CATERPILLAR 6060 AC Hydraulic Excavator Operating Instruction Manual – PDF DOWNLOAD
FILE DETAILS:
CATERPILLAR 6060 AC Hydraulic Excavator Operating Instruction Manual – PDF DOWNLOAD
Language : English
Pages : 266
Downloadable : Yes
File Type : PDF
DESCRIPTION:
CATERPILLAR 6060 AC Hydraulic Excavator Operating Instruction Manual – PDF DOWNLOAD
PREFACE:
- These operating instructions are designed to famil- iarize the operator with the machine and its
desig- nated 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 situa- tions, to reduce repair costs and downtimes and to increase the
reliability and service life of the ma- chine. - 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 available 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, troubleshooting in the course of work, care,
evacuation of pro- duction waste and disposal of fuels and con- sumables,
▪ 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 operating instructions are directed to the min- ing-machine specialist. They cannot
provide basic know-how. This can be acquired, for example, in several days’ instruction by
a qualified mechanic or by attending an Bucyrus HEX training course for operators or
maintenance personnel. - Your appropriate Bucyrus HEX dealer after-sales service will be pleased to deal with any queries
you may have after reading through the operating in- structions. - All Bucyrus HEX operating manuals are issued in German and then translated. Even a good transla-
tion may give rise to questions which Bucyrus HEX will be pleased to answer. - The operating instructions are not work instructions for carrying out major repairs. Such work is
willingly done for you by your appropriate Bucyrus HEX dealer after-sales service. - The documentation relating to the machine is listed according to scope, quantity and language in
the shipping note of the machine or in the covering letter if supplied separately. The operating
instruc- tions and spare-parts list are marked with the serial number of the machine. - On taking receipt of the consignment, please check that the documentation is complete and in the
language requested by you.
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
CATERPILLAR 6060 AC Hydraulic Excavator Operating Instruction Manual – PDF DOWNLOAD
1 INTRODUCTION 1-1
PREFACE 1-3
WARRANTY 1-4
FUNDAMENTAL SAFETY INSTRUCTIONS 1-5
Warnings and symbols 1-5
DESIGNATED USE 1-6
ORGANIZATIONAL MEASURES 1-7
Selection and qualification of personnel; basic responsibilities 1-8
Safety instructions governing specific operational phases 1-8
Special work in conjunction with utilization of the machine and maintenance and repairs as well as
troubleshooting during work; disposal of parts and consumables 1-9
Warning of special dangers 1-10
Gas, dust, steam and smoke 1-11
Hydraulic / pneumatc equipment 1-11
Noise 1-11
Oil, grease and other chemical substances 1-11
Transporting and recommissioning 1-11
ACCIDENT PREVENTION REGULATIONS FOR ELECTRICALLY POWERED EXCAVATORS 1-12
Safety instructions for excavators with electric motor 1-13
FIRE AND EXPLOSION HAZARD 1-14
NOTES 1-15
2 OPERATION 2-1
OPERATION – SAFETY INSTRUCTIONS 2-3
Operating Instructions, where to store it in the driver’s cab 2-4
FIRE AND EXPLOSION HAZARD 2-5
DESCRIPTION OF THE EXCAVATOR 2-6
Excavator layout 2-7
Undercarriage 2-8
Superstructure 2-8
Drive 2-8
Hydraulic system 2-8
Pump Managing System (PMS) 2-8
Programmable Logic Controller (PLC) 2-8
Control Management System (CMS) 2-8
Demand control / Zero-flow regulation 2-9
Board-Control-System (BCS) 2-9
Electrical system 2-9
Power supply 2-10
Operation with cable reel (optional) 2-11
Signs 2-12
Entering and leaving the machine Safety instructions 2-21
Ramp-type ladder 2-22
OPERATING INSTRUCTIONS 6060 AC
Table of contents
vi BA RH340B(3 725 092.00)-EN
Swinging ladder (optional) 2-23
Escape ladder 2-24
Cab interior lamp 2-25
Servicing lighting 2-26
Illuminating the control column 2-26
EMERGENCY STOP switch 2-27
Servicing switch 2-28
Windscreen washer 2-28
Driver’s seat 2-29
Fire extinguisher 2-31
Automatic fire-extinguishing system (optional) 2-32
Trainer’s / instructor’s seat 2-32
Emergency escape device (optional) 2-33
MONITORING, WARNING AND CONTROL ELEMENTS 2-36
PUTTING THE MACHINE INTO OPERATION 2-58
Service station (tanklift) 2-58
Battery main switch, switching on and off 2-61
Electrical system (24V), switching on and off 2-61
Switching the electric motor on and off 2-62
Time-out before restart 2-63
Electric motor can not be switched on 2-64
In case of failure 2-64
Circuit breaker, switching on and off 2-65
Motor protection relay, functions 2-67
Warm-up procedure for electric excavators 2-69
Air conditioner (option) 2-70
TRAVELLING, SAFETY INSTRUCTIONS 2-71
TRAVELLING 2-72
Superstructure basic position 2-72
Travelling forwards/backwards 2-72
Superstructure holding brake 2-76
Track parking brake 2-76
TRANSPORTING THE MACHINE 2-77
Transport – Safety instructions 2-77
WORKING OPERATION – SAFETY INSTRUCTIONS 2-78
WORKING OPERATION 2-80
Before starting work 2-80
Swinging the superstructure 2-80
Braking the superstructure 2-80
Working 2-81
Emergency lowering of the working equipment 2-82
After daily operation 2-82
ASSEMBLING WORKING EQUIPMENT – SAFETY INSTRUCTIONS 2-83
Securing the machine 2-84
OPERATING INSTRUCTIONS 6060 AC
Table of contents
BA RH340B(3 725 092.00)-EN vii
CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS) 2-85
NOTES 2-87
3 INSPECTION AND SERVICING 3-1
SAFETY INSTRUCTIONS FOR EXCAVATORS WITH ELECTRIC MOTOR 3-3
INSPECTION AND SERVICING – SAFETY INSTRUCTIONS 3-5
FIRE AND EXPLOSION HAZARD 3-9
INSPECTION AND SERVICING PLANS – INSTRUCTIONS 3-11
Intervals 3-11
Oils / Greases 3-11
Cleaning jobs 3-11
Components 3-11
Plan V 3-13
Plan N 3-15
Plan T and W 3-17
Plan A – E 3-19
LUBRICATING CHART – GREASE 3-26
Lubricating chart – Grease (legend) 3-26
Filling quantities – Grease 3-27
INSPECTION PLAN – OIL 3-28
Inspection plan – Oil (legend) 3-29
Filling quantities – oil 3-30
Filling quantities – other 3-30
LUBRICANTS 3-31
Notes on the selection of oils and greases 3-31
Avoid mixing of different hydraulic fluids 3-31
LUBRICANTS 3-32
I. Oils for combustion engines (On-Board Crane, option) 3-32
II. Oils for hydraulic system (selection) 3-33
III.a Oils for pump gearboxes 3-34
III.b Oils for swing gearboxes 3-35
III.c Oils for drive gearboxes 3-36
V. Greases for bearings and swing rings 3-37
SERVICING WORK 3-38
Hose line for oil changes 3-38
ELECTRIC MOTOR 3-39
Electric motor – Safety instructions 3-39
Cleaning the electric motor 3-39
Electric motor, greasing 3-40
ELECTRICAL SYSTEM 3-41
Electrical system – Safety instructions 3-41
Battery 3-42
Control cabinets 3-44
Slip ring assembly, servicing work 3-46
Floodlight projector, replacing the lamp 3-47
OPERATING INSTRUCTIONS 6060 AC
Table of contents
viii BA RH340B(3 725 092.00)-EN
Lighting systems in LED technonogy, instructions 3-49
HYDRAULIC SYSTEM 3-50
Hydraulic system – Safety instructions 3-50
Depressurizing the hydraulic system 3-50
Checking the hydraulic oil level 3-51
Changing the hydraulic oil return-flow filter (hydraulic oil reservoir) 3-53
Bypass valves (hydraulic oil reservoir) 3-55
Breather filter 3-56
Filter (servo control circuit), replace 3-57
High-pressure filter for working hydraulics, replace 3-58
Filters for swing charge pump, replace 3-59
Bearing flushing of the main pumps, filter replacement Bearing flushing of the main pumps, filter
replacement 3-60
Changing the hydraulic oil 3-61
Venting the hydraulic system 3-65
Cleaning the hydraulic oil cooler 3-66
Electronic excavator control 3-67
Pressure accumulator – Emergency lowering 3-68
PUMP TRANSFER GEARBOX 3-69
Pump gearbox, checking oil level / Topping up with oil 3-69
Pump gearbox, pre-chamber 3-71
Pump gearbox, venting 3-71
Pre-chambers working pumps, draining oil, changing oil 3-72
Pre-chambers swing pumps, draining oil, changing oil 3-72
Pump gearbox, oil filter 3-73
SWING GEARBOX 3-74
Swing gearbox – Checking the oil level / Topping up with oil 3-74
Changing the gearbox oil 3-74
Swing gearbox, venting , 3-75
TRAVEL GEARBOX (GEARBOX P/N 3683483) 3-76
Travel gearbox – Checking the oil level / Topping up with oil 3-76
Travel gearbox – Changing oil 3-77
Travel gearbox – Breather filter 3-78
TRAVEL GEARBOX (GEARBOX P/N 3683496) 3-79
Travel gearbox – Checking the oil level / Topping up with oil 3-79
Travel gearbox – Changing oil 3-81
Travel gearbox -Breather filter 3-82
CRAWLER TRACKS 3-83
Track rollers 3-84
Track tensioner 3-85
Pressure-accumulator inspection regulations 3-86
Checking the gas charging pressure in the pressure accumulator 3-86
SWING RING 3-87
Swing ring – Instructions 3-87
Bearing races 3-87
CENTRAL LUBRICATING 3-89
Design and function 3-89
OPERATING INSTRUCTIONS 6060 AC
Table of contents
BA RH340B(3 725 092.00)-EN ix
Function 3-90
Filling up the grease container 3-91
Breather filter 3-91
Checking the greasing pressure 3-92
Checking the greasing pressure 3-93
Unblocking a grease line. 3-94
Unblocking a grease line. 3-94
Oilfilter (hydraulic circuit grease pump) ) 3-95
Grease filter (Filling the grease container) 3-96
Grease filter (Grease lines) 3-97
OTHER MAINTENANCE 3-98
Heating and air conditioning 3-98
Equipment, check for cracks 3-98
Reservoirs for used grease at the A-frame, emptying 3-99
Hydraulic ladder, pressure accumulator 3-99
Pressure-accumulator inspection regulations 3-100
Extract from the regulations 3-100
Checking the gas charging pressure in the pressure accumulator 3-100
ON-BOARD CRANE (OPTIONAL) 3-101
Crane, monitoring, warning and control elements 3-101
Checking the on-board crane 3-101
Crane, drive unit 3-102
On-board crane, servicing 3-102
On-Board crane, checking tightness of fastening bolts 3-103
PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING 3-104
Putting the excavator out of operation 3-104
Battery storage 3-104
Recommissioning 3-104
NOTES 3-105
4 REPAIR WORK 4-1
SAFETY INSTRUCTIONS FOR EXCAVATORS WITH ELECTRIC MOTOR 4-3
REPAIR WORK – SAFETY INSTRUCTIONS 4-5
FIRE AND EXPLOSION HAZARD 4-7
HYDRAULIC SYSTEM 4-8
Repair 4-8
Hydraulic hoses – Instructions 4-8
PRESSURE ACCUMULATORS – SAFETY INSTRUCTIONS 4-9
WELDING AND FLAME CUTTING WORKS – SAFETY INSTRUCTIONS 4-10
DISPOSAL AT THE END OF THE SERVICE LIFE 4-13
Appropriate disposal of batteries 4-14
OPERATING INSTRUCTIONS 6060 AC
Table of contents
x BA RH340B(3 725 092.00)-EN
NOTES 4-15
5 ANNEX 5-1
TROUBLESHOOTING 5-3
Instructions on troubleshooting 5-3
Layout of the fault table 5-3
Possible causes 5-3
Measures 5-3
Section 5-3
FAULT TABLES 5-4
Working hydraulics – Fault table 5-4
Track drive – Fault table 5-5
Swing mechnism – Fault table 5-6
Central lubricating system – Fault table 5-7
HYDRAULIC CIRCUIT DIAGRAM 5-8
ABBREVIATIONS 5-9
TECHNICAL DATA 5-11
NOTES 5-13
6 INDEX 6-1
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