Mejoras De Fabrica Pala 6060fs Cat
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6060 / 6060 FS – History and Improvements Presenter Name
2014 Improvements
2
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New Air Cleaner Installation for 3512C engines •
Due to some problems in extremely dusty environments the air cleaners for 3512 C engines are changed – – –
Installation was successfully tested in Mauretania Clean arrangement with better service accessibility on upper deck Standard from unit 340191 (Mid 2014)
Proven Cat air-filterbox used on mining trucks
3
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Options to become standard in 2014
•
Operators Cab – – – –
4
Heating ventilating and air-conditioning system in cab Emergency rescue seat at cab Roller blinds at all windows External sun shields at side and rear Windows
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Options to become standard in 2014
•
Attachment – –
5
LED high brightness working flood lights at boom (FS & BH) Guards for shovel cylinders (FS)
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Options to become standard in 2014
•
Swing ring –
Two greasing pinions for the internal gearing of the swing ring supplied by the automatic lubrication system •
–
Two additional pinions which are made of felt will be installed inside the slew ring. These pinions are connected to the central lubrication system. The grease is distributed through holes in each tooth of that pinions. This system ensures that the slew ring teeth will be directly lubricated over their entire height which will reduce wear.
Dirt wipers at swing ring to prevent build-up of debris between swing ring and carbody •
The slew bearing will be equipped with 2 dirt wipers. These will clean the top chord of the car body
from material spillage in the area underneath the slew ring during slewing.
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2012 Improvements MDG updates
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2012 Improvements MDG updates Undercarriage
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Undercarriage
Old
New
• Revised hose routing on track frames • All hoses are separated by clams • No use of spiral wrap
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Undercarriage
• Revised hose routing track tensioning
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Undercarriage • Improved hose routing
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2012 Improvements MDG updates Superstructure
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Superstructure OLD
• Different hydraulic concept for travelling • More space on superstructure
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NEW
Superstructure
• Slew gear box covers • New routing servo lines
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2012 Improvements MDG updates Cab
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Cab
• Working lights have been moved to side and are installed underneath the FOPS structure • Lights are accessible from walkway Improved serviceability • LED lights instead of Xenon • New stainless steel panel and new switches on control tower 16
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2012 Improvements MDG updates Cab Module & Access/Egress
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Cab Module & Access/Egress • Revised design of access to cab • Step and handrail design • Revised design of emergency egress • Extended back protection • New control device • Walkway in front of cab has been removed
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Cab Module & Access/Egress
• Revised walkway and handrail design • Additional toeboards
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Access System
• Revised handrail design • New step design
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Cab Module
• All hydraulic controls on the cab module have been removed completely • All controls moved to the attachment and to the main control plate between the pumps
Optional feature
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Cab Module
• New door handles • Filter openings in door have been closed • Hoses for ladder control have been removed • Pressure vessel is now installed from underneath
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Cab Module • Working lights mounted on plate which can be opened from inside better serviceability
• Plugs for main harness going to controls on attachment
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Cab Module
• Pressure vessel for ladder control and servo system are mounted underneath the cab module Good serviceability Well protected against damage less risk 24
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2012 Improvements MDG updates Oil Cooling Module
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Oil Cooling Module
• Self closing gate on opening to attachment
450 mm
1100 mm 450 mm
• Removable handrail for walkway behind valves on attachment • Redesigned handrails and kickboards to meets Australian and ISO Standards • New door handles
125 mm
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Oil Cooling Module
• Additional pressure vessel for servo circuit in oil cooling module
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2012 Improvements MDG updates Counterweight
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Counterweight
450 mm
1100 mm 450 mm
125 mm
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• Redesigned handrails and kickboards to meets Australian and ISO Standards
Counterweight – Engine oil extension
• Tank for engine oil exchange interval extension moved from cab and oil cooler module to counterweight • Pumps and Filters moved from underneath the engine to counterweight Better serviceability
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Counterweight
• New door handles • Spyhole • Doors can only be opened by using a tool
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Counterweight • Fully enclosed muffler covers instead of meshed material
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Counterweight – Fan drive
• New hydraulic lines for fan drive • Shorter hoses • No contact between hoses/hoses and hoses/steel structures
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2012 Improvements MDG updates Service Station
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Service Station •
Completely redesigned service station – Improved hose routing • Use of pipes instead of hoses
– More functions • • • • • • • • •
Coolant (including pressure relief) Hydraulic oil Gear box oil Slew gear box oil Grease Diesel Engine oil Engine oil extension Liquid ammonia (Tier 4 final preparation)
– Height of service arm has been lowered for safe and easy refueling
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Service Station • Completely retracts into safe position
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2012 Improvements MDG updates Engine Module
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Engine Covers • Covers for exhaust system • Mitigates risk of injuries • Covers hot surfaces to prevent fires
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Coolant Tanks • Stainless steel covers for coolant extension tanks • Pressure relief caps on coolant tanks • Pressure can also be relieved from service station
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Engine Module • Redesigned handrails and toeboards • Improved sealing between engine and pump compartment
1,100 mm
• Material according to AS specifications 450 mm 125 mm 450 mm
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Engine Module • New walkways in pump bay
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2012 Improvements MDG updates Hydraulics
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Hydraulics – Former Problems
OLD
• Former hose routing design was not in line with MDG 15/41 • Many hose were rubbing and were not probably supported • Accessibility with old concept was limited
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OLD
Hydraulics • Entire hydraulic system has been redesign • 3D hose routing tools have been used
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Hydraulics
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Hydraulics
NEW NEW
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2012 Improvements MDG updates Hydraulics – Swing System
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Hydraulics – Swing System • New hose routing concept • Swing blocking valves moved underneath the walkway • New blocks on swing motors for improved serviceability • Block directly mounted to swing motor
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Hydraulics – Swing System NEW
OLD
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2012 Improvements MDG updates Hydraulics – Travel System
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Hydraulics – Travel System
• Redesigned travel system • Improved hose routing • Less hoses • More space on superstructure • More efficient hydraulic system • Less heat will be created
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Hydraulics – Travel System
OLD
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NEW
2012 Improvements MDG updates Hydraulics – Leak Oil
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Hydraulics – Leak Oil
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Hydraulics – Leak Oil
Old
New
• New leak oil collector design • Revised hose routing • New fittings for sensors on pumps
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2012 Improvements MDG updates Hydraulics – Control System
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Hydraulics – Control System (Old)
Former Problems: • Hose routing on mounting plate very untidy • Hoses going to attached are cannot be routing probably • Hose routing in accordance with MDG 41 not possible 57
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Hydraulics – Control System (New) • New location in pump module
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Hydraulics – Control System Pilot Valve Block 2
Solenoid Valve (SIL)
Pilot Valve Block 1
Proportional Valve Pump Regulation
Flushing Valve
Swing Balance Valve Proportional Valve Travel 59
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Pressure Adjustment Swing Proportional Valve Swing
Hydraulics – Control System
Swing Park Brake 50 bar Pump Regulation 50 bar
Pilot 60 bar
Supply for small valve blocks Tank Swing 35 bar 2nd Speed 50 bar
60
Pump Travel Brake 30 bar
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Pilot 35 bar
Hydraulics – Control System Pilot 50 bar Track Tensioning 80 bar Ladder / Service Arm / Grease Tank 80 bar
Pump Tank
X2 Main Pumps Pilot 100 bar 61
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Travel Boost 40 bar
Clam Boost 40 bar
Hydraulics – Control System
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Hydraulics – Control System Pilot System Filter • 60 bar test point on LH engine bay • 100 bar test point on RH engine bay
Gear Oil Filter PTO
Main Pump Bearing Flushing Filter
• New arrangement of filter for better serviceability and improved hose routing
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Hydraulics – Control System
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2012 Improvements MDG updates Attachment
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Hydraulics – Attachment
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Attachment
• Flexible mounting base for handrails on attachment
• Additional walkways behind main control valves • Removable handrail
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Attachment
• Fall arrest kit on boom
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2012 Improvements MDG updates Electrics
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Electrics
• Battery and starter Isolator Station on main deck • Easily accessible • Close to the battery box • Short cable length
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Electrics
• Clear and durable labeling of sensor cables
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Electrics
• Additional circuit breaker for alternators
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Electrics
• New electrical cabinet on main control plate for improved cable routing
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2012 Improvements MDG updates Fuel Tank
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Fuel Tank Capacity Increase •
Use of the additional engine oil tanks installed in the cab and oil cooler module (for oil change interval extension) as fuel tanks – Additional fuel capacity: 1,200 l
•
75
Additional engine oil tanks in counterweight
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2011 Improvements
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2011 Improvements New Control and Monitoring Platform (CAMP) Including new Boad Control System (BCS)
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Control And Monitoring Platform CAMP BCS III
CAN bus II CAN bus I
J1939
Drive train controller LH 78
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J1939
Servo controller
Auxiliary Controller
Drive train controller RH
Board Control System – BCS III
Control Tower in ergonomic position for the operator Cleary labeled push buttons 79
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Interfaces: USB, CAN BUS Lan (TPC/IP)
BCS Display with 12” high resolution touch screen
BCS III – Operator Comfort •
Large 12” touch screen – –
•
Monitoring of operating data – –
•
80
PDF documents on board
Beside the factory setting 3 further settings can be defined and stored
Various languages can be selected On screen PDF documentation –
•
Type of warning is programmable Detailed description of fault First action suggestions
Joystick characteristics adjustable to operator preferences –
• •
Approx. 30 analogue and 50 digital sensors Comparison with set values and indication of deviating values
Visual and acoustic warnings – – –
•
Intuitive handling Adjustable brightness for night operation
Operating instruction
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Trouble shooting assistance
2010-2011 Improvements
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2010-2011 Improvements
Second Horn on oil cooler module • •
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Standard scope of supply Field conversion kit available
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2010-2011 Improvements
Track tensioning system • • •
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Flexible connection of push tube to slider Push tube supported by additional ring Will be implemented in serial production by 2011
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2010-2011 Improvements
Bucket Clam Cylinder • • • •
Increase of piston diameter from 220 mm to 250 mm Retraction force increased by 39 % Current cylinder: 3684640 / New Cylinder: 3713737 Currently under field test; serial production will follow after successful field tests ∅250
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2010-2011 Improvements
New manhole covers for attachment
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2010-2011 Improvements
Service lights • • • • •
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New LED maintenance lights All machines since March 2010 are equipped with these lights Better light output Solid material Supplier: ABL
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2010-2011 Improvements
Fans Oil Cooling System • •
The metal fans have been replaced by plastic fans Less weight of the fans leads to increased life expectancy of fan drive system
OLD
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NEW
2010-2011 Improvements
New installation plate on cab module •
Clear arrangement of components
•
Pre-assembly possible
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2010-2011 Improvements
Installation of pipes instead of hoses where worthwhile
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2010-2011 Improvements Modified Hose Arrangement •
Extensive usage of brackets and clamps for fixed hose routing
•
In steel structure integrated hose connection brackets between modules – Easier assembly / disassembly of modules – Shorter hoses for better handling
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2010-2011 Improvements Self-aligning roller bearings
PTO • Modified PTO – New bearing of input shaft – New oil dipstick – New Shaft sealing ring
OLD Fitting key
– Gearing instead of fitting key
• Part-No: – Old: 3691273 – Modification Kit: 6004320 – New: 3705643 / 3705638
cylinder roller bearings Groove ball bearings
NEW
Gearing instead of fitting key 91
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2010-2011 Improvements New pre-assembled installation plate •
Various servo control components and hydraulic filters are pre-assembled on a new installation plate – Easier assembly/disassembly – Easier service due to clear arrangement
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2010-2011 Improvements Cat® Air Cleaners for Cat® 3512C engines New brackets
CAT Air-Filterbox with precleaner
Easy to maintain! new steel pipes 93
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New silicon adapters
2010-2011 Improvements
Main Valve Block • • • •
Main valve block completely reworked Optimized pipe routing Easy replacement through standardized pipes Optimization of all pipes through – FEM – Analysis – Natural frequency analysis
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2010-2011 Improvements
Main Pumps • •
Improvement by BoschRexroth Enlargement contact area on the sliding shoe / retainer plate by: – Downsizing of piston bore diameter on the retainer plate – Restriction on sliding shoe diameter
•
Pumps are already in field test
OLD since 04/1996 95
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NEW starting 03/2010
2010-2011 Improvements Hydraulic oil tank was optimized to increase air release • •
•
96
During testing it was found that large amounts of large bubbles 20mm and above were entering the main pumps Baffles allows a better flow of oil to increase the air release from the return oil (Even when flow rate is extremely high or oil brand and grade are not optimum) Baffle plates are a bolt on type package for easy field upgrade
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2010-2011 Improvements
Hydraulic Tank Design • •
97
Bolted hydraulic tank Bolted to both tank and excavator
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2010-2011 Improvements Steel Structure • •
Reinforced engine module frame for better support engine mounting and hydraulic tank Increased stability of steel structure
•
Reduced counterweight due to longer superstructure frame – Same stability and dynamic forces during swing like A-version
New Old 98
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2010-2011 Improvements Fuel Tank Capacity Increase (Field Solution) • • • • •
Increase of fuel tank capacity to guarantee sufficient capacity for 24 operating hours even at very high engine utilization Temporary field solution/upgrade with additional tank on top of standard tank Headroom in engine module still sufficient Tank volume increased by 768 l (each side) Total useful tank volume on even ground approx. 13000 l original tank
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complete tank modification
2010-2011 Improvements
Fuel Tank Design • •
Revised design due to cracks at the corner of the rear and front plate on the fuel tanks Repair procedure available
OLD: R = 25 mm
OLD: t = 8 mm
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NEW: R = 63mm
NEW: t =12 mm
2010-2011 Improvements New Pump Drive Coupling • • •
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Different design/supplier Same design like on RH400 First units equipped with new coupling for field testing
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2010-2011 Improvements
Handrails • •
102
New design of handrail mountings Solid base material
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History
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CAT 6060 History
The RH340 was developed on basis of the 6050 / 6050 FS model. The later upgrade to the RH340B is now called 6060 / 6060 FS
Cat® 6050 – Base Specs – – – – –
104
Bucket capacity: 26 m³ Breakout force: 1500 kN Crowd force: 1890 kN Operating weight: 505 t Engine output: 1680 kW
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CAT 6060 History
2004 – RH340 prototypes compared to 6050 / 6050 FS • New patented attachment and bucket design concept • Increased operating weight – Increased counterweight – Revised superstructure frame – Larger undercarriage
• • • • •
Shorter stick on backhoe machines Larger boom cylinders on face shovel machines Increased working pressure (320 bar) Increased digging forces longer undercarriage – 7 bottom rollers (6050: 6)
•
105
New final drive 1300 Nm (6050: 1130 Nm)
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CAT 6060 History
2004 – RH340 - Prototypes • bucket capacity: 34 m³ • breakout force: FS: 1500 kN / BH: 1240 kN • crowd force: FS: 1910 kN / BH: 1270 kN • Operating weight: FS: 552 t / BH: 547 t • Engine: 1880 kW – Cummins K1500E
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CAT 6060 History
2004/2005 – RH340 • Engine Option: Cummins QSK 45 with 2240 kW (340003) • Larger oil cooling module (+ 20 % cooling capacity) • Revised FS bucket and FS stick design • Revised BH boom structure design with man hole and new welding procedures 2005/2006 –RH340 • First machine with electric drive (340018) • Reinforced superstructure frame • New stick and bucket cylinders with increased piston diameter on Face Shovel machines – Breakout force: 1640 kN – Crowd force: 2240 kN
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CAT 6060 History
2007 – 6060 / 6060 FS (RH340B) • longer superstructure main frame (+ 300 mm) • longer engine module to fit Caterpillar 3512C engine • higher counterweight for 3512C charge air coolers • increased tank volume diesel and hydraulic oil • new main pumps – 4 x 1300 l/min (RH340: 4 x 912 l/min)
• •
new pump transfer gearbox new valve blocks – 4 units (twice RH120E installation)
•
Two engine alternatives – Cummins QSK45 (2240 kW) – Caterpillar 3512C (2240 kW)
•
108
Upgrade to B-version only for diesel machines
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Comparison: A-Version vs. B-Version Dimensions A-Version
B-Version
Length of engine module
3600 mm
3950 mm
Tail overhang
7350 mm
7700 mm
Tail swing radius
7580 mm
7955 mm
Height of counterweight
3675 mm
3975 mm
Face shovel
552.000 kg
566.600 kg
Backhoe
547.000 kg
567.500 kg
Operating weights
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Remarks had to be extended due to the longer engine blocks of the CAT engines
The CAT engines have charge air cooling which requires additional radiator space
Comparison: A-Version vs. B-Version Hydraulics A-Version
B-Version
Pump transfer gear
Same as RH200
New design
Main pumps
4 bent axis axial piston pumps
4 double pumps in swash plate design
Displacement of main pumps
1000 cm³
892 cm³ *
* The nominal capacity of (2 x 520 cm³ = 1050 cm³) is reduced to 892 cm³ to achieve a max. flow of 5200 l/min
Drive speed of main pumps
925 rpm
1457 rpm
Max. oil flow, each main pump
925 l/min
1300 l/min
All other pumps remain unchanged.
Max. total oil flow of main pumps
3700 l/min
5200 l/min
2 (like RH 200)
4 (twice RH 120E)
Hydraulic tank capacity
6100 l
7100 l
approximate
Total volume of hydraulic oil
8400 l
9400 l
Approximate
Main valve blocks
110
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Remarks Revised domensions, ratios and speeds
Necessary to cope with the higher oil flow
CAT 6060 History
2008 – Cat® 6060 • Larger (deeper) oil pan for QSK45 engines 2009 – Cat® 6060 • First RH340 electric drive according to CSA Standards for Canada • Reinforced design of backhoe boom 2010 – Cat® 6060 • Reinforced engine module frame • Revised hydraulic tank design • Revised fuel tank design • Improved hose routing • Pre-assembled installation plates for servo control components • …… 111
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Key Features of CAT 6060 Attachment Update
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CAT 6050 vs. CAT 6060: Attachment Comparison
New patented attachment design • •
Reduced stress in critical areas Reduced weight which can be added as additional payload – – – – –
Welds are out of high stress areas Material is where it needs to be Thinner plates where material is not required No internal stiffener plates Counter welded from inside
– All parts are designed in FE system
113
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CAT 6050 vs. CAT 6060: Attachment Comparison Cat® 6050
114
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Cat® 6060
Boom crack at first machine
Boom crack at the first Cat® 6060 Backhoe • • •
Cause: weld defect Change of manufacturing/welding procedure Reinforcement of bottom chord
•
Due to these improvements the problem was solved
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CAT 6050 vs. CAT 6060: Attachment Comparison
Cat® 6050 (Former design)
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Cat® 6060
CAT 6060: Stick Design
• • • •
The first FS stick design caused problems with the geometry of the attachment All following units were equipped with a new designed stick The stick on 340003 has been exchanged New stick design well proven in 48 units
Old design • Straight bottom cord
New design • Curved bottom cord
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Major Hydraulic Upgrades A-Version compared to B-Version
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Comparison: A-Version vs. B-Version Cat® 6060 – A-Version
Cat® 6060 – B-Version
• 2 Valve blocks
• 4 Valve blocks
– Same like RH 200 119
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– Same like RH120E but twice
Comparison: A-Version vs. B-Version Cat® 6060 – A-Version
Cat® 6060 – B-Version
• Bent axis main pumps • 1000 cm³
• Swash plate double pumps • Nominal 1040 cm³ Reduced to 890 cm³ – Less stress on pumps
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®
© 2013 Caterpillar. All Rights Reserved. CAT, CATERPILLAR, their respective logos, “Caterpillar Yellow,” the “Power Edge” trade dress as well as corporate and product identity used herein, are trademarks of Caterpillar and may not be used without permission.
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2014 Improvements
2
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New Air Cleaner Installation for 3512C engines •
Due to some problems in extremely dusty environments the air cleaners for 3512 C engines are changed – – –
Installation was successfully tested in Mauretania Clean arrangement with better service accessibility on upper deck Standard from unit 340191 (Mid 2014)
Proven Cat air-filterbox used on mining trucks
3
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Options to become standard in 2014
•
Operators Cab – – – –
4
Heating ventilating and air-conditioning system in cab Emergency rescue seat at cab Roller blinds at all windows External sun shields at side and rear Windows
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Options to become standard in 2014
•
Attachment – –
5
LED high brightness working flood lights at boom (FS & BH) Guards for shovel cylinders (FS)
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Options to become standard in 2014
•
Swing ring –
Two greasing pinions for the internal gearing of the swing ring supplied by the automatic lubrication system •
–
Two additional pinions which are made of felt will be installed inside the slew ring. These pinions are connected to the central lubrication system. The grease is distributed through holes in each tooth of that pinions. This system ensures that the slew ring teeth will be directly lubricated over their entire height which will reduce wear.
Dirt wipers at swing ring to prevent build-up of debris between swing ring and carbody •
The slew bearing will be equipped with 2 dirt wipers. These will clean the top chord of the car body
from material spillage in the area underneath the slew ring during slewing.
6
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2012 Improvements MDG updates
7
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2012 Improvements MDG updates Undercarriage
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Undercarriage
Old
New
• Revised hose routing on track frames • All hoses are separated by clams • No use of spiral wrap
9
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Undercarriage
• Revised hose routing track tensioning
10
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Undercarriage • Improved hose routing
11
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2012 Improvements MDG updates Superstructure
12
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Superstructure OLD
• Different hydraulic concept for travelling • More space on superstructure
13
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NEW
Superstructure
• Slew gear box covers • New routing servo lines
14
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2012 Improvements MDG updates Cab
15
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Cab
• Working lights have been moved to side and are installed underneath the FOPS structure • Lights are accessible from walkway Improved serviceability • LED lights instead of Xenon • New stainless steel panel and new switches on control tower 16
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2012 Improvements MDG updates Cab Module & Access/Egress
17
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Cab Module & Access/Egress • Revised design of access to cab • Step and handrail design • Revised design of emergency egress • Extended back protection • New control device • Walkway in front of cab has been removed
18
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Cab Module & Access/Egress
• Revised walkway and handrail design • Additional toeboards
19
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Access System
• Revised handrail design • New step design
20
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Cab Module
• All hydraulic controls on the cab module have been removed completely • All controls moved to the attachment and to the main control plate between the pumps
Optional feature
21
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Cab Module
• New door handles • Filter openings in door have been closed • Hoses for ladder control have been removed • Pressure vessel is now installed from underneath
22
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Cab Module • Working lights mounted on plate which can be opened from inside better serviceability
• Plugs for main harness going to controls on attachment
23
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Cab Module
• Pressure vessel for ladder control and servo system are mounted underneath the cab module Good serviceability Well protected against damage less risk 24
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2012 Improvements MDG updates Oil Cooling Module
25
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Oil Cooling Module
• Self closing gate on opening to attachment
450 mm
1100 mm 450 mm
• Removable handrail for walkway behind valves on attachment • Redesigned handrails and kickboards to meets Australian and ISO Standards • New door handles
125 mm
26
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Oil Cooling Module
• Additional pressure vessel for servo circuit in oil cooling module
27
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2012 Improvements MDG updates Counterweight
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Counterweight
450 mm
1100 mm 450 mm
125 mm
29
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• Redesigned handrails and kickboards to meets Australian and ISO Standards
Counterweight – Engine oil extension
• Tank for engine oil exchange interval extension moved from cab and oil cooler module to counterweight • Pumps and Filters moved from underneath the engine to counterweight Better serviceability
30
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Counterweight
• New door handles • Spyhole • Doors can only be opened by using a tool
31
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Counterweight • Fully enclosed muffler covers instead of meshed material
32
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Counterweight – Fan drive
• New hydraulic lines for fan drive • Shorter hoses • No contact between hoses/hoses and hoses/steel structures
33
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2012 Improvements MDG updates Service Station
34
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Service Station •
Completely redesigned service station – Improved hose routing • Use of pipes instead of hoses
– More functions • • • • • • • • •
Coolant (including pressure relief) Hydraulic oil Gear box oil Slew gear box oil Grease Diesel Engine oil Engine oil extension Liquid ammonia (Tier 4 final preparation)
– Height of service arm has been lowered for safe and easy refueling
35
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Service Station • Completely retracts into safe position
36
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2012 Improvements MDG updates Engine Module
37
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Engine Covers • Covers for exhaust system • Mitigates risk of injuries • Covers hot surfaces to prevent fires
38
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Coolant Tanks • Stainless steel covers for coolant extension tanks • Pressure relief caps on coolant tanks • Pressure can also be relieved from service station
39
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Engine Module • Redesigned handrails and toeboards • Improved sealing between engine and pump compartment
1,100 mm
• Material according to AS specifications 450 mm 125 mm 450 mm
40
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Engine Module • New walkways in pump bay
41
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2012 Improvements MDG updates Hydraulics
42
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Hydraulics – Former Problems
OLD
• Former hose routing design was not in line with MDG 15/41 • Many hose were rubbing and were not probably supported • Accessibility with old concept was limited
43
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OLD
Hydraulics • Entire hydraulic system has been redesign • 3D hose routing tools have been used
44
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Hydraulics
45
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Hydraulics
NEW NEW
46
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2012 Improvements MDG updates Hydraulics – Swing System
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Hydraulics – Swing System • New hose routing concept • Swing blocking valves moved underneath the walkway • New blocks on swing motors for improved serviceability • Block directly mounted to swing motor
48
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Hydraulics – Swing System NEW
OLD
49
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2012 Improvements MDG updates Hydraulics – Travel System
50
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Hydraulics – Travel System
• Redesigned travel system • Improved hose routing • Less hoses • More space on superstructure • More efficient hydraulic system • Less heat will be created
51
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Hydraulics – Travel System
OLD
52
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NEW
2012 Improvements MDG updates Hydraulics – Leak Oil
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Hydraulics – Leak Oil
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Hydraulics – Leak Oil
Old
New
• New leak oil collector design • Revised hose routing • New fittings for sensors on pumps
55
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2012 Improvements MDG updates Hydraulics – Control System
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Hydraulics – Control System (Old)
Former Problems: • Hose routing on mounting plate very untidy • Hoses going to attached are cannot be routing probably • Hose routing in accordance with MDG 41 not possible 57
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Hydraulics – Control System (New) • New location in pump module
58
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Hydraulics – Control System Pilot Valve Block 2
Solenoid Valve (SIL)
Pilot Valve Block 1
Proportional Valve Pump Regulation
Flushing Valve
Swing Balance Valve Proportional Valve Travel 59
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Pressure Adjustment Swing Proportional Valve Swing
Hydraulics – Control System
Swing Park Brake 50 bar Pump Regulation 50 bar
Pilot 60 bar
Supply for small valve blocks Tank Swing 35 bar 2nd Speed 50 bar
60
Pump Travel Brake 30 bar
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Pilot 35 bar
Hydraulics – Control System Pilot 50 bar Track Tensioning 80 bar Ladder / Service Arm / Grease Tank 80 bar
Pump Tank
X2 Main Pumps Pilot 100 bar 61
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Travel Boost 40 bar
Clam Boost 40 bar
Hydraulics – Control System
62
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Hydraulics – Control System Pilot System Filter • 60 bar test point on LH engine bay • 100 bar test point on RH engine bay
Gear Oil Filter PTO
Main Pump Bearing Flushing Filter
• New arrangement of filter for better serviceability and improved hose routing
63
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Hydraulics – Control System
64
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2012 Improvements MDG updates Attachment
65
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Hydraulics – Attachment
66
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Attachment
• Flexible mounting base for handrails on attachment
• Additional walkways behind main control valves • Removable handrail
67
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Attachment
• Fall arrest kit on boom
68
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2012 Improvements MDG updates Electrics
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Electrics
• Battery and starter Isolator Station on main deck • Easily accessible • Close to the battery box • Short cable length
70
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Electrics
• Clear and durable labeling of sensor cables
71
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Electrics
• Additional circuit breaker for alternators
72
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Electrics
• New electrical cabinet on main control plate for improved cable routing
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2012 Improvements MDG updates Fuel Tank
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Fuel Tank Capacity Increase •
Use of the additional engine oil tanks installed in the cab and oil cooler module (for oil change interval extension) as fuel tanks – Additional fuel capacity: 1,200 l
•
75
Additional engine oil tanks in counterweight
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2011 Improvements
76
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2011 Improvements New Control and Monitoring Platform (CAMP) Including new Boad Control System (BCS)
77
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Control And Monitoring Platform CAMP BCS III
CAN bus II CAN bus I
J1939
Drive train controller LH 78
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J1939
Servo controller
Auxiliary Controller
Drive train controller RH
Board Control System – BCS III
Control Tower in ergonomic position for the operator Cleary labeled push buttons 79
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Interfaces: USB, CAN BUS Lan (TPC/IP)
BCS Display with 12” high resolution touch screen
BCS III – Operator Comfort •
Large 12” touch screen – –
•
Monitoring of operating data – –
•
80
PDF documents on board
Beside the factory setting 3 further settings can be defined and stored
Various languages can be selected On screen PDF documentation –
•
Type of warning is programmable Detailed description of fault First action suggestions
Joystick characteristics adjustable to operator preferences –
• •
Approx. 30 analogue and 50 digital sensors Comparison with set values and indication of deviating values
Visual and acoustic warnings – – –
•
Intuitive handling Adjustable brightness for night operation
Operating instruction
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Trouble shooting assistance
2010-2011 Improvements
81
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2010-2011 Improvements
Second Horn on oil cooler module • •
82
Standard scope of supply Field conversion kit available
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2010-2011 Improvements
Track tensioning system • • •
83
Flexible connection of push tube to slider Push tube supported by additional ring Will be implemented in serial production by 2011
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2010-2011 Improvements
Bucket Clam Cylinder • • • •
Increase of piston diameter from 220 mm to 250 mm Retraction force increased by 39 % Current cylinder: 3684640 / New Cylinder: 3713737 Currently under field test; serial production will follow after successful field tests ∅250
84
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2010-2011 Improvements
New manhole covers for attachment
85
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2010-2011 Improvements
Service lights • • • • •
86
New LED maintenance lights All machines since March 2010 are equipped with these lights Better light output Solid material Supplier: ABL
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2010-2011 Improvements
Fans Oil Cooling System • •
The metal fans have been replaced by plastic fans Less weight of the fans leads to increased life expectancy of fan drive system
OLD
87
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NEW
2010-2011 Improvements
New installation plate on cab module •
Clear arrangement of components
•
Pre-assembly possible
88
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2010-2011 Improvements
Installation of pipes instead of hoses where worthwhile
89
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2010-2011 Improvements Modified Hose Arrangement •
Extensive usage of brackets and clamps for fixed hose routing
•
In steel structure integrated hose connection brackets between modules – Easier assembly / disassembly of modules – Shorter hoses for better handling
90
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2010-2011 Improvements Self-aligning roller bearings
PTO • Modified PTO – New bearing of input shaft – New oil dipstick – New Shaft sealing ring
OLD Fitting key
– Gearing instead of fitting key
• Part-No: – Old: 3691273 – Modification Kit: 6004320 – New: 3705643 / 3705638
cylinder roller bearings Groove ball bearings
NEW
Gearing instead of fitting key 91
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2010-2011 Improvements New pre-assembled installation plate •
Various servo control components and hydraulic filters are pre-assembled on a new installation plate – Easier assembly/disassembly – Easier service due to clear arrangement
92
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2010-2011 Improvements Cat® Air Cleaners for Cat® 3512C engines New brackets
CAT Air-Filterbox with precleaner
Easy to maintain! new steel pipes 93
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New silicon adapters
2010-2011 Improvements
Main Valve Block • • • •
Main valve block completely reworked Optimized pipe routing Easy replacement through standardized pipes Optimization of all pipes through – FEM – Analysis – Natural frequency analysis
94
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2010-2011 Improvements
Main Pumps • •
Improvement by BoschRexroth Enlargement contact area on the sliding shoe / retainer plate by: – Downsizing of piston bore diameter on the retainer plate – Restriction on sliding shoe diameter
•
Pumps are already in field test
OLD since 04/1996 95
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NEW starting 03/2010
2010-2011 Improvements Hydraulic oil tank was optimized to increase air release • •
•
96
During testing it was found that large amounts of large bubbles 20mm and above were entering the main pumps Baffles allows a better flow of oil to increase the air release from the return oil (Even when flow rate is extremely high or oil brand and grade are not optimum) Baffle plates are a bolt on type package for easy field upgrade
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2010-2011 Improvements
Hydraulic Tank Design • •
97
Bolted hydraulic tank Bolted to both tank and excavator
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2010-2011 Improvements Steel Structure • •
Reinforced engine module frame for better support engine mounting and hydraulic tank Increased stability of steel structure
•
Reduced counterweight due to longer superstructure frame – Same stability and dynamic forces during swing like A-version
New Old 98
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2010-2011 Improvements Fuel Tank Capacity Increase (Field Solution) • • • • •
Increase of fuel tank capacity to guarantee sufficient capacity for 24 operating hours even at very high engine utilization Temporary field solution/upgrade with additional tank on top of standard tank Headroom in engine module still sufficient Tank volume increased by 768 l (each side) Total useful tank volume on even ground approx. 13000 l original tank
99
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complete tank modification
2010-2011 Improvements
Fuel Tank Design • •
Revised design due to cracks at the corner of the rear and front plate on the fuel tanks Repair procedure available
OLD: R = 25 mm
OLD: t = 8 mm
100
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NEW: R = 63mm
NEW: t =12 mm
2010-2011 Improvements New Pump Drive Coupling • • •
101
Different design/supplier Same design like on RH400 First units equipped with new coupling for field testing
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2010-2011 Improvements
Handrails • •
102
New design of handrail mountings Solid base material
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History
103
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CAT 6060 History
The RH340 was developed on basis of the 6050 / 6050 FS model. The later upgrade to the RH340B is now called 6060 / 6060 FS
Cat® 6050 – Base Specs – – – – –
104
Bucket capacity: 26 m³ Breakout force: 1500 kN Crowd force: 1890 kN Operating weight: 505 t Engine output: 1680 kW
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CAT 6060 History
2004 – RH340 prototypes compared to 6050 / 6050 FS • New patented attachment and bucket design concept • Increased operating weight – Increased counterweight – Revised superstructure frame – Larger undercarriage
• • • • •
Shorter stick on backhoe machines Larger boom cylinders on face shovel machines Increased working pressure (320 bar) Increased digging forces longer undercarriage – 7 bottom rollers (6050: 6)
•
105
New final drive 1300 Nm (6050: 1130 Nm)
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CAT 6060 History
2004 – RH340 - Prototypes • bucket capacity: 34 m³ • breakout force: FS: 1500 kN / BH: 1240 kN • crowd force: FS: 1910 kN / BH: 1270 kN • Operating weight: FS: 552 t / BH: 547 t • Engine: 1880 kW – Cummins K1500E
106
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CAT 6060 History
2004/2005 – RH340 • Engine Option: Cummins QSK 45 with 2240 kW (340003) • Larger oil cooling module (+ 20 % cooling capacity) • Revised FS bucket and FS stick design • Revised BH boom structure design with man hole and new welding procedures 2005/2006 –RH340 • First machine with electric drive (340018) • Reinforced superstructure frame • New stick and bucket cylinders with increased piston diameter on Face Shovel machines – Breakout force: 1640 kN – Crowd force: 2240 kN
107
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CAT 6060 History
2007 – 6060 / 6060 FS (RH340B) • longer superstructure main frame (+ 300 mm) • longer engine module to fit Caterpillar 3512C engine • higher counterweight for 3512C charge air coolers • increased tank volume diesel and hydraulic oil • new main pumps – 4 x 1300 l/min (RH340: 4 x 912 l/min)
• •
new pump transfer gearbox new valve blocks – 4 units (twice RH120E installation)
•
Two engine alternatives – Cummins QSK45 (2240 kW) – Caterpillar 3512C (2240 kW)
•
108
Upgrade to B-version only for diesel machines
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Comparison: A-Version vs. B-Version Dimensions A-Version
B-Version
Length of engine module
3600 mm
3950 mm
Tail overhang
7350 mm
7700 mm
Tail swing radius
7580 mm
7955 mm
Height of counterweight
3675 mm
3975 mm
Face shovel
552.000 kg
566.600 kg
Backhoe
547.000 kg
567.500 kg
Operating weights
109
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Remarks had to be extended due to the longer engine blocks of the CAT engines
The CAT engines have charge air cooling which requires additional radiator space
Comparison: A-Version vs. B-Version Hydraulics A-Version
B-Version
Pump transfer gear
Same as RH200
New design
Main pumps
4 bent axis axial piston pumps
4 double pumps in swash plate design
Displacement of main pumps
1000 cm³
892 cm³ *
* The nominal capacity of (2 x 520 cm³ = 1050 cm³) is reduced to 892 cm³ to achieve a max. flow of 5200 l/min
Drive speed of main pumps
925 rpm
1457 rpm
Max. oil flow, each main pump
925 l/min
1300 l/min
All other pumps remain unchanged.
Max. total oil flow of main pumps
3700 l/min
5200 l/min
2 (like RH 200)
4 (twice RH 120E)
Hydraulic tank capacity
6100 l
7100 l
approximate
Total volume of hydraulic oil
8400 l
9400 l
Approximate
Main valve blocks
110
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Remarks Revised domensions, ratios and speeds
Necessary to cope with the higher oil flow
CAT 6060 History
2008 – Cat® 6060 • Larger (deeper) oil pan for QSK45 engines 2009 – Cat® 6060 • First RH340 electric drive according to CSA Standards for Canada • Reinforced design of backhoe boom 2010 – Cat® 6060 • Reinforced engine module frame • Revised hydraulic tank design • Revised fuel tank design • Improved hose routing • Pre-assembled installation plates for servo control components • …… 111
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Key Features of CAT 6060 Attachment Update
112
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CAT 6050 vs. CAT 6060: Attachment Comparison
New patented attachment design • •
Reduced stress in critical areas Reduced weight which can be added as additional payload – – – – –
Welds are out of high stress areas Material is where it needs to be Thinner plates where material is not required No internal stiffener plates Counter welded from inside
– All parts are designed in FE system
113
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CAT 6050 vs. CAT 6060: Attachment Comparison Cat® 6050
114
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Cat® 6060
Boom crack at first machine
Boom crack at the first Cat® 6060 Backhoe • • •
Cause: weld defect Change of manufacturing/welding procedure Reinforcement of bottom chord
•
Due to these improvements the problem was solved
115
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CAT 6050 vs. CAT 6060: Attachment Comparison
Cat® 6050 (Former design)
116
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Cat® 6060
CAT 6060: Stick Design
• • • •
The first FS stick design caused problems with the geometry of the attachment All following units were equipped with a new designed stick The stick on 340003 has been exchanged New stick design well proven in 48 units
Old design • Straight bottom cord
New design • Curved bottom cord
117
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Major Hydraulic Upgrades A-Version compared to B-Version
118
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Comparison: A-Version vs. B-Version Cat® 6060 – A-Version
Cat® 6060 – B-Version
• 2 Valve blocks
• 4 Valve blocks
– Same like RH 200 119
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– Same like RH120E but twice
Comparison: A-Version vs. B-Version Cat® 6060 – A-Version
Cat® 6060 – B-Version
• Bent axis main pumps • 1000 cm³
• Swash plate double pumps • Nominal 1040 cm³ Reduced to 890 cm³ – Less stress on pumps
120
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®
© 2013 Caterpillar. All Rights Reserved. CAT, CATERPILLAR, their respective logos, “Caterpillar Yellow,” the “Power Edge” trade dress as well as corporate and product identity used herein, are trademarks of Caterpillar and may not be used without permission.
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