulic oil 3-186
Avoid mixing of different hydraulic fluids ____ 3-186
Venting the hydraulic system _ 3-190
Cleaning the hydraulic oil cooler __ 3-191
Electronic excavator control __ 3-192
Pressure accumulator – Emergency lowering 3-193
PUMP TRANSFER GEARBOX _ 3-194
Checking the gearbox oil level / Topping up with oil 3-194
Changing the gearbox oil 3-195
Gearbox, breather valve _ 3-196
Pre-chamber, breather valve __ 3-197
Pump transfer gearbox lube oil filters 3-198
SWING GEARBOX 3-199
Gearbox – Checking the oil level / Topping up with oil __ 3-199
Changing the gearbox oil 3-199
Gearbox venting _ 3-200
TRAVEL GEARBOX (VALID FOR GEARBOX PN 3673978) __ 3-201
Travel gearbox – Checking the oil level / Topping up with oil _ 3-201
Travel gearbox – Changing oil _ 3-202
Breather filters, clean / replace 3-203
TRAVEL GEARBOX (VALID FOR GEARBOX PN 2763214) __ 3-204
Travel gearbox – Checking the oil level / Topping up with oil _ 3-204
Travel gearbox – Changing oil _ 3-205
Pre-stage – Changing the oil __ 3-205
Brake chambers – Changing oil 3-206
Breather filters, clean / replace 3-206
CRAWLER TRACKS _____ 3-207
Track roller, Support roller 3-208
Track tensioner 3-209
Pressure-accumulator inspection regulations 3-210
Checking the gas charging pressure in the pressure accumulator 3-210
SWING RING __ 3-211
Swing ring – Instructions _ 3-211
Bearing races 3-211
CENTRAL LUBRICATING _ 3-213
Design __ 3-213
Function 3-214
Filling up the grease container 3-215
Breather filter _ 3-215
Checking the greasing pressure __ 3-216
Unblocking a grease line. 3-217
Oilfilter (hydraulic circuit grease pump) _____ 3-218
Grease filter (Filling the grease container) __ 3-219
Grease filter (Grease lines) ___ 3-220
OTHER MAINTENANCE __ 3-221
Engine __ 3-221
Equipment, checking ____ 3-222
Hydraulic ladder (optional) ___ 3-222
Pressure-accumulator inspection regulations 3-223
Extract from the German regulations 3-223
Checking the gas charging pressure in the pressure accumulator 3-223
ON-BOARD CRANE, DRIVE UNIT _ 3-224
On-board crane, lubricating ___ 3-225
On-Board crane, checking tightness of fastening bolts __ 3-225
PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING__ 3-226
Putting the excavator out of operation 3-226
Battery storage 3-226
Recommissioning 3-226
NOTES ___ 3-227
4 REPAIR WORK __ 4-1
REPAIR WORK – SAFETY INSTRUCTIONS ____ 4-3
REPAIR WORK, FIRE AND EXPLOSION HAZARD __ 4-5
REPAIR WORK, ENGINE ___ 4-6
ELECTRICAL SYSTEM _____ 4-7
Assisted starting (with jumper cables) – Safety instructions 4-7
Assisted starting (with jumper cables) 4-7
Starting the engine with jumper cables (external batteries _ 4-7
HYDRAULIC SYSTEM 4-9
Repair instructions _ 4-9
Hydraulic hoses – Instructions __ 4-9
PRESSURE ACCUMULATORS – SAFETY INSTRUCTIONS ___ 4-10
WELDING AND FLAME CUTTING WORKS – SAFETY INSTRUCTIONS __ 4-11
DISPOSAL AT THE END OF THE SERVICE LIFE __ 4-14
Dismantling and removal instructions _ 4-14
Risk of deflagrations _____ 4-14
Risk of fire 4-14
Disposing of the machine without polluting the environment __ 4-15
Further hazardous substances _ 4-15
Appropriate disposal of batteries 4-16
NOTES 4-17
5 ANNEX 5-1
TROUBLESHOOTING 5-3
Instructions on troubleshooting __ 5-3
Layout of the fault table ____ 5-3
Possible causes 5-3
Measures _ 5-3
Section ___ 5-3
FAULT TABLES __ 5-4
Combustion engine – Fault table _ 5-4
Working hydraulics – Fault table _ 5-5
Track drive – Fault table ___ 5-6
Swing mechnism – Fault table __ 5-7
Central lubricating system – Fault table 5-8
Engine electronic unit, displaying stored fault codes _ 5-9
HYDRAULIC CIRCUIT DIAGRAM 5-10
ABBREVIATIONS 5-11
ABBREVIATIONS _ 5-12
TECHNICAL DATA _ 5-13
NOTES 5-15
6 INDEX 6-1
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