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CAT 6060 6060FS Hydraulic Shovel Operation & Maintenance Manual – PDF DOWNLOAD
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Description
CAT 6060 6060FS Hydraulic Shovel Operation & Maintenance Manual – PDF DOWNLOAD
FILE DETAILS:
CAT 6060 6060FS Hydraulic Shovel Operation & Maintenance Manual – PDF DOWNLOAD
Language : English
Pages : 346
Downloadable : Yes
File Type : PDF
DESCRIPTION:
CAT 6060 6060FS Hydraulic Shovel Operation & Maintenance Manual – PDF DOWNLOAD
PREFACE:
- These operating instructions are designed to fa- miliarize the operator with the machine
and its designated use. - The operating instructions contain important in- formation 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 avail- able 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
■ operation, including setting-up, troubleshoot- ing 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 operating instructions and the mandatory rules and regulations for
accident pre- vention 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 .
PREFACE:
- These operating instructions are designed to fa- miliarize the operator with the machine
and its designated use. - The operating instructions contain important in- formation 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 avail- able 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
■ operation, including setting-up, troubleshoot- ing 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 operating instructions and the mandatory rules and regulations for
accident pre- vention 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 .
- The Operation and Maintenance Manual are di- rected to the mining-machine specialist. They
can- not provide basic know-how. This can be acquired, for example, in several days’ instruction by
a quali- fied CGM-HMS GmbH (Caterpillar Global Mining Hydraulic Mining Shovels GmbH)
mechanic or by attending an CGM-HMS GmbH training course for operators or maintenance
personnel. - The CGM-HMS GmbH after-sales service will be pleased to deal with any queries you may have
after reading through the Operation and Maintenance Manual. - The Operation and Maintenance Manual does not contain work instructions for carrying out
major re- pairs. Such work is willingly done for you by the
CGM-HMS GmbH after-sales service.
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
CAT 6060 6060FS Hydraulic Shovel Operation & Maintenance Manual – PDF DOWNLOAD
TITLEPAGE..................................................................................................................................................................... 1 Important Safety Information ................................................................................................................................................. 2 This page intentionally left blank........................................................................................................................................ 4 1 INTRODUCTION................................................................................................................................................................ 13 This page intentionally left blank........................................................................................................................................ 14 PREFACE .................................................................................................................................................................. 15 About this Operation and Maintenance Manual .......................................................................................................................... 15 Further machine documentation ........................................................................................................................................ 15 WARRANTY ................................................................................................................................................................. 16 FUNDAMENTAL SAFETY INSTRUCTIONS .......................................................................................................................................... 17 Warnings and symbols ................................................................................................................................................. 17 DESIGNATED USE ........................................................................................................................................................... 18 Noise emission information ........................................................................................................................................... 19 Vibration information ................................................................................................................................................ 19 ORGANIZATIONAL MEASURES .................................................................................................................................................. 20 Personal protective equipment and the working clothing................................................................................................................ 20 Selection and qualification of personnel; basic responsibilities ..................................................................................................... 21 Safety instructions governing specific operational phases ............................................................................................................ 21 Standard operation................................................................................................................................................ 21 Special work in conjunction with utilization of the machine and maintenance and repairs as well as troubleshooting during work; disposal of parts and consumables .... 22 Warning of special dangers ........................................................................................................................................... 23 Electric energy................................................................................................................................................... 23 High-voltage system............................................................................................................................................... 23 Battery .......................................................................................................................................................... 23 Gas, dust, steam and smoke ........................................................................................................................................... 23 Hydraulic equipment .................................................................................................................................................. 24 Noise............................................................................................................................................................. 24 Oil, grease and other chemical substances......................................................................................................................... 24 Ether............................................................................................................................................................. 24 Transporting and recommissioning.................................................................................................................................. 24 FIRE AND EXPLOSION HAZARD ................................................................................................................................................ 25 This page intentionally left blank.................................................................................................................................... 26 NOTES .................................................................................................................................................................... 27 This page intentionally left blank.................................................................................................................................... 28 2 OPERATION................................................................................................................................................................... 29 This page intentionally left blank........................................................................................................................................ 30 OPERATION - SAFETY INSTRUCTIONS .......................................................................................................................................... 31 Operation and Maintenance Manual...................................................................................................................................... 31 Operating personnel................................................................................................................................................... 31 Personal protective gear and working clothing......................................................................................................................... 31 Safety belt........................................................................................................................................................... 31 State of the machine.................................................................................................................................................. 31 Entering and leaving the machine...................................................................................................................................... 31 Hazard range.......................................................................................................................................................... 31 Persons within the hazard zone........................................................................................................................................ 32 Marshallers........................................................................................................................................................... 32 Securing the machine.................................................................................................................................................. 32 Operation and Maintenance Manual, where to store it in the operator’s cab ............................................................................................ 32 FIRE AND EXPLOSION HAZARD................................................................................................................................................. 33 DESCRIPTION OF THE EXCAVATOR ............................................................................................................................................. 34 Excavator layout ..................................................................................................................................................... 35 Undercarriage..................................................................................................................................................... 35 Superstructure.................................................................................................................................................... 35 Loading bucket.................................................................................................................................................... 35 Backhoe bucket.................................................................................................................................................... 35 Undercarriage ........................................................................................................................................................ 36 Superstructure ....................................................................................................................................................... 36 Drive unit ........................................................................................................................................................... 36 Hydraulic system ..................................................................................................................................................... 36 Control and Monitoring Platform (CAMP) ............................................................................................................................... 36 Board-Control-System (BCS) ........................................................................................................................................... 37 Demand control / Zero-flow regulation................................................................................................................................. 37 Automatic reset to idling............................................................................................................................................. 37 Electrical system .................................................................................................................................................... 37 Signs ................................................................................................................................................................ 38 Warning and instruction signs..................................................................................................................................... 38 Machine number.................................................................................................................................................... 45 Engine serial number.............................................................................................................................................. 45 Engine Information Plate.......................................................................................................................................... 45 Component numbers................................................................................................................................................. 45 Entering and leaving the machine, Safety instructions ................................................................................................................ 46 Access ladder lighting ............................................................................................................................................... 46 Swinging ladder ...................................................................................................................................................... 47 Folding ladder (optional) ............................................................................................................................................ 48 Emergency exit in operator’s cab and escape ladder ................................................................................................................... 49 Switching the cab interior lighting on and off ....................................................................................................................... 50 Switching the maintenance lights on and off .......................................................................................................................... 51 Emergency shut-off function .......................................................................................................................................... 52 Emergency shut off switch in the operator’s cab................................................................................................................... 52 Emergency shut off switch at the engine compartments.............................................................................................................. 52 Emergency shut off switch on the control cabinet engine module.................................................................................................... 52 Emergency shut off switches (continued)........................................................................................................................... 53 Emergency shut off pull switch between left fuel tank and counterweight........................................................................................... 53 Emergency shut off switch on the Servicestation (tanklift)........................................................................................................ 53 Putting the machine back into operation, reset of emergency shut off function ........................................................................................ 53 Battery isolator switch, shutting off supply voltage ................................................................................................................. 54 Starter isolator switch, shutting off starter voltage ................................................................................................................ 54 Operator’s seat ..................................................................................................................................................... 55 Reducing operators exposure to vibrations ............................................................................................................................ 57 Trainer's / instructor's seat ........................................................................................................................................ 57 Windscreen washer .................................................................................................................................................... 57 Operating hours meter ................................................................................................................................................ 57 Fire extinguisher..................................................................................................................................................... 58 Extinguishing agent .............................................................................................................................................. 58 Handling.......................................................................................................................................................... 58 Inspection........................................................................................................................................................ 58 Automatic fire-extinguishing system (optional) ....................................................................................................................... 59 Inspection........................................................................................................................................................ 59 Manual activation................................................................................................................................................. 59 Harness (optional) ................................................................................................................................................... 60 Elements of the harness........................................................................................................................................... 60 Important hints................................................................................................................................................... 60 Taking on harness................................................................................................................................................. 61 This page was intentionally left blank............................................................................................................................ 63 MONITORING, WARNING AND CONTROL ELEMENTS ................................................................................................................................. 64 Engine 1 (LH), control and monitoring ................................................................................................................................ 71 Engine 2 (RH), control and monitoring ................................................................................................................................ 73 Optional equipment: Auxiliary heating; Fuel Pre-heating........................................................................................................... 87 Optional equipment: Air conditioning.............................................................................................................................. 89 Optional equipment: Air filter monitoring......................................................................................................................... 91 PUTTING THE MACHINE INTO OPERATION ....................................................................................................................................... 92 Reducing the operator's exposure to noise ............................................................................................................................ 92 Refuelling ........................................................................................................................................................... 93 Refuelling - Safety instructions ................................................................................................................................. 93 Back-up heating (option), filling in fuel ............................................................................................................................ 93 Service station (tanklift) ........................................................................................................................................... 94 To lower the service station:..................................................................................................................................... 94 To bring the service station in the upmost position:.............................................................................................................. 94 Refilling and draining ........................................................................................................................................... 95 Emergency off switch ................................................................................................................................................. 96 Switching the electrical system on and off ...........................................................................................................................101 Engines, emergency shut-off ..........................................................................................................................................101 STARTING AND STOPPING THE ENGINES ........................................................................................................................................102 Starting the engines .................................................................................................................................................102 Starting the left-hand engine.........................................................................................................................................102 Starting the right-hand engine........................................................................................................................................102 Engines – adjusting the speed ........................................................................................................................................103 Starting the engines at low temperatures .............................................................................................................................103 Shutting off the engines .............................................................................................................................................104 Shutting off the left-hand engine.....................................................................................................................................104 Shutting off the right-hand engine....................................................................................................................................104 AIR CONDITIONER (OPTIONAL) ...............................................................................................................................................105 Control unit (SIGMA dual) ............................................................................................................................................105 Back-up heating operator’s cab (optional) ............................................................................................................................106 Back-up heating (optional) ...........................................................................................................................................107 Control unit......................................................................................................................................................107 MAXIMUM MACHINE INCLINATIONS, INFORMATION ................................................................................................................................108 Instruction sign “Maximum inclination”................................................................................................................................108 Maximum machine inclinations during working operations:...............................................................................................................109 Maximum machine inclinations during travelling:.......................................................................................................................109 Maximum machine inclinations during maintenance operations:...........................................................................................................109 TRAVELLING, SAFETY INSTRUCTIONS ..........................................................................................................................................110 TRAVELLING ...............................................................................................................................................................111 Superstructure basic position ........................................................................................................................................111 Travelling forwards/backwards ........................................................................................................................................111 Regulating the travelling speed ..................................................................................................................................112 Travelling uphill and downhill ...................................................................................................................................112 Cornering ........................................................................................................................................................113 Turning ..........................................................................................................................................................113 Note..............................................................................................................................................................113 Travelling over long distances ...................................................................................................................................114 Superstructure holding brake .........................................................................................................................................115 Track parking brake ..................................................................................................................................................115 TRANSPORTING THE MACHINE .................................................................................................................................................116 Transport - Safety instructions ......................................................................................................................................116 Transport ........................................................................................................................................................116 WORKING OPERATION - SAFETY INSTRUCTIONS ..................................................................................................................................117 Running-in instructions for hydraulic cylinders.......................................................................................................................117 Warming up the hydraulic system.......................................................................................................................................117 Avoid extreme positions of the attachment.............................................................................................................................118 WORKING OPERATION ........................................................................................................................................................119 Before starting work .................................................................................................................................................119 Activating the electronic excavator control ..........................................................................................................................119 Swinging the superstructure ..........................................................................................................................................120 Braking the superstructure ...........................................................................................................................................120 Working ..............................................................................................................................................................121 Extending and retracting the bucket or backhoe bucket stick ......................................................................................................121 Opening and closing the bottom-dump bucket .......................................................................................................................121 Raising and lowering the boom ....................................................................................................................................121 Filling and emptying the bucket or the backhoe ...................................................................................................................121 Emergency lowering of the working equipment ..........................................................................................................................122 After daily operation ................................................................................................................................................123 Parking the machine ..............................................................................................................................................123 ASSEMBLING WORKING EQUIPMENT - SAFETY INSTRUCTIONS .......................................................................................................................124 Personel..............................................................................................................................................................124 Personal protective gear and working clothes..........................................................................................................................124 Tools and auxiliaries.................................................................................................................................................124 Securing the working equipment........................................................................................................................................124 Securing the machine..................................................................................................................................................124 Selecting the attachments.............................................................................................................................................124 Protective roof against falling objects...............................................................................................................................124 Securing the machine .................................................................................................................................................125 Risk of injury....................................................................................................................................................125 CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS) ...........................................................................................................126 Application of GLEITMO 815............................................................................................................................................126 ON-BOARD CRANE (OPTIONAL) ................................................................................................................................................127 Personel..............................................................................................................................................................127 On-board crane, monitoring, warning and control elements .............................................................................................................127 On-board crane, putting into operation ...............................................................................................................................128 On-board crane, drive unit ...........................................................................................................................................128 On-Board crane, – blocking the boom in position of rest ..............................................................................................................129 On-board crane, checking .............................................................................................................................................129 Extract from the inspection and testing regulations...............................................................................................................129 Monitoring cameras ...................................................................................................................................................130 NOTES ....................................................................................................................................................................131 This page intentionally left blank....................................................................................................................................132 3 INSPECTION AND SERVICING....................................................................................................................................................133 This page intentionally left blank........................................................................................................................................134 INSPECTION AND SERVICING - SAFETY INSTRUCTIONS ...........................................................................................................................135 Operation and Maintenance Manual......................................................................................................................................135 Inspection and servicing personnel....................................................................................................................................135 Personal protective equipment and working clothing....................................................................................................................135 Securing the working equipment........................................................................................................................................135 Securing the machine..................................................................................................................................................135 Climbing onto and off the machine.....................................................................................................................................135 Checking the state of tools...........................................................................................................................................135 Cleaning jobs.........................................................................................................................................................135 Handling flammable liquids............................................................................................................................................136 Fastening and securing elements.......................................................................................................................................136 Spare parts...........................................................................................................................................................136 Handling oils and greases.............................................................................................................................................136 Visible oil losses....................................................................................................................................................136 Relieving residual pressure in the hydraulic system...................................................................................................................136 Screwed connections, piping, hydraulic hoses..........................................................................................................................136 Handling of cold-starting fluid (ether)...............................................................................................................................138 INSPECTION AND SERVICING WORK, FIRE AND EXPLOSION HAZARD .................................................................................................................139 This page intentionally left blank....................................................................................................................................140 INSPECTION AND SERVICING PLANS - INSTRUCTIONS ............................................................................................................................141 Intervals.............................................................................................................................................................141 Change of engine oil..................................................................................................................................................141 Air-intake system ....................................................................................................................................................141 Oils / Greases .......................................................................................................................................................141 Cleaning jobs ........................................................................................................................................................141 Components ...........................................................................................................................................................141 This page intentionally left blank................................................................................................................................142 Plan V ...............................................................................................................................................................143 Plan N ...............................................................................................................................................................145 Plan T ...............................................................................................................................................................147 Plan A – E ...........................................................................................................................................................149 LUBRICATING CHART ........................................................................................................................................................156 Lubricating chart – Grease (legend) ..................................................................................................................................157 Filling quantities - Grease...........................................................................................................................................157 INSPECTION PLAN - OIL ....................................................................................................................................................158 Inspection plan – Oil (legend) .......................................................................................................................................159 Filling quantities - oil .............................................................................................................................................160 Filling quantities – other ...........................................................................................................................................160 LUBRICANTS / CONSUMABLES .................................................................................................................................................161 Notes on the selection of oils and greases ...........................................................................................................................161 Original CGM HMS GmbH oils and greases............................................................................................................................161 Alternative oils and greases......................................................................................................................................161 Avoid mixing of different hydraulic fluids ...........................................................................................................................161 I. Oils for combustion engines and compressors .......................................................................................................................162 II. Oil for hydraulic system .........................................................................................................................................163 III.a Oils for pump distribution gearboxes and travel gearboxes ......................................................................................................164 III.b Oils for swing gearboxes .......................................................................................................................................165 V. Grease for bearings, slew rings and track system (Central lubrication system) .....................................................................................166 Grease for idlers, track rollers and support rollers (Lifetime lubrication) ..........................................................................................167 Coolant for use on all combustion engines ............................................................................................................................168 SERVICING WORK ...........................................................................................................................................................169 Hose line for oil and cooling liquid changes .........................................................................................................................169 ENGINE ...................................................................................................................................................................170 Engine - Safety instructions .........................................................................................................................................170 Before cleaning the engines.......................................................................................................................................170 Checking the engine oil level / Topping up ..........................................................................................................................171 Engine oil reservoir, checking the oil level .........................................................................................................................172 Changing the engine oil ..............................................................................................................................................173 Drawing off engine oil with the service station...................................................................................................................173 Filling in engine oil ............................................................................................................................................174 Filling in engine oil through the service station.................................................................................................................174 Engine oil reservoir, filling in / draining off the oil ..............................................................................................................175 Draining off the oil..............................................................................................................................................175 Engine oil reservoir, filling in engine oil.......................................................................................................................176 Filters for the “Oil change interval prolongation system”, replace................................................................................................177 Replacing the oil filter .............................................................................................................................................178 Oil filters.......................................................................................................................................................178 Cold-starting fluid (ether) - Replacing the pressure vessel ..........................................................................................................179 COOLING SYSTEM ...........................................................................................................................................................180 Temperature ..........................................................................................................................................................180 Radiators ............................................................................................................................................................181 Cooling-liquid level check ...........................................................................................................................................181 Topping up cooling liquid ........................................................................................................................................182 Checking the SCA concentration ...................................................................................................................................182 Topping up cooling liquid using the Service-Station...............................................................................................................183 Cooling liquid, change ...............................................................................................................................................184 Drawing off cooling liquid .......................................................................................................................................184 Filling in cooling liquid ........................................................................................................................................185 Testing the cooling liquid composition ...............................................................................................................................186 AIR-INTAKE SYSTEM ........................................................................................................................................................187 Dust trap, cleaning .................................................................................................................................................187 Main filter elements .................................................................................................................................................188 Removal and installation .........................................................................................................................................188 Checking and cleaning the main filter element ....................................................................................................................189 Secondary filter element .............................................................................................................................................190 Removal and installation .........................................................................................................................................190 Air-intake lines .....................................................................................................................................................190 FUEL SYSTEM ..............................................................................................................................................................191 Fuel system - Safety instructions ....................................................................................................................................191 Fuel tank supply valve – function ....................................................................................................................................191 Replacing the fuel filter ............................................................................................................................................192 Venting the fuel system ..............................................................................................................................................192 Breather filter fuel tanks, replace ..................................................................................................................................192 Cleaning the fuel tanks ..............................................................................................................................................193 Water trap (option), clean / replace .................................................................................................................................195 Servicing ........................................................................................................................................................195 ELECTRICAL SYSTEM .......................................................................................................................................................197 Electrical system - Safety instructions ..............................................................................................................................197 Alternator - Instructions ............................................................................................................................................197 Electrical circuit diagrams ..........................................................................................................................................197 Electrical system switch-cabinets ....................................................................................................................................197 Replacing lamps and bulbs ............................................................................................................................................197 Xenon floodlight projector (optional), replacing the lamp ............................................................................................................198 Safety instructions...............................................................................................................................................198 Further instructions..............................................................................................................................................198 Replacing a defective Xenon-lamp..................................................................................................................................199 Lighting systems in LED technonogy, instructions .....................................................................................................................200 Battery, checking the state of charge ................................................................................................................................201 Checking the battery fluid level .................................................................................................................................201 Checking charge of batteries .....................................................................................................................................201 Battery, removing and installing .....................................................................................................................................202 Charging batteries inside the machine, safety instructions ...........................................................................................................203 Charging the batteries............................................................................................................................................203 Switchgear cabinet ...................................................................................................................................................204 Breather filter ..................................................................................................................................................204 Emptying dust trap ...............................................................................................................................................204 Emptying the dust collector ......................................................................................................................................204 Filter element ...................................................................................................................................................204 Checking and cleaning the filter element .........................................................................................................................205 HYDRAULIC SYSTEM .........................................................................................................................................................206 Hydraulic system - Safety instructions ...............................................................................................................................206 Depressurizing the hydraulic system ..................................................................................................................................206 Checking the hydraulic oil level .....................................................................................................................................207 Hydraulic oil return-flow filters, replace ...........................................................................................................................209 Remove return flow filter elements................................................................................................................................209 Install return flow filter elements...............................................................................................................................210 Remove filter-basket, inspect / clean.............................................................................................................................210 Hydraulic oil return-flow filters, replace (from machine no. 340173) .................................................................................................211 Remove return flow filter elements................................................................................................................................211 Install return flow filter elements...............................................................................................................................212 Remove filter-basket, inspect / clean.............................................................................................................................212 Bypass valves, clean / replace .......................................................................................................................................213 Cleaning the filter screens ......................................................................................................................................213 Replacing the bypass valves and sealing rings ....................................................................................................................213 Hydraulic oil tank breather filters, replace .........................................................................................................................214 Replacing the filter elements ....................................................................................................................................214 Filters (pilot control circuit), replace .............................................................................................................................215 Replacing the filter element......................................................................................................................................215 Hydraulic oil filters for working hydraulics, replace ................................................................................................................216 Replacing the filter elements ....................................................................................................................................216 Filters for swing pump charge circuit, replace .......................................................................................................................217 Replacing the filter elements ....................................................................................................................................217 Filters for swing circuits, replace ..................................................................................................................................218 Replacing the filter elements.....................................................................................................................................218 Bearing flushing for main pumps, replace filter ......................................................................................................................219 Bearing flushing, function........................................................................................................................................219 Replacing the filter element......................................................................................................................................219 Changing the hydraulic oil ...........................................................................................................................................220 Avoid mixing of different hydraulic fluids ...........................................................................................................................220 Drawing off hydaulic oil .........................................................................................................................................221 Drawing off hydaulic oil using the Service Station (tanklift).....................................................................................................221 Cleaning the hydraulic oil tank...................................................................................................................................222 Filling in hydraulic oil .........................................................................................................................................223 Venting the hydraulic system .........................................................................................................................................224 Venting / filling the hydraulic components........................................................................................................................224 Cleaning the hydraulic oil cooler ....................................................................................................................................225 Cleaning..........................................................................................................................................................225 Electronic excavator controls, clean / lubricate .....................................................................................................................226 Joystick .........................................................................................................................................................226 Pedal.............................................................................................................................................................226 Pressure accumulator - Emergency lowering ............................................................................................................................227 Fig. 3107:........................................................................................................................................................227 Pressure-accumulator inspection regulations ......................................................................................................................227 Extract from the German regulations...............................................................................................................................227 Extract from the German acceptance regulations....................................................................................................................227 PUMP DRIVE GEARBOX .......................................................................................................................................................228 Checking the gearbox oil level / Topping up with oil .................................................................................................................228 Pre-chambers, checking oil level / topping up with oil ...............................................................................................................229 Changing the gearbox oil .............................................................................................................................................230 Draining off oil..................................................................................................................................................230 Filling in oil ...................................................................................................................................................230 Pre-chambers, changing the gearbox oil ...............................................................................................................................231 Draining off oil..................................................................................................................................................231 Filling in oil ...................................................................................................................................................231 Pump drive gearbox breather valve, replace ...........................................................................................................................231 Pre-chamber breather valve, replace ..................................................................................................................................232 Pump drive gearbox lube oil filters, replace .........................................................................................................................233 SWING GEARBOX ............................................................................................................................................................234 Swing gearbox - Checking the oil level / Topping up with oil .........................................................................................................234 Gearbox venting ......................................................................................................................................................234 Changing the swing gearbox oil .......................................................................................................................................235 Draining off oil..................................................................................................................................................235 Filling in new oil / Topping up ..................................................................................................................................236 TRAVEL GEARBOX (GEARBOX P/N 3683483) ....................................................................................................................................237 Travel gearbox - Checking the oil level / Topping up with oil ........................................................................................................237 Brake housing - Checking the oil level / Topping up with oil .....................................................................................................237 Travel gearbox - Changing oil ........................................................................................................................................238 Draining off oil..................................................................................................................................................238 Filling in oil ...................................................................................................................................................238 Spur gear section - Changing the oil / Draining off oil...........................................................................................................238 Filling in oil ...................................................................................................................................................238 Brake housing - Changing oil .....................................................................................................................................239 Draining off oil..................................................................................................................................................239 Filling in oil ...................................................................................................................................................239 Travel gearbox - Breather filter .....................................................................................................................................239 TRAVEL GEARBOX(GEARBOX P/N 3683496) .....................................................................................................................................240 Travel gearbox - Checking the oil level / Topping up with oil ........................................................................................................240 Alternatively:....................................................................................................................................................240 Travel gearbox - Changing oil ........................................................................................................................................242 Draining off oil .................................................................................................................................................242 Filling in oil ...................................................................................................................................................242 Hydraulicmotor chamber - Brake housing - Changing oil ............................................................................................................243 Draining off oil..................................................................................................................................................243 Filling in oil ...................................................................................................................................................243 Travel gearbox - Breather filter .....................................................................................................................................243 TRAVEL GEARBOX(GEARBOX P/N 3749598) .....................................................................................................................................244 Travel gearbox - Checking the oil level / Topping up with oil ........................................................................................................244 Alternatively:....................................................................................................................................................244 Travel gearbox - Changing oil ........................................................................................................................................246 Draining off oil .................................................................................................................................................246 Filling in oil ...................................................................................................................................................246 Hydraulicmotor chamber - Brake housing - Changing oil ............................................................................................................247 Draining off oil..................................................................................................................................................247 Filling in oil ...................................................................................................................................................247 Travel gearbox - Breather filter .....................................................................................................................................247 CRAWLER TRACKS ...........................................................................................................................................................248 Cleaning .............................................................................................................................................................248 Track roller, lubricating ............................................................................................................................................249 Track roller fastening ...........................................................................................................................................249 Support roller fastening .........................................................................................................................................249 Track tensioner ......................................................................................................................................................250 Design ...........................................................................................................................................................250 Technical data ...................................................................................................................................................250 Function .........................................................................................................................................................250 Pressure-accumulator inspection regulations ..........................................................................................................................251 Extract from the German regulations...............................................................................................................................251 Extract from the German acceptance regulations....................................................................................................................251 Checking the gas charging pressure in the pressure accumulator........................................................................................................251 SWING RING ...............................................................................................................................................................252 Swing ring - Instructions.............................................................................................................................................252 Bearing races.........................................................................................................................................................252 Internal gearing..................................................................................................................................................252 Swing ring - Checking the grease filling..........................................................................................................................253 Swing ring - Filling in grease....................................................................................................................................253 Swing ring - Checking the bolts for tightness.....................................................................................................................253 CENTRAL LUBRICATING SYSTEM ...............................................................................................................................................254 Design ...............................................................................................................................................................254 Function .............................................................................................................................................................255 Filling up the grease container ......................................................................................................................................256 Breather filter grease container, check / replace ....................................................................................................................256 Checking the greasing pressure .......................................................................................................................................257 Unblocking a grease line .............................................................................................................................................257 Oilfilter replace (hydraulic circuit grease pump) ....................................................................................................................258 Replacing the filter element......................................................................................................................................258 Grease filter replace (filling the grease container) .................................................................................................................259 Replacing the filter element......................................................................................................................................259 Grease filter replace (Grease lines) .................................................................................................................................259 Replacing the filter element......................................................................................................................................259 OTHER MAINTENANCE ........................................................................................................................................................260 Engine ...............................................................................................................................................................260 Cleaning .........................................................................................................................................................260 Before cleaning the engines.......................................................................................................................................260 Means of fastening ...............................................................................................................................................260 Exhaust system ...................................................................................................................................................260 Cooling system ...................................................................................................................................................260 Reservoirs for used grease at the A-frame, emptying ..................................................................................................................261 Heating and air conditioning .........................................................................................................................................261 Working equipment, check for cracks ..................................................................................................................................262 HYDRAULIC LADDER .........................................................................................................................................................263 Pressure-accumulator inspection regulations .........................................................................................................................264 Extract from the German regulations...................................................................................................................................264 Extract from the German acceptance regulations....................................................................................................................264 Checking the gas charging pressure in the pressure accumulator........................................................................................................264 ON-BOARD CRANE, DRIVE UNIT ...............................................................................................................................................265 Crane engine..........................................................................................................................................................265 Hydraulic system......................................................................................................................................................265 On-board crane, lubricating ..........................................................................................................................................266 Servicing work....................................................................................................................................................266 On-Board crane, checking tightness of fastening bolts ................................................................................................................266 PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING ...............................................................................................................267 Putting the excavator out of operation ...............................................................................................................................267 Battery storage ......................................................................................................................................................267 Recommissioning ......................................................................................................................................................267 This page intentionally left blank................................................................................................................................268 NOTES ....................................................................................................................................................................269 This page intentionally left blank....................................................................................................................................270 4 REPAIR WORK.................................................................................................................................................................271 This page intentionally left blank........................................................................................................................................272 REPAIR WORK - SAFETY INSTRUCTIONS ........................................................................................................................................273 Operating instructions................................................................................................................................................273 Repair personnel......................................................................................................................................................273 Working in greater heights............................................................................................................................................273 Prestressed units.....................................................................................................................................................273 Dismantling components................................................................................................................................................273 Never remove lead seals...............................................................................................................................................273 After the repair work.................................................................................................................................................273 CONFINED SPACES - SAFETY INSTRUCTIONS ....................................................................................................................................274 REPAIR WORK, FIRE AND EXPLOSION HAZARD ...................................................................................................................................275 REPAIR WORK, ENGINE ......................................................................................................................................................276 Before cleaning the engines...........................................................................................................................................276 HYDRAULIC SYSTEM .........................................................................................................................................................277 Repair instructions ..................................................................................................................................................277 Hydraulic hoses – Instructions ......................................................................................................................................277 PRESSURE ACCUMULATORS - SAFETY INSTRUCTIONS...............................................................................................................................278 WELDING AND FLAME CUTTING WORKS - SAFETY INSTRUCTIONS ....................................................................................................................279 Welding work by qualified personnel only..............................................................................................................................279 Increased risk of fire during welding work............................................................................................................................279 Health hazards........................................................................................................................................................279 Tanks, pressure vessels and pressure accumulators.....................................................................................................................280 Slewing rings and articulated joints..................................................................................................................................280 Information relating to the electrical system and to electronic modules...............................................................................................280 Welding on the counterweight..........................................................................................................................................281 Welding on components of the working equipment and on other fully or partly closed steel structures...................................................................281 Welding on the cab....................................................................................................................................................281 Further information...................................................................................................................................................281 DISPOSAL AT THE END OF THE SERVICE LIFE .................................................................................................................................282 Dismantling and removal instructions .................................................................................................................................282 Risk of deflagrations ................................................................................................................................................282 Risk of fire .........................................................................................................................................................282 Disposing of the machine without polluting the environment ...........................................................................................................283 Further hazardous substances .........................................................................................................................................283 Appropriate disposal of batteries ....................................................................................................................................284 NOTES ....................................................................................................................................................................285 This page intentionally left blank....................................................................................................................................286 5 ANNEX.......................................................................................................................................................................287 This page intentionally left blank........................................................................................................................................288 BOARD-CONTROL-SYSTEM .....................................................................................................................................................289 BCS III, what’s that? ................................................................................................................................................289 What it is........................................................................................................................................................289 What it does......................................................................................................................................................289 Benefits for the operator.........................................................................................................................................289 SIL2 functionality................................................................................................................................................289 Want more information?............................................................................................................................................289 The keys on the front side ...........................................................................................................................................290 Other elements on the front side .....................................................................................................................................290 BCSIII, the start screen .............................................................................................................................................291 Information given on the start screen, top section ...................................................................................................................292 Information given on the start screen, central section ...............................................................................................................293 Information given on the start screen, lower section .................................................................................................................294 Emergency Stop, reset function .......................................................................................................................................295 Swing circuit lock-out function ......................................................................................................................................296 Information given on the “Service” screen ............................................................................................................................297 Engine data screen ...................................................................................................................................................298 Hydraulic data screen ................................................................................................................................................299 Lubrication data screen ..............................................................................................................................................300 Controls adjustment data screen ......................................................................................................................................301 View documents screen ................................................................................................................................................302 Signal table screen ..................................................................................................................................................303 Signal table screen, location ........................................................................................................................................304 Signal table screen, diagram .........................................................................................................................................305 Signal table screen, diagram configuration ...........................................................................................................................306 Code table screen ....................................................................................................................................................307 Slew brake test screen ...............................................................................................................................................308 BCS III, interfaces ..................................................................................................................................................309 USB interface, data storage ..........................................................................................................................................309 Saving data to a USB stick ...........................................................................................................................................310 Saving data to a USB stick, continued ................................................................................................................................311 Saving data to a USB stick, continued ................................................................................................................................312 BCSIII, cleaning .....................................................................................................................................................313 BCSIII, disposal .....................................................................................................................................................313 TROUBLESHOOTING ..........................................................................................................................................................314 Instructions on troubleshooting ......................................................................................................................................314 Layout of the fault table ............................................................................................................................................314 Fault.............................................................................................................................................................314 Possible causes ......................................................................................................................................................314 Measures .............................................................................................................................................................314 Section ..............................................................................................................................................................314 FAULT TABLES .............................................................................................................................................................315 Combustion engine - Fault table ......................................................................................................................................315 Working hydraulics – Fault table .....................................................................................................................................316 Track drive – Fault table ............................................................................................................................................317 Swing mechnism – Fault table .........................................................................................................................................318 Central lubricating system – Fault table .............................................................................................................................319 HYDRAULIC CIRCUIT DIAGRAM ................................................................................................................................................320 Vibration data .......................................................................................................................................................320 ABBREVIATIONS ............................................................................................................................................................321 ABBREVIATIONS.........................................................................................................................................................322 PRODUCT SPECIFICATION SHEET ..............................................................................................................................................323 Titlepage_6060_Specifications.........................................................................................................................................325 NOTES ....................................................................................................................................................................337 6 INDEX.......................................................................................................................................................................339 This page intentionally left blank........................................................................................................................................340
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